service MITSUBISHI 3000GT 1991 Service Manual

22-52 MANUAL TRANSAXLE - Service Adjustment Procedures
DRIVE SHAFT OIL SEALS REPLACEMENTMZZFDAJ)(I) Disconnect the drive shaft from the transaxle.
(Refer to GROUP 26
- Drive Shaft.)
(2) Remove the transfer assembly.ij(3) Using a flat-tip
(-) screwdriver, remove the oil seal.
L.H. side\
For L.H.
Dust seal.
For R.H.(4) Install the oil seals using the following procedure:Using the special tool, tap the oil seal into the transaxle.
Note that there are two types of oil seals, one for R.H. and
the other for L.H., and the shape of each type is different,
as shown.
(5) Drive shaft
011 seal must be installed in the direction shown.(6)
$4~1~ a coatrng of the transmission oil to the lip of the oil
Transmission oil: Hypoid gear oil, SAE
75W-90 or
75W-85W conforming to API classi-fication GL-4 or higher
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MANUAL TRANSAXLE -Service Adjustment Procedures / Shift Lever Assembly22-53
Front exhaust p6eU.09FOO64
& MD998304-01
LJ -3 ‘=-----XL I
TRANSFER OIL SEAL REPLACEMENTMUFGAH
(1) Pull out the propeller shaft from the transfer. (Refer to
GROUP 25 - Propeller Shaft.)
(2) Using a flat-tip (-) screwdriver, remove the oil seal.
(3) Using the special tool, tap the drive shaft oil seal into the
transfer.
(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
SPEEDOMETER CABLE REPLACEMENTMZ2FEAH
Refer to
P.22-9.
SHIFT LEVER ASSEMBLYRefer to
P.22-13.M22GE-B
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MANUAL TRANSAXLE - Transaxle Control22-55
03FOO
Air‘mtakehose A Air intake
hose C
Air intake hose B05FOO2:
Air hose A
05FOOZE
8
INSPECTIONM22JCAFZ
lCheck the transaxle control cable assembly for function and
for damage.l Check the boot for damage.
lCheck each bushing for wear or abrasion, sticking, impeded
action, and damage.
SERVICE POINTS OF INSTALLATIONM22JDAM5.
CdNNECTlON OF TRANSAXLE CONTROL CABLE
ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE)Refer to
P.22-12.3. INSTALLATION OF VACUUM PIPE
If the vacuum pipe has a stepped part, connect the vacuum
hose to the pipe securely, up to the stepped part, as shownin the figure.
2. CONNECTION OF AIR CLEANER COVER, AIR INTAKE
HOSE A
Align slots indicated by arrows in air intake hose A with n
markings on air intake hoses B and C; then, insert hoses Band C all the way into air intake hose A.
1. CONNECTION OF AIR HOSE A
Connect the hoses ensuring that paint marks are alignedwith projections.
Insert air hoses B and C into air hose A all the way, or up tothe step in hose A.
Caution‘Be careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.
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22-58
MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF REMOVALMPMBBB11. REMOVAL OF CLUTCH RELEASE CYLINDER
/ 12.
CONNECTION OF TRANSAXLE MOUNT
Refer to
PZ-15.‘L-J
18. DISCONNECTION OF TIE ROD END / 19. LOWER ARM
BALL JOINTRefer to
P.22-16.
23. REMOVAL OF DRIVE SHAFT (LEFT SIDE), INNER SHAFTASSEMBLY
/ 24. DRIVE SHAFT (RIGHT SIDE) / 27.
TRANSAXLE ASSEMBLY LOWER COUPLING BOLT / 28.
TRANSAXLE ASSEMBLYRefer to
P.22-16.
SERVICE POINTS OF INSTALLATIONM22MDAU24. INSTALLATION OF DRIVE SHAFT (RIGHT SIDE)
/ 15.
MOUNTING STOPPERRefer to
P.22-17.
03FOOE
Air intake hose B
05FOO23
Air hose A
Air hoseC/4. INSTALLATION OF VACUUM PIPE
If the vacuum pipe has a stepped part, connect the vacuum
hose to the pipe securely, up to the stepped part, as shownin the figure.
3. INSTALLATION OF AIR CLEANER COVER, AIR INTAKE
HOSE A
Align slots indicated by arrows in air intake hose A with LI
markings on air intake hoses B and C; then, insert hoses Band 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.2. INSTALLATION OF AIR HOSE A
Connect the air hoses ensuring that alignment marks arealigned 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.
#L.&J
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MANUAL TRANSAXLE - Transfer Assemblv
22-59
TRANSFER.ASSEMBLY
REMOVAL AND INSTALLATION
M22VA- _
i
Pre-removal and Post-installation
Operation
l Draining and Supplying of Transfer Oil(Refer to P.22-51.)l Removal and Installation of Active Front
Venturi Skirt
(Refer to GROUP 51 -Front Bumper.)
l Removal and Installation of Front ExhaustPioe
(defer to GROUP 15 - Exhaust Pipe andMain Muffler.)
