service MITSUBISHI 3000GT 1991 Service Manual

MANUAL TRANSAXLE - Input Shaft AssemblY22-33
SpriprotKey2010018
MD998348-01
SPEED -GEARS
lCheck the bevel gear and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough surface, damage
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
13. INSTALLATION OF SYNCHRONIZER SPRING
Assemble the synchronizer spring so that its projection maybe engaged in the groove of the synchronizer key.
Take care to prevent the projections of the front and rearspring from sitting in the groove of the same key.
12. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(I) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove atthe hub end.
NOTE
If the installation is in the opposite way, press-in mightnot be possible. This is because the edge of the hub
inner diameter spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
CautionWhen installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-
rectly in respective grooves of the synchronizer
ring.(3) Check the 3rd speed gear rotates smoothly.
10. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.
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22-36MANUAL TRANSAXLE - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLY
IMZZMJAS
DISASSEMBLY AND REASSEMBLY
64
I
Disassembly steps
I)* 1. Snap ringl * **2. Taper roller bearing
** 3. Bearing sleevel *4. 1 st speed gear
5. Needle bearing
l a6. Synchronizer ring
l **C7. Synchronizer spring8. 1 st-2nd speed synchronizer sleeve
I)* 9. Synchronizer key*I) I)+ IO. 1 st-2nd speed synchronizer hubl * 11. Synchronizer ringl *12. 2nd speed gear13. Needle bearing** l * 14. Taper roller bearing
d
I
15. Intermediate gear-
MD998348-01
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SERVICE POINTS OF DISASSEMBLY
2.REMOVAL OF TAPER ROLLER BEARING / 4.1ST SPEED
GEARRemove the taper roller bearing, 1 st speed gear and bearing
sleeve using the special tool as illustrated.
Caution1. Do not reuse the bearing removed from the shaft.
2.Replace the inner and outer races of the taper rollerbearing as a set.d

MANUAL TRANSAXLE - Intermediate Gear Assembly
22-39
/
MD998350-01
Identificationmark
Front +
Identi-
fication
markSERVICE POINTS OF REASSEMBLY
14. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearingusing the special tool.over the intermediate gear
Caution
When installing the bearing, push the inner race only.
Springprotrusion11.8. INSTALLATION OF SYNCHRONIZER RINGS
The 1 st speed synchronizer ring has an identification mark.
10. INSTALLATION OF lST-2ND SPEED SYNCHRONIZERHUB
/ 9. SYNCHRONIZER KEY / 8. lST-2ND SPEED
SYNCHRONIZER SLEEVE / 7. SYNCHRONIZER SPRING(1) Combine the Ist-2nd speed synchronizer hub and
sleeve as illustrated.
(2) Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
NOTE
(1) Take care to prevent the projections of the front andrear spring from sitting in the groove of the same
key.(2) A synchronizer spring of a different shape from
what is shown may be installed; however, there isno difference in installation procedure.
i
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MANUAL TRANSAXLE - Output Shaft.Assembly22-41
OUTPUT SHAFT ASSEMBLYMZZMKAH
DISASSEMBLY AND REASSEMBLY
L
/
id
I I
SERVICE POINTS OF DISASSEMBLY
8Press1. 2. REMOVAL OF TAPER ROLLER BEARINGS
Remove the taper roller bearing using the special tool asillustrated.
Caution
1.Do not reuse the bearings removed from the shaft.
2.Replace the inner and outer races of the taper rollerbearing as a set.
Disassembly steps**
l *I. Taper roller bearing*I) I)*2. Taper roller bearing3. Output shaft
210028
71 nn75
MD998350-01
SERVICE POINTS OF REASSEMBLY1. 2. INSTALLATION OF TAPER ROLLER BEARINGS
Install the taper roller bearing using the special tool.
Caution
When installing the bearing, push the inner race only.
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22-42MANUAL TRANSAXLE - Shift Rails and Forks
SHIFT RAILS AND FORKSMZZMLAF
DISASSEMBLY AND REASSEMBLY
7-5i-s
Disassembly steps
1.1st-2ndspeedshiftfork2.1st-2ndspeedshiftrail3. 3rd4th speed shift fork
4. 5th-reverse speed shift raill a5. Interlock plunger
6. 3rd-4th speed shift rail
7. Reverse shift lug
201073
InterlockReverse shift lugSERVICE POINT OF REASSEMBLY5. INSTALLATION OF INTERLOCK PLUNGER
Insert the interlock plunger at illustrated position of the
3rd-4th speed shift rail.
