MITSUBISHI 3000GT 1991 Service Manual

CLUTCH - Clutch Control21-13
14UOO6514U006t14GOO50
08FOO27. ADJUSTMENT OF CLEARANCE BETWEEN CLUTCH
BOOSTER PUSH ROD AND PISTON
<AWD>Adjust the clearance (A) between the clutch booster push
rod and piston as follows:
(1) Measure the dimension
(B) between the master cylin-
der end face and piston.
NOTETo obtain
(B), first take measurement with a square
placed on the master cylinder end’ face. Then, subtract
the thickness of the square to arrive at (B).
(2) Obtain the dimension
(C) between the clutch booster
mounting surface on the master cylinder and the end
face.(3) Measure the dimension
(D) between the master cylin-
der mounting surface on. clutch booster and the push
rod end.
NOTETo obtain
(D). first take measurement with a square
placed on the clutch booster. Then, subtract the
thickness of the square to arrive at
(D).
(4) Using the measured values obtained in (1) through (3).obtain the clearance (A) between the clutch booster
push rod and piston.
Standard value: [A (A = B
- C - D )]
0.2j - 0.46 mm (.0082 - .0181 in.)
[Atmospheric pressure][When the clutch booster negative pressure of 66.7
kPa(9.7 psi) is applied, the clearance (A) becomes 0.1 to 0.3
mm
(.0039 to .0118 in.).]
(5) If the clearance is not within the standard value range,
adjust by changing the push rod length by turning the
adjustable end of the push rod.
CautionImproper clearance may cause excessive brake
drag.JTSB Revision
I

21-14CLUTCH i Clutch Master Cylinder
CLUTCH MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
M21NA. -Disassembly steps
1. Piston stop bolt <FWD>2. Gasket <FWD>a*3. Piston stop ring <FWD>*I)4. Snap ring <AWD>5. Push rod <FWD>
6. Boot <FWD>
c*7. Piston assembly
8. Reservoir cap
9. Reservoir band
10. Reservoir11. Master cylinder body
<FWD>Master cvlinder kit..--_-.-I------- --.-
6.0 Nm4.0 ft.lbs
08FOO40
13 Nm9.0 ftlbs.
---&08FOO39
r
08FOO41
<AWD>8
6.0 Nm4.0 ft.lbs:Master
cvlinder kit1
109FOl3414LO193
SERVICE POINTS OF DISASSEMBLYM21NSAE3. DISASSEMBLY OF PISTON STOP RING
<FWD> / 4.
SNAP RING
<AWD>Remove the piston stop ring or snap ring, while depressing
the piston.
7. REMOVAL OF PISTON ASSEMBLY
Caution
1.Do not damage the master cylinder body and piston
assembly.2. Do not disassemble piston assembly.
INSPECTIONMZlNCAD
l Check the inside cylinder body for rust or scars.
l Check the piston cup for wear or deformation.
Idl Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.
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CLUTCH - Clutch Release Cylinder21-15
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
L.4/
/
iJ
Lubricant: Conforming to DOT3Disassembly steps
1.Valve plate2.Spring3.Push rod4.Boots*I) l *5. Piston and cup6.Conical spring
7.Cap
8.Bleeder plug9.Release cylinder7CLOOOl
6CLO3!
SERVICE POINTS OF DISASSEMBLYM2lLBAF5. DISASSEMBLY OF PISTON AND CUP
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
compressed air.
Caution1. Cover with rags to prevent the piston from
popping out.
2. Apply compressed air slowly to prevent brake
fluid from splashing.
1 TSB Revision

21-16CLUTCH - Clutch Release Cylinder
6CLOOO3
DCLOOE,
INSPECTIONM21LCAF
(1) Check the inner surface of the release cylinder for scratch-
es or irregular wear.
(2) Replace if the piston cup outer circumference is scratched
LIor shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
SERVICE POINTS OF REASSEMBLYMZlLDAH
5. APPLICATION OF FLUID TO PISTON AND CUP
Apply specified brake fluid to the release cylinder inside and
outer surface of the piston and piston cup and push the
piston cup assembly in the cylinder.
Specified brake fluid: Conforming to DOT3
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CLUTCH - Clutch Vacuum Line, Vacuum Tank <AWD>
CLUTCH VACUUM LINE, VACUUM TANK <AWD>
REMOVAL AND INSTALLATION
21-17M21VA-
_
I
i6
Hose clamp
4.0 NmI2.9 ftlbs.
.lO15
\
;308FOO21
II
l +1. Vacuum hose AI)* 2. Vacuum hose B+I) W+3. Vacuum hose C with check,valve4. Fitting
Vacuum pipe A removal steps
l *5. Air hose AI)+6. Air cleaner cover, air intake hose A
7. Vacuum pipe AVacuum pipe B, vacuum hose D removal steps
8. Brake booster(Refer to GROUP 35 - Brake Booster.)9. Vacuum pipe B
l + 10. Vacuum hose DVacuum tank assembly, vacuum hose E,
vacuum pipe C removal steps
11. Right member(Refer to GROUP 32 - Right Member, Left
Member and Crossmember)
12. Vacuum tank assembly
l * 13. Vacuum hose E
14. Vacuum pipe CTSB Revision

