MITSUBISHI 3000GT 1991 Service Manual

22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE <AWD>. . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE <MID>....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT.(2)The SRS includes the following components: impact sensors, SRS diagnosis unit: SRS warning light, air bagmodule, clock spring, interconnecting wiring. Other SRS-related components (that may have to be
removed/installed in connection with SRS service or maintenance) are indicated in the table of contents byan asterisk (*).
WARNING!(1)Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (fromrendering the
SRS inoperative).(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B
-Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.

22-2MANUAL TRANSAXLE <FWD> - General Information
MANUAL TRANSAXLE <FWD>
GENERAL INFORMATIONM226AAU
F5M33
R Cl/utch housing
2nd speed gear
Bearing retainer
1 st weed
Input shaftI
get
I
3r’
1 st-2ndspeed
synchro-
nizerassembly
I
3rdbeed gear
3rd-LIth
:
L
speed synchronizer assembly
Lth speed gear
I
5th speed gear
Spacer
\i
5th speedsynchronizerassembly
noise-prevention
Filter
5th speed inter-mediate gear
’ Intermediate gear
rcer
t-Output shaft
:er
Differential drive gear
TFMOlll
I
‘d ’
‘\
I
1
I1
I~
\
d!TSB Revision
1

MANUAL TRANSAXLE <FWD> - Specifications22-3
SPECIFICATIONS
L
GENERAL SPECIFICATIONSM22CA.A
items
Model
Applicable engine
Type
Gear ratio
1 st
2nd
3rd
4th
5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
Specifications
F5M33-2-SNZR
6G72-DOHC MPI
5-speed transaxle floor shift
3.090
1.833
1.217
0.888
0.741
3.166
4.153
28136
2.3 (2.4)
SERVICE SPECIFICATIONSM22CB-A
mm (in.)
L.J
Items
Standard value
Transaxle
Input shaft end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
Limit
Specifications
0 - 0.05 (0 - ,002)
0.01 - 0.09 i.0004 - ,004)0.01 -0.14 (.0004-
,006)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - .004)
0.025 - 0.150 (.OOl - ,006)
Synchronizer ring and clutch gear clearance0.5 (.02)
SNAP RING (FOR ADJUSTMENT) AND SPACERM22CF.A
Part name
Spacer
(For adjustment of input shaft end play)Thickness mm (in.)
0.80
i.0315)
0.83 (.0327)
0.86(.0338)
0.89t.0350)
0.92
(.0362)
Identificationsymbol
80
83
86
89
92
Part No.
MD727661
MD720937
M D720938
MD720939
MD720940TSB Revision

22-4MANUAL TRANSAXLE <FWD> - Specifications/ - ,
Part name
Spacer
(For adjustment of input shaft end play)
Snap ring
(For adjustment of intermediate gear front bearingend play)
Spacer:Foradjustmentofintermediategearpreload)Thickness mm (in.)
IdentificationsymbolPart No.
0.95 l.0374)
95
MD7209410.98
t.0386)98MD720942
1
.Ol t.0398)01M D720943
0.04 (.0409)04MD7209441.07(.0421)
07MD7209451.10(.0433)
JMD71 04541.13 l.0445)
DMD7002701.16 i.0457)
KMD7104551.19
(.0468)LMD710456l.ZZ(O.480)
GMD7002711.25 i.0492)
MMD7104571.28
t.0504)NMD7104581.31
(.0516)EMD7065741.34(.0527)0
M D7 104591.37
(.0539)PMD71 04601.40(.0551)
-MD7065731.43
t.0563)QMD710461
1.46l.0575)RMD7104621.4 l.0551)
NoneMD703779
1.5 l.0591)
BrownMD7037801.6
f.0630)BlueMD7037810.80
t.0315)80MD7241 420.83 l.0327)
83MD7241 43
0.86f.0338)86MD7241440.89
t.0350)89MD7241 450.92 f.0362)
92MD7241 460.95 l.0374)
95MD7241470.98 i.0386)
98MD7241 48
1 .Ol t.0398)01MD724149
1.04 (.0409)04MD7241501.07(.0421)
07MD7241 51
1 .I0 (.0433)10MD7241521.13 f.0445)
13MD7241531.16
t.0457)16MD7241 541.19
(.0468)19MD724155
1.22 (.0480)22MD7241 561.25 t.0492)25
MD7241571.28 f.0504)
28MD7241581.31 l.0516)
31MD7241 591.34(.0527)
34MD7241 601.37
(.0539)37MD724161
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MANUAL TRANSAXLE <FWD> - Specifications22-5
Part name
Spacer
(For adjustment of output shaft preload)
Spacer
(For adjustment of differential case preload)
Spacer
(For adjustment of differential pinion backlash)Thickness mm (in.)IdentificationsymbolPart No.
0.83 (.0327)83MD720937
0.86
(0338)86MD720938
0.89
(.0350)89MD720939
0.92
(.0362)92MD720940
0.95
(.0374)95MD720941
0.98 (.0386)98MD720942
1
.Ol t.0398)01MD720943
1.04 (.0409)04MD720944
1.07 (.0421)07MD729945
1 .I 0 (.0433)JMD71 0454
1
.I 3 (.0445)DMD700270
1.16(.0457)KMD71 0455
1 .I9 (0468)LMD71 0456
1.22 (.0480)GMD700271
1.25 (0492)MMD710457
1.28
(.0504)NMD710458
1.31
(.0516)EM D706574
1.34 (0527)0MD71 0459
0.80 (0315)80MD727661
0.83 (0327)83M D720937
0.86 (.0338)86M D720938
0.89 (0350)89M D72d939
0.92 (0362)92MD720940
0.95
(.0374)95M D720941
0.98 (.0386)98MD720942
1
.Ol (.0398)01MD720943
1.04 (.0409)04MD720944
1.07 (0421)07MD720945
1 .I 0 (.0433)JMD71 0454
1.13 (.0445)DMD700270
1.16
(.0457)KMD710455
1.19
(.0468)LMD71 0456
1.22 (.0480)GMD700271
1.25 LO4921MMD71 0457
0.75
- 0.82-MA1 80862
LO295 - .0323)
0.83 - 0.92-MA1 80861
(0327 - .0362)
0.93 - 1 .oo-MA1 80860(0366
- .0394)
1.01 -1.08-MA1 80875
(.0398 - .0425)1.09-1.16
-MA1 80876
t.0429 - .0457)TSB Revision

