1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Front Differential21-107SERVICE POINTS OF REASSEMBLY
9. INSTALLATION OF SPACER
! 8. SIDE GEAR / 7.
WASHER
/ 6. PINION / 5. PINION SHAFT
(1) Fit a spacer on to the back of the side gear and then
install the gear in the differential case.
Caution
When a new side gear is used, use a spacer of
intermediate thickness
[0.93-l .OO mm (.0366-
.0394 in.)]
160124Differential case
PinionshaftLot\ pin\-I\m Dir&ion ofInstallation
‘$ IS more chamtereXSide of lock pi? d,
II II2200096
MD99881 2
MD99881 9
TFMOOOE(2) Place a washer at the back of each of the two pinions
and insert the two pinions at the same time, meshing
them with the side gear and rotating them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gear and
pinion.Standard value: 0.025
- 0.150 mm (.OOOl - .0060 in.)
(5) If the backlash is out of specification, disassemble and
reassemble the gears with a new spacer.
Caution
Adjust to provide the same backlash for both side
gears.4. INSTALLATION OF LOCK PIN
Align the lock pin hole in the pinion shaft with that in the
case and press the lock pin into position.
Caution
1. Do not reuse the lock pin.
2.Make sure that the lock pin head is lower than the
differential case flange surface.
3. INSTALLATION OF BALL BEARINGS
Install the ball bearings in both sides of the differential case.

21-108MANUAL TRANSAXLE - Front Differential
Numerals (I) through (8) indicate
the bolt tlghtenlng sequence.1. INSTALLATION OF BOLTS
Apply adhesive to the entire thread section of the bojts and
quickly tighten bolts to specification in the order shown.iii
-2Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No.4318032
or equivalent
Caution
If the bolts are to be reused, completely remove the old
adhesive from the threads.

,-’ DISASSEMBLY AND REASSEMBLY
II-
Disassembly steps1.
3rd-4th speed shift fork
2.
1
st-2nd speed shift
fork
3.
1 st-2nd speed shiftrail4. 5th-Rev. speed shift raill 45.
interlock plunger
6.
3rd-4th speed shift railNOTE7. Reverse shift lug(1)Reverse the disassembly procedures to reassemble.(2)l 4: Refer to “Service Points of Reassembly”.-
\3rd-4th speed shift rail201088210027
SERVICE POINTS OF REASSEMBLY5. INSTALLATION OF INTERLOCK PLUNGER
Fit the interlock plunger into the position shown in
3rd-4thspeed shift rail.

21-I 10MANUAL TRANSAXLE - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLYNPlMJAR
DISASSEMBLY AND REASSEMBLY
j”r:
Disassembly steps
** 1. Snap ringl * l +2. Taper roller bearing
l * 3. Bearing sleeve
l *4. 1 st speed gear
5. Needle bearing
l a6. Synchronizer ringl +7. Synchronizer springl a8. 1 st-2nd speed synchronizer sleeve
l *9. Synchronizer keyw l a IO. 1 st-2nd speed synchronizer hub
l * II. Synchronizer ringa*12. 2nd speed gear
13. Needle bearing
l * l * 14. Taper roller bearing
15. Intermediate gearNOTE(I) Reverse the disassembly procedures to reassemble.Ah..(2)+*: Refer to “Service Points of Disassembly”.(3)l C: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.

MANUAL TRANSAXLE - intermediate Gear Assembly21’-111
MD998801
I
70106:
Sphnes201065
SERVICE POINTS OF DISASSEMBLY
2.REMOVAL OF TAPER ROLLER BEARING / 4. IST SPEED
GEARUsing the special tool, remove the taper roller bearing, the
1st speed gear, and the bearing sleeve.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
10. REMOVAL OF
IST-2ND SPEED SYNCHRONIZER HUB /12. 2ND SPEED GEAR
Using the special tool, remove the lst-2nd speed synchro-
nizer assembly and
2nd speed gear.
14. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
INSPECTIONINTERMEDIATE GEAR
l
Check the outer surface of the intermediate gear where the
needle bearing is mounted for damage; abnormal wear, andseizure (portion
@I.l Check splines for damage and wear.

21-112MANUAL TRANSAXLE - Intermediate Gear Assembly
201051
Damage, breakage
I
-FM0119Synchronizer ring
Gear FM0117
NEEDLE BEARING
lMate the needle bearing with the shaft or bearing sleeve
and gear, and check to see if rotation is smooth with no
++binding, noise, or play.
l Check the needle bearing cage for possible deformation.
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if the measurement is below
the limit.
Limit: 0.5 mm
(.020 in.),-W
I-.SYNCHRONIZER SLEEVE AND HUB
lMate the synchronizer sleeve with the hub and check to
see if they slide smoothly.
lCheck to see if the sleeve is free from damage at its inside
front and rear ends.
l Check the hub front and rear end faces (in contact with
each speed gear) for wear.
Caution
When replacement is necessary, replace the synchro-
nizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
l Check the synchronizer key center protrusion for wear.
lCheck the spring for proper tension, possible deformation
and breakage.
A

-.
MANUAL TRANSAXLE - Intermediate Gear Assemblv21-113
D99835021002:
r$J$ch housingc
prorruslon
Sprinprotrusion
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough surface, damage,
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY14. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the taper roller bearing overthe intermediate gear.
Caution
Apply pressure with the special tool only to the inner
race when installing the bearing.
11. / 6. INSTALLATION OF SYNCHRONIZER RINGNote the identification mark made on the
1st speed
synchronizer ring.
10. INSTALLATION OF lST-2ND SYNCHRONIZER HUB / 9.
SYNCHRONIZER KEY
/ 8. lST-2ND SYNCHRONIZER
SLEEVE
/ 7. SYNCHRONIZER SPRING
(1) Mate the 1 st-2nd speed synchronizer hub and sleeve asshown.
(2) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key.
Caution-Make sure that the protrusions in the front and rear
springs are not in the groove of the same key.
NOTEA synchronizer spring different from the one shown in
the figure may be used but the explanation is the same.

21-I 14MANUAL TRANSAXLE - Intermediate Gear Assembly(3) Using the special tool, press-fit the lst-2nd speed
synchronizer assembly over the intermediate gear.
fkCaution1. When installing the synchronizer assembly,
-imake sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
2. After installing the synchronizer assembly,
check to see if the
3rd speed gear rotates
smoothly.
TFM0023,
MD9983503. INSTALLATION OF BEARING SLEEVE
Using the special tool, press-fit the 1st speed gear and
bearing sleeve.
42. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the taper roller bearing.
Caution
Apply pressure with the special tool only to the inner
race when installing the bearing.
1. INSTALLATION OF SNAP RING
Select and install the snap ring so that the end play of the
intermediate shaft is up to specification.
Standard value:
0.01-0.11 mm (.0004-.OO43 in.)