brake MITSUBISHI 3000GT 1991 Workshop Manual

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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23-44AUTOMATIC TRANSAXLE - Troubleshootina
A/T SAFETY-LOCK SYSTEM TROUBLESHOOTINGbe selectedinto
Rfrom P by depressing
brake pedal with
ignition key in
position other than
LOCK.n or sagging outer cable(shift
loteck andadjust slide lever
ide lever and ca
Selector lever
Iperation from P to Rs not smooth.
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23-46AUTOMATIC TRANSAXLE - Service Adjustment Procedures
Fluid level must be
within this range.
TFA038:
SERVICE ADJUSTMENT PROCEDURE!5
MZ3FElBJ
TRANSMISSION FLUID LEVEL INSPECTION
1.Drive until the fluid temperature reaches the usual tempera-
ture
170 - 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.
4. Before removing dipstick, wipe all dirt from area
arouniddipstick. 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 transmission fluid until level
reaches “HOT” range.
Transmission fluid: MITSUBISHI PLUS ATF/Automatictransmission fluid “DEXRON”
abr“DEXRON II”
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, causing delayed shift,
slippy clutch and brakes, etc.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam
anldcause the same conditions which occur with low fluid level,
resulting in accelerated deterioration of automatic
transaxllefluid.
In 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.
TRANSMISSION FLUID REPLACEMENTM23FCBHRefer to GROUP 00
- Maintenance Service.
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AUTOMATIC TRANSAXLE - Service Adjustment Procedures23-47
MD998916-3-01
KICKDOWN SERVO ADJUSTMENTM23FRAC(1) Remove dust, dirt, and other contaminants completely fromkickdown (K/D) servo cover and surrounding areas.
(2) Snap off the snap ring and remove K/D servo switch.
(3) Fit claw of special tool into cutout in piston to prevent
piston from turning and use adapter to fix the piston into
position.
Caution
1. Do not push piston with the special tool.
2.Secure adapter only hand-tight to L/R brake press-
ure take-up port and do not apply
excessiwe torque.
(4) Loosen lock nut to immediately before V-groove in adjust
rod (see illustration on left) and tighten special tool (Inner
Wrench) until it contacts lock nut.
(5) Fit special tool (Outer Wrench) over the lock nut. Turn Outer
Wrench counterclockwise and turn inner cylinder clockwise
to lock the lock nut and special tool (Inner Wrench).
(6) Fit torque wrench to special tool (Inner Wrench) and repeat
tightening and loosening cycle two times with a torque of
10 Nm (7.2 ft.lbs.). Then, torque to 5 Nm (3.6 ftlbs.).Next, back off special tool (Inner Wrench) 2 to
2’/4 turns.
(7) Fit special tool (Outer Wrench) to lock nut.
Turn Outer Wrench clockwise and Inner Wrench counter-
clockwise to unlock the lock nut from special tool (Inner
Wrench).
Caution
Be sure to apply even torque to the two special tools
when unlocking.
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23-48AUTOMATIC TRANSAXLE - Service Adjustment Procedures
Adjusting screw4
or~0\====m00~7/IIIITFAm
c-1
Pi(8) Tighten lock nut by hand until it contacts piston. Then, using
torque wrench, tighten to specification.
Lock nut: 29 Nm (21
ftlbs.)Caution
Use of socket wrench or torque wrench could result in
lock nut being turned with adjust rod.
(9) Remove the special tool to secure the piston and torque
plug to specification at L/R brake pressure take-up port.
LINE PRESSURE ADJUSTMENT
(I) Discharge AFT.
(2) Remove oil pan.
(3) Remove oil filter.
(4) Remove oil temperature sensor.
M23FSAC(5) Press solenoid valve harness grommet catch to push in
grommet; then, remove valve body assembly.
Caution
Do not let manual valve fall.
(6) Turn adjusting screw of regulator valve to obtain the
specified line pressure
(K/D brake pressure).
Standard value:870
- 890 kPa (124 - 127 psi)
Oil pressure change for
each turn of adjustment screw:38
kPa (54 psi)
(7)Check that an O-ring is fitted at the location shown on top off
valve body.
(8) Replace O-ring of solenoid valve intermediate grommet
with a new one and then fit the O-ring into case.6
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AUTOMATIC TRANSAXLE - Service Adjustment Procedures23-49
1(9) Install valve body and oil temperature sensor.
Bolt A
= Length 18 mm (.709 in.)
