1991 MITSUBISHI 3000GT service

MANUAL TRANSAXLE - Transaxle Assembly
Lock nut‘;
201021
SERVICE POINTS OF DISASSEMBLYMZZMFAW
14. REMOVAL OF SPRING PINRemove the spring pin using a pin punch.
NOTE\,/If the spring pin interferes with the synchronizer ring or
cone gear, rotate the gear for dislocation and remove the
spring pin.15.16. REMOVAL OF LOCK NUTS
(1) Unstake lock nuts of the input shaft and intermediate
gear.
(2) Shift the transaxle in reverse using the control lever and
select lever.(3) Install the special tool onto the
inout shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery ofclutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.48.49. REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using a pin punch.
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MANUAL TRANSAXLE - Transaxle Assembly22-23
50. REMOVAL OF SHIFT RAIL ASSEMBLY
(I 1 Shift the Ist-2nd speed shift fork to the 2nd speed.
(2) Shift the 3rd-4th speed shift fork to the 4th speed.
MD998325-01
II
MD998325-01
/I\I2010291(3) Remove the shift rail assembly.
INSPECTIONM22MOAB
BACKUP LIGHT SWITCHOperate the backup light switch to check continuity with a
circuit tester.If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLYMZZMGAX
54. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
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MANUAL TRANSAXLE -5th Speed Synchronizer Assembly
22-29
i
Oil groove
Springprotrusion
201001a
SERVICE POINTS OF REASSEMBLY5. INSTALLATION OF SYNCHRONIZER HUB
/ 4. SYN-
CHRONIZER KEY / 2. SYNCHRONIZER SPRING
(1) Assemble the synchronizer hub, and key noting their
direction.
(2) Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
NOTETake care to prevent the projections of the front and
rear spring from sitting in the groove of the same key.
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MANUAL TRANSAXLE - Input Shaft Assembly22-31
i4th speed gear
MD998i48-01
2150012
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF TAPER ROLLER BEARING
Remove the front bearing using the special tool as
illustrated.2. REMOVAL OF BEARING SLEEVE
Remove the bearing sleeve using the special tool as
illustrated.4. REMOVAL OF TAPER ROLLER BEARING
Remove the taper roller bearing together using the special
tool as illustrated.
18.
REMOVAL OF 3RD SPEED GEARRemove the bearing sleeve,
3rd-4th speed synchronizer
assembly and 3rd speed gear together using the special
tool as illustrated.
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INSPECTION
INPUT SHAFT
lCheck the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear and seizure[portion
@I.l Check the splines for damage and wear.

MANUAL TRANSAXLE - Input Shaft AssemblY22-33
SpriprotKey2010018
MD998348-01
SPEED -GEARS
lCheck the bevel gear and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough surface, damage
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
13. INSTALLATION OF SYNCHRONIZER SPRING
Assemble the synchronizer spring so that its projection maybe engaged in the groove of the synchronizer key.
Take care to prevent the projections of the front and rearspring from sitting in the groove of the same key.
12. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(I) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove atthe hub end.
NOTE
If the installation is in the opposite way, press-in mightnot be possible. This is because the edge of the hub
inner diameter spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
CautionWhen installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-
rectly in respective grooves of the synchronizer
ring.(3) Check the 3rd speed gear rotates smoothly.
10. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.
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22-36MANUAL TRANSAXLE - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLY
IMZZMJAS
DISASSEMBLY AND REASSEMBLY
64
I
Disassembly steps
I)* 1. Snap ringl * **2. Taper roller bearing
** 3. Bearing sleevel *4. 1 st speed gear
5. Needle bearing
l a6. Synchronizer ring
l **C7. Synchronizer spring8. 1 st-2nd speed synchronizer sleeve
I)* 9. Synchronizer key*I) I)+ IO. 1 st-2nd speed synchronizer hubl * 11. Synchronizer ringl *12. 2nd speed gear13. Needle bearing** l * 14. Taper roller bearing
d
I
15. Intermediate gear-
MD998348-01
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SERVICE POINTS OF DISASSEMBLY
2.REMOVAL OF TAPER ROLLER BEARING / 4.1ST SPEED
GEARRemove the taper roller bearing, 1 st speed gear and bearing
sleeve using the special tool as illustrated.
Caution1. Do not reuse the bearing removed from the shaft.
2.Replace the inner and outer races of the taper rollerbearing as a set.d

MANUAL TRANSAXLE - Intermediate Gear Assembly
22-39
/
MD998350-01
Identificationmark
Front +
Identi-
fication
markSERVICE POINTS OF REASSEMBLY
14. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearingusing the special tool.over the intermediate gear
Caution
When installing the bearing, push the inner race only.
Springprotrusion11.8. INSTALLATION OF SYNCHRONIZER RINGS
The 1 st speed synchronizer ring has an identification mark.
10. INSTALLATION OF lST-2ND SPEED SYNCHRONIZERHUB
/ 9. SYNCHRONIZER KEY / 8. lST-2ND SPEED
SYNCHRONIZER SLEEVE / 7. SYNCHRONIZER SPRING(1) Combine the Ist-2nd speed synchronizer hub and
sleeve as illustrated.
(2) Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
NOTE
(1) Take care to prevent the projections of the front andrear spring from sitting in the groove of the same
key.(2) A synchronizer spring of a different shape from
what is shown may be installed; however, there isno difference in installation procedure.
i
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MANUAL TRANSAXLE - Output Shaft.Assembly22-41
OUTPUT SHAFT ASSEMBLYMZZMKAH
DISASSEMBLY AND REASSEMBLY
L
/
id
I I
SERVICE POINTS OF DISASSEMBLY
8Press1. 2. REMOVAL OF TAPER ROLLER BEARINGS
Remove the taper roller bearing using the special tool asillustrated.
Caution
1.Do not reuse the bearings removed from the shaft.
2.Replace the inner and outer races of the taper rollerbearing as a set.
Disassembly steps**
l *I. Taper roller bearing*I) I)*2. Taper roller bearing3. Output shaft
210028
71 nn75
MD998350-01
SERVICE POINTS OF REASSEMBLY1. 2. INSTALLATION OF TAPER ROLLER BEARINGS
Install the taper roller bearing using the special tool.
Caution
When installing the bearing, push the inner race only.
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