1991 MITSUBISHI 3000GT Manual transaxle

MANUAL TRANSAXLE - Transaxle Assembly
22-25
L
Slit
#Jl
Spring pin
/
II-+Shift rail1 I I201034
er
2150008
MD998325-01
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
35.37. 40. 42. INSTALLATION OF SPACERS
(1) Place two pieces of solder measuring about 10 mm (.4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If solder is not crushed, perform steps (1) to (4) with a
solder with a larger diameter.
(6) Measure the thickness of the crushed solder with a
micrometer and select and install a spacer of thicknessthat gives standard preload and end play.
Standard value:Input shaft end play
0
- 0.05 mm (0 - .002 in.)
Intermediate gear preload
0.05
- 0.10 mm (.002 - .004 in.)
Output shaft preload
0.05
- 0.10 mm (.002 - .004 in.)
Differential case preload0.05
- 0.10 mm (.002 - .004 in.)
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
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22-26MANUAL TRANSAXLE . - Transaxle Assembly
Amountl-2 mm
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outer
race and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gearshaft’s head is facing in the direction indicated in the
illustration.
NOTE
If there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified’ sealant: MITSUBISHI genuinePart No. MD997740 or equiva-
lentLJ
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
[8 mm (.32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten thebolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
torque.(8) Tighten the reverse idler gear shaft bolt to specified
torque.16.15. INSTALLATION OF LOCK NUTS
(1) Install the special tool to the splined end of input shaft.(2) Screw a bolt
[lo mm (.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
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MANUAL TRANSAXLE - Transaxle Assembly22-27
(3) Shift the transaxle in reverse using control lever and
select lever.
(4) Tighten the lock nut to specified torque, while using thebolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
IMD998245-01Spring pir
Shift rail
14. INSTALLATION OF SPRING PIN(1)
rr;‘tl.the spring pin using the special tool or a pin
CautionDo not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
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22-28
MANUAL TRANSAXLE -5th Speed Synchronizer Assembly
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
TEMOl18
Disassembly steps
1. Reverse brake ringl *2. Synchronizer spring
3. Synchronizer sleeve
** 4. Synchronizer keyl *5. Synchronizer hub
@
/r /
JI,::. ‘..-‘. .\:’201045
INSPECTION
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check thatthey slide smoothly.
lCheck that the sleeve is free from damage at its inside front
and rear ends.l
Check for wear of the hub front end (surface in contact withthe 5th speed gear).
Caution
When replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRINGl
Check for wear of the synchronizer key center protrusion.
lCheck the spring for weakness, deformation and breakage.
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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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22-30
MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY
MZZMICA
DISASSEMBLY AND REASSEMBLY2150009
Disassembly steps
l * l a1. Taper roller bearingl * *a2. Bearing sleeveI)+3.Snap ringl * l a4. Taper roller bearingl 45.Snap ring**6.Conespringl *7.Subgear
8. 4th speed gear
9.Needlebearingl * 10. Bearing sleeveII. Synchronizer ring
l * 12. 3rd-4th speed synchronizer assembly** 13. Synchronizer spring
14. Synchronizer sleeve
15. Synchronizer key
16.Synchronizer hub
17. Synchronizer ring
18.
3rd speed gear
19.Needle bearing20.Input shaft
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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.

22-32MANUAL TRANSAXLE - Input Shaft Assembly
20105'
Damage, breakage
Damage, wearTFMOll!
Synchnizer ringGLar
TFMOll201044
/
NEEDLE BEARINGl Combine the needle bearing with the shaft or bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.l Check the needle bearing cage for deformation
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check paper lining on cone I.D. for damage, wear, and
flaking.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm
(.02 in.)
SYNCHRONIZER SLEEVE AND HUBl
Combine the synchronizer sleeve and hub and check thatthey slide smoothly.
l
Check that the sleeve is free from damage at its inside front
and rear ends.
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRINGl
Check for wear of the synchronizer key center protrusion.
lCheck the spring for deterioration, deformation and break-
age.
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