1989 MITSUBISHI GALANT maintenance

MANUAL TRANSAXLE - k% :;%t,rtb’kkii%i22-l 7
SPECIAL TOOLSMZSDA-
ToolNumberNameI Use
w
MB99
1193
r
PlugPrevention of entry of foreign objects into
the transaxle and transfer
L
MD998803Differential 011 sealInstallation of differential oil seal
t&-
installer
MD998304-0 1Oil seal installer Installation of front output shaft bearing and
transfer extention
housing oil seal
TROUBLESHOOTING
Refer to P.22-3.
M22EAAE
SERVICE ADJUSTMENT PROCEDURES
TRANSAXLE OIL LEVEL INSPECTIONm
Refer to GROUP 00-Maintenance Service.
\ //’ 09AOO24

23-22 AUTOMATIC
TRANSAXLE
- Troubleshooting
Based upon use of the troubleshooting
guide, the probable location of the prob-
lem should be estimated.
Checks should be made of fluid levels
and the condition of the ATF, as well as
1 found to be necessary
.
the condition of the manual control ca-
bles; adjustments should then be made if
If a presumption has been made that
there is an abnormal condition some-
where in the electronic-control system,
check the fault code, in order to determine
the probable location of the problem, by using a scan tool or voltmeter.
When the abnormal system is discovered,
check each element (sensors, etc.) one by
one, and make repairs as necessary.
When the abnormal condition is pre- sumed to be in the oil-pressure-control
When the result of the oil-pressure test does not satisfy the specified pressure,
1 passages for leakage, etc
.
check each system at places related to
the valve body, check the oil-pressure
If the problem is unusually dirty ATF,
abnormal noises, oil leakage, or slippage
L##t he traniaxle.1
of the clutch or brakes or an abnormal
condition of the transaxle Itself,
disassem-
TROUBLESHOOTING
Functional malfunctions of the ELGWT can lead to other
problems,
such
as those described
below:
(1) Improper
maintenance
and/or
adjustments
(2) Malfunctions of the electronic control functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of hydraulic control functions
(5) Malfunctions of engine performance
etc.
In order

to properly
determine (“Troubleshoot”)
the
source
of
these
malfunctions,
it is first essential
to methodically ques-
tion
the
user
concerning

the details
of the problem,
such as
the

condition of
the
problem,
the
situation at
the
time the
problem
occurred,

and any other relevant
information, all in as much detail

as possible.
The user
should
also be asked
whether or not the problem has occurred more than once,
and under
what conditions. Subsequently,
certain

tests should
be conducted in a certain
order,
as described
at
the
left.
1 TSB Revision

23-82AUTOMATIC TRANSAXLE - Service Adjustment Procedures
HOTTFA0715
AWD
LT FA0700J
SERVICE ADJUSTMENT PROCEDUR&g
TRANSAXLE FLUID LEVEL INSPECTION
1. Drive until the fluid temperature reaches the usual tem-
perature [70-80°C

(160- 18O”F)I.
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 around
dipstick. 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.
l
If 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 transaxle fluid until level
reaches “HOT” range.
Transaxle fluid: DIAMOND ATF SP or equivalent
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 and
cause the same conditions which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle
fluid.
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.
TRANSAXLE FLUID REPLACEMENTM23FcsGa
Refer to GROUP 00-Maintenance
Service.
TRANSFER OIL LEVEL INSPECTIONMm=xM
Transfer oil level inspection is the same as for the manual
transaxle transfer.
Refer to GROUP 00
- Maintenance Service.
TRANSFER OIL REPLACEMENTM23FYAA
Transfer oil replacement is the same as for manual transaxle
transfer.
Refer to GROUP 22-Service
Adjustment Procedures.
TSB Revision

