1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Clutch Housing Assembly21-12315. INSTALLATION OF OIL SEAL
Using a socket wrench, install the control shaft oil seal.
7. INSTALLATION OF SPRING PIN
/ 6. LOCK PIN
Using the special tool, drive a new spring pin and lock pin
into position.
Caution
1. Do not reuse the spring pin or lock pin.
2.Install the spring pin so that its slit will be at right
angles to the control shaft centerline.

21-124MANUAL TRANSAXLE - Transfer Assembly
TRANSFER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
8-10Nm
6-7ft.‘bs.Y15-22Nm
2210130
Disassembly steps
1. Cover
2. Cover gasket
l *3. Extension housing assembly
l *4. Transfer case sub assembly
l * 5. Spacer
6. O-ring
l *7. Transfer case adapter sub assembly
NOTE(I)Reverse the disassembly proceduresto reassemble
(2)l +: Refer to “Service Points of Reassembly”.(3) a: Non-reusable parts.

MANUAL TRANSAXLE - Transfer Assembly22100507
P
MB990900
TFMOOIP
SERVICE POINTS OF REASSEMBLY7. INSTALLATION OF TRANSFER CASE ADAPTER SUB-
ASSEMBLY
Using a brush, apply a thin even coat of machine blue or
minium to both tooth surfaces of the driven bevel gear.
5. INSTALLATION OF SPACER
Install the spacer which has been used so far.
4. INSTALLATION OF TRANSFER CASE SUBASSEMBLY
(1) Tighten the transfer case adapter subassembly on the
transfer case subassembly to the specified torque.
(2) Using the special tool, turn the drive bevel gear shaft
one turn each in the direction of normal and reverse
rotation.Caution
Do not rotate the drive bevel gear shaft more thanone turn as it cause a blurred tooth contact pattern.
(3) Make sure that the contact pattern of the driven bevel
gear teeth is correct.
NOTE
See Tooth Contact Adjustment Procedure on next pagefor the standard tooth contact pattern.

21-126MANUAL TRANSAXLE - Transfer Assembly2210061
2210092
2210093
I
3.(4) Check to see if the backlash between the drive and
driven bevel gears is up to specification.
Standard value
Bevel gear set backlash:
0.08-0.13 mm (.0031-.005 in.)
INSTALLATION OF EXTENSION HOUSING
Apply sealant to the flange surface of the adapter and installthe housing.
Specified sealant: Mitsubishi genuine Part
CautionNo. 997740 or equivalent
Squeeze out the sealant from the tube uniformly
without excess or discontinuities.
TOOTH CONTACT ADJUSTMENT PROCEDURE
1. Standard tooth contact pattern
A: Small end
B: Drive side tooth surface
(The side receiving force in forward motion)
C: Big end
D: Coast side tooth surface
(The side receiving force in reverse motion)
2. Tooth contact pattern when driven bevel gear is too
highPossible cause:
The driven bevel gear is too close to the drive bevel gear.
Remedy:Use a thicker spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is further away
from the drive bevel gear.

MANUAL TRANSAXLE - Transfer Assembly2210094
2210095
Spacer for
adjusting drive
bevel gear mount
ISpacer foradjusting drive
bevel gear preload
Spacer for
adjustingdriven bevel
gear mount
Spacer for
adjustingdriven bevel
gear preloac3. Tooth contact pattern when driven bevel gear is too
low
Possible cause:,
The driven bevel gear is further away from the drive bevel
gear than necessary.
Remedy:Use a thinner spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is closer to the
drive bevel gear.
NOTE(1) If correct tooth contact cannot be obtained by replace-
ment of spacer for adjusting driven bevel gear mount,
change the spacers for adjustment of drive bevel gear
preload and drive bevel gear mount adjustment to thoseof appropriate thickness as described below and adjust
the tooth contact again.
lIf the driven bevel gear height is still too small whenthe thinnest spacer for driven bevel gear mount
adjustment
[0.13 mm (.005 in.)] is used;
Change the spacer for drive bevel gear mount
adjustment to the next thicker one and change the
spacer for drive bevel gear preload adjustment to
the next thinner one.
lIf the driven bevel gear height is still too large whenthe thickest spacer for driven bevel gear mount
adjustment
[0.52 mm (020 in.)] is used;
Change the spacer for drive bevel gear mount
adjustment to the next thinner one and change the
spacer for drive bevel gear preload adjustment to
the next thicker one.
Repeat above steps until standard tooth contact
pattern is obtained.
(2) If the tooth contact pattern cannot be brought close
,tothe standard pattern by the adjustment described
above, replace the drive bevel gear and driven bevel
gear as a set and adjust the tooth contact again.

21-128MANUAL TRANSAXLE - Extension Housing Assembly
EXTENSION HOUSING ASSEMBLYN21MTAA
DISASSEMBLY AND REASSEMBLY
TFM0039
Disassembly steps
6+ 1. Air breather
2. Dust seal guardI)+ 3. Oil seal
4. Extension housing
NOTE(I)(2)Reverse the disassembly procedures to reassemble.(3)l *: Refer to “Service Points of Reassembly”.q : Non-reusable parts.
.
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF OIL SEAL
Using the special tool, install the oil seal.
1. INSTALLATION OF AIR BREATHER
Apply sealant to the air breather port and fit the air breatherin position.
Specified sealant: MOPAR Part No.4318025
or equivalent

MANUAL TRANSAXLE - Transfer Case Sub Assembly21;129
TRANSFER CASE SUB ASSEMBLYN21MUAA
- DISASSEMBLY AND REASSEMBLY
I-
-2210079
‘35-42Nm26 - 30 ft.lbs.
Disassembly steps
I. Transfer cover
2. O-ring
l a 3. Spacer
4. Outer race
5. Drive bevel gear assembly6. Outer race
*a 7. Spacer
l *8. Oil seal
9. Transfer case
NOTE(1)Reverse the disassembly procedures to reassemble(2)*a: Refer to “Service Points of Reassembly”.(3)q : Non-reusable parts.

21-130MANUAL TRANSAXLE - Transfer Case Sub Assembly
SERVICE POINTS OF REASSEMBLY8. INSTALLATION OF OIL SEAL
Using the special tool, install the oil sea
jP,
II..-67. INSTALLATION OF SPACER
Install the spacer which has been used so far
3. INSTALLATION OF SPACER
Install the spacer which has been used so far
INSPECTIONDRIVE BEVEL GEAR ASSEMBLY
Using the special tools, check to see if the turning drive torque
of the drive bevel gear is up to specification.
Standard value: 1.7
- 2.5 Nm (1.23 - 1.81 ft.lbs.)Caution
1.If the turning drive torque is out of specification, adjust
by using adjusting spacers.
2.Select spacers of nearly same thickness on both sides.
h