1991 MITSUBISHI 3000GT height adjustment

CLUTCH - Service Adjustment Procedures21-5
Clutch pedal height
08YO41
auto-cruise control
L-l
\ \ 0Cl;tchswitch
\ \08F0010
Clutch pedal stroke
Lock nut
08F005414110052
SERVICE ADJUSTMENT PROCEDURES
CLUTCH PEDAL INSPECTION AND ADJUSTMENTMZlFAAP
1.Measure the clutch pedal height (from the face of the pedal
pad to the firewall).
Standard value: 177
- 182 mm (6.97 - 7.17 in.)
If the clutch pedal height is not within the standard value
range, adjust as follows:
For vehicles without auto-cruise control system, turn and
adjust the bolt so that the pedal height is the standard
value, and then secure by tightening the lock nut to the
specified torque.
Vehicles with auto-cruise control system, disconnect the
clutch switch connector and turn the switch for standard
clutch pedal height. Tighten the lock nut to the specified
torque.
Specified torque: 13 Nm (9
ft.lbs.)
NOTEWhen the pedal height is lower than the standard value,
loosen the bolt or clutch switch, and then turn the push rod
to make the adjustment. After making the adjustment,
tighten the bolt or clutch switch to reach the pedal stopper,
and then lock with the lock nut.
2. Measure the clutch pedal stroke.
Standard value: 160 mm (6.29 in.) or more
If the clutch pedal stroke deviates from the standard value,
turn the push rod to adjust the stroke.
3. Return the clutch pedal gradually from its full-stroke
position to measure amount of the return made by the
pedal
u,ntil the interlock switch makes an operating sound.
Standard value: 10
- 15 mm (.394 - .591 in.)
If the amount of pedal return deviates from the standard
value, adjust it by loosening the lock nut and turning the
interlock switch.
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21-6CLUTCH - Service Adjustment Procedures
08YO4Z
Distance between the clutch pedaland the firewall when the clutchis disengaged
08NOOl C
Good
c1‘14UOO61
When engine is
stoppedNo good
\)‘14UOO6:
When engine isstarted
14UOO604. Measure pedal play. In the case of AWD vehicles, depress~
the pedal 2 or 3 times to eliminate booster negative
pressure with the engine stopped and then push the pedal
with a finger to measure the play.
LJClutch pedal play (including play of clevis pin)
Standard value: 6
- 13 mm (.24 - 51 in.)
2
CHECK VALVE OPERATION CHECK I
MZlFOAAWhen checking the check valve, keep the check valve fit in the
vacuum hose.
1. Remove the vacuum hose.
CautionL’The check valve is press-fit inside the vacuum hose and
do not remove the check valve from the vacuum hose.
5.Measure the clearance to the toe board (or pedal stopper)
when the clutch disengages. In the case of AWD vehicles,
measure with the engine running.
Clearance to toe board when clutch disengages:
Standard value: 55 mm (2.2 in.) or more
6.If the play and/or clearance is out of specification, bleed the
hydraulic system or check the master cylinder, release
cylinder or clutch proper.
CLUTCH BOOSTER OPERATING INSPECTION
MZlFCAAFor simple checking of clutch booster operation, carry out the
following tests.
(I) Run the engine for one or two minutes, and then stop it.
(2) Step on the clutch pedal several times. with normal
pressure.
If the pedal depressed fully the first time but gradually
becomes higher when depressed succeeding times the
dbooster is operating properly.
If the pedal height remains unchanged, the booster is
faulty.
(3) With the engine stopped, step on the clutch pedal several
times with the same foot pressure to make sure that the
pedal height will not change.
Then step on the clutch pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is faulty.
(4) With the engine running, step on the clutch pedal and then
stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition.
If the pedal rises, the booster is faulty.
If the above three tests are okay, the booster performance can
be determined as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose, or booster will be faulty.
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27-28
REAR AXLE - Differential Carrier
Standard tooth contact pattern
1 Narrow tooth side
2 Drive-side tooth surface (the side applying
power during forward movement)
3 Wide tooth side
4 Coast-side tooth surface (the side applying
power during reverse movement)
2
34
ProblemTooth contact pattern resulting from exces-
sive pinion heightSolution
The drive pinion is positioned too far from the center ofthe drive gear.Increase the thickness of the pinion height adjustingshim, and position the drive pinion closer to the centerof the drive gear.
