1991 MITSUBISHI ECLIPSE service

21-130MANUAL TRANSAXLE - Transfer Case Sub Assembly
SERVICE POINTS OF REASSEMBLY8. INSTALLATION OF OIL SEAL
Using the special tool, install the oil sea
jP,
II..-67. INSTALLATION OF SPACER
Install the spacer which has been used so far
3. INSTALLATION OF SPACER
Install the spacer which has been used so far
INSPECTIONDRIVE BEVEL GEAR ASSEMBLY
Using the special tools, check to see if the turning drive torque
of the drive bevel gear is up to specification.
Standard value: 1.7
- 2.5 Nm (1.23 - 1.81 ft.lbs.)Caution
1.If the turning drive torque is out of specification, adjust
by using adjusting spacers.
2.Select spacers of nearly same thickness on both sides.
h

MANUAL TRANSAXLE - Transfer Case Adapter Sub Assembly
TRANSFER CASE ADAPTER SUB ASSEMBLY
1’” DISASSEMBLY AND REASSEMBLY
2143’1
N2lhlVAS.-
Disassembly steps
w l a 1. Locknuta*2. Driven bevel gear assemblyl *3. Taper roller bearing
l * 4. Spacer
5. Collar
l *6. Outer racel *7. Outer race
8. Transfer case adapter
I2210133
140 - 160 Nm102-115ft.lbs.
NOTE(1)Reverse the disassembly procedures to reassemble.(2)+*: Refer to “Service Points of Disassembly”.(3)*+: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.

21-132MANUAL TRANSAXLE - Transfer Case Adapter Sub Assembly
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF LOCK NUT
(1) Unstake the lock nut.
(2) Remove the driven bevel gear’s lock nut by using the
special tool.
2. REMOVAL OF DRIVEN BEVEL GEAR ASSEMBLY
Using a press, remove the driven bevel
‘gear assembly.6.17. REMOVAL OF OUTER RACE
Apply a screwdriver to the outer race and tap it to remove
the outer race.
SERVICE POINTS OF REASSEMBLY4. INSTALLATION OF SPACER
Install the spacer which has been used so far.

21-134MANUAL TRANSAXLE - Drive Bevel Gear Assembly
DRIVE BEVEL GEAR ASSEMBLYNZlMWAA
DISASSEMBLY AND REASSEMBLY
Disassembly steps
4~ WI1. Taper roller bearing+* l 42. Taper roller bearing
3. Drive bevel gearl *4. Drive bevel gear shaft
TFM0053
NOTE(I)Reverse the disassembly procedures to reassemble.(2)**: Refer to “Service Points of Disassembly”.(3)*a: Refer to “Service Points of Reassembly”.
22100851
SERVICE POINTS OF DISASSEMBLY
1.12. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing.

MANUAL TRANSAXLE - Drive Bevel Gear Assembly2f-135
v22100873. REMOVAL OF DRIVE BEVEL GEAR
Using the special tool,
remgve the drive bevel gear.
SERVICE POINTS OF REASSEMBLY
2.11. INSTALLATION OF TAPER ROLLER BEARINGUsing the special tool, install the taper roller bearing.

21-136MANUAL TRANSAXLE - Driven Bevel Gear Assembly
DRIVEN BEVEL GEAR ASSEMBLY
DISASSEMBLY AND REASSEMBLY
Disassembly steps
a* I)*1. Taper roller bearing2. Driven bevel gear
NOTE(I)(2)Reverse the disassembly procedures to reassemble,(3)+*: Refer to “Service Points of Disassembly”.l +: Refer to “Service Points of Reassembly”.
2210143
9988012210144
SERVICE POINTS OF DISASSEMBLY
1. REMOVAL OF TAPER ROLLER BEARINGUsing the special tool, remove the taper roller bearing.
A
SERVICE POINTS OF REASSEMBLY
1. INSTALLATION OF TAPER ROLLER BEARINGUsing the collar, install the taper roller bearing.