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MANUAL TRANSAXLE - Differential Assembly22-43
DIFFERENTIAL ASSEMBLY
IDISASSEMBLY AND REASSEMBLY
Disassembly steps
** 1. Bolt2. Differential drive gear** *+3. Taper roller bearingl * l +4. Lock pinl *5. Pinion shaftl * 6. Pinion
l * 7. Washer
** 8. Side gearl *9. Spacer (Select)10. Differential caseTFM0054
/Adhesive: 3M Stud Locking- . .] _PartNo.417Ooreqr
130-i40Nnl94- 101 ft.lbs.
Press
ti Bearmg
SERVICE POINTS OF DISASSEMBLY
3. REMOVAL OF TAPER ROLLER BEARING
Remove the taper roller bearing using the special tool as
illustrated.
Caution1. Do not reuse the bearing removed from the dif-
ferential case.
2.Replace the inner and outer races of the taper rollerbearing as a set. ,
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22-44MANUAL TRANSAXLE - Differential Assembly
Lock pin
Pinion shaft
2 150020160124
Differen-ock pinend with4. REMOVAL OF LOCK PIN
Drive out the lock pin from the hole A using a
punch.
:,,)
SERVICE POINTS OF REASSEMBLY9. INSTALLATION OF SPACER
/ 8. SIDE GEAR / 7.
WASHER
/ 6. PINION / 5. PINION SHAFT
(I 1 Install the spacer on the back of the side gear and theninstall the gear in the differential case.
CautionWhen installing a new side gear, use a spacer of
medium thickness
[0.93 - 1.00 mm (.036 - .04 in.)].
(2) Set the washer on the back of each pinion and insert the
two pinions to specified position while engaging themwith the side gears and turning them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gears and
pinions.Standard value: 0.025
- 0.150 mm (.OOl - .006 in.)
(5) If the backlash is out of specification, disassemble againand using correct spacer, reassemble and adjust.
CautionAdjust for same backlash of both side gears.
4. INSTALLATION OF LOCK PIN
Align the pinion shaft lock pin hole with the case lock pin
hole and insert the lock pin.
Caution1. Do not reuse the lock pin.
2. The lock pin head must be sunk from the flange
surface of the differential case.
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MANUAL TRANSAXLE Differential Assembly / Speed-
- ometer Driven Gear Assembly22-45
TFYOO4Q
The numerals @to @ indicate
the tightening sequence.
9
SPEEDOMETER DRIVEN GEAR ASSEMBLY
DISASSEMBLY AND REASSEMBLY
3. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearings on both sides of the
differential case.
CautionWhen press-fitting the bearings, push the inner race
only.
1.INSTALLATION OF BOLTS
Apply specified adhesive to the entire threads of the bolts
and quickly tighten in the order shown to specified torque.
Specified adhesive: 3M Stud Locking Part No. 4170 or
equivalent
CautionIf a bolt is reused, remove traces of oil adhesive
completely from the threads.MZ2MNAE
Disassembly steps
I. O-ringl *2. Spring pin
l *3. Speedometer driven gear4. Oil seal
5. Sleeve201078
201075
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF SPEEDOMETER DRIVEN GEAR
Apply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft.
2. INSTALLATION OF SPRING PIN
Install the spring pin in such a way that its slit does not facethe gear shaft.
J
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MANUAL TRANSAXLE - Clutch Housing Assembly22-47
1
Oil sealSocketwrench
SERVICE POINTS OF DISASSEMBLY6. REMOVAL OF LOCK PIN
Drive out the lock pin from the control finger using the pin
punch.
CautionWhen removing the lock pin, turn the control lever to
such position that the lock pin will not contact the
clutch housing.7. REMOVAL OF SPRING PIN
Drive out the spring pin from the stopper body using the pin
punch.
Caution
When removing the spring pin, pull the control shaft inthe direction illustrated so that the spring pin will not
contact the clutch housing.
SERVICE POINTS OF REASSEMBLY
17.16. INSTALLATION OF NEEDLE BEARINGSInstall the needle bearing flush with the surface A of the
clutch housing.
15. INSTALLATION OF OIL SEALInstall the control shaft oil seal using a socket wrench.
7. INSTALLATION OF SPRING PIN
/ 6. LOCK PIN
(I) Install new spring pin and lock pin using the special tool.
CautionDo not reuse the spring pin and lock pin.
(2) Install the spring pin with its slit at right angle to the
control shaft center.
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MANUAL TRANSAXLE - Service Adjustment Procedures22-51SERVICE ADJUSTMENT PROCEDURES
TRANSMISSION OIL LEVEL INSPECTIONM22FBAE2
Refer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEiVlENTMUFCAJ
(I) Position vehicle on a flat level and remove filler and drainplugs to drain transmission oil.
(2) Pour in fresh transmission oil through filler port.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherTransaxle: 2.4 liters (2.5 qts.)
Transfer: 0.27 liters
(.29 qts.)
(3) After checking to be sure that the oil level is the specifiedlevel, tighten the filler plug at the specified torque.
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