23-100AUTOMATIC TRANSAXLE - Transaxle Oil Cooler Hoses
TRANSAXLE OIL COOLER HOSES
REMOVAL AND INSTALLATION
3-5 Nm2-4 ft.lbs.4-6 Nm\3-4 ft.lbs.
3-4 ft.lbs.
4-6 Nm3-4 ft.lbs.09A0041
< 1993 models>
2Pre-removal and Post-installation
Operationl
Drainage and Filling of Automatic Trans-axle Fluid(Refer to GROUP 00 - MaintenanceService.)
Removal steps
1. Hose clamp
2. Cable clamp
3. Oil cooler hose assembly
Caution1.Take care not to spill the transaxle fluidwhen removing components.2. After removing the oil cooler hose as- sembly, plug so that foreign materials
cannot enter the transaxle.
2-4 ftlbs.
bs.I /-\nhu-l,no
INSPECTION
l Check the hose for crack, damage and clog.
l Check for rusted or clogged radiator oil cooler.
TSB Revision

AUTOMATIC TRANSAXLE - Transaxle Assembly
TRANSAXLE ASSEMBLY
REMOVAL AND INSTALLATION
23-101
mz3u-
Pre-removal and Post-installation Op-eration@Draining and Supplying of the TransaxleFluid(Refer to GROUP 00-Maintenance Ser-vice.)*Removal and Installation of the Batteryand Battery TrayofRemoval and Installation of the Air Clean-
fRrefer to GROUP 15-Air
Cleaner.)*Removal and Installation of the Air Com-pressor(Vehicles with ACTIVE-ECS)(Refer to GROUP 33B-Air Compressor.)
cl989 models>27-34 Nm20-25ft.lbs.I360-80Nm43-58ft.lbS.60-80Nm43-58ft.lbs.
43-55 Nm
IO-12 Nm7.2-8.7 ft.lbs.
27-34 Nm20-25 ft.lbs.
30-35 km
b22-25 ft.lbs.
Iii ’30-35 Nm
22-25 ft.lbs.
ternoval steps
1. Snap pin
3. Connection for transaxle control cable
(Refer to
P.23-84.)4. Solenoid connector5. Park/neutral position switch connector
6. Pulse generator connector
7. Kickdown
servo switch connector
8. Oil temperature sensor connector 9. Connection for sppedometer cable
10. Connection for oil cooler hose
11. Connection for starter motor
12. Upper coupling bolt for transaxle assembly and engine assembly
13. Transaxle mount bracket
TSB Revision

AUTOMATIC TRANSAXLE - Transaxle Assembly 23-I 05
TRANSAXLE ASSEMBLY hl33lA-1
REMOVAL AND INSTALLATION
Pre-removal and Post-installation
Operation
eDraining and Supplying of the Trans-axle Fluid(Refer to GROUP 00-MaintenanceService.)l Removal and Installation of the Bat-tery and Battery Tray
*Removal
and Installation of the Air
Cleaner(Refer to GROUP 15-Air Cleaner.)20-27 Nmlo-14 Nm
14.5-19 ft.lbs.0 /7-10 ft.lbs.
/
, \ fp,/7-9 f%.lbs.
27-34 Nm20-25 ft.lbs.
-27-34 Nm20-25 ft.lbs.
30-35 Nm
22-25 ft.lbs.
30-35 Nm
22-25 ft.lbs. OSA0183
Removal steps
1. Connection for transaxle control cable
(Refer to P.23-86.)2. Connection for oil cooler hose
3. Automatic transaxle dipstick
4. Connection for solenoid connector 5. Park/neutral position switch (Refer to
P.23-86.)6. Connection for kickdown servo switch
connector 7. Connection for pulse generator connector
8. Connection for oil temperature sensor
connector
9. Connection for speedometer cable
10. Starter motor
11. Upper coupling bolt for transaxle
assembly and engine assembly
TSB Revision

ALPHABETICAL INDEX1
A
ABS
Checking by the ABS Warnrng Light................
. 35-68-l
Troubleshooting ...........................
35-l 5-l
ABS POWER RELAY, Chec
k 35-74-l
ACCELERATOR CABLE
Inspection and Adjustment
13-398-l
Inspection and Adjustment ........ 13-329-l
ACCELERATOR SWITCH, Inspection and Adjustment 13-329-I
A/C COMPRESSOR CLUTCH RELAY
On-vehicle Inspection
.............
. 13-285-l
On-vehrcle
Inspection
.........
. 13-83-t
On-vehicle Inspection
......
. 13-176-l
ACTIVE-ECS ON-BOARD DIAGNOSTIC, Check......