Also, for backlash adjustment, position the drive gearfarther from the drive pinion.
Tooth contact pattern resulting from insuffi-
cient pinion height
ectdb
e52 34&$%$I$&2 3 4
The drive pinion is positioned too close to the center ofthe drive gear.Decrease the thickness of the pinion height adjustingshim, and position the drive pinion farther from the
center of the drive gear.
Also, for backlash adjustment, position the drive gearcloser to the drive pinion.
11 S642
NOTE(I)Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear
backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until tooth contactpatterns bear a similarity to the standard tooth contact pattern.
(2)When adjustment is not able to obtain a correct pattern, it may be judged that the drive gear and drive pinion haveexceed their usage limits and both gears should be replaced as a set.
,
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DISASSEMBLYREAR AXLE
- Differential Carrier27-29
M27lF- -
inspection Before Disassemblyl Final Drive Gear Backlash(Refer to P.27-26.)l Drive Gear Runout(Refer to P.27-26.)l Final Drive Gear Tooth Contact(Refer to P.27-26.)Disassembly steps
1. Differential cover assembly2.Vent plug
3.Oil seal
4.Snap ring4*5. Side bearing nut4*6. Side bearing outer race7. Differential case assembly4*8. Side bearing inner race4*9. Drive gear (for 4WS)4*10. Drive gear
11. Spring pin (for 4WS)4*12. LSD case (refer to P.2759.)4*13. Self-locking nut14:Washer
4*
4*
4*4*4*
64 111 FO032
15. Drive pinion assembly
16. Companion flange
17. Drive pinion front shim
(for preload adjustment)18. Drive pinion spacer19. Drive pinion rear bearing inner race20. Drive pinion rear shim
(for pinion height adjustment)
21. Drive pinion
22. Oil seal
23. Drive pinion front bearing
24. Drive pinion rear bearing outer race
25. Differential carrier’
SERVICE POINTS OF DISASSEMBLYM27lGBD5. REMOVAL OF SIDE BEARING NUT
Using the special tool, remove the side bearing nut.
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27-32
REAR AXLE - Differential Carrier
REASSEMBLYM2711- .
1Reassembly steps
**1. Spring pin (for 4WS)l *2. Drive gear (for 4WS)3. Differential carrierl *4. Drive pinion rear bearing outer race**5. Drive pinion front bearing outer race*aDrive pinion height adjustment
6. Drive pinion
7. Drive pinion rear shim
(for drive pinion height adjustment)
8. Drive pinion rear bearing inner race
9. Drive pinion spacer
l *Drive pinion preload adjustment10. Drive pinion front shim
11. Drive pinion assembly
12. Drive pinion front bearing inner race
13. Oil seal
14. Companion flange
15. Washer
16. Self-locking nut
17. LSD case (Refer to
P.27-39.)** 18. Drive gear** 19. Side bearing inner race
20. Side bearing outer race
l *Final drive gear backlash adjustment21. Differential case assembly
22. Side bearing nut
23. Snap ring
** 24. Oil seal
25. Vent plug
26. Differential cover assembly
NOTE*:Tightening torque with oil applied.TSB Revision

27-34
REAR AXLE - Differential Carrier
YYW!-01
I1 11AOlOl
MB99Y2232. PRESS-IN OF THE DRIVE GEAR (FOR 4WS)
(1) With the beveled (large) part of the rear wheel oil pump
drive gear at the inner side, press in the drive gear (by
using the special tool) until the drive gear contacts theend surface of the
.differential case.
(2) Check to ensure that the drive gear and the spring pin
are flush.4. INSTALLATION OF DRIVE PINION REAR BEARING
OUTER RACE
/ 5. DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer racesinto the gear carrier by using the special tools.
CautionBe careful not to press in the outer race at an angle.
. DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequenceshown in the illustration.
NOTE
Apply a thin coat of multipurpose grease to the matingface of the washer of the special tool.
(2) Tighten the handle of the special tool until the standardvalue of drive pinion rotation torque is obtained.
