1991 MITSUBISHI ECLIPSE Service Manual

CLUTCH - Clutch Master Cylinder6-l 1
CLUTCH MASTER CYLINDER
-. DISASSEMBLY AND REASSEMBLYNOGNA- A> B>
Disassembly steps
1. Piston stop ringl + 2. Push rod3. Boot
+e W 4. Piston assembly5. Reservoir cap
l + 6. Reservoir band
7. Reservoir
8. Master cylinder body
@Installation of the Clutch MasterCylinder (Refer to P.6-9.)
Nmftlbs.
NOTE(I) Reverse the disassembly procedures to reassemble.(2)+e: Refer Points of (3)I)+: Refer to “Service Points of Reassembly’.(4) : Vehicles with auto-cruise control system : Vehicles without auto-cruise control sys-tem
\\08AOOi4
NO6NBAC
4.REMOVALOFPISTON ASSEMBLY
Caution
1.Do not damagethe master cylinder body and piston
assembly.
2. Do not disassemble piston assembly.
INSPECTIONNO9NCACl Check the inside cylinder body for rust or scars.
l Check the piston cup for wear or deformation.
l Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.

6-12CLUTCH - Clutch Master CylinderResew&r
bandk
oaA0058
08Y517
Grease
SERVICE POINTS OF REASSEMBLYNaaNciAN
6. INSTALLATION OF RESERVOIR BAND
Tighten the resetver band at the illustrated position.
4. APPLICATION OF CLUTCH FLUID TO PISTON ASSEM-
BLYApply specified clutch fluid to the inner surface of the
cylinder and to the entire periphery of the piston assembly.
Specified fluid: MOPAR Brake Fluid/Conforming to
DOT3
2. APPLICATION OF GREASE TO PUSH RODApply a suitable amount of rubber grease on the contact
surfaces between the damper push rod and piston and
between the push rod and boot.

CLUTCH - Clutch Release Cvlinder6-13
CLUTCH RELEASE CYLINDER
-‘- REMOVAL AND INSTALLATIONNaaHA--Pre-removal Operation
@Draining of the Clutch Fluid@Supplying of the Clutch Fluid@Bleeding of the Clutch Line (Refer to
@Adjustment of the Clutch Pedal (Re-
2518EL.
113117 Nm
IO-12 ftlbs.08A0004
Removal steps
1. Connection of clutch tube
I)4 2. Clutch release cylinder
NOTE(I) Reverse the removal procedures to reinstall.(2) l * : Refer to “Service Points of Installation”
INSPECTIONNOMCAAl Check the clutch release cylinder for fluid leakage.
l Check the clutch release cylinder boots for damage.
SERVEICE POINTS OF INSTALLATIONNO6HDAJ
2. APPLICATION OF GREASE TO CLUTCH RELEASE
CYLINDERApply grease
\\ :\Apply a coating of multipurpose grease at the contact part
of the release cylinder push rod and the release fork.
Grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent

6-14CLUTCH - Clutch Release CylinderDISASSEMBLY AND REASSEMBLY
Post-reassembly Operationl installation of the Clutch ReleaseCylinder (Refer to P.6-13.)

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7
3
2-36CLO37
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3
Disassembly steps
I. Valve plate2. Spring
6
3. Push rod4. Boots
6CLOOlO
*+ l 5. Piston and cup6. Conical spring
7. Cap
8. Bleeder plug
9. Release cylinder
NOTE(1) Reverse the removal procedures to reassemble.(2) W : Refer to “Service Points of Disassembly”.(3) I)4 : Refer to “Service Points of Reassembly”.
rISERVICE POINTS OF DISASSEMBLYNOOLBAE
5. DISASSEMBLY OF PISTON AND CUP(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
++,compressed air.
-JCaution
1.Cover with rags to prevent the piston from popping
out.
2.Apply compressed air slowly to prevent brake fluidfrom
splashing.

