Stealth International WSMG1 User manual

MANUAL TRANSMISSION
Service ."anual ~L.
., •• 1.'1 •••
Dodg_ St_lth A/T Turbo
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M~.ublehl IIIIrTl 00 TlNIn Turbo
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Mlt.ubi.hl 30QOElT VA4

WSMG1,W6MG1
MANUAL TRANSMISSION
Preface
This book was translated from the original
Japanese language service manual published
by Mitsubishi Motors Corporation ofJapan.
Translation was performed by volunteers from
3000GT/Stealth International, an owners and
enthusiast group focused
on the Mitsubishi
3000GT, Dodge Stealth and Mitsubishi GTO.
Great care has been taken to ensure the
accuracy
of the information contained in this
manual, but errors may still be possible due
to the nature ofthe translation. Therefore,
this manual is presented as a guide only,
and repair procedures should not be
undertaken by unskilled individuals who do
not posess a thorough understanding
of the
subject material.
The authors ofthis manual will not be held
responsible for any personal injury or damage
to property incurred while performing the
procedures described within.
All tasks in this manual are undertaken at your
own risk.
Group Index
c::lut;ct1 .................................. ~
Manaul Transmission ....... ~
Transfer C::ase Recall ....... E33
Applicable Models
This book covers the Getrag W5MG1 and
W6MG1 all-wheel drive manual transaxles
found in the following models:
1991 -1996 Dodge Stealth RlT Turbo
1991 -1999 Mitsubishi 3000GT VR4
1990 -1999 Mitsubishi GTO Twin Turbo
This book would not be possible without the
contributions
of the following people:
Translation, and layout
JeffVanOrsdal
Additional Translation
Frank Chen, Kotaru Yamaguchi,
Corumisri
Technical Assistance
Bret Brinkmann
Jeff Lucius
Financial assistance
Many generous members of 3000GT I Stealth
International
Visit 3000GT I Stealth International on the web at www.3si.org

Introduction
Introduction
Scope of this manual
This book explains the main service points
regarding the transmission itself. However,
please utilize the relevant service manual
for the car model and year in question
when concerns arise regarding onboard
inspection and service.
Important points
(1) Component diagrams are published
at the beginning of each section so that
you may more easily visualize the
assembled state of the component or
su b-assembly.
(2) Numbered service procedures are
displayed in the component diagrams
along with indications of non-reusable
parts and torque specifications.
(3) Main service points and maintenance
points are explained
in detail, along with
usage and descriptions
of special tools.
About inspection
Descriptions are provided for procedures
to
be taken when defective or damaged
parts are discovered during inspection.
Symbols for lubricants, sealants and adhesives
Information concerning the locations of lubricarion
and for application of sealants and adhesives is
provided, by using symbols, in the diagram of
component parts or on the page following the
component parts page.
4IiN ................. Grease (multipurpose unless there
is a brand or type specifed)
t ................ Brake fluid or automatic transmission
fluid
..... ..... .. ......... .. ......... .. ...........Sealant or adhesive
r,. ............................................................. Gear oil
Removal procedures
The part designation number corresponds to the
number
in the illustration to indicate removal
procedures.
Disassembly procedures
The part designation number corresponds to the
number
in the illustration to indicate disassembly
procedures.
Installation procedures
Specified in case installation is impossible in
reverse order of removal procedures. Omitted if
installation is possible in reverse order of removal
procedures
Reassembly procedures
Specified in case reassembly is impossible in
reverse order of disassembly procedures. Omitted
if reassembly is possible in reverse order of
disassembly procedures.
Classification of major maintenance or service
points
(JAQ
: Indicates that there are essential points for
removal or disassembly.
.A,
: Indicates that there are essential points for
installation or reassembly.
I--
,-----
l-
f---
r--
-
f---

Group number and page number
21 - B
Disassembly /
Reassembly
Introduction
Group title
~
Section title
Clutch - Clutch Release Cylinder
Torque specification 2
Jia
6 6 1
Denotes non-
reusable part
Coat all internal
parts in brake fluid
before reassembly
Disassembly Procedure
1. Pushrod
2. Boot
(:lAO_A. 3. Piston cup
(:lAO_A. 4. Piston
5. Conical spring
6. Cap
7. Bleeder screw
8. Release cylinder
Disassembly service points
(JAc') Removal of piston cup / piston
TFM0494
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
compressed air.
Caution
1. Cover with rags to prevent the piston from
6CL035 popping out.
~------------------------~
2. Apply compressed air slowly to prevent brake
fluid from splashing.