. 338-88-I
ACTIVE-ECS RELAY.......................

. 338-141
-I
ACTIVE-ECS SENSOR....

.
...... ............ 338-138-I
ACTIVE-ECS SYSTEM
Checking by Using Alarm Light
.................
. 338-87-I
Operation Check ........................... 338-90-I
AERO PARTS..

.
........................... 51-18-l
AIR CLEANER...............................

. 15-9-I
AIR CLEANER ELEMENT
Inspection and Replacement
....................
. 15-6-l
Maintenance .......................... 00-39-l
AIR COMPRESSOR..........................

. 338-125-I
AIR CONDITIONING SWITCH
Emission control
...........................
.
17-21 -I
Heater, Air
Conditionrng
and Ventilation .............. 55-29-l
On-vehicle Inspection ................. 13-285-l
On-vehicle Inspection
...........
. 13-83-l
On-vehicle Inspection

..........
. 13-176-l
AIR TUBE..............

.
....................... 338-133-I
ALARM LIGHT, Check. ......................... 338-87-I
ALARM SYSTEM, Theft ..........................
54-165-11
ALIGNMENT
Front Wheel, Adjustment .......................
. 33A-5-l
Rear
Wheel, inspection ..................
. 34-23-l
Rear Wheel, Inspection
....................
. 34-5-l
ANTENNA ......................................
54-153-11
ANTI-LOCK BRAKING SYSTEM, Troubleshooting .........
.
35-15-1
ARM
Lower
......................
. 338-103-I
Lower Suspension>......................
.
33A-10-I
Lower
................... 34-28-l
Torsion
................
.
338-l 19-l
Torsion Suspension-FWD>
...................34-l 5-lTrailing
................. 34-31-l
Upper
.................. 34-28-l
AUDIO
SYSTEM................

.
.................
54-l 12-11
AUTO-CRUISE CONTROL. ..........................
. 13-408-I
AUTO-CRUISE CONTROL INDIVIDUAL PARTS, inspection..

. 13-401-I
AUTO-CRUISE CONTROL SYSTEM...................

. 13-332-l
AUTO-CRUISE CONTROL SYSTEM, Inspection..........

. 13-397-l
AUTOMATIC TRANSAXLE, Maintenance ................. 00-43-I
AXLE
Rear, Maintenance
...............................
. 00-45-I
Torsion
........................
.
338-l 19-l
Torsion .....

.
......................... 34-15-l
AXLE HUB
Rear
Disc Brakes> ...................... 27-8-l
Rear CFWD-Rear
Drum Brakes> ................... 27-6-l
AXLE SHAFT ..............................

.
27-17-1
B
BACKLASH. Total, Rear Axle, Check ............
. 27-15-l
BALL JOINT
Rotation Starting Torque Check ...................... 378-8-I
Tie Rod End, Staning Torque Check .................. 37A-15-l
Tie Rod End, Variation Check ....................... 37A-15-l
BALL JOINT SEALS, Maintenance ..................... 00-45-I
BAR
Stabilizer ....................

. 338-106-I
Stabilizer
...................
. 33A-13-l
Stabilizer Suspension-AWD>...............
. 34-37-l
BAROMETRIC PRESSURE SENSOR
On-vehicle Inspection
................
. 13-266-l
On-vehicle Inspection
13-53-l
On-vehicle Inspection
..........
. 13-154-l
BASIC IDLE SPEED
Adjustment
...........................
. 13-245-l
Adjustment
..................... 13-33-l
Adjustment
...................
. 13-133-l
BATTERY.........................................

.
54-2-11
BATTERY, Flat Remedy.
.............................
. 35-75-l
BEARING
Wheel, Adjustment ................

. 338-87-I
Wheel, Adjustment ............. 33A-5-l
BELT
Drive, Compressor, Adjustment
....................
. 55-17-l
Drive (For Water Pump and Generator), Maintenance ..... 00-41-I
Drive, Tension Adjustment ................. 11-61-I
Drive, Tension Adjustment ................. 11-12-l
Seat..........................................