7
09FOOO6
1. Transfer assembly85-
61 -
* \Sleeve yokelOGO
Gear oil: Hypoid gear oil, SAE 75W-90or 75W-85W conforming to APIclassification GL-4 or higher
I09FOOO8 I09FOOO9 I09AOO27
SERVICE POINT OF REMOVALM22VBAC1. REMOVAL OF TRANSFER ASSEMBLY
Caution
1.Be cautious to avoid damaging the transfer oil seal
lip.
2.Cover the transfer opening with the special tool toprevent transaxle oil discharge and the entry of
foreign objects.
3.The propeller shaft should be suspended so that it isnot sharply bent.
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22-60MANUAL TRANSAXLE - Transaxle Assembly
TRANSAXLE ASSEMBLY
The W5MGl transaxle cannot be disassembled.
If any parts other than describes below are defective, replace the transaxle assembly.
REPLACEABLE PART
1.l * 2.
3.
*a 4.l 4 5.6.
Transaxle to transfer connecting boltTransfer case oil seal
Transfer oil seal guide
Input shaft rear seal cap
Center shaft oil sealAir vents (breather caps) for transaxle and
transfer
Oil filler plugs for transaxle and transfer
Oil drain plugs for transaxle and transfer
TFM0157
SERVICE POINTS OF INSTALLATION6. INSTALLATION OF CENTER SHAFT OIL SEAL
Fabricate a tool having the following dimensions from a
pipe to install the oil seal.
Dimension :
I.D.. . . ..___........._...................... Approx. 27 mm (1.06 in.)
O.D.
. . . . . .._...........___............_.....Approx. 31 mm (1.22 in.)
Length . . . . . . . . . . . . . . . ..__......._____.Approx. 200 mm (7.87 in.)
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23-1
AUTOMATIC
TRANSAXLE
CONTENTSMZJAA- _
ANNULUS GEAR AND TRANSFER DRIVE GEARTransmission Fluid Level Inspection................................46SET................................................................................................
102Transmission Fluid Replacement........................................
46
DIFFERENTIAL........................................................................104SPECIAL TOOLS........................................................................
16
:......................................... 12IEND CLUTCH ASSEMBLY....................................................99SPECIFICATIONS..........................
FRONT CLUTCH ASSEMBLY................................................95
GENERAL INFORMATlON....................................................2
KICKDOWN SERVO................................................................
107
LOW-REVERSE BRAKE............................................................
107
OIL PUMP....................................................................................93
PLANETARY GEAR................................................................
100
REAR CLUTCH ASSEMBLY....................................................97
SELECTOR LEVER ASSEMBLY............................................58
SERVICE ADJUSTMENT PROCEDURES............................46
Accelerator Switch
Inspection and Adjustment................
50Drive Shaft Oil Seals Replacement....................................
52Inhibitor Switch and Control Cable Adjustment................
52Key Interlock Mechanism Check........................................50KickdownServo Adjustment................................................
47Line Pressure Adjustment....................................................
48Reducing Pressure Adjustment........................................
49Selector Lever Operation Check........................................
50Shift Lock Mechanism Check............................................51Speedometer Cable Replacement....................................53
General Specifications........................................................12Lubricants............................................................................15Service Specifications........................................................12Spacer and Snap Ring........................................................13Valve Body Spring Identification Chart............................13
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................106
TRANSAXLE ASSEMBLY........................................................62
TRANSAXLE CONTROL*........................................................54
TRANSAXLE OIL COOLER, HOSES, TUBES
....................66
TRANSFER SHAFT....................................................................92
TROUBLESHOOTING............................................................
19
A/T Safety-lock System Troubleshooting........................44Converter Stall Test............................................................
43
Diagnosis and Test
................................................................
22
Element in Use at Each Position of Selector Lever........31Inspection
of ControlSystem............................................
28Inspection of Electronic Control System Components....32Oil Pressure Tests................................................................
39ShiftPatterns....................................................................
31,42Troubleshooting Guide........................................................
20
VALVE BODY. . . .._._.................................................................... 108
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3668GT.(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 beremoved/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 topersonal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from
rendering 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) MlTSUBISHI 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 the
ISRS or any SRS-related component.

23-12AUTOMATIC TRANSAXLE - Specifications
SPECIFICATIONSGENERAL SPECIFICATIONS~
M23CA.C
Items
Model
TypeTorque converter
WeEngine stall speed
Stall torque ratioSpecifications
F4A33-I-MNN2Full automatic
4 speed transaxle
3 element with damper clutch
2,200- 3,200 rpm
1.80Transaxle
TypeGear ratio
First
Second
Third
Fourth
Reverse
Final gear ratio
Speedometer gear ratio (Drive/Driven)Electronically controlled4-speed full-automatic
2.551
1.488
1.000
0.6852.176
3.95836128
SERVICE SPECIFICATIONS
M23CB-Cmm (in.)
