1991 MITSUBISHI 3000GT Service Manual

CLUTCH - Clutch Cover and Disc
CLUTCH COVER AND DISC
REMOVAL AND INSTALLATION
21-19
M21GA-.
I
)Il Removal of the Transaxle Assembly
30-42Nm
\\115-21 Nm11 - 15 klbs.2Removal steps
M w1. Clutch cover assembly+e W+ 2. Clutch disc3. Return clipI)* 4. Clutch release bearingW+ 5. Release fork6. Fulcrum
7. Release fork bootTSB Revision

CLUTCH - Clutch Cover and Disc
6CLOl f
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
7CLOOO8
Lubricant: MITSUBISHI genuine grease
Part No. 0101011 or eauivalent
6CL03:
Lubricant: MITSUBISHI genuine greasePart No. 0101011 or equivalent
SERVICE POINTS OF REMOVALMZlGBAK
1.REMOVAL OF CLUTCH COVER ASSEMBLY / 2. CLUTCH
DISCDiagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at a
time, to avoid bending cover flange.
CautionDO NOT clean clutch disc or release bearing with
d
cleaning solvent.TSB Revision
1

CLUTCH - Clutch Cover and Disc21-21
Sleeve
Bearing
TFM0131
INSPECTIONMZlGCAG
CLUTCH COVER ASSEMBLYl Check the diaphragm spring end for wear and uneven
height.
lReplace if wear is evident or height difference exceeds the
limit.
Limit
: 0.5 mm (02 in.)
lCheck the pressure plate surface for wear, cracks and color
change.
lCheck the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISC
lCheck the facing for loose rivets, uneven contact, deteriora-
tion due to seizure, adhesion of oil or grease and replace the
clutch disc if defective.
lMeasure the rivet sink and replace the clutch disc if it is out
of specification.
Limit
: 0.3 mm (.012 in.)
lCheck for torsion spring play and damage and if defective,
replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.
If it does not slide smoothly, check after cleaning and
reassembling. If the play is excessive, replace the clutch
disc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
1.The release bearing is packed with grease, so don’t usecleaning oil, etc. to clean it.
2.Do not disassemble the bearing and sleeve of the clutch
release bearing. If disassembled, replace. (AWD only)l Check for bearing heat damage, other damage, abnormal
noise and/or improper rotation. Also check whether or not
there is wear at the point of contact with the diaphragm
spring.
lIf there is abnormal wear at the point of contact with the
release fork, replace the bearing.
RELEASE FORKIf there is abnormal wear at the point of contact with the
bearing, replace the release fork.
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21-22CLUTCH - Clutch Cover and Disc
APPLYgrease
6CLOlE
lir#LClutch disc
Clutch cover
assembly
v-l6CL02EITSB Revision
SERVICE POINTS OF INSTALLATIONMZIGDAU5. APPLICATION OF GREASE TO RELEASE FORK
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact
withthe release bearing.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
CautionWhen installing the clutch, apply grease to each
part, but be careful not to apply excessive grease;excessive grease will cause clutch slippage and
shudder.(2) Apply a coating of the specified grease to the end of the
release cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
4.APPLICATION OF GREASE TO CLUTCH RELEASE BEAR-ING (FWD)
Pack the inner surface of the clutch release bearing and the
groove with the specified grease.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
2. APPLICATION OF GREASE TO CLUTCH DISC
/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
(2) Using the universal clutch disc aligner, position the
clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.I

22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE . . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE ....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT.(2)The SRS includes the following components: impact sensors, SRS diagnosis unit: SRS warning light, air bagmodule, clock spring, interconnecting wiring. Other SRS-related components (that may have to be
removed/installed in connection with SRS service or maintenance) are indicated in the table of contents byan asterisk (*).
WARNING!(1)Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (fromrendering the
SRS inoperative).(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B
-Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.

