1991 MITSUBISHI ECLIPSE service

REAR AXLE - Differential Carrier3-23
DISASSEMBLYInspection Before Disassembly
@Final Drive Gear Backlash (Refer to P.3-20.)*Differential Gear Backlash(Refer to P.3-21.)
/ ;3-21.)’1
@Drive Gear Runout (Refer to P.3-21.)aFInal Drove Gear Tooth Contact (Refer to

\ \\Oi6 27i0
q l7 18 20llA0260

Disassembly steps
1. Differential cover
2. Vent plug
3. Bearing caps
*I)4. Differential case assembly5. Side bearing spacers
6. Side bearing outer race
:z
7. Side bearing inner race8. Drive gear
l * l *9. Lock pin 9. Lock pin10. Pinion shaft11. Pinion gears12. Pinion washers
13. Side gears
14. Side gear spacers15. Differential case
16. Limited slip differential case assembly
*I)17. Self-locking nut18. Washer
4*19. Drive pinion assembly
20. Companion flangellvlI , ,,,igellA0290llA0290
21. Drive pinion front shim-:-- ‘--nt shim
(for preload adjustment)Jstment)22. Drive pinion spacer3cerl *23. Drive pinion rear bearing inner racerr bearing inner race
24. Drive pinion rear shimrr shim,Ivl PJ” llUl I I IcIyIit adjustment)(for pinion height adjustment)?Cl3.r;. I,-. ..:..;A-25. Drive pinion
::
26. Oil seal“II >twI27. Drive pinion front bearingDrive pinion front bearing
4*28. Drive pinion rear bearing outer racen-‘..- -‘-‘-- --lr bearing outer race
29. Oil seal
30. Gear carrier
NOTE(1) +I) : Refer to “Service Points of Disassembly”.(2) m : Non-reusable parts.

3-24REAR AXLE- Differential Carrier
SERVICE POINTS OF DISASSEMBLYN03lGSC4. REMOVAL OF DIFFERENTIAL CASE ASSEMBLY
kPrize out the differential case assembly using hammer
‘-
shafts.
NOTEWhen removing the differential case assembly, the
re’mov-
al should be accomplished slowly and carefully and cautionpaid to ensure that the side bearing outer race is not
dropped.
Keep the right and left side bearings separate, so that theydo not become mixed at the time of reassembly.
7. REMOVAL OF SIDE BEARING INNER RACES
Pull out the side bearing inner races by using the special
tools.8. REMOVAL OF DRIVE GEAR
(1) Make the mating marks to the differential case and the
drive gear.
(2) Loosen the drive gear attaching bolts in diagonal
fisequence to remove the drive gear.
9. REMOVAL OF LOCK PIN
Drive out the lock pin with a punch and remove the pinion
gears, pinion washers, side gears and side gear spacers.
17. REMOVAL OF SELF-LOCKING NUT
Use the special tools to hold the companion flange and
remove the companion flange self-locking nut.

3-26REAR AXLE - Differential Carrier
REASSEMBLYN0311-40-60
Nm*B-43 ft.lbs.*
80-90 Nm*58-65 ft.lbs.*

11 BOO86Differential gear setFinal drive gear set
Reassembly steps
1. Gear carrierl * 2. Oil seale+3. Drive pinion rear bearing outer racel +4. Drive pinion front bearing outer race
l *Adjustment of pinion height
5. Drive pinion
6. Drive pinion rear shim
(for pinion height adjustment)
7. Drive pinion rear bearing inner race8. Drive pinion spacer
l 4Adjustment of drive pinion preload9. Drive pinion front shim
(for preload adjustment)10. Drive pinion assembly11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential casellA0260llA0290
17. Limited slip (viscous coupling) differential
case
l *Adjustment of differential gear backlash
18. Side gear spacers
19. Side gears20. Pinion washers
21. Pinion gears22. Pinion shaft
l * 23. Lock pin
l + 24. Drive gear
+4 25. Side bearing inner race
26. Side bearing outer race
l 4Adjustment of final drive gear backlash
27. Side bearing spacers28. Differential case assembly
29. Bearing capsl 30. Vent plug
l
31. Differential cover
NOTE(I) I)+ : Refer to “Service Points of Reassembly”.[Z!/ m : Non-reusable parts.*: Tightening torque with oil applied.