21
CLUTCH
Maintenance Standards ............................................ 21-2
Torque Specifications ................................................ 21-2
Lu brication .................................................................... 21-2
Special Tools ................................................................. 21-3
Clutch Assembly .......................................................... 21-4
Clutch Release Cylinder ............................................. 21-8
Clutch Damper ............................................................ 21-10

21 - 2
Clutch - Standards, Torque and Lubrication
Maintenance Standards
Item Limit Value mm
Clutch disk facing rivet sink Below 0.3
Diaphragm spring end height difference Within 0.5
Opening of release cylinder bore and piston major diameter Above 0.15
Torque Specifications
Item Torque
Clutch damper bracket attachment bolt 6.5 tUbs / 9 Nm
Clutch damper installation bolt 14 fUbs / 19 N.m
Clutch oil tube filling nut
11 ftlbs /15 Nm
Release fork fulcrum 26 ftlbs / 36 Nm
Clutch oil line bracket attachment bolt 14 tUbs / 19 N.m
3-way type connector mounting bolt 14 tUbs / 19 N.m
Clutch release cylinder mounting bolt 14 tUbs / 19 N.m
Union bolt
17 ft.lbs / 23 Nm
Clutch cover installation bolt 14 ftlbs / 19 N.m
Clutch release cylinder air breather 8 fUbs /11 Nm
Clutch damper air breather 6.5 ft.lbs / 9 Nm
Lubricants
Item Specified lubricant
Clutch release bearing sleeve diameter
Clutch release bearing and shift fork contact section Molykote
TA #2
Shift fork and fulcrum contact section
Clutch release cyliner pushrod tip
Inside splines of clutch disk Molykote TA
#1 or #2
Clutch release cylinder piston and piston cup SAE J1703 (DOT3)
Clutch damper O-ring

Clutch - Special Tool
Tool Part Number
MD998126
Name
Clutch disk
centering guide
21 - 3
Use
Positioning the clutch disk

21 - 4
Removal/
Installation
18
4IiM
Removal Procedure
27 fUbs
36Nm
22
4IiM 20
17
4IiM
1. Clutch cylinder release tube
2. Clutch cylinder release tube
3. Clutch cylinder release tube
4. Clip
5. Bracket
6. Clutch damper
7. 3-way junction block
8. Insulator
9. Bracket
10. Insulator
11. Banjo bolt
12. Crush washer
23
19
c?4iM
Clutch - Clutch Assembly
14 ft.lbs
19 Nm
4 5 ~
~~
1 ~ fI-~o 6
3---{
2
11 ft.lbs
y-----, 15 Nm
--7
14 fUbs
19 Nm
~ 13 ~
16 rf ~ ¥
@--10
15 1~ 1/ 11 ft.lbs 115 Nm
1D12 117 ft.lbs
11 23 Nm
13.
Union
14. Release cylinder valve
15. Release cylinder spring
"0' 16. Clutch release cylinder
.. C. 17. Clutch cover
.. C. 18. Clutch disk
ClAo .. a; 19. Clutch release fork
.. U 20. Throw-out bearing
21. Boot
22. Release fork fulcrum
23. Clutch housing

