1991 MITSUBISHI ECLIPSE torque

MANUAL TRANSAXLE - Transaxle Assembly 2%3T
IMD998245(5)
Insert a Phillips screwdriver [8 mm (.32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt
hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
(8)
E$r& the reverse idle gear shaft bolt to specified
torque.
15./ 16. INSTALLATION OF LOCK NUTS(1) Install the special tool to the splined end of input shaft.
(2) Screw a bolt
(10 mm) into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(3) Shift the transmission in reverse using control lever andselect lever.
(4) Tighten the lock
nut,to specified torque, while ‘using the
bolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
14. INSTALLATION OF SPRING PIN(1) Install the spring pin using the special tool or a pin
punch.
Caution
Do not reuse the spring pins.

MANUAL TRANSAXLE - Transaxle Assembly Spring pin
/Shift rail
11-t201034er
2150008
220004E46./49.
INSTALLATION OF SPRING PINS(1) Install the spring pins using the special tool or a pin
punch.
Caution
Do not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
’
35. /37. /40./42. INSTALLATION OF SPACERS(1) Place two pieces of solder measuring about
10 mm (4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
’(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If the solder is not broken, carry out the work- in steps
(l)-(4) with large diameter solder.
(6) Measure the thickness of the crushed soid& with a
micrometer and select and install a spacer of thickness
that gives standard preload and end play.
Standard value:
Input shaft end play
O-0.05 mm (O-.002 in.)
Intermediate gear preload0.05-0.10 mm (.002-.004
in.)
Output shaft preload0.05-0.10 mm (.092-.004 in.)
Differential case preload
9.05-0.10 mm (.002-.004 in.)

21-40 MANUAL TRANSAXLE - Transaxle Assembly Amount
1-2 mm
J
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
.‘p,
/
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outerrace and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear
hshaft’s head is facing in the direction indicated in the
.-
illustration.
NOTEIf there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified sealant: MITSUBISHI Genuine
Part No.
MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
18 mm (32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
*
torque.,-(8) Tighten the reverse idler gear shaft bolt to specified
torque.

MANUAL TRANSAXLE - Transaxle Assembly ,214
10 mm (.40 in.)
16. / 15. INSTALLATION OF LOCK NUTS(1) install the special tool to the splined end of inputshaft.
(2) Screw a bolt [IO mm
(.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
MD998245\ISlit
,+i 1I I
r
Spring pin
, Shift rail(3) Shift the transaxle in reverse using control lever and
select lever.
(4) Tighten the lock nut to specified torque, while using the
bolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6)
&tighten the lock nuts to the specified torque.
(7) Stake the lock nut.
14. INSTALLATION OF SPRING PIN(1) Install the spring pin using the special tool or a pin
punch.,
Caution
Do not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
13. APPLICATION OF SEALANT TO AIR BREATHER
Apply specified sealant to air breather mounting portion andinstall to the clutch housing.
Specified sealant: MOPAR Part No.4318025
or equivalent

bierential Assembl /MANUAL TRANSAXLE - SDeedometer Gear ksemblv
, .Bearing
TFYOOIO
The numerals 0 to (8 indicate1 the tiqhtening Gequeice.210029I
SPEEDOMETER GEAR ASSEMBLY
3. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearings on
bqth sides of the
differential case.
Caution
When press-fitting the bearings, push the inner race
only.
1. INSTALLATION OF BOLTSApply
spec.ified adhesive to the entire threads of the bolts
and quickly tighten in the order shown to specified torque.
Specified adhesive: MOPAR Part No.4318031or MOPAR Part
No.4318032
or equivalent
CautionIf a bolt is reused, remove traces of old adhesive
completely from the threads.
DISASSEMBLY AND REASSEMBLY
NZlMNABDisassembly steps
1.O-ring
l 42.Springpin
~4 3. Speedometer driven gear
4. Oil seal5. Sleeve
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ,+ : Refer to “Service Points of Reassembly”.(3) q : Non-reusable parts201078
Slit
SERVICE POINTS OF REASSEMBLY
3. INSTALLATlON OF SPEEDOMETER DRIVEN GEARApply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft.
2. INSTALLATION OF SPRING PIN
Install the spring pin in such a way that its slit does not facethe gear shaft.