. 52-39-l
Timing ...................... ......... 11-80-I
Timing................................

. 11-34-l
Timing, Maintenance ............................... 00-40-I
Timing, Tension Adjustment ................ 11-10-I
BLEEDING
Clutch
..........................................
. 21-6-l
4ws...........................................

. 370-4-I
Service Brakes. .................................. 35-57-l
Steering ........................................ 37A-22-l
BLOWER..........................................

. 55-32-l
BOOSTER
Brake
.........................................
. 35-85-l
Brake, Operating Inspection ......................... 35-54-l
BOOST METER, On-vehicle Inspection ... 13-311-l
BOOTS, Drive Shaft, Maintenance ....................... 00-45-I
BRAKE
Disc, Front
......................................
. 35-94-l
Disc, Rear.....................................

.
35-l 14-l
BRAKE BOOSTER
...................................
. 35-85-l
BRAKE BOOSTER, Operating Inspection .................. 35-54-l
BRAKE DISC
Front, Run-out Check.
.............................
. 35-63-l
Front, Run-out Correction ........................... 35-64-l
Front, Thickness Check ............................. 35-65-l
Rear, Run-out Check ............................... 35-66-l
Rear, Run-out Correction. ........................... 35-66-l
Rear, Thickness Check............................

. 35-66-l
BRAKE DRUM, tnside
Diameter, Check ................... 35-67-l
BRAKE FLUID LEVEL SENSOR, Check...................

. 35-54-l
BRAKE FLUID PRESSURE SWITCH
AWD-ABS (Up to 1991 Models)
....................
.
35-133-l
AWD-ABS
(Up to 1991 models), Check ...............
. 35-75-l
BRAKE HOSES, Maintenance ........................... 06-45-t
BRAKELINE
........................................
35-87-l

2ALPHABETICAL INDEX
BRAKE LINING ThicknessCheck

.., ..,............
Drum, Rear, Maintenanc
e
BRAKE LINING AND BRAKE DRUM, Connection Check..
BRAKE PAD
Drsc, Front, Check and Replacemen
t
Disc, Rear, Check and Replacement BRAKEPEDAL..
BRAKE PEDAL, Inspection and Adjustment
BUMPER..... 35-67-l
00-44-l
35-67-l
35-59-l
35-65-l
35-76-l
35-53-l
51-7-I
C
CABLEAccelerator, Inspection and Adjustment
13-398-l
Accelerator, Inspection and Adjustment Control> 13-329-I
High
Tensron, Spark Test ........
.
16-42-11Parking Brake................................

.
36-5-l
Spark
Plug, Tes
t
........................
16-42-11Speedometer, Replacement ...............
.
23-93-l
Speedometer, Replacement
.........
.
22-19-I
Speedometer, Replacement
............
.
22-5-l
CAMSHAFTDOH

C
...................
1 l-68-lSOHC.................................

.
11-19-I
CAMSHAFT OIL SEALS
DOHC
...................................
.
11-68-I
SOHC........................................

.
11-19-I
CAMSHAFT POSITION SENSOR
On-vehrcle Inspection
..................
.
13-277-l
On-vehicle Inspection
............
.
13-69-l
On-vehicle Inspection
........
.
13-165-I
CANISTER,
Evaporatjve Emission.................

.
17-21-l
CATALYTIC CONVERTER............................

.
17-24-l
CENTERMEMBER...................

.
....... 32-8-l
CENTRAL DOOR LOCKING SYSTEM..................

.
42-101-I
CHARGE AIR COOLER...............................

.
15-l

2-l
CHARGING..................
.
..... 55-17-I
CHARGING SYSTEM....................

.
...........
16-2-11CHARGING SYSTEM, Inspection.......................
.
16-5-11CHECK VALVE, Operation Check......................

.
35-54-l
CIGARETTE LIGHTER..........................

