MITSUBISHI GALANT 1989 Service Repair Manual
Manufacturer: MITSUBISHI, Model Year: 1989, Model line: GALANT, Model: MITSUBISHI GALANT 1989Pages: 1273, PDF Size: 37.62 MB
Page 661 of 1273
CLUTCH- Clutch Control
Clutdh hose-Clutch tube
.., Hose clip
Secure side
08W507
SERVICE POINTS OF REMOVALM2lJBAD
6. DISCONNECTION OF HOSE CLIPSI7. CLUTCH HOSE
To disconnect clutch hose from the clutch tube, proceed.
as follows:
(1) Secure the nut on the clutch hose and loosen the flare nut on the clutch tube.
(2) Remove the clip from the clutch hose to remove clutch hose from bracket.
INSPECTION M21JCAC
l Check the clutch hose or tube for cracks or clogging.
SERVICE POINTS OF INSTALLATIONhl21JiW
7. INSTALLATION OF CLUTCH HOSE/S. CLUTCH TUBE/4.
CLUTCH TUBE
Temporarily tighten the flare nut by hand, and then tighten it to the specified torque, being careful that the clutch
hose does not become twisted.
Page 662 of 1273
21-12CLUTCH - Clutch Master Cylinder
CLUTCH MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
MZlNA-
Disassembly steps
1. ‘Piston stop ring2.Push rod3.Boot
*I)4. Piston assembly5.Reservoircap6.Reservoirband7.Reservoir8. Master cylinder body
08AOO34
Brake Fluid: Conforming to DOT3or DOT4
SERVICE POINTS OF DISASSEMBLYMZlNBAC
4. REMOVAL OF PISTON ASSEMBLY
Caution
1.Do not damage the master cylinder body and piston
assembly.
2. Do not disassemble piston assembly.
\\08AOOi4
INSPECTIONM21NcAc
l Check the inside cylinder body for rust or scars.
l Check the piston cup for wear or deformation.
l Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.
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Page 663 of 1273
CLUTCH - Clutch Release Cylinder
CLUTCH RELEASE CYLINDER
{EMOVAL AND INSTALLATION
Pre-removal Operationl Draining of the clutch fluidl Bleeding of the clutch line (Refer
Release cylinder O(Ivl,,push rod
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20-25 Nm
Removal steas
1. Clutch tube
2. Union
3. Clutch release cylinder
INSPECTIONm21ncAA
l Check the clutch release cylinder for fluid leakage.
l Check the clutch release cylinder boots for damage.
Page 664 of 1273
NOTES
Page 665 of 1273
22-1
MANUAL
TRANSAXLE
CONTENTS
--m
MANUAL TRANSAXLE
SERVICE ADJUSTMENT
PROCEDURES..............................................17
Drive Shaft Oil Seals Replacement .........
18
Speedometer Cable
Replacement...........19
Transaxle Oil Level Inspection
.................17
TransaxleOilReplacement......................18
Transfer OilSealReplacement
................19
SERVICE ADJUSTMENT
PROCEDURES ..............................................4
Drive Shaft Oil Seals Replacement .........4
Speedometer Cable Replacement...........5
TransaxleOil
LevelInspection .................4
Transaxle Oil Replacement ......................4
SHIFT LEVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . .9
SPECIAL TOOLS ......................................... 17
SHIFT LEVER ASSEMBLY..........................19
SPECIFICATIONS
.........................................15
GeneralSpecifications..............................15
Lubricants
..................................................16
Sealants and
Adhesives ...........................16
Torque Specifications ...............................15
TRANSAXLE
................................................20
TRANSAXLE CONTROL
..............................19
TRANSFER ...................................................23
TROUBLESHOOTING ..................................17
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . .3
SPECIFICATIONS.........................................2
GeneralSpecifications
..............................2
Lubricants..................................................3
Torque Specifications ...............................2
TRANSAXLE
................................................10
TRANSAXLE CONTROL.............................. 6
TROUBLESHOOTING..................................3
Page 666 of 1273
22-2MANUAL TRANSAXLE
- Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSMZXA-A
ItemsSpecifications 4G63-SOHC 4G63-DOHC
Model KM206
<1989 models> KM206
F5M31 < 1992 and F5M22
models> 1991models>
Type5-speed5-speed 5-speed
Gear ratio
1 St3.363
3.083
2.8462nd
1.947 1.947 1.8333rd
1.285 1.285 1.2174th
0.9390.9390.888
5th0.7560.756
0.731
Reverse
3.083 3.083
3.166
Frnal reductron
ratio4.02 14.592 4.913
Speedometer gear ratio (driven/drive)
2913630/3630/36 (30/36
. 1993 models only)
NOTEOnly the model code for KM206 and F5M22
is different.
TORQUE SPEClFlCATiONSMUCC-A
ItemsNmftlbs.
