1988 Mitsubishi Mighty Max Repair Manual

The 1988 Mitsubishi Mighty Max is a compact pickup truck featuring a 2.0L or 2.6L gasoline engine, 5-speed manual transmission, rear-wheel drive, independent front suspension, and leaf spring rear suspension. This repair manual covers maintenance procedures, troubleshooting, engine repair, transmission service, brake systems, electrical systems, and routine maintenance schedules. Below are key sections for specifications, maintenance, repair procedures, and troubleshooting.

Vehicle Specifications

Key components: Engine options, transmission types, chassis specifications, and electrical system details.

Maintenance Schedule

Regular maintenance intervals for optimal performance and longevity.

1. Oil and filter change: Every 3,000 miles or 3 months.
2. Air filter replacement: Every 15,000 miles.
3. Spark plugs: Replace every 30,000 miles.
4. Coolant flush: Every 30,000 miles or 2 years.
5. Brake fluid: Check and replace every 2 years.
6. Transmission fluid: Check every 15,000 miles, replace every 60,000 miles.

WARNING! Always disconnect battery before performing electrical work. Use jack stands when lifting vehicle.

Engine Repair

Procedures for common engine repairs and maintenance.

1. Timing belt replacement: Recommended every 60,000 miles.
2. Valve adjustment: Check every 15,000 miles.
3. Compression test: Perform if engine misfires or lacks power.
4. Oil leak diagnosis: Check valve cover gasket, oil pan seal, and front/rear main seals.
5. Cooling system: Check for leaks at water pump, hoses, and radiator.

CAUTION! Allow engine to cool before opening cooling system. Use proper torque specifications.

Transmission Service

• Transmission Type: 5-speed manual.
• Fluid Capacity: 2.1 quarts of 75W-90 gear oil.
• Shift Linkage: Adjust if shifting becomes difficult.
• Clutch System: Hydraulic clutch with master and slave cylinder.
• Common Issues: Grinding gears, difficult shifting, clutch slippage.
• Service Procedures: Fluid change, clutch replacement, shift linkage adjustment.

Brake Systems

Front disc brakes and rear drum brakes maintenance and repair.

Front Brakes: Disc brake pad replacement, rotor resurfacing or replacement, caliper service.

Rear Brakes: Drum brake shoe replacement, wheel cylinder inspection, brake adjustment.

Brake Fluid: DOT 3 or DOT 4. Bleed brakes after any component replacement. Parking Brake: Adjust cable tension for proper operation.

Electrical Systems

12-volt electrical system with alternator, battery, and wiring diagrams.

1. Battery: Check terminals for corrosion, test voltage (12.6V fully charged).
2. Alternator: Output should be 13.5-14.5 volts with engine running.
3. Starter: Test draw current if engine cranks slowly.
4. Lights: Check bulbs, fuses, and wiring for proper operation.

Tip: Use multimeter for electrical diagnostics. Refer to wiring diagrams for complex issues.

Suspension & Steering

Independent front suspension with torsion bars and recirculating ball steering.

1. Front suspension: Check ball joints, tie rod ends, and torsion bars.
2. Rear suspension: Inspect leaf springs and shackles.
3. Steering system: Check for play in steering box and linkage.
4. Wheel alignment: Perform after suspension repairs.
5. Shock absorbers: Replace if leaking or worn.

WARNING! Always support vehicle properly when working under it. Replace worn components in pairs.

Cooling System

Radiator, water pump, thermostat, and cooling fan maintenance.

Fuel System

Carburetor or fuel injection system service and maintenance.

CAUTION! Relieve fuel pressure before servicing fuel system. No smoking or open flames near fuel work.

Troubleshooting

Reset: Disconnect battery for 15 minutes to reset ECU if applicable.

Service: Refer to Mitsubishi dealership for complex diagnostics and parts.