1990 MITSUBISHI SPYDER ESP

CONTENTS
MANUAL TRANSAXLE ENGINEMANUAL TRANSAXLE ENGINE
(NON-TURBO)>(TURBO) AND ENGINE>
GENERAL INFORMATION . . . . . . . . . . . . . . 22GENERAL INFORMATION . . . . . . . . . . . . . . . .
2
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . 24LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . .6
ON-VEHICLE SERVICE. . . . . . . . . . . . . . . . .
2 4
Transaxle Oil Level Check . . . . . . . . . . . . . . . .
24
Transaxle Oil Replacement . . . . . . . . . . . . . . .
24
SERVICE SPECIFICATIONS. . . . . . . . . . . . .24
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . .24
TRANSAXLE ASSEMBLY. . . . . . . . . . . . . . .28
TRANSAXLE CONTROL*. . . . . . . . . . . . . . . .25ON-VEHICLE SERVICE
. . . . . . . . . . . . . . . . 8
Shift Lever Assembly
. . . . . . . . . . . . . . . . . . . . .
27
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . .24
Transaxle Oil Level Check . . . . . . . . . . . . . . . . .8
Transaxle Oil Replacement
. . . . . . . . . . .. . .
Transfer Oil Level Check ...... . . . . . . . . . . .
Transfer Oil Replacement. . . . . . . . . . . . . . . . . .8
SERVICE SPECIFICATIONS. . . . . . . . . . ...
SPECIAL TOOLS 7. . . . . . . . . . . . . . . . . .
TRANSAXLE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . ... . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 1 2
TRANSAXLE CONTROL*... . . . . . . . .
Shift Lever Assembly. . . . . . . . . . . . . . . . . . . . . .1 1
TRANSFER ASSEMBLY . . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRA
INT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1)Improper service or maintenance of any component of the or any component, can lead to personalinjury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from
rendering the inoperative).Service or maintenance of any or component must be performed only at an authorized MITSUBISHI dealer.(3)MITSUBISHI dealer personnel must thoroughly review this manual,and especially its GROUP
Restraint System and GROUP 00 Maintenance Service, before beginning any or maintenance of
any component of the or any component.
NOTEThe SRS includes the following components: warning light, air bag module,clock spring, and interconnecting
wiring. Other
components (that may have to be removed/installed in connection with service or maintenance)
are indicated in the table of contents by an asterisk

MANUALTRANSAXLE OVERHAUL
Transaxle
APPLICATION TO
RETAINER MOUNTING BOLT
s e a l a n t :
STUD Locking or equivalent
SHIFT RAIL ASSEMBLY
(1) Set the speed shift sleeve at speed.
(2) Set the speed shift sleeve at ,
(3) Install the shift fdrks
respective sleeves. .
(4) the shift rail into the shift fork hole, while tur ning
so as to prevent the shift lug from interfering wit h the
stopper plate.
(5) Turn the shift rail to engage shift lug.
P I N S S PEE D
FORK SPEED SHIFT FORK
INSTALLATION
IDLER GEAR
Install in the direction as
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MANUAL TRANSAXLE OVERHAUL
Synchronizer
SYNCHRONIZER
DISASSEMBLY AND REASSEMBLY
Disassembly steps
1. Reverse brake ring 2. Synchronizer spring 3. Synchronizer sleeve
72
4. Synchronizer key 5. Synchronizer hub
REASSEMBLY SERVICE POINTS
SYNCHRONIZER HUB SYNCHRONIZER SLEEVE
INSTALLATION
SYNCHRONIZER SPRING INSTALLATION
When installing the synchronizer springs, be sure t o position
each spring with respect to the keys as illustrated.
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MANUAL TRANSAXLE OVERHAUL
Input Shaft
gear
spee
gear
side
Identificationmark
Spring
stepped
SPEED SYNCHRONIZER HUB
SPEED
INSTALLATION
SYNCHRONIZER SPRING
INSTALLATION
When installing the be sure position
each spring with respect to the keys illustrated.
SLEEVE FOR
INSTALLATION
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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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. .

