1991 MITSUBISHI 3000GT lock

CLUTCH - Specifications
SPECIFICATIONSI
GENERAL SPECIFICATIONSMZlCA--i
Type
Facing diameterSingle dry disc type
Single dry disc type
Diaphragmspring strap
SERVICE SPECIFICATIONS
terns
Standard value
Clutch pedal heightmm (in.)
Clutch pedal strokemm (in.)
Amount of clutch pedal return from full pedal stroke
position to where operating sound of interlock switch
is producedmm (in.)
Clutch pedal
clevis pin playmm (in.)
Clutch pedaLfree playmm (in.)
Distance between the clutch pedal and the firewall when
the clutch is disengagedmm (in.)
Specifications
177 - 182 (6.97 - 7.17)
160 (6.29)
IO-15(.394-,591)
I-3 (.04-.12)
6-13(.24-.51)
55 (2.2) or more
Booster push rod to master cylinder piston clearance
0.21 - 0.46 (.0082 - .0181)mm (in.)
Vacuum hose insertion distancemm (in.) 20 - 25 (0.8 - 1 .O)
Limit
Facing rivet sinkmm (in.)0.3 l.012)
Diaphragm spring end height differencemm (in.)0.5 (.020)
1 TSB RevisionI

CLUTCH - Service Adjustment Procedures21-5
Clutch pedal height
08YO41
auto-cruise control
L-l
\ \ 0Cl;tchswitch
\ \08F0010
Clutch pedal stroke
Lock nut
08F005414110052
SERVICE ADJUSTMENT PROCEDURES
CLUTCH PEDAL INSPECTION AND ADJUSTMENTMZlFAAP
1.Measure the clutch pedal height (from the face of the pedal
pad to the firewall).
Standard value: 177
- 182 mm (6.97 - 7.17 in.)
If the clutch pedal height is not within the standard value
range, adjust as follows:
For vehicles without auto-cruise control system, turn and
adjust the bolt so that the pedal height is the standard
value, and then secure by tightening the lock nut to the
specified torque.
Vehicles with auto-cruise control system, disconnect the
clutch switch connector and turn the switch for standard
clutch pedal height. Tighten the lock nut to the specified
torque.
Specified torque: 13 Nm (9
ft.lbs.)
NOTEWhen the pedal height is lower than the standard value,
loosen the bolt or clutch switch, and then turn the push rod
to make the adjustment. After making the adjustment,
tighten the bolt or clutch switch to reach the pedal stopper,
and then lock with the lock nut.
2. Measure the clutch pedal stroke.
Standard value: 160 mm (6.29 in.) or more
If the clutch pedal stroke deviates from the standard value,
turn the push rod to adjust the stroke.
3. Return the clutch pedal gradually from its full-stroke
position to measure amount of the return made by the
pedal
u,ntil the interlock switch makes an operating sound.
Standard value: 10
- 15 mm (.394 - .591 in.)
If the amount of pedal return deviates from the standard
value, adjust it by loosening the lock nut and turning the
interlock switch.
TSB Revision

21-8CLUTCH - Clutch Pedal
CLUTCH PEDAL
REMOVAL AND INSTALLATIONMZlPA-
.
0‘@- D.,
a
;
IGsdRemoval steps
1. Connection of brake boosterAdjustment of brake pedal
(Refer to GROUP 35 - ServiceAdjustment Procedures.)
2. Connection of clutch master cylinder
3. Clevis pin4. Clevis pin
5. Return spring
6. Pedal support bracket
;: EIe;i; pin
9. Turn over spring10. RodB
11. Bush
12. Clutch pedal shaft
30 Nm22 ftlbs.
9 ft.lbs.
13 Nm
9 ft.lbs.Gw+,
8 !!
79 I_a 9ft.lbs.
k1608FOO47
13. Clutch pedal14. Bushing15. Spacer
16. Clutch pedal pad
17. Brake pedal shaft
18. Brake pedal
19. Stop light switch
20. Bolt
21. Clutch switch
22. Interlock switch
1 TSB Revision

IICLUTCH - Clutch Pedal
Removal steps
23. Brake booster(Refer to GROUP 35 - Brake Booster.)24. Connection of clutch master cylinder
25. Connection for vacuum hose
26. Pedal support bracket
27. Clevis pin
28. Clevis pin
29. Clevis pin30. Yoke
31. Clutch pedal shaft32. Clutch pedal08FOO25
33.Bushing
34.Spacer
$ E$ch pedal pad
37.Lever assembly38.Bushing
39.Spacer
40.Support bracket
41.
Clutch booster42.Clutch switch43.Interlock switch
Ohmmeter
08AOO4L
INSPECTIONMZlPCAL
l Check the pedal shaft and bushing for wear.
l Check the clutch pedal for bend or torsion.
l Check the turn over spring for damage or deterioration.
l Check the pedal pad for damage or wear.
INTERLOCK SWITCH INSPECTION
(1) Disconnect the connector.
(2) Check to be sure that there is continuity between connec-
tor terminals 1 and 2.
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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.

22-6MANUAL 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

MANUAL TRANSAXLE - Special Tools22-7
MD998348-0 1
Bearing remover
Removal of gears and bearings of input
shaft, intermediate gear and output shaft
andintermediate shaft lock nut
M
D998808-01Snap ring installerInstallation of input shaft rear snap ring
MD998822installer adapterInstallation of differential case bearings
iTSB Revision

22-16MANUAL TRANSAXLE - Transaxle Assembly
9. DISCONNECTION OF TRANSAXLE MOUNT
Raise transaxle assembly with a jack up to a level where
mount bracket no longer receives its weight and remove
transaxle mount insulator bolt.
CautionSupport the transaxle assembly with the jack so that
no localized force is applied to the assembly.
13. DISCONNECTION OF TIE ROD ENDUsing the special tool, disconnect the tie rod end from the
knuckle.
Caution1. Be sure to tie the cord of the special tool to the
nearby part.2. Loosen the nut but do not remove it.
14. DISCONNECTION OF LOWER ARM BALL JOINTUsing the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution1. Be sure to tie the cord of the special tool to the
nearby part.2. Loosen the nut but do not remove it.
17. REMOVAL OF DRIVE SHAFT (LEFT SIDE), INNER SHAFT
ASSEMBLY(1) Remove the bearing bracket mounting bolts and insert
the pry bar between the bearing bracket and the
cylinder block.
(2) Remove drive shaft (left side) and inner shaft assembly
from transaxle assembly.
NOTERemove drive shaft and inner shaft assembly as an
assembly together with hub, knuckle, and other parts.
(3) Suspend the removed drive shaft (left side) and inner
shaft assembly with wire or something similar to
prevent it from sharply bending or turning at each joint.
TSB RevisionI