1991 MITSUBISHI ECLIPSE service

21-116MANUAL TRANSAXLE - Input Shaft Assembly
c
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the front bearing.
2. REMOVAL OF BEARING SLEEVE
Remove the bearing sleeve using the special tool as
illustrated.4. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the bearing sleeve and rear
bearing.15. REMOVAL OF
3RD SPEED GEAR;;c.Using the special tool, remove the bearing sleeve,
3rd-4thi”-speed synchronizer assembly, and
3rd speed gear.
INSPECTIONINPUT SHAFT
l
Check the outer surface of the input shaft where the needlebearing is mounted for damage, abnormal wear, and
seizure (portion
&I).l Check the splines for damage and wear.h
4

MANUAL TRANSAXLE - Input Shaft Assemblylama
vear210018
Springprotrusion
Key
201001::
TFM0023
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
.6
wear.l Check the synchronizer cone for rough surfaces, damage,
-‘and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POlNTS OF REASSEMBLY18. INSTALLATION OF SUB
GEAR/17. CONE SPRING/16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, andthen install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing inthe correct direction.
10. INSTALLATION OF SYNCHRONIZER SPRINGS
(1) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
in,groove of the same key.
9. INSTALLATION OF
3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTEIf the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter
spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Using the special tools, press-fit the
3rd-4th speed
synchronizer assembly over the input shaft.
Caution
1. When installing the synchronizer assembly,
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
h2. After installing the synchronizer assembly, --
check to see if the
3rd speed gear rotates
smoothly.

MANUAL TRANSAXLE - Clutch Housing Assembly21-121
CLUTCH HOUSING ASSEMBLY
-- DISASSEMBLY AND REASSEMBLY
NZlMPAH
-20-27 Nm
15-
19 ft.lbs.
15-22 Nm15 ft.lbs.18'
Disassembly steps
I, Bolt
2. Select lever assembly
3. Select lever shoe4. Interlock plate bolt
5.Gasket+* WC 6. Lock pinl * l *7. Spring pin
8. Neutral return spring
9.Stopper body10.Control finger11,Interlock plate
12. Neutral return spring assembly
13.Control shaft14. Control shaft boot
2210128
l * 15. Oil seal*I) l * 16. Needle bearing
a* l + 17. Needle bearing18. Clutch housing
19. Pin
20. Return spring21. Stopper plate
22. Spring pin
NOTE(1)Reverse the disassembly procedures to reassemble.(2)l +: Refer to “Service Points of Disassembly”.(3)l C: Refer to “Service Points of Reassembly”.(4) a: Non-reusable parts.

21-122MANUAL TRANSAXLE - Clutch Housing Assembly
SERVICE POINTS OF DISASSEMBLY
6. REMOVAL OF LOCK PIN
Drive out the lock pin from the control finger using the
special tool or a pin punch.
Caution
When removing the lock pin, turn the control lever to a
position so that the lock pin will not contact the clutch
housing.13mm
socket wrench
A
Needle bearingII2010847. REMOVAL OF SPRING PIN
Using the special tool or a pin punch, drive out the spring
pin from the stopper body.
Caution
When removing the spring pin, pull the control shaft in
the direction shown so that the spring pin will not
contact the clutch housing.
16.7 17. REMOVAL OF NEEDLE BEARING
Drive out the needle bearing using a socket wrench.
SERVICE POINTS OF REASSEMBLY17.
/ 16. INSTALLATION OF NEEDLE BEARINGS
(1) Using a socket wrench, press-fit the needle bearing
flush with surface A in the clutch housing.
(2) Make sure that the side of the bearing with a stamped
type number faces surface A.

21-124MANUAL TRANSAXLE - Transfer Assembly
TRANSFER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
8-10Nm
6-7ft.‘bs.Y15-22Nm
2210130
Disassembly steps
1. Cover
2. Cover gasket
l *3. Extension housing assembly
l *4. Transfer case sub assembly
l * 5. Spacer
6. O-ring
l *7. Transfer case adapter sub assembly
NOTE(I)Reverse the disassembly proceduresto reassemble
(2)l +: Refer to “Service Points of Reassembly”.(3) a: Non-reusable parts.

MANUAL TRANSAXLE - Transfer Assembly22100507
P
MB990900
TFMOOIP
SERVICE POINTS OF REASSEMBLY7. INSTALLATION OF TRANSFER CASE ADAPTER SUB-
ASSEMBLY
Using a brush, apply a thin even coat of machine blue or
minium to both tooth surfaces of the driven bevel gear.
5. INSTALLATION OF SPACER
Install the spacer which has been used so far.
4. INSTALLATION OF TRANSFER CASE SUBASSEMBLY
(1) Tighten the transfer case adapter subassembly on the
transfer case subassembly to the specified torque.
(2) Using the special tool, turn the drive bevel gear shaft
one turn each in the direction of normal and reverse
rotation.Caution
Do not rotate the drive bevel gear shaft more thanone turn as it cause a blurred tooth contact pattern.
(3) Make sure that the contact pattern of the driven bevel
gear teeth is correct.
NOTE
See Tooth Contact Adjustment Procedure on next pagefor the standard tooth contact pattern.

21-128MANUAL TRANSAXLE - Extension Housing Assembly
EXTENSION HOUSING ASSEMBLYN21MTAA
DISASSEMBLY AND REASSEMBLY
TFM0039
Disassembly steps
6+ 1. Air breather
2. Dust seal guardI)+ 3. Oil seal
4. Extension housing
NOTE(I)(2)Reverse the disassembly procedures to reassemble.(3)l *: Refer to “Service Points of Reassembly”.q : Non-reusable parts.
.
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF OIL SEAL
Using the special tool, install the oil seal.
1. INSTALLATION OF AIR BREATHER
Apply sealant to the air breather port and fit the air breatherin position.
Specified sealant: MOPAR Part No.4318025
or equivalent

MANUAL TRANSAXLE - Transfer Case Sub Assembly21;129
TRANSFER CASE SUB ASSEMBLYN21MUAA
- DISASSEMBLY AND REASSEMBLY
I-
-2210079
‘35-42Nm26 - 30 ft.lbs.
Disassembly steps
I. Transfer cover
2. O-ring
l a 3. Spacer
4. Outer race
5. Drive bevel gear assembly6. Outer race
*a 7. Spacer
l *8. Oil seal
9. Transfer case
NOTE(1)Reverse the disassembly procedures to reassemble(2)*a: Refer to “Service Points of Reassembly”.(3)q : Non-reusable parts.