1991 MITSUBISHI 3000GT Service Manual

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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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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22-34
MANUAL TRANSAXLE - Input Shaft Assembly
2nd speedi
MD99831 8-0121500147. INSTALLATION OF SUB GEAR
/ 6. CONE SPRING / 5.
SNAP RING
Install the sub gear and cone spring to 4th gear, and theninstall the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing in
the correct direction.
4. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using the
special tool.3. REASSEMBLY OF SNAP RING
(1) Select thickest possible snap ring which can enter the
snap ring groove.Standard value: 0.01
- 0.09 mm (.0004 - .004 in.)
(2) Using a special tool, attach the snap ring to the input
shaft.
Caution1. Don’t reuse the old snap ring.
2. If snap ring pliers are used, the snap ring may
sometimes be expanded excessively. This will
prevent proper mounting of the sleeve.
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MANUAL TRANSAXLE - Input Shaft Assembly22-35
i2. REASSEMBLY OF BEARING SLEEVE
(1) Using a special tool, fit the bearing sleeve to the input
shaft.
Caution
After fitting, check that the sleeve flange is closelyfit to the bearing.
1. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using the
special tool.
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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