1990 MITSUBISHI SPYDER differential

T R A N S A X L E
CONTENTS
CENTER DIFFERENTIAL . . . . . .60
CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . .65
DIFFERENTIAL. . . . . . . . . . . . . . . . . .57. . . . . . . .
DRIVE BEVEL GEAR
. . . . . . . . . . .76
DRIVEN BEVEL GEAR . . . . . . . . . .80
EXTENSION. . . . . . . . . .73
SYNCHRONIZER . . . . . . . . . . . . . .36
FRONT OUTPUT SHAFT . . . . . . . .56
GENERAL INFORMATION. . . . . . . . . . . . . . . . . .2
INPUT SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . .38
INTERMEDIATE GEAR. . . . . . . . . . . . . . . . . . . .48
OUTPUT SHAFT . . . . . . . . .
55
SHIFT 3SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . . . . . .13
SPECIFICATIONS. . . . . . . . . . . . . . . . . ... . . . . . . .
G e a r R a t i o T a b l e . . .
...
. . . . . . . . . . . . . . . . . . . . . .5
Sealants and Adhesives . . . . . . . . . . . . . . . . . . . . .13
Service Specifications . . . . . . .6
Service Specifications . . . . .. . . . . . . .6
Snap Rings and Spacers for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . .12
Transaxle Model Table. . . . . . . . . . . . . .. . . . . . .5
SPEEDOMETER GEAR. . . . . . . . . . . . . . . . . . . .64
TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .17
TRANSFER . . . . . . . . . . . . . . . . . . . 68
TRANSFER CASE . . . . . . . . . . . . .
TRANSFER CASE ADAPTER .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .76

MANUAL TRANSAXLE OVERHAUL Information
SECTIONAL VIEW
Clutch housingBearing retainer
speed gear
speed gear
1 speed gearI speed synchronizer assembly
Input shaft
1
I
Rear cover
Reverse
brake
gear
gear
S p a c e r
Output
Differentialdrive gear
Spacer
Drain plug Spacer
case
Differential
TSB Revision

MANUAL TRANSAXLE OVERHAUL Information
Clutch housing speed gear
I
speed synchronizer assembly
speed gear
Bearing retainerI
Sub gearIntermediate gear
Revision
speed gear
speed synchronizer assembly
speed gear
speed gear
speed
synchronizer
Center differential
Frontoutput shaft
Front differential
coupling

MANUAL, TRANSAXLE OVERHAUL
Items
Differential case preload mm (in.)
Differential pinion backlash mm (in.)
Input shaft front bearing end play
mm (in.)
Input shaft end play
mm (in.)
Input shaft rear bearing end play mm (in.)
Intermediate gear bearing end play
mm (in.)
Intermediate gear bearing end play
mm (in.)
Intermediate gear preload mm (in.)
shaft preload mm (in.)
Standard value .
Center differential case end play mm (in.)
Center differential side gear end play mm (in.)
Front differential case end play mm (in.)
Front differential pinion backlash mm (in.)
Front output shaft preload mm (in.)
Input shaft end play mm (in.)
Input shaft front bearing end play mm (in.)
Input shaft rear bearing end play mm (in.) Intermediate gear bearing end play mrn (in.)
Intermediate gear preload mm (in.)
Transfer bevel gear set backlash mm (in.)
drive bevel gear rotating torque Nm
driven bevel gear rotating torque Nm
coupling end play mm (in.) Standard value
1.7-2.5
TSB Revision

