1991 MITSUBISHI 3000GT clutch

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.
TSB Revision

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.

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

22-6MANUAL TRANSAXLE - Specifications / Special Tools
LUBRICANTS
M22CD-A
Items
Manual transmission oil
Drive shaft oil seal lip
Specified lubricant
Hypoid gear oil, SAE
75W-90 or75W-85W conforming to APIclassification GL-4 or higherQuantity lit.
(qts)
2.3 (2.4)
As required
SEALANTS AND ADHESIVES
Items
Transaxle case - clutch housing mating surfaces
Transaxle case
- rear cover mating surfaces
Differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
MUCE- _
Specified sealants and adhesives
Mitsubishi genuine part No. 997740 or equivalent
3M Stud Locking part No. 4170 or equivalent
Air breather
3M ATD part No. 8001 or equivalent
SPECIAL TOOLSM22DA-A.
nstallation of spring pin and lock
MD998323-01TSB Revision

22-14MANUAL TRANSAXLE - Transaxle Assembly
TRANSAXLE ASSEMBLY
REMOVAL AND INSTALLATION
(Refer to GROUP 51 -Front Bumper.)
4.0 Nm2.9ft$bs. t09FO112
19 Nm
13 ft.lbs.M22MA-A
Removal steps
1. Side under cover2. Battery
3. Battery seat, Washer tank
4. Air cleaner cover,
Air intake hose
5. Connection for clutch release cylinder
6. Connection for clutch tube bracket
and clutch damper assembly7. Connection for transaxle controlcable
8. Connection for speedometer cable09FOO89
TSB Revision

MANUAL TRANSAXLE - Transaxle Assembly22-15
idPost-installation Operationl Installation of Front Under Cover(Referto GROUP 51 -Front Bumper.)l Supplying of Transmission Oil (Refer to P.22-9.)l Filling of Engine Coolant (Refer to GROUP 14-
Service Adjustment Procedures.)70 Nm
l Checking Operation of Shift Lever at Each Positionl Checking the Operation of the Meters and Gauges26
ft.lbs.09FOO84
4*9. Connection for transaxle mount16. Starter10. Transaxle mount bracket4*17. Drive shaft (Left side),
l * 11. Mounting stopperinner shaft assembly12. Transaxle assembly upper part+* ** 18. Drive shaft (Right side)
coupling bolt19. Transaxle stay (Front bank side)4*13. Connection for tie rod end20. Transaxle stay (Rear bank side)4*14. Connection for lower arm4*21. Transaxle assembly lower part
ball jointcoupling bolt15. Right member4*22. Transaxle assembly
SERVICE POINTS OF REMOVALMZZMBBA6. DISCONNECTION OF THE CLUTCH TUBE BRACKET
AND CLUTCH DAMPER ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the body side
without disconnecting the oil line coupling.
1 TSB Revision

MANUAL TRANSAXLE - Transaxle Assembly
15-22Nm5211-15
ft.lbs..I 53
-22Nm
-15 ftlbs.
67
litI63
62
51.Screw52.Bolt53.Bearing retainer54. Intermediate gear assembly
55. Input shaft assembly
56. Output shaft assembly
57. Differential gear assembly
58. Bearing outer race
59. Bearing outer race60.Oil guide61. Bearing outer race
62. Bearing outer race
** 63. Oil seall 464.Oil seal65.Magnet66.Magnet holder
67. Clutch housing assembly
TSB Revision