1991 MITSUBISHI 3000GT clutch

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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22-24
MANUAL TRANSAXLE - Transaxle Assembly
63. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
MD998321-01
Oil seal2010041
50. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Set the 1 st-2nd speed shift sleeve at 2nd speed.
(2) Set the 3rd-4th speed shift sleeve at 4th speed.
(3) Fit the shift forks of shift rail assembly to groove of
sleeves.
‘LJ(4) Insert the shift rails into the shift rail holes of clutch
housing.
(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and the interlock
plate.48.49. INSTALLATION OF SPRING PINS
(1) Install the spring pins using the special tool or a pin
punch.
CautionDo not reuse the spring pins.
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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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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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22-38
MANUAL TRANSAXLE - Intermediate Gear Assembly
Damage and breakage
TFMOllE
Syndhronizer ringGAarTFMOll:201045
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 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.
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 weakness, deformation and breakage.
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.
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22-46MANUAL TRANSAXLE - Clutch Housing Assembly
CLUTCH HOUSING ASSEMBLYM22MPAM
DISASSEMBLY AND REASSEMELY
iJ15-22Nm
II- 15 ft.lbs.
/
1443q 15-
m16----@20-27Nm
15- 19ft.lbs.
2100019
Disassembly steps
1.Bolt
2. Select lever assembly
3. Select lever shoe
4. Interlock plate bolt
5.Gasket
4~ l a6. Lock pin+* I)* 7. Spring pin8. Neutral return spring
9.Stopper body10.Control finger11.Interlock plate12. Neutral return spring assembly13.Control shaft14. Control shaft boot
l * 15. Oil seal
l *16.Needle
bearingI)+ 17. Needle bearing
; 98: F:;tch housing
20.Return
spring21. Stopper plate
22. Spring pin
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MANUAL TRANSAXLE - Clutch Housing Assembly22-47
1
Oil sealSocketwrench
SERVICE POINTS OF DISASSEMBLY6. REMOVAL OF LOCK PIN
Drive out the lock pin from the control finger using the pin
punch.
CautionWhen removing the lock pin, turn the control lever to
such position that the lock pin will not contact the
clutch housing.7. REMOVAL OF SPRING PIN
Drive out the spring pin from the stopper body using the pin
punch.
Caution
When removing the spring pin, pull the control shaft inthe direction illustrated so that the spring pin will not
contact the clutch housing.
SERVICE POINTS OF REASSEMBLY
17.16. INSTALLATION OF NEEDLE BEARINGSInstall the needle bearing flush with the surface A of the
clutch housing.
15. INSTALLATION OF OIL SEALInstall the control shaft oil seal using a socket wrench.
7. INSTALLATION OF SPRING PIN
/ 6. LOCK PIN
(I) Install new spring pin and lock pin using the special tool.
CautionDo not reuse the spring pin and lock pin.
(2) Install the spring pin with its slit at right angle to the
control shaft center.
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