Bolt B
= Length 25 mm (.984 in.)
Bolt C
= Length 40 mm (1.575 in.)
CautionSecure solenoid valve and oil temperature sensor
harness at locations shown.
(1O)lnstall oil filter.(1l)lnstall new oil pan gasket and oil pan.
(12)Add the specified amount of ATF.
(13)Carry out hydraulic test.
Readjust as necessary.
REDUCING PRESSURE ADJUSTMENTh323FfADWhen multi-use tester is not used
(1) Following the same steps as those in line pressure
adjustment, remove parts up to oil filter.
There is no need to remove valve body.
(2) Turn adjusting screw of lower valve body to obtain the
specified reducing pressure. Turn it counterclockwise to
increase the pressure.
Standard value:425 f 10 kPa (60 f 1 psi)
Oil pressure change for
each turn of adjusting screw:45 kPa (6 psi)(3) In the same way as in line pressure adjustment,
/nstall oil
filter and oil pan.
(4) Perform hydraulic test.
Adjust as necessary.
When multi-use tester is used
(1) Adjust to obtain the specified K/D brake pressure when PC
solenoid is energized at duty 50% with the multi-use tester.
Standard value:275 kPa (39 psi)
Oil pressure change for
each turn of adjusting screw:50 kPa (7 psi)(2) After adjustment has been made, check that the recuding
pressure is in the range 360
- 480 kPa (51 - 68 psi).
Caution
This adjustment should be made with oil temperature70
- 80°C (160 - 180°F).
The adjustment made with high oil temperature couldresult in improper adjustment due to a line pressure
drop at idle.
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23-50AUTOMATIC TRANSAXLE - service AdiustmentProcedures
09FO117
m09FOO19
L Pushbuttonv09FOO61
@ Button pressed (while brakepedal is depressed)c Button not pressed@ Button pressed
/\ \\ OSFODdACCELERATOR SWITCH INSPECTION AND
ADJUSTMENTM23FZAACheck that current flows between terminals of accelerator
switch when accelerator pedal is in free state and that no
dcurrent flows when the pedal is depressed and the specified
stroke A is obtained.
Standard value: 2
- 6 mm (.079 - .24 in.)
‘If stroke A is out of specification, adjust with adjusting bolt.
SELECTOR LEVER OPERATION CHECKM23FIAG
1.. Shift selector lever to each range and check that lever
moves smoothly and is controlled. Check that position
indicator is correct.
2.Check to be sure the selector lever can be shifted to each
position (by button operation as shown in the illustration).
3. Start the engine and check if the vehicle moves forward
dwhen the selector lever is shifted from N to
D, and moves
backward when shifted to R.
4.When the shift lever malfunctions, adjust control cable and
selector lever sleeve. Check for worn shift lever assembly
sliding parts.
I
NOTETo move the selector lever from the “P” position to any
other position, first turn the ignition key to any position
other than “LOCK” and depress the brake pedal.
KEY INTERLOCK MECHANISM CHECKM23FlJACCompletely stop the vehicle and switch OFF the engine before
making the check
1.Check to be sure that, under the following conditions, the
selector lever cannot be moved from the “P” position to
any other position.
Also check, at the same time, that the button cannot be
pressed.
Ignition key position: “LOCK” or removed
Brake pedal: Depressed
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AUTOMATIC TRANSAXLE - Service Adiustment Procedures23-51
D9N007SPush button
II
2.Check to be sure that, under the following conditions, the
selector lever can be moved from the “P” position to any
other position.
Press the button a few times and check to be sure that the
selector lever moves smoothly.
Ignition key position: “ACC”
Brake pedal: Depressed
Button
: Pressed
3.Check to be sure that, at all positions of the selector lever
(other than “P”), the ignition key cannot be turned to the
“LOCK” position.
Check to be sure that the ignition key smoothly turns to the
“LOCK” position when the selector lever is then set to the
“P” position and the button is released.
4. If above are not checked okay, adjust key interlock cable
mechanism as follows.
(1) Remove front console assembly.
(2) Place selector lever into “P” position.
(3) Turn ignition key to the “LOCK” position.
(4) Loosen nut that secures key interlock cable.
(5) Lightly pressing lock cam A in the direction of arrow,
lightly push key interlock cable to take up slack and
tighten nut to secure key interlock cable.
(6) Reinstall front console assembly.
SHIFT LOCK MECHANISM CHECKMZ3FVAC
1.
