1991 MITSUBISHI ECLIPSE Service Manual

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.

REAR AXLE - Differential Carrier (Limited Slip Differential)3-370
,.,:*,> ..’~ .;;s, ,~ ,$.’ j0
h
MB990990Feeler gauge ”
/
Feeler
gauge
@ Insert the special tool at the spline part of differen-
tial side gear (right) and check to be sure the side
gear (right) rotates.
@I Then insert a 0.09 mm (0035 in.) feeler gauge to
replace a 0.03 mm
(.0012 in.) gauge.
@ Insert the special tool at the spline part of the
differential side gear (right) and check to be sure theside gear (right) does not rotate.
Differential gear backlash
Standard value (clearance in thrust direction of side
gear):
0.03-0.09 mm (.OOlZ-.0035 in.)
NOTE
If the clearance in the thrust direction of the side gear iswithin the standard value range, the backlash of the
differential side gear is normal.
@I If the clearance in the thrust direction of the side
gear is not within the standard value range, removedifferential case A and make the adjustment by
adjusting the thickness of the thrust washer (left).
Thrust washer (left)
Part No.Thickness mm (in.)
0.8
t.031)0.9
f.035)1
.o i.039)1 .I
($043)1
.15 (.045)MB5692431.2
LO4711.25
(.049)1.3
i.051)1.35
(.053)1.4
l.055)1.5
i.059)Thrust washer (right) (reference)
NOTESelect one thrust washer (left) from the eleven types in the kit.

NOTES

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.

5-2BRAKES - SDecifications
SPECIFICATIONS
GENERAL SPECIFICATIONS

NO!iCA-- -
ItemsItems
NNVehicles without ABS Vehicles without ABSVehicles with ABS Vehicles with ABS
BIBI
PlPl
Fr Frlaster cylinder
TypeTandem typeTandem type
(with level sensor)(with level sensor)
I.D.mm (in.) 22.2 (7/8)23.8 (‘%6)rake booster
TypeVacuum typeVacuum type
Effective dia. of power cylinder
mm (in.) 230 (9.0)Front side: 180 (7.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.0 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]
.oportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
4,200 (597)
Decompression ratio
0.3
0.3ont brakes
TypeFloating caliper, single-piston,ventilated disc (M-R44V)Floating caliper, single-piston,ventilated disc (M-R44V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thicknessmm (in.) 16.0 (63)
16.0
(.63)Wheel cylinder I.D.
mm (in.) 53.9 (2
l/8)53.9 (2%)
Clearance adjustmentAutomaticAutomatic
3ar disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD30P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)
Disc thickness
mm (in.)
10 (39)10 i.39)Pad thickness
mm (in.) 14.5 (57)
14.5 (57)
Wheel cylinder I.D.
mm (in.) 30.1
(1 3/16)30.1 (1 346)Clearance adjustment
AutomaticAutomatic
)tor teeth
Front wheel side
-47Rear wheel side
-47
leed sensor-Magnet coil type
rking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever type
Lever type
Lever type
Cable arrangement
V-type
V-type
Rc Rc
SP SP
Pa Pa

-.
BRAKES - Specifications5-3
ItemsFWDAWDMaster cylinder
TypeTandem type
(with level sensor)Tandem type
(with level sensor)
I.D.mm (in.) 23.8 (‘%a)25.4 (1)Brake booster
TypeVacuum type
Vacuum type
Effective dia. of power cylinder
mm (in.) Front side: 180 (7.0)
Front side: 180 (7.0)
Rear side: 205 (8.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.5 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]Proportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
3,700 (526)
Decompression ratio
0.30.3Front brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (M-R44V)ventilated disc (M-R46V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thickness
mm (in.) 16.0
(.63)16.0 (.63)Wheel cylinder I.D.
mm (in.)
53.9 (2 ‘16)60.3 (23%3)Clearance adjustment
AutomaticAutomatic
Rear disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD35P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)Disc thicknessmm (in.) 10
(.39)10 f.39)Pad thicknessmm (in.) 14.5
(.57)14.5 (.57)Wheel cylinder I.D.mm (in.) 30.1 (1
3/16)34.9 (1 3h)Clearance adjustmentAutomaticAutomatic
qotor teeth*
Front wheel side
4747Rear wheel side
4747
speed sensor*Magnet coil typeMagnet coil type‘arking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever typeLever typeLever type
Cable arrangementV-typeV-type
NOTEThe *symbol indicates vehicles with ABS.

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