REAR AXLE - Differential Carrier3-27
llK010
71
llY181llY182
.MB990836(MB990835)
llrm3
V223
SERVICE POINTS OF REASSEMBLYNOJUBD2. PRESS FITTING OF OIL SEAL
(1) With the special tool, press fit the oil seal until it is flushwith the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
3. lNSTALLATlON OF DRIVE PINION REAR BEARING
OUTER RACE/4. DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer racesinto the gear carrier by using the special tools.
CautionBe careful not to press in the outer race at an angle.
l ADJUSTMENT OF PINION HEIGHT
Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequenceshown in the illustration.
NOTEApply a thin coat of multipurpose grease to the mating
face of the washer of the special tool.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
(2) Tighten the handle of the special tool until the standardvalue of drive pinion turning torque is obtained.
(3) Measure the drive pinion turning torque (without the oil
seal).Standard value:
Rotation torque
(starting friction torque)Nm
(in.lbs.)
I
NoneNew(with rust-I0.9-1.2 (8-10)prevention oil)New/reused Oil application
NOTE
0.4-0.5 (3-4)(I) Gradually tighten the nut of the special tool while
checking the drive pinion turning torque.
(2) Because the special tool cannot be turned one turn, turnit several times within the range that it can be turned;then, after fitting to the bearing, measure the rotation
torque.

REAR AXLE - Differential Carrier (Limited Slip Differential)3-35ferential side gear
(right)Differential
Differential
pinion mate
llPO12BThrust washer
Pinion mate
Pinion mate
washerThrust washer
,,po,29Differential case
BerentiieA11
PO1311(3) Insert the special tool at the spline part of differential
case
B (right) and check to be sure the side gear (right)
rotates.(4) Then insert a 0.09 mm
(.0035 in.) feeler gauge to
replace a 0.03 mm (0012 in.) gauge.
(5) Insert the special tool at the spline part of the
differential side gear (right) and check to be sure the
side gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thrust direction of side
gear):
0.03-0.09 mm (.0012-.0035 in.)
NOTE
If the clearance in the thrust direction of the side gear iswithin the standard value range, the backlash of the
differential gear is normal.
(6)If the clearance in the thrust direction of the side gear is
not within the standard value range, remove differentialcase A and make the adjustment by adjusting the
thickness of the thrust washer (left).
SERVICE POINTS OF DISASSEMBLYNO3lLBB3. REMOVAL OF THE THRUST WASHER (LEFT)/
9. THRUST WASHER (RIGHT)
The thrust washers (left and right) are of different thick-
ness, and so should be discriminated in some way for
reference during installation.
INSPECTIONN03lMBB(1) Check the gears and differential pinion shaft for unusual
wear or damage.
(2) Check the spline part of the differential side gear (right) for
stepped wear or damage.
(3) Check the thrust washer and pinion mate washer for
unusual wear of contact surfaces, heat damage or other
damage.(4) Check differential cases A and
B for unusual wear of
contact surfaces, heat damage or other damage.
0: Contact surface with the viscous unit
0: Contact surface with the pinion mate washer
@ and @I: Contact surfaces with thrust washer

3-36REAR AXLE - Differential Carrier (Limited Slip Differential)Contact surface
with differential
viscous unit
llPO142
Mamaifferential case
BPinion mate
washer
bDifierential7-pinion matellPO134Feeler gauge
Feeler
gaugeFeeler gauge
lifferential gear (right)Thrust washer (right),\llPO130
1(5) Check the
spline part of the viscous unit for stepped
wear or damage, and check the contact surface with
differential case B.
45
(6)Check the side gear (left) of the viscous unit for unusualwear or damage.
SERVICE POINTS OF REASSEMBLYNOOINBE
10. INSTALLATION OF THE DIFFERENTIAL CASE B/2. DIFFERENTIAL CASE A
Align the mating marks of differential cases
B and A, and
assemble the cases.
6. INSTALLATION OF THE DIFFERENTIAL PINION
MATE/5. PINION MATE WASHER
With the washer in the position shown in the figure, install
to the differential pinion shaft, and then install to differentialM.case
B.3. SELECTION OF THE THRUST WASHER (LEFT)
(1) If the differential side gear and pinion mate gear have
been replaced, select the thrust washer (left) by
following the steps below.
@ Wash the differential side gear and pinion mate gear
in unleaded gasoline to remove all oil, grease, etc.
@ Install the previously used thrust washers (being
careful the left and right ones are used at the
correct side), together with the gears, viscous unit,
pinion mate washer and pinion shaft, to differential
cases A and
B, and then, using screws, secure
them temporarily.
@ Secure the differential case assembly in a vise so
that the differential side gear (right) is facing
upward.Caution
When securing in the vise, be sure not to hold the
differential case assembly too tightly.
@I Insert a 0.03 mm LOO12 in.) feeler gauge at two
places (diagonally) between differential case
B and
the thrust washer (right).
CautionDo not insert a feeler gauge in the oil groove of
rsrdifferential case B.