2.
3.
4.Check to be sure that, under the following
condi,tions, the
selector lever cannot be moved from the “P” position to
any other position.
Ignition key position: “ACC”
Brake pedal: Not depressed
Button: PressedCheck to be sure that, under the following conditions, the
selector lever can be moved smoothly from the “P”
position to other position.
Ignition key position: “ACC”
Brake pedal : Depressed
Button: PressedCheck to be sure that, under the following conditions, the
selector lever can be moved smoothly from the “R”
position to the “P” position.
Ignition key position: “ACC”
Brake pedal: Released
Button: PressedIf a malfunction is discovered when following the above
checking procedures, either adjust or check the shift lock
cable mechanism. (Refer to
P.23-56.)
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23-56AUTOMATIC TRANSAXLE - Transaxle ControlOQPOOQQ
09FOO5
INSPECTIONM231CAMl Check the control cable for function and for damage.
lCheck the outer cable (key interlock cable, shift lock cable)
’for damage and spring for breakage and tension.~J
lCheck the inner cable (key interlock cable, shift lock cable)
for extension.
REVERSE
(R) POSITION ALARM BUZZER
Check that the buzzer sounds when battery voltage is applied
across terminals.
SERVICE POINTS OF INSTALLATIONM231DAW
19. CONNECTION OF SHIFT LOCK CABLE (BRAKE PEDAL
SIDE)Connect the shift lock cable so that its threads measure
about 4 mm
(.16 in.).
CautionDo not change the routing of shift lock cable to the
selector lever assembly.
16. INSTALLATION OF SLIDE LEVER / 15. KEY INTERLOCK
CABLE (STEERING LOCK ASSEMBLY SIDE) / 14. CAM
LEVER(1) Place the ignition key at the “LOCK” position or keep it
removed.
(2) Install the slide lever, key interlock cable, and cam lever
to the steering lock assembly as shown.
Caution
Do not change the routing of key interlock cable tothe selector lever assembly.
5. CONNECTION OF TRANSAXLE CONTROL CABLE
(SELECTOR LEVER ASSEMBLY SIDE)Connect the transaxle control cable, then make the follow-
ing adjustment.
(1) Place the selector lever in “N” position.
(2) Loosen the nut and slightly pull the transaxle control
cable in the direction of the arrow; then, tighten the nut.
4.CONNECTION OF SHIFT LOCK CABLE (SELECTOR LEV-
ER ASSEMBLY SIDE)(1) Place the selector lever in “P” position.
(2) Disconnect the key interlock cable from the selector
lever assembly side.
(3) Turn the lock cam B counterclockwise (arrow
0) to
move the set lever upward (arrow
0)._.-(4) Frt the cutout in set lever to the jock pm ot lock cam B. u
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i
LJ
AUTOMATIC TRANSAXLE - Transaxle Assembly
DISASSEMBLY AND REASSEMBLY23-65
M23LEAN
11
Z:4.
::
;:9.10.11.
12.
13.
14.
15.
16.8
%&,kd!~~ / I!- 1A8 ii9
-114Torque converter~.I~I~~~ assembly
Thrust washer
#IFront clutch assembly
Thrust race #3
Thrust bearing #4Thrust washer #2Rear clutch assemblyThrust bearing #5Rear clutch hubThrust race #6Thrust bearing #7Kickdown bandKickdown drumSnap ring
17.Center support18.Wave spring19.Return spring
20.Pressure plate21.Brake disc
22.Brake plate
23.Reaction plate
24. Reverse sun gear
25. Thrust bearing #8
26. Thrust race #927. Forward sun gear
28. Planetary carrier asseml
29.Thrust bearing #I030.Output flange
31. Oil level gauge
32. Oil filler tube33.Snap ring34. Kickdown servo switch35.Snap ring26
25
24
TFA040936.
Kickdown servo piston37.Spring
38.Anchor rod39.Detent assembly
40. Manual control shaft
41. Parking roller support
42.Oilpan43.Gasket44. Oil temperature sensor45.Oil screen46. Valve body assembly
47. Manual control lever
48.Inhibitor switch
49. End clutch shaft
50.Bearing retainer51.Thrust bearing #I1
52. End clutch hub53.Thrust washer
54. End clutch assembly
55.O-ring56. End clutch cover57.Pulse generator
58:Lock bolt
59.Idler shaft
60.Idlergear
61.Spacer
62.Gasket
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