MANUALTRANSAXLE OVERHAUL
Spacer: (For adjustment of fron
Identification symbol Thickness mm (in.)
0.56 56
0.6565
0.7474
0.8383
0.9292
differential case end play)
Part No.Thickness mm (in.) Identification symbolPart No.
101
1 . 1 0
1
1 . 2 8 0458
1 . 3 7 0460
Spacer: (For adjustment of front differential case end play)
Identification symbolThickness mm (in.)Identification symbolPart No.Thickness mm (in.)
0.80800.92
0.83830.95
0.86860.98
0.89891
1.04041
1.07071.19
1 04541.22
1.131.25
Part No.
P a r t N o .
80675
92
95
98
01
Spacer (For adjustment of front differential pinion backlash)
Identification symbolThickness mm (in.)Identification symbolThickness mm (in.) No.
80862
80861
80860
Spacer: (For adjustment of front output shaft preload)
Identification symbolPart No.Thickness mm (in.)Identification symbolPart No.
1.28
671.61
1.31 681.64
1.34 691.67
1.371.70
1.73
1.431.76
1.461.79
1.491.82
1.521.85
1.551.88
1.581.91
Thickness mm (in.)
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Snap ring: [For adjustment of viscous coupling end play (with VCU)]
Thickness mm (in.)Identification symbolPart No. Thickness mm (in.) Identification symbolPart No.
1.3
1.4
1.5
1.6
Orange
Red
Blue
None
1.7
1.8
1.9
White
Yellow
Green
Spacer: (For adjustment of center differential pinion back lash front side)
Thickness mm (in.)Identification symbolPart No.Thickness mm (in.)Identification symbolPart No.
2.25-2.32
2.33-2.42
412
410
409
2.59-2.66
2.67-2.74
2.75-2.82
4 3
2
408
407
405
Spacer: (For adjustment of center differential case preloa d)
Thickness mm (in.)Identification symbol
1.13
13
1.1616
1.1919
1.222 2
1.2525
1.2828
1.3131
1.3737
1.4040
1.43
43
1.4646 Part No.
66
8520
8522
8523
Revision
Thickness mm (in.)
Identification symbolPart No.
1.49
49 8524
1.5252 8525
1.5555 8526
1.5858 8527
1.6161 8528
1.6464 8529
1.6787 8530
1.7070 8531
1.73
73 959
1.7676 960
1.7979
Spacer: (For adjustment of center differential pinion back lash, rear side)
Thickness mm (in.)IdentificationPart No.Thickness mm (in.)Identification symbol No.
74 1 78
501 1.0876
8077
7949

MANUAL TRANSAXLE OVERHAUL
Items
Transaxle
Backup light switch
Bearing retainer bolt
Bell housing cover mounting bolt
Center differential lock actuator mou
Center differential lock indicator
Center differential shift lever
Differential drive gear bolt
Input shaft lock nut
Interlock plate bolt
Intermediate gear lock nut
3324
33
24
Output gear mounting bolt
Poppet plug
Rear cover bolt
Rear cover bolt
Restrict ball
Reverse brake cone machine screw
Reverse idler gear shaft bolt
Reverse shift lever assembly
Select lever mounting bolt
Shift cable bracket mounting bolt
Speedometer sleeve bolt
Starter motor mounting bolt
Stopper bracket bolt
Transaxle case tightening bolt
Transaxle mount bracket mounting
Transaxle mounting bolt mm
Transaxle mounting bolt mm diamet
Transaxle mounting bolt
mm diamet
Transaxle switch
Revision

MANUAL TRANSAXLE OVERHAUL Tools
Items Nm
Transfer
Cover mounting bolt
,
97
Driven bevel gear lock nut
Extension housing150109
Oil drain plug 3324
Oil filler plug3324
Transfer case adapter mounting bolt
Transfer cover mounting bolt
39 29
39
Transfer mounting bolt
5942
SEALANTS AND ADHESIVES
Items
Transaxle case rear cover mating surfacesSpecified sealants and adhesives
Mitsubishi genuine sealant
Part
or equivalent
Transaxle case clutch housing mating surfaces
Adapter-transaxle case mating surfaces
Adapter rear cover mating surfaces
Output gear bolt STUD Locking 70 or equivalent
Differential drive gear bolts
Bearing retainer bolt (Countersink head bolt only)
Air breather
SUPER WEATHERSTRIP or
equivalent
Transfer extension housing
adapter mating
surfaces
Transfer cover gasket Mitsubishi genuine sealant
Part
or equivalent
ATD Part or equivalent
SPECIAL TOOLS
Tool Tool number and Application
Oil seal installer
Oil seal installer
Quantity
As required
As.
As
Asrequired
As required
Installation of
extension
housing oil seal,
Installation of input seal
Revision