MITSUBISHI GALANT 1989 Service Repair Manual

MANUAL TRANSAXLE
- Transaxle Control22-7
ect- cable\
I Lever

(B)
09A0160
IIncorrect-I I
SERVICE POINTS OF INSTALLATIONM22JDAK
6. INSTALLATION OF SELECT CABLE
(1) Move the transaxle shift lever to the neutral position.
NOTE
The select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral position.
(2) Move lever
(B) to the neutral position.
(3) Adjust, by using the adjuster, so that the end of the select cable is positioned as shown in the illustrationrelative to lever
(B).
(4) The flange side of the resin bushing at the select cable end should be at the lever
(B) end surface.
5. INSTALLATION OF SHIFT CABLE
(1) With the select lever in neutral, move the transaxle shiftlever (in the direction shown in the illustration) to set it
to 4th
gear.
NOTE
If the shift lever does not move easily, depress and hold
the clutch pedal.
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22-8MANUAL TRANSAXLE
- Transaxle Control
09A0037
Incorrect Shift
lever
Correct
Incorrect09AO159
(2) Move the shift lever (at the vehicle interior side)
downward, in the direction (4th gear position) shown in
the illustration until it contacts the stopper.
(3) Adjust, by using the adjuster, so that the end of the shift cable is positioned as shown in the illustration relative
to the shift lever (interior side).
(4) The flange side of the resin bushing at the shift cable end should be at the split pin side.
(5) Adjust the length of the shift cable, by using the adjuster, so that the clearance (A) and
(B) between the
shift lever and the two stoppers are equal when the shift lever is shifted to 3rd
gear
and 4th
gear.
(6) Move the shift lever to each position and check that the
shifting is smooth.
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MANUAL TRANSAXLE
- Shift Lever Assembly
SHIFT LEVER ASSEMBLYMZZGE-A
DISASSEMBLY AND REASSEMBLY

1
19-28Nm
13-20\ft.lbs.12 A .2
19-28 Nm6-
6
w*- “y
k!3
m8 /
17-28 Nm13T18 ft.lbs.
Disassembly steps
1.Shift lever2.Bushingl + 3. Return spring4.Bushing5.Lever (A)
6.Bushing7.Collar models>8.Bushing9.Snap ring10.Lever (B)11.Bushing12.Bracket assembly
- i9AOl60
SERVICE POINTS OF REASSEMBLYM22GHAJ
3. INSTALLATlON OF RETURN SPRING
Make sure that the end of the spring contacts the part
(shown in the illustration) of the bracket.
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22-10MANUAL TRANSAXLE - Transaxl
e
TRANSAXLE
REMOVAL AND INSTALLATION
MZMA-A
27-34 Nm20-25 ft.lbs.
60-80
Nm*
43-58 ft.lbs.*
11-16
ft.lbs.71
11-16 ftlbs.
Removal steps
l *1, Connection for compressor assembly
2. Cotter pin
3. Connection for select cable
4. Connection for shift cable
a*5. Connection for clutch release cylinder
6. backup light switch connector
7. Connection for speedometer cable
l +8. Connection for starter
9. Transaxle assembly upper part coupling
tJ01t10. Transaxle mount bracket
Pre-removal Operation@Draining of the Transaxle Oil (Refer to P.22-4.) *Removal of the Battery and Battery Tray
l Removal of the Air Cleaner Assembly(Refer to GROUP 15-Air Cleaner.)
Post-installation Operation
asupplying of Transaxle Oil
(Refer to P.224.)l Installation of the Air Cleaner Assembly(Refer to GROUP 15-Air Cleaner.)l Installation of the Battery and Battery Tray*Checking the Operation of the Shift Leverl Checking the Ooeration of the Meters and Gauaes
NOTE
-t-or tightening locations indicated by the * symbol, firsttighten temporarily, and then make the final tightening with
the entire weight of the engine applied to the vehicle body.
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MANUAL TRANSAXLE - Transaxle
60-72 Nm
43-52 ftfbs.
i“1
30-35
Nm
22-25
ft.lbs. /(
7-4 filhs
60-72 Nm
43-52 ftlbs.
/-
.,- 17-25 ft.lbs.17-26 Nm12-19 ft.lbs.
09A0019
+I)Il. Under cover
12. Cotter pin
*I)13. Connection for tie rod end
14. Self-locking nut
l 4 15. Front height sensor rod 18. Circiip
19. Bell housing cover
20.
/?a;saxle assembly lower part coupling
21. Transaxle assembly
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22-12MANUAL TRANSAXLE
- Transaxle
* ’TransaxlellK611I-I-1 TSB Revision
SERVICE POINTS OF REMOVALM22MBAK
1. DISCONNECTION OF COMPRESSOR ASSEMBLY
FROM TRANSAXLE ASSEMBLY
Remove the compressor assembly from the bracket, and
then secure at the body side without disconnecting the air hose coupling.
5. DISCONNECTION OF CLUTCH RELEASE CYLINDER
FROM TRANSAXLE ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the body side
without disconnecting the oil line coupling.
11. REMOVAL OF UNDER COVER
Lift the vehicle before removing the under cover.
13. DISCONNECTION OF TIE ROD END FROM KNUCKLE
Using the special tool, disconnect the tie rod end from the
knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loosen the nut but do not remove it.
16. DISCONNECTION OF LOWER ARM BALL JOINT
Using the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loosen the nut but do not remove it.
17. DISCONNECTION OF DRIVE SHAFT
(1) Insert a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the
transaxle.
Caution
1. Do not pull on the drive shaft; doing so will
damage the inboard joint; be sure to use the pry
bar.
2. Do not insert the pry bar so deep as to damaged
the oil seal.

