Manual transaxle MITSUBISHI 3000GT 1991 Workshop 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.
rTSB Revision

22-34
MANUAL TRANSAXLE - Input Shaft Assembly
2nd speedi
MD99831 8-0121500147. INSTALLATION OF SUB GEAR
/ 6. CONE SPRING / 5.
SNAP RING
Install the sub gear and cone spring to 4th gear, and theninstall the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing in
the correct direction.
4. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using the
special tool.3. REASSEMBLY OF SNAP RING
(1) Select thickest possible snap ring which can enter the
snap ring groove.Standard value: 0.01
- 0.09 mm (.0004 - .004 in.)
(2) Using a special tool, attach the snap ring to the input
shaft.
Caution1. Don’t reuse the old snap ring.
2. If snap ring pliers are used, the snap ring may
sometimes be expanded excessively. This will
prevent proper mounting of the sleeve.
TSB Revision

MANUAL TRANSAXLE - Input Shaft Assembly22-35
i2. REASSEMBLY OF BEARING SLEEVE
(1) Using a special tool, fit the bearing sleeve to the input
shaft.
Caution
After fitting, check that the sleeve flange is closelyfit to the bearing.
1. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using the
special tool.
TSB Revision

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
TSB Revision
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 Assemblv
22-37
210022Spine
10. REMOVAL OF lST-ZND SPEED SYNCHRONIZER HUB /
12. 2ND SPEED GEAR
Remove the 1 st-2nd speed synchronizer assembly and 2ndspeed gear together using the special tool as illustrated.
14. REMOVAL OF TAPER ROLLER BEARINGUse 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.
INSPECTION
INTERMEDIATE GEAR
lCheck the outer surface of the intermediate gear where the
needle bearing is mounted for damage, abnormal wear andseizure [portion
@I.l Check the splines for damage and wear.
NEEDLE BEARINGl Combine the needle bearing with the shaft or bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.l Check the needle bearing cage for deformation.
TSB Revision

22-38
MANUAL TRANSAXLE - Intermediate Gear Assembly
Damage and breakage
TFMOllE
Syndhronizer ringGAarTFMOll:201045
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check paper lining on cone I.D. for damage, wear, and
flaking.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm
(.02 in.)
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.
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen 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.
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.
TSB Revision
1

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
TSB Revision

22-40
MANUAL TRANSAXLE - Intermediate Gear Assembly
MD998350-01
/
1 st-2ndspeedsynchronizer
assembly
MD998348-012100022
MD998350-01
1st speed
gear
20106
(2) Install the Ist-2nd speed synchronizer assembly over
the intermediate gear using the special tool.
Caution1. When installing the synchronizer assembly,
L/:make sure that three synchronizer keys are
seated correctly in respective grooves of the
synchronizer ring.2. After installation of the synchronizer assembly,
check that the 3rd speed gear rotates smoothly.3. INSTALLATION OF BEARING SLEEVE
Install the 1st speed gear and bearing sleeve together overthe intermediate gear using the special tool.
2. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the intermediate usingthe special tool.
Caution
When installing the bearing, push the inner race only.1. INSTALLATION OF SNAP RING
Select and install a snap ring that will result in an
intermediate gear bearing end play that is the standard
value.Standard value: 0.01
- 0.14 mm (.0004 - .006 in.)
TSB Revision

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.
TSB Revision1

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.
TSB Revision