1991 MITSUBISHI ECLIPSE clutch

MANUAL TRANSAXLE - Transaxle Assembly(3) Rotate the shift controls in the direction of the arrow in
numerical order. Remove the shift lugs from the controlfinger and interlock plate.
(4) Raise each of the shift rails upward and remove them
from the clutch housing.
(5) Remove the all shift rails and forks.
59. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY/
60. INPUT SHAFT ASSEMBLY
Lift up the input shaft assembly and remove the intermedi-
ate gear assembly.
61./62./64. REMOVAL OF OUTER RACE
Using the special tool, remove the outer race.
SERVICE POINTS OF REASSEMBLYN21MGAPa69. INSTALLATION OF MAGNET HOLDER/68. MAGNET
Install the magnet and magnet holder, ensuring they are
installed in the correct direction.
67. INSTALLATION OF OIL SEAL
Using the special tool, install the rear output shaft oil seal.

21-94MANUAL TRANSAXLE - Transaxle Assembly
5mm(.21 in.)TFM006357. INSTALLATION OF BOLT
Apply adhesive to the bolt threads.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No.4318032
or equivalent
Caution
Be careful not to apply to adhesive to the bold head.
56. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Shift the Ist-2nd synchronizer sleeve into 2nd speed.
(2) Shift the
3rd-4th synchronizer sleeve into 4th speed.
(3)Fit the shift forks of shift rail assembly to their groove of
sleeves.
(4) Install the shift rails, rail holes of clutch housing.
(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and interlock
plate.
55./54. INSTALLATION OF SPRING PINS
Using the special tool, drive the spring pins into position.
Make sure that the slit in the spring pin is aligned with the
shift rail centerline.
Caution
Do not reuse the spring pins.

21-96MANUAL TRANSAXLE - Transaxle Assembly
/._~~1 - 2 mm l.039 - ,078 in.)2200051
41./40. INSTALLATION OF OIL GUIDE
Install the oil guide or the transaxle case.
39. INSTALLATION OF TRANSAXLE CASE
Apply sealant (liquid gasket) to the clutch housing side of
the transaxle case.
Specified sealant: Mitsubishi genuine Part
No. 997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
36. INSTALLATION OF REVERSE IDLER GEAR SHAFT BOLT(1) Center the shaft with a screwdriver [shaft diameter 8
mm
(.31 in.) or similar object].
(2) Tighten the reverse idler gear shaft bolt to specification.33.131.129 INSTALLATION OF SPACER
(1) Place four pieces of approximately 10 mm (.39 in.) long,
1.6 mm
(06 in.) dia. solder at the locations shown on
the transaxle case adapter assembly and install each
outer race.
(2) Install the transaxle case adapter assembly and rear
Acover, and tighten bolts to specification.
(3) Remove the transaxle case adapter assembly and rear
cover.

MANUAL TRANSAXLE - Transaxle Assembly/Backup Light Switch21-99
sealant
TFM0041
TFM003513. INSTALLATION OF AIR BREATHER
Apply sealant to the areas with which the air breather
makes contact, and
isntall the air breather on the clutch
housing.Specified sealant: MOPAR Part No.4318025
or equivalent
3. INSTALLATION OF SCREW BOLTS
Apply specified adhesive to screw bolts mounting portion.
Specified adhesive: MOPAR Part No.4318031
or MOPAR
Part No.4318032
or equivalent
1. INSTALLATION OF REAR COVER
Apply sealant to the rear cover.
Specified sealant: Mitsubishi genuine Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
BACKUP LIGHT SWITCH
INSPECTION
lActuate the switch and check for continuity with a circuit
tester. If there is no continuity, replace the backup light
switch.

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.

MANUAL TRANSAXLE - Input Shaft Assemblv214 IO
_.Damage, breakage
TFMO119Synchronizer ring
GearTFM0117
20104~
201045
1NEEDLE 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 RING
l 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 clearance is below the
limit.Limit: 0.5 mm
(.020 in.)
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.

MANUAL TRANSAXLE - Input Shaft Assemblylama
vear210018
Springprotrusion
Key
201001::
TFM0023
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
.6
wear.l Check the synchronizer cone for rough surfaces, damage,
-‘and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POlNTS OF REASSEMBLY18. INSTALLATION OF SUB
GEAR/17. CONE SPRING/16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, andthen install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing inthe correct direction.
10. INSTALLATION OF SYNCHRONIZER SPRINGS
(1) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
in,groove of the same key.
9. INSTALLATION OF
3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTEIf the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter
spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Using the special tools, press-fit the
3rd-4th speed
synchronizer assembly over the input shaft.
Caution
1. When installing the synchronizer assembly,
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
h2. After installing the synchronizer assembly, --
check to see if the
3rd speed gear rotates
smoothly.