CONTENTS
AUTOMATIC TRANSAXLE
ENGINE (NON-TURBO)> . . . . . 115
AUTOMATIC TRANSAXLE KEY INTERLOCK
AND SHIFT LOCK MECHANISMS* . . . . . . . . 192
GENERAL INFORMATION
. . . . . . . . . . . . . . . . 115
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . .117
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 159
Automatic Transaxle Control Component
Oil Temperature Sensor Continuity Check . . . . 160
Pinion Factor Writing Procedure After
TCM Replacement or Tire Size Change
. . . 159
Selector Level Operation Check . . . . . . . . . . . . . . ,166
Shift Lock Mechanism Check. . . . . . . . . . . . . . .
1 8 6
TCM Resetting Procedure . . . . . . . . . . . . .
..159
Torque Converter Stall Testing. . . . . . . . . . . . . .166
Transaxle Fluid Level Check . . . . . . . . . . .. . .159
Transaxle Fluid Replacement. . . . . . . . . . . . . . .
Transaxle Range Sensor Continuity . . .
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163SERVICE SPECIFICATIONS.. . . .. . .Automatic Transaxle Control Component Layout
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . .117Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . .168
Fluid Leakage-Torque Converter Housing Area
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Hydraulic Pressure Tests. . . . . . . . . . . . . . . . . . .169
Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . .173
TRANSAXLE ASSEMBLY. . . . . . . . . . . . . . . .
TRANSAXLE CONTROL*. . . . . . . . . . . . . . . . .187
Selector Lever Assembly. . . . . . . . . . . . . . . . . . .189
Key Interlock Mechanism Check . . . . . . . . . . .
. 186CONTINUED ON NEXT PAGE
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL EQUIPPED VEHICLES
WARNING! (1) Improper service or maintenance of any componen t of the
or any component, can lead to personal
injuryordeath inadvertent the inoperative).
(2) Service or maintenance of any component or SRS-related component must be perform ed only at an authorized
MITSUBISHI dealer.
(3)MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Supplemental Re-
straint System (SRS) and GROUP 00 -Maintenance Serv ice before beginning any service or maintenance of any com-
ponent of the
or any component.
NOTEThe SRS includes the following components: SRS-ECU, SRS warning light, air bag module, clockspring and inte rconnecting wiring.Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indi-cated in the table of contents by an asterisk

SHIFT PATTERN
Throttle opening .
. .100
II ,
,
A U T O M A T I C T R A N S A X L E . . . ENGINE
. de--
3.
.
I20
I
00100020003 0 0 0
' 4 0 0 06 0 0 0
Transfer drive , , , , , , , , , ,
0
Vehicle speed km/h
LOCK-UP
Throttle opening
4 0
I I .I I
20
0I
1000
I.
I
2000
I
3 0 0 04000
Transfer drive
II5 0 0 0 .
0
Vehiclespeed (mph)
Revision,

AUTOMATIC TRANSAXLE
ENGINE (NON-TURBO)> Troubleshootihg
Code Scan tool 31Hydraulic pressure switch: ODProbable
No.General scan tool
Pressure switch falls to respond within specified time for given temperature range.
l Low/high fluid level in transaxle
l Malfunction of pressure switch assembly
l Internal transaxle problem
OKNGHydraulic pressure check Check the following Repair
l Measure the overdrive clutch pressure
l
l engine
l Disconnect the solenoid and pressure switchOK
assembly connector and apply system voltage
between terminals (6) (8).
WARNING: FRONT WHEELS MUST BE OFFReplace the solenoid and pressure switch bly.
THE GROUND BEFORE PRO-CEEDING.
NOTE: Step on the brake pedal so the wheels won’t rotate.
l Select lever: Increase the engine speed slightly.
S t a n d a r d
(75-95 psi)
every 3 seconds
Check the transmission fluid level.
NG
Repair
l Solenoid and pressure switch assembly
Internal transaxle failure. (Refer to
Code Scan tool 32 Hydraulic pressure switch: 2-4 Probable cause
No.General scan tool
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Pressure switch falls to respond within specified t
ime for given temperature range.l
Low/high fluid level in transaxle
l Malfunction of pressure switch assembly
l Internal transaxle problem
Hydraulic pressure check
l Measure the 2-4 clutch pressure
Start engine
following connector
WARNING: FRONT WHEELS MUST BE OFF THE GROUND BEFORE PRO-
CEEDING. on the brake pedal so that wheels
won’t rotate.
l Select lever:
l increase the engine speed slightly.
S t a n d a r d
(75-95 psi)
everv 3 seconds
NGOK
NG Repair
OK
the solenoid and pressure switch assem-
Check the transmission fluid level.
NG
Possible causes:
l Solenoid and pressure switch assembly
linternal transaxle failure. (Refer to