.-CLUTCH - Clutch Release Cvlinder6-15
\
Piston
@*
CUP6CLOOO3DCLOOE
,
INSPECTIONNWLCAV(1) Check the inner surface of the release cylinder for
scratches or irregular wear.
(2) Replace if the piston cup outer circumference is scratched
or shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
SERVICE POINTS OF REASSEMBLYNO6LDAB
5. APPLICATION OF FLUID TO PISTON AND CUP
Apply specified brake fluid to the release cylinder inside andouter surface of the piston and piston cup and push the
piston cup assembly in the cylinder.
Specified brake fluid: MOPAR Brake Fluid/Conforming
to DOT3

6-16CLUTCH - Clutch Cover and Disc
CLUTCH COVER AND DISCREMOVAL AND INSTALLATION
Pre-removal Operation
l Removal of the transaxle assembly(Refer to GROUP 21 - Transaxleassembly.)
Post-installation Operation*Installation of the transaxle assem-bly (Refer to GROUP 21 -Transaxleassembly.)35-42 Nm25-30 ft.lbs.\15-22 Nm
11-16
ft.lbs.
6CLOOO4Removal steps
+e l 1. Clutch cover assembly+**a 2. Clutch disc3. Return clipl + 4. Clutch release bearingl * 5. Release fork
6. Fulcrum
7. Release fork boot
FyEeverse the removal procedures to reinstall.(2) 4e : Refer to “Service Points of Removal”.(3) I)4 : Refer to “Service Points of Installation”

CLUTCH - Clutch Cover and Disc647
08A0038
6CLOO3SERVICE POINTS OF REMOVAL
NO6OSAH
1. REMOVAL OF CLUTCH COVER ASSEMBLY/P.
CLUTCH DISCDiagonally loosen bolts which attach clutch cover to
flywheel. Back off bolts in succession, one or two turns at atime, to avoid bending cover flange.
Caution
DO NOT clean clutch disc or release bearing with
cleaning solvent.
INSPECTIONNlNGCAB
CLUTCH COVER ASSEMBLYl Check the diaphragm spring end for wear and uneven
height.
Replace
If wear is evident or height difference exceeds the
limit.Limit
: 0.5 mm (.02 in.)l
Check the pressure plate surface for wear, cracks and color
change.lCheck the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISCl
Check the facing for loose rivets, uneven contact, deteriora-tion due to seizure,
adhesron of oil or grease and replace
the clutch disc if defective.
l
Measure the rivet sink and replace the clutch disc if it is outof specification.Limit
: 0.3 mm (.012 in.)l
Check for torsion spring play and damage and if defective,replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.If it does not slide smoothly, check after cleaning and
reassembling. If the play IS excessive, replace the clutch
drsc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
The release bearing is packed with grease, so don’t use
cleaning oil, etc. to clean it.l Check for
beanng heat damage, other damage, abnormal
noise and/or improper rotation. Also check whether or not
there IS wear at the point of contact with the diaphragm
spring.lIf there is abnormal wear at the pornt of contact with the
release fork, replace the bearing.
RELEASE FORKlIf there is abnormal wear at the
pornt of contact with the
bearing, replace the release fork.

6-18CLUTCH - Clutch Cover and Disc
I6CLO33
Clutch disc
T& assemblyClutch cover
6CLO26
SERVICE POINTS OF INSTALLATIONNWGDAT
5. A,PPLlCATlONOF GREASE TO RELEASE FORKAi&
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact withi(the release bearing.
Specified grease: MOPAR Multi-mileage Lubricant
Part Nq.2525035 or equivalentCautionWhen installing the
clutch, apply grease to each
part, but be careful not to apply excessive grease;
excessive grease will cause clutch slippage and
shudder.
(2) Apply a coating of the specified grease to the end of therelease cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
4. APPLICATION OF GREASE TO CLUTCH RELEASE
BEARING
Pack the inner surface of the clutch release bearing and thegroove with the specified grease.
L4r
Specified grease: MOPAR Multi-mileage Lubricant _
Part No.2525035 or equivalentCaution
For the release bearing of a resin sleeve, grease mustnot
be applied to the sleeve part.
2. APPLICATION OF GREASE TO CLUTCH DISC/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MOPAR Multi-mileage Lubricant
Part No.2525035 or equivalent
(2) Using the special tool (clutch disc center guide),
position the clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.