1991 MITSUBISHI ECLIPSE service

21-34MANUAL TRANSAXLE - Transaxle Assembly
? ,‘,
30-35 Nm77-25 fLlbs.35-42 Nni26-30 ftlbs.
25
APi 77
--2lRl 26
\\15-22 Nm
---- -_ . .23
II-15 lt.lDS.
I
..d.. -Disassembly steps
23. Reverse idler gear shaft bolt24.Gasket
25.Bolt
l + 26. Transaxle case+4 ;I. ;$yrde
29:Springwasher30.Stopper bracket31. Restrict ball assembly
32.Gasketl 433.Oil seal34. Bearing outer racel * 35. Spacer
36. Bearing outer racel 437.Spacer38.Oil filter39. Bearing outer race32-39
ft.lbs.
TFMOlO9
l 4 40. Spacer41. Bearing outer race
I)* ;I. Sggcer
44: Reverse shift lever assembly
45. Reverse shift lever shoe
l + 46. Reverse idler gear shaft47. Reverse idler gear+e l + 48. Spring pinl * l + 49.Spring pin+I) l 50. Shift rail assembly
NOTE(I) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) e* : Refer to “Service Points of Reassembly”.(4) 19 : Non-reusable parts

_-MANUAL TRANSAXLE
- Transaxle Assembly 2%35
11-15 ftlbs.
5115-22 Nm
11-15
ftlbs.
l,451.Bolt
52.Bolt
53.Bearing retainer54.Intermediate gearassembly
55. Input shaft assembly
56. Output shaft assembly
57. Differential gear assembly
58. Bearing outer race
59. Bearing outer race60. Oil guide
61. Bearing outer race62. Bearing outer race
/’
62
+463.Oil seal+464.Oil seal
65.Magnet
66.Magnetholder67. Clutch housing assembly
; .,
FFkeverse the disassembly procedures to rdassembte.(2) ++ : Refer to “Service Points of Reassem’bly”.(3) m : Non-reusable parts

IMD99801 9I
21-36MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF DISASSEMBLYNZlMFAS
14. REMOVAL OF SPRING PINRemove the spring pin using a special tool.
NOTEIf the spring pin interferes with the synchronizer ring or
cone gear, rotate the gear for dislocation and remove the
spring pin.
15. / 16. REMOVAL OF LOCK NUTS(1) Unstake lock nuts of the input shaft and intermediate
gear.
(2) Shift the transaxle in reverse using the control lever andselect 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.
48.149. REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using a pin punch.

MANUAL TRANSAXLE - Transaxle Assemblv 21-37
18
50. REMOVAL OF SHIFT RAIL ASSEMBLY(1) Shift the
1st~2nd speed shift fork to the 2nd speed.
(2) Shift the
3rd4th speed shift fork to the 4th speed.
.”(3) Remove the shift rail assembly.
INSPECTIONNZlMOM
BACKUP LIGHT SWITCHOperate the backup light switch to check continuity with a
circuit tester.
If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLY64. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.
:

21-42MANUAL TRANSAXLE Transaxle Assembly /- 5th Speed Synchionizer AssemblyTFM0041
8” in.)TFM0044
4. INSTALLATION OF SCREW BOLTSApply specified adhesive to screw bolts mounting portion.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No. 4318032
or ‘equivalent
2. APPLICATION OF SEALANT TO THE REAR COVERApply specified 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 discontinuity.
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
43
NZlMHAK
1Disassembly steps
1. Reverse brake ring (F5M22-2, F5M33)
2. Stop plate (F5M22-1)I)4 3. Synchronizer spring4. Synchronizer sleeveWI 5. Synchronizer key*+ 6. Synchronizer hubTFM0055
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Reassembly”.

..-MANUAL TRANSAXLE
-5th Speed Synchr’onizer Assembly tq-43
201044
201045TFM0046
Springprotrusion
Key
2010018
INSPECTION_ -.‘-
SYNCHRONIZER SLEEVE AND HUB-_
lCombine the synchronizer sleeve and hub and check thatthey slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear ends.
lCheck for wear of the hub front end (surface in contact withthe
5th speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for weakness, deformation and breakage.
SERVICE POINTS OF REASSEMBLY6. INSTALLATION OF SYNCHRONIZER HUB/5. SYN-
CHRONIZER KEY.Assemble the synchronizer hub, and key noting their
direction.
NOTEOnly the direction of the keys for the
F5M22-1 has to be
observed.3. INSTALLATION OF
SYNCHRONliER $PRlNGAssemble the synchronizer spring so that
:its projection
may be engaged in the groove of the synchronizer key.
NOTETake care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.

21-44 MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY N2tMW
DISASSEMBLY AND REASSEMBLY
18
16
17 IDisassembly steps
*+ 1. Snap ring+1)1)+ 2. Ball bearing
+I) I)+ 3. Bearing sleevel + 4. Snap ring4+*+ 5. Ball bearingl + 6. Spacer
7.
4th speed gear8.Needle bearing~~ 9. Bearing sleeve10.Synchronizer ringl + 11. 3rd-4th speed synchronizer assemblyl + 12. Synchronizer spring2060019
l *
13.Synchronizer sleeve14.Synchronizer key15.Synchronizer hub16.Synchronizer ring
17. 3rd speed gear18.Needle bearing19.Input shaft
NOTE(I) Reverse the disassembly procedures to reassemble(2) l * : Refer to “Service Points of Disassembly”.(3) +* : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

MANUAL TRANSAXLE -Input Shaft Assemblir 2145
MD998801
201048SERVICE POINTS OF DISASSEMBLY
2. REMOVAL OF BALL BEARINGRemove the front bearing using the special tool
as
illustrated.:
j, /I’ ’:”VI
3. REMOVAL OF BEARING SLEEVERemove the bearing sleeve using the special tool as
illustrated.
5. REMOVAL OF BALL BEARING
Remove the ball -bearing together using the special tool as
illustrated.
17. REMOVAL OF 3RD SPEED GEARRemove the bearing sleeve,
3rd-4th speed synchronizer
assembly and
3rd speed gear together using the special
tool as illustrated.
INSPECTION
INPUT SHAFT
lCheck the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear and seizure[portion
@I.l Check the
splines for damage and wear.