1990 MITSUBISHI SPYDER clutch

MANUAL TRANSAXLE OVERHAUL
bear
Identification mark RINGS
GEAR INSTALLATION .
The speed gear and of
r i n g s h a v e a n i d e n t i f i c a t i o n m a r k .
Clutch housing
Identification markTooth missing here
Synchronizer key
1 SPEED
SYNCHRONIZER KEY
SLEEVE
(1) the speed
as
(2) The synchronizer sleeve has tooth missing at si x portions.
Assemble the hub to the sleeve in such a way that t he
center tooth
between two missing teeth will touch
the synchronizer key.
SYNCHRONIZER SPRING INSTALLATION
When installing the synchronizer springs, be sure t o position
each spring with respect to the keys as illustrated.
BEARING SLEEVE INSTALLATION
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MANUAL TRANSAXLE OVERHAUL
Gear
ring
201051
Gear2110009
and wear
Scratches and damage
and wear
I N S P E C T I O N
INTERMEDIATE GEAR
(1) Check the outer surface of the
the needle bearing is mounted’ abnormal
wear and seizure
(2) Check the splines for and
NEEDLE BEARING
(1) Combine the bearing or bearing’
sleeve and gear and check it rotates Smoothly without
abnormal noise or play.
(2) Check the needle bearing for’
SYNCHRONIZER RING
(1) Check the clutch gear teeth for damage breakage.
(2) Check the internal surface for damage,, broken
threads.
(3) Force the ring toward
check clearance “A”. if it is of specification.
Limit: 0.5 mm
in.)
SYNCHRONIZER OUTER RING, INNER RING AND CONE (1) Check that there are no scratches of damage on the
clutch gear teeth and cone surface.
(2) Check that there are no scratches, wear or peel ing on
the paper lining

MANUAL TRANSAXLE OVERHAUL
Intermediate Gear
the outer ring, inner ring and cone, and press them
onto the clutch gear. Check clearance and replace
if
is below the limit value..
Limit: 0.5 mm in.)
Replace the outer ring, inner ring cone, as
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SYNCHRONIZER SLEEVE AND HUB
(1) Combine the synchronizer
and hub and check
that they slide smoothly.
(2) Check that the sleeve is free from damage
its
front and rear ends.
(3) Check for wear of the end contact
each speed gear).
Caution
Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
(1)Check for wear of the protrusion.
(2) Check the spring for break-
age.
SPEED GEARS (1) Check the bevel gear and clutch gear teeth for damage
and wear.
(2) Check the synchronizer cone for damage
and wear.
(3) Check the gear bore and front arid rear ends fo r
and wear.

MANUAL TRANSAXLE OVERHAUL
Housing
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
19 Nm14
24 Nm
16
Lubricate all internalparts with engine oil
during reassembly.
22100019
Disassembly steps
1.Bolt2. Select lever assembly3.Select lever shoe4. Interlock plate bolt5.Gasket 6. Lock pin
7. Spring pin 8. Neutral return spring
9.Stopper body10.Controlfinger
1
Interlock plate
12. Neutral return spring assembly
13. Control shaft
14. Control shaft boot
15. Oil seal 16. Needle 17. Needle,
Return spring
21. plate
22. Spring pin
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MANUAL TRANSAXLE OVERHAUL Clutch Housing
2200064
Extension barsocket wrenchI
Needle bearing
DISASSEMBLY SERVICE
,
Caution
When removing the lock pin, turn the control lever to
such position that the lock pin will not contact the clutch
housing.
SPRING PIN REMOVAL
Caution
When spring pin, pull control shaft
the direction illustrated so that the pin will not
contact the clutch housing.
NEEDLE BEARING REMOVAL
REASSEMBLY SERVICE POINTS
NEEDLE
(1) Install the needle bearing flush surface A of
the
housing using a
(2) Install with the part type stamped the
A. . . .ii
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MANUAL TRANSAXLE OVERHAUL
Clutch Housina
bar socketwrench
Extension bar
socket wrench
SEAL INSTALLATION
PIN LOCK PIN
Caution
lDo not reuse the spring pin and lock pin.
lInstall the spring pin In such a way its will
at right angle to the control shaft center.
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MANUAL TRANSAXLE Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Applicable engine
Gear ratio1
Reverse
Final gear ratio
Speedometer gear ratio (driven/drive)
SERVICE SPECIFICATIONS
Differential side gear end playmm (in.)
Differential case preload mm (in.)
Specifications
-1
floor shift floor shift
3.54
3.54
2.132.13
1.36 1.36
1 . 0 3
3.94 ,
3.55
Specifications,
. 0.18
TORQUE SPECIFICATIONS22210040017
ItemsN m
Back-up light switch 2418
Differential ring boltgear81
End cover bolt2921
Output bearing race retainingstrap9.6
R e v e r s e i d l e r b o l tgear2619
Reverse fork bracket bolt119.6
Shift cable bracket-transaxle28 20
Transaxle case clutch housing bolt2921
SEALANTS22210050010
ItemsSpecified sealant
End cover and bolts
Clutch housing to transaxle case
Loctite 18718 or equivalent
Loctite 51817 or equivalent
As required
As required
Clutch housing to transaxle case bolts Loctite 51817 or equivalent
As requiredI
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MANUAL TRANSAXLE Case
I \Differential
ing
(1) Line up bearing race race bore.
(2) tool into output bearing
race. Tap race into bore.
Tighten bolts to’ 11 Nm
__
,
INPUT BEARING AND SLEEVE
The input bearing is a one-piece bearing and sleeve
The sleeve is the slide point for the clutch release bearing
and lever.
__
R E M O V A L
tool over input bearing on.
the gear case side of the transaxle clutch housing.
(2) Tap the input bearing out housing.’
INSTALLATION.
(1)Apply coating of Loctite sealant
Position sleeve and bearing
bore.
(2) Install tool input
.
.
,
(3)Using the spacer tool and shop press, install input bearing
into bore until it is fully seated.
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