MITSUBISHI 3000GT 1991 Service Manual

MANUAL TRANSAXLE <FWD> - Transaxle Assembly
15-22Nm5211-15
ft.lbs..I 53
-22Nm
-15 ftlbs.
67
litI63
62
51.Screw52.Bolt53.Bearing retainer54. Intermediate gear assembly
55. Input shaft assembly
56. Output shaft assembly
57. Differential gear assembly
58. Bearing outer race
59. Bearing outer race60.Oil guide61. Bearing outer race
62. Bearing outer race
** 63. Oil seall 464.Oil seal65.Magnet66.Magnet holder
67. Clutch housing assembly
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MANUAL TRANSAXLE <FWD> - Transaxle Assembly
Lock nut‘;
201021
SERVICE POINTS OF DISASSEMBLYMZZMFAW
14. REMOVAL OF SPRING PINRemove the spring pin using a pin punch.
NOTE\,/If the spring pin interferes with the synchronizer ring or
cone gear, rotate the gear for dislocation and remove the
spring pin.15.16. REMOVAL OF LOCK NUTS
(1) Unstake lock nuts of the input shaft and intermediate
gear.
(2) Shift the transaxle in reverse using the control lever and
select lever.(3) Install the special tool onto the
inout shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery ofclutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.48.49. REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using a pin punch.
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MANUAL TRANSAXLE <FWD> - Transaxle Assembly22-23
50. REMOVAL OF SHIFT RAIL ASSEMBLY
(I 1 Shift the Ist-2nd speed shift fork to the 2nd speed.
(2) Shift the 3rd-4th speed shift fork to the 4th speed.
MD998325-01
II
MD998325-01
/I\I2010291(3) Remove the shift rail assembly.
INSPECTIONM22MOAB
BACKUP LIGHT SWITCHOperate the backup light switch to check continuity with a
circuit tester.If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLYMZZMGAX
54. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
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MANUAL TRANSAXLE <FWD> - Transaxle Assembly
63. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
MD998321-01
Oil seal2010041
50. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Set the 1 st-2nd speed shift sleeve at 2nd speed.
(2) Set the 3rd-4th speed shift sleeve at 4th speed.
(3) Fit the shift forks of shift rail assembly to groove of
sleeves.
‘LJ(4) Insert the shift rails into the shift rail holes of clutch
housing.
(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and the interlock
plate.48.49. INSTALLATION OF SPRING PINS
(1) Install the spring pins using the special tool or a pin
punch.
CautionDo not reuse the spring pins.
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MANUAL TRANSAXLE <FWD> - Transaxle Assembly
22-25
L
Slit
#Jl
Spring pin
/
II-+Shift rail1 I I201034
er
2150008
MD998325-01
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
35.37. 40. 42. INSTALLATION OF SPACERS
(1) Place two pieces of solder measuring about 10 mm (.4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If solder is not crushed, perform steps (1) to (4) with a
solder with a larger diameter.
(6) Measure the thickness of the crushed solder with a
micrometer and select and install a spacer of thicknessthat gives standard preload and end play.
Standard value:Input shaft end play
0
- 0.05 mm (0 - .002 in.)
Intermediate gear preload
0.05
- 0.10 mm (.002 - .004 in.)
Output shaft preload
0.05
- 0.10 mm (.002 - .004 in.)
Differential case preload0.05
- 0.10 mm (.002 - .004 in.)
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
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22-26MANUAL TRANSAXLE .<FWD> - Transaxle Assembly
Amountl-2 mm
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outer
race and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gearshaft’s head is facing in the direction indicated in the
illustration.
NOTE
If there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified’ sealant: MITSUBISHI genuinePart No. MD997740 or equiva-
lentLJ
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
[8 mm (.32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten thebolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
torque.(8) Tighten the reverse idler gear shaft bolt to specified
torque.16.15. INSTALLATION OF LOCK NUTS
(1) Install the special tool to the splined end of input shaft.(2) Screw a bolt
[lo mm (.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
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MANUAL TRANSAXLE <FWD> - Transaxle Assembly22-27
(3) Shift the transaxle in reverse using control lever and
select lever.
(4) Tighten the lock nut to specified torque, while using thebolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
IMD998245-01Spring pir
Shift rail
14. INSTALLATION OF SPRING PIN(1)
rr;‘tl.the spring pin using the special tool or a pin
CautionDo not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
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MANUAL TRANSAXLE <FWD> -5th Speed Synchronizer Assembly
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
TEMOl18
Disassembly steps
1. Reverse brake ringl *2. Synchronizer spring
3. Synchronizer sleeve
** 4. Synchronizer keyl *5. Synchronizer hub
@
/r /
JI,::. ‘..-‘. .\:’201045
INSPECTION
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check thatthey slide smoothly.
lCheck that the sleeve is free from damage at its inside front
and rear ends.l
Check for wear of the hub front end (surface in contact withthe 5th speed gear).
Caution
When replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRINGl
Check for wear of the synchronizer key center protrusion.
lCheck the spring for weakness, deformation and breakage.
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MANUAL TRANSAXLE <FWD> -5th Speed Synchronizer Assembly
22-29
i
Oil groove
Springprotrusion
201001a
SERVICE POINTS OF REASSEMBLY5. INSTALLATION OF SYNCHRONIZER HUB
/ 4. SYN-
CHRONIZER KEY / 2. SYNCHRONIZER SPRING
(1) Assemble the synchronizer hub, and key noting their
direction.
(2) Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
NOTETake care to prevent the projections of the front and
rear spring from sitting in the groove of the same key.
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MANUAL TRANSAXLE <FWD> - Input Shaft Assembly
INPUT SHAFT ASSEMBLY
MZZMICA
DISASSEMBLY AND REASSEMBLY2150009
Disassembly steps
l * l a1. Taper roller bearingl * *a2. Bearing sleeveI)+3.Snap ringl * l a4. Taper roller bearingl 45.Snap ring**6.Conespringl *7.Subgear
8. 4th speed gear
9.Needlebearingl * 10. Bearing sleeveII. Synchronizer ring
l * 12. 3rd-4th speed synchronizer assembly** 13. Synchronizer spring
14. Synchronizer sleeve
15. Synchronizer key
16.Synchronizer hub
17. Synchronizer ring
18.
3rd speed gear
19.Needle bearing20.Input shaft
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