21-18CLUTCH - Clutch Vacuum Line. Vacuum Tank <AWD>
Check valve
OSFOOO
OSFOO7
- iA&ir$ke
Air intake hose A
Air intake hose B05FOO23
Air hose CAir hose AI
SERVICE POINTS OF REMOVALM2lVBAA3. REMOVAL OF VACUUM HOSE C WITH CHECK VALVE
NOTESince the check valve is fit to the vacuum hose C, replace
the check valve as an assembly unit together with the
vacuum hose C if the check valve is defective.
INSPECTIONM2lWcAAl Check the hose and pipes for cracks, bend, deformation
and clogging.
l Check the vacuum tank for deformation or crack.
SERVICE POINTS OF INSTALLATIONMZlVDAA13. INSTALLATION OF VACUUM HOSE E
/ 10. VACUUM
HOSE D / 3. VACUUM HOSE C WITH CHECK VALVE / 2.VACUUM HOSE B
/ 1. VACUUM HOSE A
If a hose is connected to a pipe with a stepped part, insert
the hose up to the stepped part.
aIf it is connected to a pipe without any stepped part, insert
the hose until the insertion amount reaches the standard
value.
Standard value: 20
- 25 mm (.8 - 1.0 in.)
6. INSTALLATION OF AIR CLEANER COVER, AIR INTAKEHOSE A
Align slots indicated by arrows in air intake hose A with
nmarkings on air intake hoses B and C; then, insert hoses B
and C all the way into air intake hose A.
Insert air intake hoses B and C all the way up to the roots on
the turbocharger end.
5. INSTALLATION OF AIR HOSE A
Connect tha air hoses ensuring that alignment marks are
aligned with projections.
Insert air hoses B and C into pipe all the way to its step.
CautionBe careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.
;i
J
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CLUTCH - Clutch Cover and Disc
CLUTCH COVER AND DISC
REMOVAL AND INSTALLATION
21-19
M21GA-.
I
)Il Removal of the Transaxle Assembly
30-42Nm
\\115-21 Nm11 - 15 klbs.2Removal steps
M w1. Clutch cover assembly+e W+ 2. Clutch disc3. Return clipI)* 4. Clutch release bearingW+ 5. Release fork6. Fulcrum
7. Release fork bootTSB Revision

CLUTCH - Clutch Cover and Disc
6CLOl f
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
7CLOOO8
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or eauivalent
6CL03:
Lubricant: MITSUBISHI genuine greasePart No. 0101011 or equivalent
SERVICE POINTS OF REMOVALMZlGBAK
1.REMOVAL OF CLUTCH COVER ASSEMBLY / 2. CLUTCH
DISCDiagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at a
time, to avoid bending cover flange.
CautionDO NOT clean clutch disc or release bearing with
d
cleaning solvent.TSB Revision
1

CLUTCH - Clutch Cover and Disc21-21
Sleeve
Bearing
TFM0131
INSPECTIONMZlGCAG
CLUTCH COVER ASSEMBLYl Check the diaphragm spring end for wear and uneven
height.
lReplace if wear is evident or height difference exceeds the
limit.
Limit
: 0.5 mm (02 in.)
lCheck the pressure plate surface for wear, cracks and color
change.
lCheck the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISC
lCheck the facing for loose rivets, uneven contact, deteriora-
tion due to seizure, adhesion of oil or grease and replace the
clutch disc if defective.
lMeasure the rivet sink and replace the clutch disc if it is out
of specification.
Limit
: 0.3 mm (.012 in.)
lCheck for torsion spring play and damage and if defective,
replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.
If it does not slide smoothly, check after cleaning and
reassembling. If the play is excessive, replace the clutch
disc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
1.The release bearing is packed with grease, so don’t usecleaning oil, etc. to clean it.
2.Do not disassemble the bearing and sleeve of the clutch
release bearing. If disassembled, replace. (AWD only)l Check for bearing heat damage, other damage, abnormal
noise and/or improper rotation. Also check whether or not
there is wear at the point of contact with the diaphragm
spring.
lIf there is abnormal wear at the point of contact with the
release fork, replace the bearing.
RELEASE FORKIf there is abnormal wear at the point of contact with the
bearing, replace the release fork.
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21-22CLUTCH - Clutch Cover and Disc
APPLYgrease
6CLOlE
lir#LClutch disc
Clutch cover
assembly
v-l6CL02EITSB Revision
SERVICE POINTS OF INSTALLATIONMZIGDAU5. APPLICATION OF GREASE TO RELEASE FORK
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact
withthe release bearing.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
CautionWhen installing the clutch, apply grease to each
part, but be careful not to apply excessive grease;excessive grease will cause clutch slippage and
shudder.(2) Apply a coating of the specified grease to the end of the
release cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
4.APPLICATION OF GREASE TO CLUTCH RELEASE BEAR-ING (FWD)
Pack the inner surface of the clutch release bearing and the
groove with the specified grease.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
2. APPLICATION OF GREASE TO CLUTCH DISC
/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
(2) Using the universal clutch disc aligner, position the
clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.I