Manual transaxle MITSUBISHI 3000GT 1991 Repair Manual

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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22-54
MANUAL TRANSAXLE - Transaxle Control
TRANSAXLE
CONT.ROL
REMOVAL AND INSTALLATION
3
Pre-removal and Post-installationOperationl Removal and Installation of Front
Console Assembly
(Refer to GROUP 52A-Floor
Console.)
Transaxle control cable assembly removal stepsl * 1.
AirhoseA**2. Air cleaner cover, Air intake hose A** 3. Vacuum pipe
Shift lever assembly removal stepsl * 1.
AirhoseAI)+2. Air cleaner cover, Air intake hose A
l *
l *4. CD amp. (vehicles with CD player)3. Vacuum pipeI)*5. Connection for transaxle control cable
assembly (Shift lever assembly side)6. Retainer
7. Transaxle control cable assembly
5. Connection for transaxle control cable
assembly (Shift lever assembly side)
8. Shift lever assembly
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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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22-56
MANUAL TRANSAXLE - Transaxle Assembly
TRANSAXLE ASSEMBLY
REMOVAL AND INSTALLATION
Hose clamp4.0 Nm
Removal steps
Post-installation Operationl Installation of Transfer Assembly
(Refer to P.22-59.)l Supplying of Transmission Oil
(Refer to P.2351,)l Checking Operation of Shift Leverat Each Positionl Checking the Operation of Meters andGauges
MUMA-B~
19 Nm
13 f;t.lbs.
OSFOllO
1. Side under coverl *2. Air hose Al 43. Air cleaner cover, Air intake hose AI)* 4. Vacuum pipe5. Air cleaner element
6. Air cleaner body7. Battery
8. Battery seat, Washer tank
9. Connection for transaxle control cable
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MANUAL TRANSAXLE - Transaxle Assembly
22-57
45 Nmaa 33ftlbs..,.,
31 Nm
09FOO91.15
28
50-72Nm43 - 52 ft.lbs.
\
22 ftlbs.9.0Nm
4.0 ftlbs.
10. Connection for clutch tube bracket11. Connection for clutch release cylinder
12. Connection for transaxle mount
13. Plug
14. Transaxle mount bracket (Body side)I)* 15. Mounting stopper16. Transaxle mount bracket (Transaxle side)17. Transaxle assembly lower part
coupling bolt
4*18. Connection for tie rod endl *19. Connection for lower armball joint
20. Right member
21. Starter cover
22. Starter
Mb23. Drive shaft (Left side),Inner shaft assembly+* l * 24. Drive shaft (Right side)25. Connection for transaxle stay (Front bankside)26. Connection for transaxle stay(Rear bank side)27. Transaxle assembly lower part
coupling bolt
28. Transaxle assembly
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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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MANUAL TRANSAXLE - Transaxle Assembly22-61
MD99,8812
5. INSTALLATION OF INPUT SHAFT REAR SEAL CAPInstall the input shaft rear seal
.cap.
2. INSTALLATION OF TRANSFER CASE OIL SEAL
Using the special tool, install the transfer case oil seal.
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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.