22-6MANUAL TRANSAXLE <FWD>- Specifications / Special Tools
LUBRICANTS
M22CD-A
Items
Manual transmission oil
Drive shaft oil seal lip
Specified lubricant
Hypoid gear oil, SAE
75W-90 or75W-85W conforming to APIclassification GL-4 or higherQuantity lit.
(qts)
2.3 (2.4)
As required
SEALANTS AND ADHESIVES
Items
Transaxle case - clutch housing mating surfaces
Transaxle case
- rear cover mating surfaces
Differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
MUCE- _
Specified sealants and adhesives
Mitsubishi genuine part No. 997740 or equivalent
3M Stud Locking part No. 4170 or equivalent
Air breather
3M ATD part No. 8001 or equivalent
SPECIAL TOOLSM22DA-A.
nstallation of spring pin and lock
MD998323-01TSB Revision

MANUAL TRANSAXLE <FWD> - Special Tools22-7
MD998348-0 1
Bearing remover
Removal of gears and bearings of input
shaft, intermediate gear and output shaft
andintermediate shaft lock nut
M
D998808-01Snap ring installerInstallation of input shaft rear snap ring
MD998822installer adapterInstallation of differential case bearings
iTSB Revision

22-8MANUAL TRANSAXLE <FWD> - Troubleshooting
TROUBLESHOOTING
Symptom
Vibration, noise
3il leakage
t-lard shiftProbable cause
a. Loose or damaged transaxle and
engine mounts
b. Inadequate shaft end play
c. Worn of damaged gears
d. Use of inadequate grade of oil
e. Low oil level
f. Inadequate engine idle speed
a. Broken or damaged, oil seal or O-ring
a. Faulty control cable
b. Poor contact or wear of synchronizer ringand gear cone
c. Weakened synchronizer spring
d. Use of inadequate grade of oil
a. Worn gear shift fork or broken poppet
spring
b. Synchronizer hub to sleeve spline
clearance too largeRemedy
a. Tighten or replace mounts
b. Correct end play
c. Replace gears
d. Replace with specified oil
e. Replenish
f. Adjust idle speed
a. Replace oil seal or O-ring
a. Replace control cable
-
Jumps out of gear
b. Correct or replace
c. Replace synchronizer spring
d. Replace with specified oil
a. Replace shift fork or poppet spring
b. Replace synchronizer hub and sleew
1 TSB RevisionI

MANUAL TRANSAXLE <FWD>- Service Adiustment Procedures22-9
110*u011009FO12
SERVICE ADJUSTMENT PROCEDURES
MZZFBAEl
TRANSMISSION OIL LEVEL INSPECTIONRefer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEMENTM22FCAI(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transmission oil
to drain.
(3) Refill the transaxle to the proper level with specified
transmission oil. The oil level should be the bottom of the oil
filler hole.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherC2.3 liters (2.4 pts.)]
SPEEDOMETER CABLE REPLACEMENTMUFEALl
1.Correctly insert the adapter into the instrument panel, and
fasten the new speedometer cable.
2.Install the grommet so that, as shown in the illustration, the
cable attachment part and the projecting part are horizontal.
CautionThe cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
3.At the transaxle end of the speedometer cable, the key joint
should be inserted into the transaxle, and the nut should be
securely tightened.
Caution
If the cable is not correctly and securely connected, it
may cause incorrect indication. by the speedometer, orabnormal noise. Be sure to connect it correctly.
DSB RevisionI

22-10 MANUAL TRANSAXLE <FWD>- Service Adjustment ProceduresI
I09K5671160024
Oil seallip
* Transaxleside2200037
DRIVE SHAFT OIL SEALS REPLACEMENTM2ZFDAI
(I) Disconnect the drive shaft from the transaxle.
(Refer to GROUP 26
- Drive Shaft.)’ )
(2) Using a flat-tip (-) screwdriver, remove the oil seal.d,(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
The drive shaft oil seal must be installed in the direction
shown.
(4) Apply a coating of the transmission oil to the lip of the oil
seal.
Transmission oil: Hypoid gear oil, SAE 75W-90 or
75W-85W conforming to API classi-
fication GL-4 or higher
‘d
TSB Revision