Clutch - Clutch Assembly
21 - 5
Fulcrum
Release
fork
Clip
Removal service points
oAQ Release fork removal
(1 )Slide release fork in direction of arrow and disengage
fulcrum from clip to remove release fork. Be careful not to
cause damage to clip by pushing release fork
in the direction
other than that
of arrow and removing it with force.
L---- ___________ D_C_LO-----'02 Inspection
Rivet sink
~~ifk~
6CL003
Clutch cover assembly
(1 )Check the diaphragm spring end for wear and uneven
height. Replace
if wear is evident or height difference
exceeds the limit.
Limit: 0.5 mm (.020 in.)
(2)Check the pressure plate surface for wear, cracks and
seizure.
(3)Check the strap plate rivets for looseness and replace
the clutch cover assembly if loose.
Clutch disk
(1 )Check the facing for loose rivets, uneven contact,
deterioration due to seizure, adhesion of oil or grease,
and replace the clutch disc if defective.
(2)Measure the rivet sink and replace the clutch disc if it
is out of specification.
Limit: 0.3 mm (.012 in.)
(3)Check for torsion spring play and damage and if defective,
replace the clutch disc.
(4)Combine the clutch disc with the input shaft and check
sliding condition and play in the rotating direction. If it
does not slide smoothly or the play is excessive, check
after cleaning and reassembling. Ifthe play is excessive,
replace the clutch disc and/or the input shaft.
Clutch release bearing
Caution
Release bearing is packed
with grease. Therefore do not
wash it in cleaning solvent or the like.
(1 )Check bearing for seizure, damage, noise, or improper
rotation. Check also diaphragm spring contact surface
for wear.
(2)Replace bearing if its release fork contact surface is
abnormally worn.
Release fork
(1 )Replace release fork if its bearing contact surface is
abnormally worn.

21 - 6
6C lDI 6
3C l 0003
Clutch - Clutch Assembly
Installation service points
• A. Installation of clutch release bearing
(1) Fill the lip section with grease as illustrated
Specified grease:
Molykote TA #2
• B. Lubrication of release fork
(1) Apply grease to release fork as illustrated
Specified grease:
Molykote TA #2

Clutch - Clutch Assembly
21 - 7
Flywheel
~~7+-- Clutch disk
Clutch cover
6CL028
i
Apply 4iH
3CL0004
.C' Installation of clutch disk cover
(1) Apply specified grease to clutch disc splines and
squeeze it
in place with a brush.
Specified grease:
Molykote TA #1 or #2
(2) Use the clutch disc guide to position clutch disc
on
flywheel.
(3) When installing the clutch cover, tighten the bolts
in a diagonal pattern.
(4) Remove clutch guide tool
.0. Installation of clutch release
cylinder
(1) Apply grease to tip of release cylinder pushrod
as illustrated.
Specified grease:
Molykote TA#2

21 - B
Disassembly /
Reassembly
e 6
Clutch - Clutch Release Cylinder
1
2
Disassembly Procedure
1. Pushrod
2. Boot
OAO.A, 3. Piston cup
OAO.A, 4. Piston
t Coat all internal
parts in brake fluid
before reassembly
5. Conical spring
6. Cap
7. Bleeder screw
8. Release cylinder
TFM0494
Disassembly service points
OAt; Removal of piston cup / piston
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
compressed
air.
Caution
6CL035 1. Cover with rags to prevent the piston from
L- ________________________ ~
popping out.
2.
Apply compressed air slowly to prevent brake
fluid from splashing.

Clutch - Clutch Release Cylinder 21 - 9
.....................................................
Ii
;----++-Apply
:.:.: .............................................. .
7ClDDD7
IiApply
\ Apply
'"-r---",.L--,
Piston cup ,
Piston Ii
6ClDDD3
Inspection
(1) Remove any rust or corrosion from the inside of
the release cylinder
(2) Measure the inside diameter of the cylinder at 3
places (bottom, middle and top) Ifthe diameter of the
cylinder exceeds the outside diameter of the piston by
more than the limit value, replace the release cylinder
assembly.
Limit value:
0.15 mm
Assembly service points
.A. Installation of piston / piston cup
(1 )Apply specified brake fluid to the release cylinder
inside and outer surface ofthe piston and piston cup
and push the piston cup assembly
in the cylinder.
Specified brake fluid:
SAE J1703 (DOT3)

21 - 10
Disassembly /
Reassembly
3-----1
Disassembly Procedure
1. Cap
2.
Bleeder screw
3. Clutch damper
itA" 4. O-Ring
5. Clutch damper bracket
...--..- Scratches
f"J-V''- Scratches
TFM0292
I
~- - ----"I
TFM0373
Clutch - Clutch Damper
~f---
k2
6.5 ft.lbs
9Nm
Inspection
Clutch damper
5
6.5 ft.lbs
9Nm
TFM0392
(1) Check that there are no scratches on the parts
indicated
in the illustration.
(2) Clean completely the inside of the clutch damper and
confirm that there is no foreign material left.
Clutch damper bracket
(1) Check that there are no scratches of cracks on
the part indicated in the drawing.