22-2MANUAL TRANSAXLE - General Information
MANUAL TRANSAXLE
GENERAL INFORMATIONM226AAU
F5M33
R Cl/utch housing
2nd speed gear
Bearing retainer
1 st weed
Input shaftI
get
I
3r’
1 st-2ndspeed
synchro-
nizerassembly
I
3rdbeed gear
3rd-LIth
:
L
speed synchronizer assembly
Lth speed gear
I
5th speed gear
Spacer
\i
5th speedsynchronizerassembly
noise-prevention
Filter
5th speed inter-mediate gear
’ Intermediate gear
rcer
t-Output shaft
:er
Differential drive gear
TFMOlll
I
‘d ’
‘\
I
1
I1
I~
\
d!TSB Revision
1

MANUAL TRANSAXLE - Specifications22-3
SPECIFICATIONS
L
GENERAL SPECIFICATIONSM22CA.A
items
Model
Applicable engine
Type
Gear ratio
1 st
2nd
3rd
4th
5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
Specifications
F5M33-2-SNZR
6G72-DOHC MPI
5-speed transaxle floor shift
3.090
1.833
1.217
0.888
0.741
3.166
4.153
28136
2.3 (2.4)
SERVICE SPECIFICATIONSM22CB-A
mm (in.)
L.J
Items
Standard value
Transaxle
Input shaft end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
Limit
Specifications
0 - 0.05 (0 - ,002)
0.01 - 0.09 i.0004 - ,004)0.01 -0.14 (.0004-
,006)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - .004)
0.025 - 0.150 (.OOl - ,006)
Synchronizer ring and clutch gear clearance0.5 (.02)
SNAP RING (FOR ADJUSTMENT) AND SPACERM22CF.A
Part name
Spacer
(For adjustment of input shaft end play)Thickness mm (in.)
0.80
i.0315)
0.83 (.0327)
0.86(.0338)
0.89t.0350)
0.92
(.0362)
Identificationsymbol
80
83
86
89
92
Part No.
MD727661
MD720937
M D720938
MD720939
MD720940TSB Revision

22-4MANUAL TRANSAXLE - Specifications/ - ,
Part name
Spacer
(For adjustment of input shaft end play)
Snap ring
(For adjustment of intermediate gear front bearingend play)
Spacer:Foradjustmentofintermediategearpreload)Thickness mm (in.)
IdentificationsymbolPart No.
0.95 l.0374)
95
MD7209410.98
t.0386)98MD720942
1
.Ol t.0398)01M D720943
0.04 (.0409)04MD7209441.07(.0421)
07MD7209451.10(.0433)
JMD71 04541.13 l.0445)
DMD7002701.16 i.0457)
KMD7104551.19
(.0468)LMD710456l.ZZ(O.480)
GMD7002711.25 i.0492)
MMD7104571.28
t.0504)NMD7104581.31
(.0516)EMD7065741.34(.0527)0
M D7 104591.37
(.0539)PMD71 04601.40(.0551)
-MD7065731.43
t.0563)QMD710461
1.46l.0575)RMD7104621.4 l.0551)
NoneMD703779
1.5 l.0591)
BrownMD7037801.6
f.0630)BlueMD7037810.80
t.0315)80MD7241 420.83 l.0327)
83MD7241 43
0.86f.0338)86MD7241440.89
t.0350)89MD7241 450.92 f.0362)
92MD7241 460.95 l.0374)
95MD7241470.98 i.0386)
98MD7241 48
1 .Ol t.0398)01MD724149
1.04 (.0409)04MD7241501.07(.0421)
07MD7241 51
1 .I0 (.0433)10MD7241521.13 f.0445)
13MD7241531.16
t.0457)16MD7241 541.19
(.0468)19MD724155
1.22 (.0480)22MD7241 561.25 t.0492)25
MD7241571.28 f.0504)
28MD7241581.31 l.0516)
31MD7241 591.34(.0527)
34MD7241 601.37
(.0539)37MD724161
1 TSB Revision ~~~