differential MITSUBISHI 3000GT 1991 Service Manual

00-18
GENERAL - Towing and Hoisting
Frame contact support location:
1,070 mm (42.0 in.): 1,130 mm (44.0 in.) OOFOO3'
Front OOFO046HOISTING
POST TYPESpecial care should be taken when raising the vehicle on a
\frame contact type hoist. The hoist must be equipped with theL)proper adapters in order to support the vehicle at the proper
locations.
Caution
When service procedures require removing rear suspen-sion, fuel tank, spare tire and liftgate, place additional
weight on rear end of vehicle or anchor vehicle to hoist toprevent tipping of center of gravity changes.
FLOOR JACKThe usual type of floor jack is used at the following locations.
Front: Under the mid point of No. 1 crossmember
NOTEOn vehicles with active-aero system, the front jacking point
can be accessed by removing the center cover panel from
the under cover. Be sure to reinstall the center cover panel
after jack-up operation.
Rear:
Under the jack up bracket of crossmember
Under the rear differential
Caution1. When lifting the No. 1 crossmember, do not allow jack
lifting plate to contact under cover.
2. In order to prevent scarring the crossmember, place a
piece of cloth on the jack’s contact surface (to prevent‘corrosion caused by damage to the coating).
d3. A floor jack must never be used on any part of the
underbody.
4.Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.This practice may result in permanent damage to the
body.
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GENERAL - Scheduled Maintenance Table00-35
SCHEDULED MAINTENANCE TABLE
MOOOA- _SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER
L VEHICLE PERFORMANCE
Inspection and services should be performed any time a malfunction is observed or suspected. Retain
receipts for all vehicle emission services to protect your emission warranty.
No, Emission Control SystemServiceKilometersinThousands 24 48 72 80 96
MaintenanceIntervalsMileage in Thousands 15 30 45 50 60
1Check Fuel System (Tank. Line and Connections and Fuel Filler Cap) forLeaks Every 5 Yearsorx
2Check Fuel Hoses for Leaks or Damage Every 2 YearsorXX
3Replace Air Cleaner ElementatXX
4Replace Spark PlugsatXGENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE
-
10.
-
5-
6-
7
-
8
-
9-
10
-
11-
12-
13
-
14
-
15
-
16
-
17
-
General Maintenance
Automatic Transaxle Fluid
Exhaust System (ConnectionCheck and Service as RequiredPortion of Muffler, Pipings andEvery 2 YearsorXXConverter Heat Shields)
NOTELSD: Limited-slip differential
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GENERAL - Maintenance Service00-43
15. DRIVE SHAFT BOOTS (Inspect for grease
leaks and damage)
MOOSBJD1. These components, which are permanently lubricated at
the factory, do not require periodic lubrication. Damaged
boots should be replaced to prevent leakage or contamina-
tion of the, grease.
2.Inspect the boots for proper sealing, leakage and damage.
Replace it if defective.
16. REAR AXLE (CONVENTIONAL DIFFEREN-
TIAL) (Inspect oil level)
- AWDMOOSBPDRemove the filler plug and inspect the oil level at bottom of filler
hole. If the oil level is slightly below the filler hole, it is in
satisfactory condition.
16. REAR AXLE (LIMITED-SLIP DIFFERENTIAL)
(Oil change)
- AWDMOOSBQEBefore changing the rear axle oil, check to make sure that there
is no oil leakage from the rear axle housing.
Remove the drain plug and drain out of the oil.
Put the oil plug
,back in place, and then pour new oil in through
the filler hole.
17. EXHAUST SYSTEM (CONNECTION PORTION
OF MUFFLER, PIPINGS AND CONVERTER
HEAT SHIELDS) (Check and service as re-
quired)
MOOSBLB1. Check for holes and gas leaks due to damage, corrosion,
etc.
2. Check the joints and connections for looseness and gas
leaks.3. Check the hanger rubber and brackets for damage.
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00-44
GENERAL - Main Sealant and Adhesive Table
MAIN SEALANT AND ADHESIVE TABLEMWZA- -
ApplicationRecommendedbrand
1. Sealants for engine accessories
(I 1Sealing between rocker
3M ATDcover and camshaft
Part No. 8660
bearing cap
(4G6 DOHC and 6G7or equivalent
engines only)
(2) l Sealing between semi-3M ATD
circular packing and
Part No. 8660
rocker cover and between
semi-circular packing andor equivalent
cylinder head
l Oil pressure switch
(except 4Gl and 6G7engines)
(3) Engine coolanttemperature switch,Engine coolanttemperature sensor,Therm0 valve,Therm0 switch, Joints,Engine coolanttemperature gauge unit(large size)
3M Nut LockingPart No. 4171
or equivalent
(4) Engine coolanttemperature gauge unit(;.s;il size, MD091 0563M ATDPart No. 8660
or equivalent
(5) Oil pan(except 4G5 engine)MITSUBISHI
GENUINE Part No.