BRAKES
SERVICE AND PARKING
CONTENTS
ANTI-LOCK BRAKING SYSTEM
TROUBLESHOOTING
......................................
9
BRAKEBOOSTER...........................................
60BRAKE LINE
....................................................
62
BRAKE PEDAL.................................................
53ELECTRONIC CONTROL UNIT
ABS>...............................87
- FRONT DISC BRAKE......................................
65G-SENSOR
..............................86
HYDRAULIC UNIT
ABS>...............................
77
MASTERCYLINDER
........................................56
PARKING BRAKES
..........................................88
REAR
DISC BRAKE.........................................70SERVICE ADJUSTMENT PROCEDURES..
.....41
ABSPowerRelayCheck.............................52
Bleeding........................................................
45Brake Booster Operating
Inspection...........43
BrakeFluidLevelSensor Check.................
42Brake Pedal Inspection and Adjustment
.....41Check Valve
OperationCheck.....................
44
FlatBattery
Remedy....................................52
FrontBrakeDiscRun-out Check................47Front Brake Disc Run-out Correction
..........48Front Brake
Disc Thickness Check
.............47Front Disc Brake Pad Check and
Replacement.................................................46
Parking
BrakeLever Stroke Check.............42
Parking
BrakeSwitchCheck.......................43
Proportioning
ValveFunctionTest...............44Rear Brake
DiscRun-out Check.................50Rear Brake Disc Run-out Correction
...........50Rear Brake
Disc Thickness
Check..............49Rear Disc Brake Pad Check and
Replacement.................................................48Observation of Wheel Speed Sensor
Output Voltage Variations
with
ABS>..................................51
SPECIAL TOOLS.............................................6
SPECIFICATIONS.............................................
2General Specifications
..................................2
Lubricants
......................................................5
Service
Specifications...................................4
Torque
Specifications...................................4
TROUBLESHOOTING......................................7WHEEL SPEED SENSOR
...............................80
_ CAUTION
When servicing brake assemblies or components, do not create dust by sanding, grinding or by cleaning
brake parts with a dry brush or with compressed air. A WATER DAMPENED CLOTH SHOULD BE USED.
Many brake components contain asbestos fibers which can become air-borne if dust is created duringservice operations. Breathing dust which contains asbestos fibers can cause serious bodily harm.

5-4BRAKES - Specifications
SERVICE SPECIFICATIONS
NO5CB-
ItemsSpecifications
Standard value
Brake pedal heightmm (in.) 176-181 (6.9-7.1)
Brake pedal free playmm (in.) 3-8
(l-.3)Brake pedal to floorboard clearance
mm (in.) 80 (3.1) or more
Parking brake lever stroke
5-7 notches
Output pressure proportioning valve
MPa (psi)
Split point
3.95-4.45 (561-633)
3.45-3.95 (491-561)
Output pressure [input pressure]
5.15-5.65 (732-804) [8.2 (1 ,I 63)l
4.65-5.15 (661-732) (7.7 (1,095)1Disc brake dragging force at hub bolt
N (Ibs.) [Nm (ftlbs.)]70 (15) or less [4 (3) or less1Booster push rod to master cylinder piston clearance
mm (in.)
9 inch brake booster
0.8-l .O (.031-,039)
7
+8 inch brake booster0.5-0.7 (.020-.028)
Speed sensor’s internal resistance
kQ 0.8-l .2*
Clearance between the speed pole piece and
the toothed rotor
mm (in.)
0.3-0.9 (.012-,035)”Limit
Left/right proportioning valve out pressure difference
MPa (psi)0.4 (57)
Disc brake pad thickness
mm (in.) 2.0 (08)
Front disc thickness
mm (in.) 22.4 (882)
Rear disc thickness
mm (in.) 8.4
(.331)Disc
runoutmm (in.) 0.08 (.0031)Hub end play
mm (in.) 0.008
(.00031)
NOTE
*: Vehicles with ABS
TORQUE SPECIFICATIONS
ItemsNmft.lbs.
Pedal support bracket installation bolts
8-12
6-9
Pedal support bracket installation nut
IO-157-11
Pedal rod to pedal support bracket
17-26
12-19
Pedal rod to clutch pedal bracket
17-26
12-19
Clutch pedal bracket installation bolt
8-12
6-9
Turn-over spring mounting bolt
17-26
12-19
Stop lamp switch mounting nut
IO-157-l 1‘Clutch master cylinder installation nuts
10-157-11
Clutch pedal installation nut
20-2514-18
Lever assembly (A) installation nut
20-2514-18
Lever assembly
(B) installation nut20-2514-18