1991 MITSUBISHI ECLIPSE service

MANUAL TRANSAXLE - Transaxle’
---
-..
2) ’TransaxlellK611
SERVICE POINTS OF REMOVALNlZMBAR4. DISCONNECTION OF CLUTCH ‘RELEASE CYLINDER
FROM TRANSAXLE ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the
! body side
without disconnecting the oil line coupling.
”
10. REMOVAL OF UNDER COVER
Lift the vehicle before removing the under cover.
12. DISCONNECTION OF TIE ROD END FROM KNUCKLE
Using the special tool, disconnect the tie rod end from the
knuckle.Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
14. DISCONNECTION OF LOWER ARM BALL JOINT
Using the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
I15. DISCONNECTION OF DRIVE SHAFT
(1)
Insert a pry bar between the transaxle case and the
drive shaft, and then pry the drive shaft
~from the
transaxle.Caution
1. Do not pull on the drive shaft; doing so will
damage the inboard joint; be sure to use the pry
bar.2. Do not insert the pry bar so deep as to damaged
the oil seal.
(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.

21-22MANUAL TRANSAXLE - Transaxle
1 Transaxleside1 Radiator lower hose
1 Transaxle side1 Radiator lower hosepart ofdrive shaft
I
-Transaxle
09LOO5819. REMOVAL OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
+Gthe lower hose of the radiator with the end of the
’transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
Support the transaxle assembly by using a transaxle jack;
then, after moving the transaxle assembly to the right,
lower it.
NOTEWhen supporting the transaxle assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to awide area, not to only a small localized area.
SERVICE POINTS OF INSTALLATION
NZlMDAP19. INSTALLATION OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
Athe lower hose of the radiator with the end of the
-transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
15. INSTALLATION OF DRIVE SHAFT
(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bent
relative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serratedpart of the drive shaft.
(2) Align the serrations and securely insert the drive shaft
into the transaxle.
7. INSTALLATION OF STARTER
Tighten the starter installation bolts with the wiring harness
clip and the ground cable.

MANUAL TRANSAXLE - Transaxle Assemblv 2743
TRANSAXLE ASSEMBLY
.._DISASSEMBLY AND REASSEMBLYN21ME-A
__
30-42 Nm22-30 ft.lbs.30-35 Nm22-25 ftlbs.q l4
ig5 !
----7m
IQ15-22 Nm
II-15 ft.lbs.
4.0-5.5 Nm2.9-3.9 ft.lbs.1I”I
a
140-160 Nmf
102-115 ft.lbs.
Disassembly steps
1. Bolt
l + 2. Rear cover
3. Wave spring
l 4. Screw bolts
5. Reverse brake cone
6. Backup light switch
7. Gasket
8. Poppet plug
9. Poppet spring
10. Poppet ball
11. Bolt
12. Speedometer driven gear assembly
l * 13. Air breather
*I) l * 14. Spring pin+I) l * 15. Lock nut
140-160102-115
TFMOOl6
+e I)+ 16. Lock nut
17. 5th speed synchronizer assembly
18. 5th speed shift fork
19. Synchronizer ring
20. 5th speed gear
21.Needle
bearing
22. 5th speed intermediate gear
NOTE(1) Reverse the disassembly procedures to reasseinble.
(2) ++ : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of ReaSsembly”:(4) m : Non-reusable parts

21-24MANUAL TRANSAXLE - Transaxle Assemblv 48
3e42 Nm22-30 ft.lbs.30-35
NmI
122-25 ft.lbs.26
2527
1!&22 Nm\
\
Disassembly steps23. Reverse idler gear shaft bolt
24.Gasket25.Bolt++ 26. Transaxle casel + 27. Oil guide
28.Bolt
29.Spring washer30.Stopper bracket
31. Restrict ball assembly
32.Gasketl 433.Oil seal
34. Bearing outer race
+*35.Spacer
36. Bearing outer race
l * 37. Spacer38. Bearing outer race
l + 39. Spacer40. Bolt41. Reverse shift lever assembly
42. Reverse shift lever shoe
43. Reverse idler gear shaft
44. Reverse idler gear
+I) l 4 45. Spring pin~~ ~~ 46. Spring pin+* l + 47. Shift rails and forks+* l 48. Shift rails and forks
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +* : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of Reassembly”y(4) m : Non-reusable parts

MANUAL TRANSAXLE - Transaxle Assembly
2i &
15-22 Nm50 11-15 ft.lbs.
Disassembly steps
l +49. Bolt50. Screw
51. Bearing retainer
+e l + 52.Intermediate gear assemblyl + 53.Input shaft assembly54. Output shaft assembly
55. Differential gear assembly
56. Bearing outer race57. Oil guide
58. Bearing outer race
59. Bearing outer race
l 4 60. Oil seal
W 61. Oil seal
62. Magnet
63. Magnet holder
64. Clutch housing assembly
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.(3) e+ : Refer to “Service Points of Reassembly”.
(4) m : Non-reusable parts
21421

21-26 MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF DISASSEMBLY
14. REMOVAL OF SPRING PINIMD99801 9\I
NZlMFARRemove the spring pin using the special tool.
Bolt10 mm
15.116. REMOVAL OF LOCK NUTS(1) Unstake lock nuts of the input shaft and intermediate
gear.(2) Shift the transmission in reverse using the control lever
and select lever.
(3) install the special tool onto the input shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.45./46.
REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using the pin punch.

MANUAL TRANSAXLE - Transaxle Assemblv 21-27
206001E
47./48. REMOVAL OF SHIFT RAILS AND FORKS’(1) Shift the Ist-2nd speed shift fork to the
2nd speed.
(2) Shift the
3rd~4th speed shift fork to the 4th speed.
(3)Rotate the the shift controls in the direction of the arrowin numerical order. Remove the shift lugs from the
control finger 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.
52. REMOVAL OF INTERMEDIATE GEAR ASSEMBLYLift up the input shaft assembly and remove the intermedi-
ate gear assembly.
INSPECTION
BACKUP LIGHT SWITCH
N21MOdOperate the backup light switch to check continuity with a
circuit tester. If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLYN2mnGAU
61. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.

MANUAL TRANSAXLE - Transaxle Assembly n-33
TRANSAXLE ASSEMBLY
3 DISASSEMBLY AND REASSEMBLYNZlME-6
--42 Nm
-30
ft.lbs.
\8I Q
30-35Nm
22-25ft.lbs.ml4
ff3d6 i
18
4.0-5.5Nm2.9-3.9ft.lbs.
-n
140-160 Nm102-115ft.&s.
3-5 Nm
16-22 Nm11-15 ft.lbs.1Disassembly steps
‘I. Bolt
l *2. Rear cover3.Wave springe4 4. Screw bolts5. Reverse brake cone6. Backup light switch
7.Gasket
8.Poppet plug9.Poppert spring
10.Poppet ball11.Bolt
12. Speedometer driven gear assembly
l 13. Air breather
4* l * 14. Spring pin
,I
2
TFMool6
4+ e4 15. Lock nut+e l 16. Lock nut17. 5th speed synchronizer assembly18. 5th speed shift fork19. Synchronizer ring20. 5th speed gear21. Needle bearing22.
5th speed intermediate gear.’
$?everse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly:.(3) l C : Refer to “Service Points of Reassembly(4) q : Non-reusable parts