MANUAL TRANSAXLE
- Transaxl
e
22-13
part ofirive shaftITransaxle
09LOO58
12R0124
Normal
12R036:s
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(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.
21. REMOVAL OF TRANSAXLE ASSEMBLY
Support the transaxle assembly by using a transaxle jack;
then, after moving the transaxle assembly to the right, lower it.
NOTE
When supporting the transaxle’assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to a
wide area, not to only a small localized area.
SERVICE POINTS OF INSTALLATION MZ?MDAK
17. INSTALLATION OF DRIVE SHAFT
(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bentrelative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serrated
part of the drive shaft.
(2) Align the serrations and securely insert the drive shaft into the transaxle.
15. INSTALLATION OF FRONT HEIGHT SENSOR ROD
Install the rod so that dimension A in the figure is within the
following range.
Dimension A:
254.5* 0.5 mm (lo& .02 in.)
NOTE
(1) Adjust the rod length so that dimension B is equal.
(2) The ball joint on the end of the rod should be installed with the ball centered.
Defective
I

22-WMANUAL TRANSAXLE
- Transaxle
rI8. INSTALLATION OF STARTER
Tighten with the lower starter installation the wiringharness clip bolt.
09POOl3
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MANUAL TRANSAXLE - SDecifications2245
SPECIFICATIONSM?zcA-B
GENERAL SPECIFICATIONSItems
Specifications
Model W5M31
Applicable engine 4G63
Tvw
5-speed
Gear ratio
1 St2.846
2nd1.684
3rd1.115 4th
0.833
5th
0.690
Reverse 3.166
Reduction ratio Primary
1.680
Secondary 3.100
Transfer
1.090
Speedometer gearratio(driven/drive)30136
NOTE: The AWD vehicles have been discontinued from 1993 models. W5M33
4G63-TIC
5-speed
2.846
1.684
1.115
0.833 0.666
3.166
1.275
3.866
1.090
30136
TORQUE SPECIFICATIONS
TRANSAXLE
Items
Bell housing cover mounting bolt
10-127-
9
Starter motor mounting bolt 27-34
20-25
Transaxle mount bracket mounting bolt60-8043-5
8
Shift cable and select cable bracket mounting bolt
15-2211-16
Rear cover mounting bolt 35-42
26-30
Transaxle case mounting bolt 35-4226-30
Clutch release cylinder mounting bolt 15-2211-16
Clutch tube to transaxle assembly 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
18 mm diameter bolt]IO-127-
9
Tie rod end to knuckle 24-35
17-25
Lower arm ball joint to knuckle60-7243-52
Center bearing bracket installation bolts 36-4626-33
Front exhaust pipe to exhaust fitting
30-4022-29
Front exhaust pipe clamp
30-4022-29
Right member installation bolt (front)30- 10058-72
qight member installation bolt (rear)70-80jl-58 rransfer
assembly mounting bolt
55-60IO-43
Nm M22CGBft.lbs.
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22-16MANUAL TRANSAXLE - Specifications
ItemsNmftlbs.
Restrict ball30-3522-25
Speedometer mounting bolt 3-
5
2.5-3.5
Oil filler plug
30-3522-25
Oil drain plug
30-3522-25
Input shaft lock nut
140-160102-115
Intermediate shaft lock nut140-160102-115
Center differential drive gear mounting bolt70-8051-57
Front differential drive gear mounting bolt130-14095-101
Stopper bracket mounting bolt 15-2211-15
Reverse idler gear shaft mounting bolt 43-5532-39
Reverse shift lever mounting bolt 15-22
71-15
Bearing retainer mounting bolt15-2211-15
Interlock plate mounting bolt
20-2715-19
Center member mounting bolt
60-8043-58
Drive shaft center bearing mounting bolt 36-4626-33
Driven bevel gear lock nut
740-160lOl-‘1’15
Select lever assembly mounting bolt 15-2211-15qeverse
brake cone screw bolts
4.0-5.53-
4
TRANSFER
1
Items
) Nm) ft.lbs.I
Transfer assembly mounting bolt55-6040-43
Hanger bracket mounting bolt15-2211-15
Front exhaust pipe and exhaust manifold 30-4022-2
9
Front exhaust pipe to exhaust fitting
40-6029-43
Front exhaust pipe clamp bolt
30-4022-29
LUBRICANTSMz2co-B
Items
Transaxle
Transfer Specified lubricant
Quantity drnj
(qts.)
Hypoid gear oil, SAE 75W/8OW conforming to API classification GL-4 or higher 2.3 (2.4)
Hypoid gear oil, SAE
75W/8OW conforming to API classification GL-4 or higher 0.6 t.6)
SEALANTS AND ADHESIVES
Transaxle
M22cE.B
IItems1 Specified sealant and adhesiveI
Faying surfaces of transaxle case and clutch housing
Mitsubishi genuine sealant
Part No. MD997740 or equivalent
Faying surfaces of clutch housing and adapter
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