MD9971 10or equivalent
2. Sealing between glass and
weatherstrip
(I 1 l Sealing between
tempered glass and
weatherstrip
l Sealing between body
flange and weatherstrip3M ATD
Part No. 8513or equivalent
3M ATD
Part No. 8509or equivalent
(2) Sealing betweenlaminated glass andweatherstrip
3. Adhesion with ribbon sealer
l Waterproof film for doorl Fender panell Splash shieldl Mudguardl Rear combination lamp
3M ATDPart No. 8509
or equivalent
3M ATDPart No. 8625or equivalent
ApplicationRecommended
brand
4. Adhesives for interior trim
(1)Adhesion of polyvinyl-chloride sheet3M Part No.EC-l 368or equivalent
(2)Adhesion of door
3M ATD
weatherstrip to body
Part No. 8001 or3M ATDPart No. 8011or equivalent
(3) Sealing betweengrommet or packing and
metal seal
(4) l Adhesion of headliningand other interior trimmaterialsl Adhesion of fuel tank
to pad
3M ATDPart No.851 3or equivalent3M
Part-No.
EC-l 368
or 3M ATD Part No.
8080 or equivalent
5. Body sealant3M ATDl Sealing of sheet metal,
Part No. 8531 or
drip rail, floor, body side3M ATDpanel, trunk, front panel and
Part No.8646the like jointsl Sealing of tailgate hingesor equivalent
6. Chassis sealant
(I 1 l Sealing of flange surfaces3M ATD
and threaded portions
Part No. 8659l Fuel gauge unit packingor equivalent
(2)Sealing of flange surfaces,3M ATD
threaded portions, packingPart No.8663
and dust cover
l Differential carrier packingor equivalent
l Dust covers for ball jointand linkage
l Steering gear box packing
and shims
l Steering gear housingrack support cover andtop coverl Mating surface of knucklearm flange
(3)Sealing between accelerator
arm bracket and toeboardDrying sealant
(4)Sealant for drum brakeshoe hold-down pin andwheel cylinder3M ATDPart No.851 3or equivalent
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GENERAL - Main Sealant and Adhesive Table
I,i
ApplicationRecommendedbrand
7. Fast bonding adhesive
Adhesion of all materials3M ATD
except polyethylene, poly-Part No. 8155propylene, fluorocarbon resinor equivalentor other materials withhighly absorbent surface
8. Anaerobic fast bonding
adhesives
(I) Fixing of bolts and screws3M Stud lockingl Tightening of drive gearPart No. 4170to differential caseor equivalentl Bolts for coupling tilt
steering upper column
with lower column
(2) Fixing of bearing, fan, pulley
and gear connections
(3) Sealing of small recess or
flange surface
(4)Steering angle stopper bolt
(jeep)
3M Nut lockingPart No. 4171or equivalent
9. Undercoat3M ATD
Part No. 8864
or equivalent
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ENGINE - Service Adjustment Procedures11-15COMPRESSION PRESSURE CHECKMllFFAK
(1) Before checking compression, ensure that engine oil, the
starter motor, and battery are all in normal operating
condition.
(2) Start the engine and wait until engine coolant temperature
has risen to 80
- 95°C (176 - 205°F).
(3) Remove the all spark plugs.
(4) Crank the engine to remove any foreign objects in the
cylinders.
CautionCover the spark plug holes with shop towel, etc., in
order to keep expelled foreign objects from flying out,and keep away from the holes. When measuring
compression with water, oil, or fuel having entered the
cylinder through a crack, etc., these will come flying out
of the spark plug hole hot and fast, so be sure to take
the proper precautions.(5) Set the compression gauge to the spark plug hole.
(6) Holding the throttle valve full open, crank the engine and
measure compression.
Limit:
min. 980 kPa (139 psi)
min. 810 kPa (115 psi)(7) Perform (5) and (6) above for all the cylinders, ensuring that
compression pressure differential for each of the cylinders
is within the specified limit.
Limit: max.