Shift lever to lever (A) 19-2813-20
Lever (A) to bracket assembly19-2813-20
Drain plug30-3522-25
Filler plug
30-3522-25
Starter motor mounting bolt 27-34
20-25
Transaxle bracket60-8043-58
Shift lever knob 4.5-7.53-
5
Shift cable and select cable to body 9-14
7-10
Shift lever assembly to body
9-1
4
7-10
Clutch release cylinder mounting bolt
15-2211-16
Clutch tube to transaxle assembly15-2211-16
Transaxle mount bracket to transaxle
60-8043-58
Shift cable and select cable to transaxle 15-2211-16
Front height sensor rod to lower arm 17-2612-19
Transaxle mounting bolt
[I2 mm diameter bolt] 43-5
5
32-39
Transaxle mounting bolt [IO mm diameter bolt]
30-3522-25
Transaxle mounting bolt
[8 mm diameter bolt]IO-127-
9
Tie rod end to knuckle 24-3517-25
Lower arm ball joint to knuckle
60-7243-52
Bell housing cover
10-127-
9
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Page 667 of 1273
MANUAL TRANSAXLE
- Soec~cations/SpeciI
Tools/Troubleshooting 22-3
LUBRICANTSYZZCD-A
Items1 Specified lubricant1 Quantity
Manual transaxle oil Hypoid gear oil SAE
75W-85Wconforming to API classificationGL-4 or higher1.8
dma
(1.9 qts.)
2.3 dma
Shift lever bushing Front Wheel Bearing
Grease Part Number 3837794
or eauivalent As required
SPECIAL TOOLSWDA-A
Tool
NumberName1 UseI MB991
113-01
Steering linkage
puller
OPTIONAL: AVAIlABLE FROM 0.T.C
MD998325-01Differential oil seal
installer 0
Disconnection of the coupling of the
knuckle and lower arm ball joint 0
Disconnection of the coupling of the
knuckle and tie-rod end ball joint
Installation of input shaft front oil seal
TROUBLESHOOTING
Symptom
Vibration, noise
3il leakage -lard
shift
lumps out of gear Probable cause
Remedy
a. Loose or damaged transaxle and a. Tighten or replace mounts
engine mounts
b. Inadequate shaft end play b. Correct end play
c. Worn of damaged gearsc. Replace gears
d. Use of inadequate grade of oil
d. Replace with specified oil
e. Low oil level e. Replenish
f. Inadequate engine idle speed f. Adjust idle speed
a. Broken or damaged, oil seal or O-ring a. Replace oil seal or O-ring
a. Faulty control cable a. Replace control cable
b. Poor contact or wear of synchronizer ring b. Correct or replace
and gear cone
c. Weakened synchronizer spring c. Replace synchronizer spring
d. Use of inadequate grade of oil d. Replace with specified oil
a. Worn gear shift fork or broken poppet a. Replace shift fork or poppet\
spring spnng
b. Synchronizer hub to sleeve spline
clear-
b. Replace synchronizer hub and sleeveante too large
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Page 668 of 1273
22-4MANUAL TRANSAXLE
09”011009FO12
R.H. side
x
I I09K567I
Front exhaust pipe
SERVICE’ ADJUSTMENT PROCEDURAF
TRANSAXLE OIL LEVEL INSPECTION
Refer to GROUP 00-Maintenance Service.
TRANSAXLE OIL REPLACEMENTMZZFCAD
(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transaxle oil to
drain.
(3) Refill the transaxle to the proper level with specified transaxle oil. The oil level should be the bottom of the oil
filler hole.
Transaxle oil: Hypoid gear oil SAE 75W-85W conform-
ing to API classification GL-4 or higher
DRIVE SHAFT OIL SEALS REPLACEMENT MYSDAG
(1) Disconnect the drive shaft from the transaxle. (Refer to GROUP
26-Drive Shaft.)
(2) Using a flat-tip
(-) screwdriver, remove the oil seal.
(3) Using the special tool, tap the drive shaft oil seal into the transaxle.
(4) Apply a coating of the transaxle oil to the lip of the oil seal.
Transaxle oil: Hypoid gear oil, SAE
75W-85W con-
forming to API
GL-4 or higher
MD998325-01160024
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Page 669 of 1273
MANUAL TRANSAXLE
Adapter09A0058
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SPEEDOMETER CABLE REPLACEMENT~~FEIE
1.Correctly insert the adapter into the instrument panel, and
fasten the new speedometer cable.
2.Install the grommet so that, as shown in the illustration, the’
cable attachment part is positioned upward.
Caution 1. The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2. The arrangement of the speedometer cable should be such that it does not interfere with brake tubes,
etc.
3. At the transaxle end of the speedometer cable, the key
joint should be inserted into the transaxle, and the nutshould be securely tightened.
Caution
If the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.
Page 670 of 1273
22-6MANUAL TRANSAXLE
- Transaxle Control
TRANSAXLE CONTROL
REMOVAL AND INSTALLATION hl22JA-A
Removal steps
1.Cotter pin
2. Retainer
3.Retainer4.Cotter pinl * 5. Shift cable
l + 6. Select cable
7. Shift lever assembly
Pre-removal and Post-installation 1Operation*Removal and Installation of ConsoleI
~$%!m$$NP Z-Floor
Con-l
9-14 Nm7-10 ftlbs.
09A0060
OSAO185
INSPECTION
l Check the select cable for function and for damage.
l Check the shift cable for function and for damage.
l Check the boot for damage.
l Check each bushing for wear or abrasion, sticking,
impeded action, and damage.
l Check the spring for deteriorated strength.
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