.
54-106-11
CLOCK........................................
.
54-109-11CLOSED THROTTLE POSITION SWITCHAdjustment GVALVE>
.................. 13-136-I
Frxed SAS, Adjustment
..................
.
13-250-I
On-vehicle inspection .................. 13-274-l
On-vehicle Inspection
............
.
13-61-I
On-vehicle Inspection

.........
. 13-160-I
CLUTCH CONTROL.................................

.
21-10-I
CLUTCH MASTER CYLINDER.........................

.
21-12-l
CLUTCH PEDAL.....................................

.
21-7-l
CLUTCH PEDAL, Inspection and Adjustment ................
21-5-1CLUTCH RELAY, A/C Compressor, On-vehicle Inspection
>
....................................... 13-285-l
CLUTCH RELEASE CYLINDER.........................
21-13-lCOIL
Ignition, On-vehicle
Inspectron 13-302-I
Ignition, On-vehicle
InspectIon
......
. 13-96-l
Ignition. On-vehicle Inspection
13-186-l
COLUMN SWITCH............................

.
54-100-11COMBINATION LIGHT, Rear.
.........................
.
54-95-11COMPRESSION PRESSURE
Check
...............................
.
1
i-59-1Check
..................................
11-8-l
COMPRESSOR...................................
.
55-38-l
COMPRESSOR, Air.......

.
........................ 338-125-I
COMPRESSOR DRIVE BELT, Adjustment, ................. 55-17-l
COMPRESSOR NOISE, Adjustment ...................... 55-23-l
CONDENSER, ............ .......................... 55-48-l
CONDENSER FAN MOTOR...........................

.
55-48-l
CONSOLE, Floor....................................

.
52-29-l
CONTROL
Engine
........................................
.
13-328-l
Transaxle ............................... 23-94-l
Transaxle
..........................
.
22-19-I
Transaxle
...........................
.
22-6-l
CONTROL SYSTEM
Evaporative Emission
.............................
.
17-15-l
Intake Charge Pressure, Inspection.
....................
15-7-lMixture (MFI
)
.............................. 17-29-l
Purge, Inspection .................... 17-17-l
Purge, Inspection ....................... 17-18-l
CONTROL UNIT
ABS
........................................
.
35-134-l
Active-ECS ................................... 338-140-I
EPS.....................................

.
...37A-59-lCONTROL VALVE <4WS>..........................

.
378-12-I
COOLANT
Engine, Concentration Test ..........................
14-8-lEngine, Leak Check ................................
.
14-8-l
Engine, Maintenance. ............................ 00-44-I
Engine, Replacement ...........
................... 14-8-lCRANKCASE VENTILATION SYSTEM, inspection..........

.
17-14-l
CRANKSHAFT POSITION SENSOR
On-vehicle Inspection
..................
.
13-280-I
On-vehicle Inspection
............
.
13-73-l
On-vehicle Inspection
13-167-l
CROSSMEMBER....................................

.
32-8-l
CURB IDLE SPEED
Inspection
.......
.
.................... 13-245-l
Inspection
13-32-l
Inspection
....................
.
13-133-l
CYLINDER
Master
.........................................
.
35-81 -IPower
.........................................
.
378-9-I
Wheel,RearBrake...............................

. 35-111-l
Wheel, Rear, Maintenance .......................... 00-44-I
CYLINDER HEAD GASKET
DOHC
.......................................
.
11-73-l
SOHC.................: ......................... 11-25-l
D
DASH POT, Inspection and Adjustment
1 l-58-lDEFOGGER, Rear Window 64-156-11
DEFOGGER RELA
Y
.54-163-11DEFOGGER SWITCH, Rear Window. 54-163-11
DEFOGGER TIMER 54-164-11
DELAY VALVE, Check
35-74-l
DIAPHRAGM, Rolling, Check 33B-89-l
DIFFERENTIAL CARRIER
27-26-l
DISC
Brake, Front, Run-out Check
35-63-l
Brake, Front, Run-out Correction 35-64-l
Brake, Front.
Thichness Check 35-65-l
Brake, Rear, Run-out Check 35-66-l
Brake, Rear, Run-out Correction 35-66-l
Brake, Rear,
Thichness Chec
k
35-66-l