Clutch - Clutch Damper 21 - 11
Assembly service point
.A. Installation of O-ring
(1) Apply the specified brake fluid onto the O-ring, and
securely install it onto the position of the clutch damper
indicated
in the illustration.
Specified brake fluid:
SAE J1703 (DOT3)

22
MANUAL
TRANSMISSION
Su~~ary ...................................................................... 22-2
Specifications .............................................................. 22-4
Maintenance Standards ........................................... 22-5
Sealants ........................................................................ 22-5
Lu brication ................................................................... 22-6
Adjust."ent Spacers ................................................. 22-7
Torque Specifications ............................................... 22-8
Special Tools ................................................................ 22-9
Transn'1ission .............................................................. 22-13
Input Shaft ................................................................ 22-34
Intern'1ediate Shaft .................................................. 22-40
3rd-4th Gear Synchronizers
5th-6th Gear Synchronizers
< W6MG1 >......... 22-50
< W6MG1 >.......... 22-51
Center Differential ................................................... 22-52
Front Output Shaft ................................................. 22-55
Rear Cover ................................................................. 22-57
Front Differential ...................................................... 22-62
Speedon'1eter Gear .................................................... 22-64
Transfer Case ............................................................ 22-65

22 - 2
Cross-section
W5MG1
Manual Transmission - Summary

Manual Transmission - Summary
Cross-section
WSMG1
22 - 3

22 - 4
Manual Transmission - Specifications
Transmission types
1991 Model Vear
Transaxle model Ratio
set
W5MG1-0-FNBR A
1992 Model Vear
Transaxle model Ratio
set
W5MG1-1-FNCR A
1993 Model Vear
Transaxle model Ratio
set
W5MG1-2-FNCR A
1994 + Model Vear
Asian Market
Transaxle model Ratio
set
W6MG1-0-GNCR B
Speedometer Final Drive
gear ratio
27/36 3.972
Speedometer Final Drive
gear ratio
27/36 3.972
Speedometer Final Drive
gear ratio
27/36 3.972
Speedometer Final Drive
gear ratio
28/36 4.155
1994 + Model Vear
North American Market
Transaxle model Ratio Speedometer Final Drive
set gear ratio
W6MG1-0-FNBR B 28/36 3.869
Gear ratio sets
A
1st Gear 3.071
2nd Gear 1.739
3rd Gear 1.103
4th Gear 0.823
5th Gear 0.659
6th Gear NA
Reverse 3.076
Transfer Case 0.814
Chassis Engine type
Z15A,Z16A 6G72-DOHC TIC
Chassis Engine type
Z15A,Z16A 6G72-DOHC TIC
Chassis Engine type
Z15A,Z16A 6G72-DOHC TIC
Chassis Engine type
Z15A,Z16A 6G72-DOHC TIC
Chassis Engine type
Z15A,Z16A 6G72-DOHC TIC
B
3.266
1.904
1.241
0.918
0.733
0.589
3.153
0.958

Manual Transmission - Standards and Sealants 22 - 5
Maintenance Standards
Item Standard Value in mm Model
Input shaft bearing end play 0.02 -0.05
--
Intermediate shaft preload 0.15 -0.25 W5MG1
0.20 -0.30 W6MG1
Center differential preload 0.10 -0.20 W5MG1
0.15 -0.20 W6MG1
Front output shaft preload 0.15 -0.25 W5MG1
0.10 -0.15 W6MG1
Front differential preload 0.15 -0.25 W5MG1
0.15 -0.20 W6MG1
Sealants
Item Type
Input shaft lock bolt
Rear cover to center case installation bolt
Stopper plate installation bolt
Center case to clutch housing installation bolt
Shift shaft to clutch housing installation bolt
Shift shaft guide bolt Loc-tite #242
Select lever installation bolt
Poppet cover installation bolt
Reverse idler gear shaft bolt
Reverse shift damper
Mating surface
of rear cover and center case Loc-tite #17430
Mating surface of center case and clutch housing or
Mating surface
of clutch housing and shift shaft Mitsubishi Geunine
Sealant MD997740
Mating surface of poppet cover and rear cover