AUTOMATIC TRANSAXLE - Specifications
SPECIFICATIONS
-+ GENERAL [email protected]
TypeTorque converter
TypeEngine stall speed
Stall speed ratio
Transaxle
TypeGear ratio
First
Second
Third
Fourth
ReverseFinal ratio
gearSpeedometer gear ratio
[drive/driven)
1.8L Engine2.0L DOHC Engine 2.0L DOHC
2.0 DQHCTurbo Engine
T”‘pJyine.
F4A22-2-M PDF4A22-2-M PD 1F4A33-U P61W4A33-1 -U P6Full automatic
Full automatic
Full automatic
Full automatic
4 speed transaxle
4 speed transaxle4 speed transaxle
4 speed transaxle
3 element with
3 element with3 element with
3 element with
damper clutch
damper clutchdamper clutch
damper clfi&h
1,800-2,800 rpm1,800-2,800 rpm1,800-2,800 rpm1,800-2,806 ipm
2.051.901.741.74 *,
Electronically
Electronicallycontrolled 4 speed controlled 4 speedElectrbnicallyElectrotiicallyfull automaticcontrolled 4 speed controlled,i4’ speed
full automatic
full automatic
full automatic
2.846
2.8462.551
2.551c1.5811.5811.4881.488 f *r
1 .ooo
1 .ooo1 .ooo1 .ooo
0.685
0.6850.6850.685
2.176
2.1762.176
2.176
4.007
4.0074.3764.42’2
””
*36129361293612936129‘,!
SERVICE SPECIFICATIONS
TransaxleItems
Standard valueTransfer driven gear preload
(Center differential case
preload) mm (in.)
Transfer shaft end play
mm (in.)
Low reverse brake end play
mm (in.)
Input shaft end play
mm (in.)
Differential case end play
mm (in.)
Differential case preload
mm (in.)
Differential case end play
mm (in.)
Differential gear and pinion backlash
mm (in.)
Oil pump side clearance
mm (in.)
Output flange bearing play
mm (in.)Specifications
0.075-0.135 (.0030-.0053)O-0.025
(O-.001 0)
1.0-l .2 (.039-,047)
0.3-l .o (.012-.039).,O-O.1 5 (O-.006),*, ,_ ,”0.075-O. 135
(.0030- .0053)1.
0.045-0.165 (.0017-.0064)
0.025-0.150 (.OOlO-.0059).,‘.a .;.; ‘>
o.03-o.05 (~oo12-~o(j~o’) ” i.u:-., ‘~O-0.06
(O-.0024)

21-178AUTOMATIC TRANSAXLE - Troubleshooting
09P0010Fluid level must be
within this range.09PoOll
0”
Two302
DIAGNOSIS AND TEST
FLUID LEVEL AND CONDITION1. Drive until the fluid temperature reaches the usual tem-
perature
[70-80°C (160- 18O”F)I.2. Place vehicle on level floor.
3. Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position. This operation is necessary tobe sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the conditionof the fluid.
The transaxle should be overhauled under the following
conditions.l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
lIf there is a noticeably great amount of metal particles inthe fluid.
5.Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add automatic transaxle fluid until level
reaches “HOT” range.
Low fluid level can cause a variety of conditions because itallows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of automatic transaxle
fluid.In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch,
and servo operation. Foaming can also result in fluid
escaping from transaxle vent where it may be mistaken for
a leak.
6. Be sure to examine fluid on dipstick closely.
CONTROL CABLE
Whether control cable is properly adjusted can be confirmed bychecking whether inhibitor switch is performing well.
1. Apply parking brakes and service brakes securely.
2. Place selector lever to “R” range.
3. Set ignition key to “ST” position.
4. Slowly move the selector lever upward until it clicks as it
fits in notch of “P” range. If starter motor operates when
lever makes a click, “P” position is correct.
5.Then slowly move selector lever to “N” range by the same
procedure as in foregoing paragraph. If starter motor
operates when selector lever fits in “N”, “N” position is
correct.6. Also check to be sure the vehicle doesn’t begin to move
and the lever doesn’t stop between P-R-N-D.
7. The control cable is properly adjusted if, as described
above, the starter motor starts at both the “P” range and
the “N” range.