‘dterns
Standard value
Accelerator switch switching point
Sleeve and selector lever assembly end play
Transfer driven gear preload
Low-reverse brake end playSpecifications
2
- 6 (.079 - .24)
15.2
- 15.9 (598 - .625)0.075-0.135
(.0030- .0053)1
.O - 1.2 (.0394 - .0472)Input shaft end play
0.3
- 1 .O t.0118 - .0394)Differential case preload
0.075
- 0.135 (0030 - .0053)Differential gear and pinion backlash
0.025
- 0.150 LOOI 0 - .0059)Oil pump side clearance
0.03
- 0.05 (.0012 - .0020)Output flange bearing end play
0
- 0.09 (0 - .0035)Front clutch end play
0.8
- 1 .O (0315 - .0394)Rear clutch end play
1 .O - 1 .j (.0394- .0472)End clutch end play
0.60
- 0.851.0236 - .0335)
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23-22AUTOMATIC TRANSAXLE - Troubleshooting
0”
TM362
DIAGNOSIS AND TEST
FLUID LEVEL AND CONDITION
1.Drive until the fluid temperature reaches the usual tempera-
ture
[70 - 80°C (160 - 18O”F)].2. Place vehicle on level floor.
3. Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position. This operation is necessary to
be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the condition
of the fluid.
The transaxle should be overhauled under the following
conditions.
l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
lIf there is a noticeably great amount of metal particles in
the fluid.
5.Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add automatic transaxle fluid until level
reaches “HOT” range.
Low fluid level can cause a variety of conditions because it
allows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of automatic transaxle
fluid.
dIn either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch, and
servo operation. Foaming can also result in fluid escaping
from transaxle vent where it may be mistaken for a leak.
6. Be sure to examine fluid on dipstick closely.
,CONTROL CABLEWhether control cable is properly adjusted can be confirmed by
checking whether inhibitor switch is performing well.
1. Apply parking brakes and service brakes securely.
2. Place selector lever to “R” range.
3. Set ignition key to “ST” position.
4. Slowly move the selector lever upward until it clicks as it
fits in notch of “P” range. If starter motor operates when
lever makes a click, “P” position is correct.
5.Then slowly move selector lever to “N” range by the same
procedure as in foregoing paragraph. If starter motor
operates when selector lever fits in
“N”, “N” position is
correct.
6. Also check to be sure the vehicle doesn’t begin to move
and the lever doesn’t stop between P-R-N-D.
7. The control cable is properly adjusted if, as described
above, the starter motor starts at both the “P” range and
the “N” range.
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AUTOMATIC TRANSAXLE - Troubleshootinn23-43
CONVERTER STALL TESTStall test consist of determining maximum engine
speed obtained at full throttle in “D” and
“I?”positions. This test checks torque converter
statoroverrunning clutch operation, and holding ability of
transaxle clutches and low-reverse brake.
Caution
During this test, make sure that no one stand in
front of or behind vehicle.
1. Check transaxle fluid level. Fluid should be at
normal operating temperature
[70 - 80°C (160 -
18O”F)I. Engine coolant should also be at normal
operating temperature
[80 - 90°C (180 - 19O”F)l.2. Apply chocks to both rear wheels.
3. Attach engine tachometer.
4. Apply parking and service brakes fully.
5. Start engine.
6. With selector lever in “D” position, depress
accelerator pedal fully to read engine maximum
rpm. Do not hold throttle wide open any longer
than is necessary to obtain maximum engine
rpm reading, and never longer than 5 seconds at
a time. If more than one stall test is required,
operate engine at approximately 1,000 rpm in
neutral for 2 minutes to cool transaxle fluid
between tests.
Stall speed: 2,200
- 3,200 rpm
7.Place selector lever to “R” position and perform
stall test by the same procedure as in foregoing
item.
Stall Speed Above Specification in “D”
If stall speed is higher than specification, rear clutch
or overrunning clutch of transaxle is slipping. In this
case, perform hydraulic test to locate cause of
slippage.
Stall Speed Above Specification in “R”
If stall speed is higher than specification, front
clutch of transaxle or low-reverse brake is slipping.
In this case, perform hydraulic test to locate cause
of slippage.
Stall Speed Below Specification in “D” and “R”
If stall speed is lower than specification, insufficient
engine output or faulty torque converter is sus-
pected. Check for engine misfiring, ignition timing,
valve clearance, etc. If these are good, torque
converter is faulty.
TRANSAXLE CONTROL
Symptom
Selector lever operationis stiff
Probable cause
Incorrect adjustment of sleeve
Remedy
Adjust
Incorrect adjustment of control cable
Excessive wear of detent plate
Worn contact surfaces of pushbutton
and sleeve
Adjust
Replace
Replace
Starter motor does notMalfunction in inhibitor switchReplace
operate with the selector
lever in the “N” or “P”Incorrect adjustment of control cableAdjust
position
Will not shift to
4-speed
Malfunction of starter relay
Malfunction of OD switchReplace
Replace
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