(3) Measure the drive pinion rotation torque (without the oil
seal).
Standard value
Bearing
classificationBearing
lubricationRotation torqueNm (in.lbs.1
INew
None (with0.3 - 0.5rust-prevention oil)(3 - 4)I
New/reused
NOTEGear oil
application0.15 - 0.25
(1 - 2)
(1) Gradually tighten the nut of the special tool while checkingthe drive pinion rotation torque.
(2) Because the special tool cannot be turned one turn, turn it
several times within the range that it can be turned; then,after fitting to the bearing, measure the rotation torque.
L/1 1
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SERVICE BRAKES - Set-vice Adiustment Procedures35-45lUF51F
Pedal
7\ \!4FOO7.
F14511
F14519
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SERVICE ADJUSTMENT PROCEDURES
BRAKE PEDAL INSPECTION AND ADJUSTMENT
1.Measure the brake pedal height as illustrated. If the’brakepedal height is not within the standard value, adjust as
follows.
Standard value (A): 177
- 182 mm (7.0 - 7.2 in.)
(I) Disconnect the stop light switch connector, loosen the
lock nut, and move the stop light switch to a position
where it does not contact the brake pedal arm.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating. rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) After screwing in the stop light switch until it contacts
the brake pedal stopper (just before the brake pedal is
caused to move), return the stop light switch
l/2 to 1
turn and secure by tightening the lock nut.
(4) Connect the connector of the stop light switch.
(5) Check to be sure that the stop light is not illuminated
with the brake pedal unpressed.
Reference value (6): 0.5
- 1.0 mm (.02 - .04 in.)
2. On vehicles with automatic transaxle, check the shift-lock
mechanism. (Refer to GROUP 23
- Transaxle Control.)
3. With the engine stopped, depress the brake pedal two or
three times. After eliminating the vacuum in the power
brake booster, press the pedal down by hand, and confirm
that the amount of movement before resistance is met (the
free play) is within the standard value range.
Standard value (C): 3
- 8 mm (.I - .3 in.)
If the free play is less than the standard value, confirm that
the clearance between the stop light switch and brake
pedal is within the standard value.
If the free play exceeds the standard value, it is probably
due to excessive play between the clevis pin and brake
pedal arm. Check for excessive clearance and replace faulty
parts as required.
4.Start the engine, depress the brake pedal with approximate-
ly 500 N (110
Ibs.) of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value (D): 80 mm (3.1 in.) or more
If the clearance is less than the standard value, check for air
trapped in the brake line and for brake fluid leaks. If
necessary, check the brake system mechanism (excessive
shoe clearance due to faulty auto adjuster) and repair faulty
parts as required.~1~1
I
I
I
I
I

35-46SERVICE BRAKES - Service Adjustment Procedures
BRAKE FLUID LEVEL SENSOR CHECK
I
MBSFBAF
Good
k‘14UOO61
When engine is
stoppedNo good
When engine isstarted
14UOO6C)Checkvalve/1. Connect a circuit tester to the brake fluid level sensor.
I
2.Move the float from top to bottom and check for continuity.
3. The brake fluid level sensor is in good condition if there is
‘k&Jno continuity when the float surface is above “A”, and if,there is continuity when the float surface is below “A”.
BRAKE BOOSTER OPERATING INSPECTION
M35FCAOFor simple checking of brake booster operation, carry out the
following tests.
1.Run the engine for one or two minutes, and then stop it.
2. Step on the brake pedal several times with normal
pressure.If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly.
If the pedal height remains unchanged, the booster is
faulty.
3. With the engine stopped, step on the brake pedal several
times with the same pressure to make sure that the pedal
height will not change.
Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is faulty.
4.With the engine running, step on the brake pedal and then
stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition. If
the pedal rises, the booster is faulty.
If the above three tests are okay, the booster performance can
be determined as good.
If one of the above three tests is not okay at last, the check
valve, vacuum hose, or booster will be faulty.
CHECK VALVE OPERATION CHECKM35FNALWhen checking the check valve, keep the check valve fit in the
vacuum hose.
1. Remove the vacuum hose.
Caution
The check valve is press-fit inside the vacuum hose and
do not remove the check valve from the vacuum hose.1
d~
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