MANUAL TRANSAXLE 2 S~ecifCca?io’iik
2f.46g
\ ,...,
,,, .,
SPECIFICATIONS
1 L,‘S. / ,‘; ,< ’,f. : ,: ; .>r
“. . ..&
. ’ GENERAL SPECIFICATIONSNZ1.pA.B’
Items
ModelApplicable engine
TypeGear ratio
1 st
2nd
3rd
4th
5th
ReverseReduction ratio
PrimaryFront differential
TransferSpeedometer gear ratio (driven/drive)
Oil quantity
Transaxle
TransferSpecifications
(I
W5M33-2-N PZV.,A I
4G63
5-speed transaxle floor shift
3.083
I .684
1.115
0.833
0.666
3.166
1.275
3.866
1.090
29136lit.
(qts.)2.3 (2.43)
0.6
l.63)
SERVICE SPECIFICATIONSN21CB-B
d-...
Items
Standard value
TransaxleInput shaft end play
Input shaft rear bearing end play
Intermediate gear preload
Intermediate gear bearing end play
Front output shaft preload
Center differential
Viscous coupling end play
Differential case preload
Differential pinion backlash
Front differential
Differential case end play
Differential pinion backlash
TransferBevel gear set backlash
Driven bevel gear turning drive torque
Drive bevel gear shaft turning drive torqueSpecifications
o-0.05 (O-.002)
0.01-0.09 (.0004-,004)
0.08-0.14 (.0031-,006)
0.01-0.11 (.0004-,004)
0.08-0.13 (.0031-,005)
0.1-0.26 (.0039-.OlO)0.08-O. 13
LOO31 - ,005)
0.025-0.150 LOO01 -.006)
0.05-0.17 (.0020-,007)
0.025-0.150 (.OOOl-,006)
0.08-0.13 (.0031-.005)
1
.O- 1.7 Nm (0.72- 1.23 ft.lbs.11.7-2.5 Nm (1.23-1.81
ft.lbs.1
mm,.(in.)

21-74MANUAL TRANSAXLE - Specifications
Part nameThickness mm (in.)Identification
symbolPart No.
Spacer
1.61
(.0634)61MD722094(For adjustment of driven bevel gear trainpreload)
1.64
(.0646)64MD7220951.67
(0657)67MD722096
1.70(.0669)70MD7220971.73
(0681)73MD7220981.76
(.0693)76M D7220991.79
(0705)79MD7221 00
1.82
(0717)82MD7221 011.85
(.0328)85MD7221 02
1.88
(.0740)88MD7221 03
1.91
(.0752)91MD7221 04
1.94
(0764)94MD722105Spacer
0.13
(0051)13MD720353(For adjustment Of driven bevel gear
mOWIt)o,16 ( 0063)16M D7203540.19
(0075)19MD7203550.22
(.0087)22MD7203560.25
(.0098)25MD7203570.28(.Ol
IO)28MD7203580.31
(0122)31MD7203590.34
(0134)34MD7203600.37
(0146)37MD7203610.40
(0517)40M D7203620.43
(.0169)43MD7203630.46
(0181)46MD7203640.49
(.0193)49MD7203650.52
(0205)52MD720366
TORQUE SPECIFICATIONSNZlCC-B
TRANSAXLEItems
Bell housing cover mounting bolt
Starter motor mounting bolt
Transaxle mount bracket mounting bolt
Shift cable and select cable bracket mounting bolt
Rear cover mounting bolt
Transaxle case mounting bolt
Clutch release cylinder mounting bolt
Clutch tube to transaxle assembly
Under cover
Transaxle mounting bolt
[I2 mm (47 in.) diameter bolt]
Transaxle mounting bolt [IO mm
(40 in.) diameter bolt]
Transaxle mounting bolt [8 mm (.31 in.) diameter bolt]
Tie rod end to knuckleNm
ft.lbs.
IO-127-9
27-34
20-25
60-8043-58
15-22
11-1635-42
26-3035-42
26-3015-22
11-1615-22
11-169-13
7-1043-55
32-39
30-3522-25
IO-127-9
24-3517-25

MANUAL TRANSAXLE - Special Tools21-77Tool
Number
Name
MD998321Oil seal installer
M D998323Bearing installer
MD998325Differential oil seal
installer
MD998350Bearing installer
MD998369Bearing installer
MD998806Wrench adapter
MD998801Bearing remover
MD998802Input shaft holder
M D998803Differential oil seal
installerUse
Installation of input shaft front oil seal
Installation of rear output shaft oil seal and
transfer case oil seal
Installation of differential oil seal
Installation of front output shaft, intermediate
gear, transfer drive bevel gear, and
intermediate gear
Installation of input shaft front bearing
Removal of input shaft, intermediate gear, ant
output shaft bearing and gears
nstallation and removal of input shaft and
Ttermediate gear lock nut
lstallation of differential oil seal
rdjustment of tooth contact and inspection ofJrning drive torquexstallation of input shaft rear snap ring