100 kPa (14 psi)
(8) If a cylinder’s compression or pressure differential exceeds
the limit, add a small amount of oil through the spark plug
hole and repeat steps (5)
- (7).@If the addition of oil brings compression up, it is possible
that there is
harmf,uI friction between the piston ring
and cylinder wall.@If not compression up, valve seizure, poor valve seating,
or a compression leak from the gasket are all possible.
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22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE . . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE ....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT.(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 be
removed/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 to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (fromrendering 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) MITSUBISHI 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 theSRS or any SRS-related component.

22-2MANUAL TRANSAXLE - General Information
MANUAL TRANSAXLE
GENERAL INFORMATIONM226AAU
F5M33
R Cl/utch housing
2nd speed gear
Bearing retainer
1 st weed
Input shaftI
get
I
3r’
1 st-2ndspeed
synchro-
nizerassembly
I
3rdbeed gear
3rd-LIth
:
L
speed synchronizer assembly
Lth speed gear
I
5th speed gear
Spacer
\i
5th speedsynchronizerassembly
noise-prevention
Filter
5th speed inter-mediate gear
’ Intermediate gear
rcer
t-Output shaft
:er
Differential drive gear
TFMOlll
I
‘d ’
‘\
I
1
I1
I~
\
d!TSB Revision
1

MANUAL TRANSAXLE - Specifications22-3
SPECIFICATIONS
L
GENERAL SPECIFICATIONSM22CA.A
items
Model
Applicable engine
Type
Gear ratio
1 st
2nd
3rd
4th
5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
Specifications
F5M33-2-SNZR
6G72-DOHC MPI
5-speed transaxle floor shift
3.090
1.833
1.217
0.888
0.741
3.166
4.153
28136
2.3 (2.4)
SERVICE SPECIFICATIONSM22CB-A
mm (in.)
L.J
Items
Standard value
Transaxle
Input shaft end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
Limit
Specifications
0 - 0.05 (0 - ,002)
0.01 - 0.09 i.0004 - ,004)0.01 -0.14 (.0004-
,006)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - .004)
0.025 - 0.150 (.OOl - ,006)
Synchronizer ring and clutch gear clearance0.5 (.02)
SNAP RING (FOR ADJUSTMENT) AND SPACERM22CF.A
Part name
Spacer
(For adjustment of input shaft end play)Thickness mm (in.)
0.80
i.0315)
0.83 (.0327)
0.86(.0338)
0.89t.0350)
0.92
(.0362)
Identificationsymbol
80
83
86
89
92
Part No.
MD727661
MD720937
M D720938
MD720939
MD720940TSB Revision

MANUAL TRANSAXLE - Specifications22-5
Part name
Spacer
(For adjustment of output shaft preload)
Spacer
(For adjustment of differential case preload)
Spacer
(For adjustment of differential pinion backlash)Thickness mm (in.)IdentificationsymbolPart No.
0.83 (.0327)83MD720937
0.86
(0338)86MD720938
0.89
(.0350)89MD720939
0.92
(.0362)92MD720940
0.95
(.0374)95MD720941
0.98 (.0386)98MD720942
1
.Ol t.0398)01MD720943
1.04 (.0409)04MD720944
1.07 (.0421)07MD729945
1 .I 0 (.0433)JMD71 0454
1
.I 3 (.0445)DMD700270
1.16(.0457)KMD71 0455
1 .I9 (0468)LMD71 0456
1.22 (.0480)GMD700271
1.25 (0492)MMD710457
1.28
(.0504)NMD710458
1.31
(.0516)EM D706574
1.34 (0527)0MD71 0459
0.80 (0315)80MD727661
0.83 (0327)83M D720937
0.86 (.0338)86M D720938
0.89 (0350)89M D72d939
0.92 (0362)92MD720940
0.95
(.0374)95M D720941
0.98 (.0386)98MD720942
1
.Ol (.0398)01MD720943
1.04 (.0409)04MD720944
1.07 (0421)07MD720945
1 .I 0 (.0433)JMD71 0454
1.13 (.0445)DMD700270
1.16
(.0457)KMD710455
1.19
(.0468)LMD71 0456
1.22 (.0480)GMD700271
1.25 LO4921MMD71 0457
0.75
- 0.82-MA1 80862
LO295 - .0323)
0.83 - 0.92-MA1 80861
(0327 - .0362)
0.93 - 1 .oo-MA1 80860(0366
- .0394)
1.01 -1.08-MA1 80875
(.0398 - .0425)1.09-1.16
-MA1 80876
t.0429 - .0457)TSB Revision