1991 MITSUBISHI ECLIPSE differential

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

MANUAL TRANSAXLE - Transaxle Asshmblv 21-23TFM0006
47./48. INSTALLATION OF SHIFT RAILS AND FORKS(1) Set the
lst-2nd speed shift sleeve at 2nd Speed.
(2) Set the
3rd-4th speed shift sleeve at 4th spe$d.(3) Fit the shift forks of shift rail assembly to groove of
sleeves.(4) Insert the shift rails into the shift rail holes of clutch
housing.(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and interlock
plate.
45.146. INSTALLATION OF SPRING PINS
Install the spring pins using the special tool or a pin Punch.When installing, make sure that the slit of the spring pin is
aligned with the shift rail center line.
Caution
Do not reuse the spring pins.
35.137.139. SELECTION OF SPACERS
(1) Place two pieces of solder measuring about Ia mm (.4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races of intermediate
gear and differential.
(2) With a solder puddle measuring
10 mm (.39 in.) long
and 1.6 mm (.06 in.) across on the transaxle case at thelocation shown in the figure, install the
bearing outer
race of the shaft.
(3) Install the transaxle case and tighten the bolts to
specified torque.
(4) Remove the transaxle case.
(5) Remove the outer races and take out the crushed
solder.(6) If the solder is not broken, carry out the work in steps
(l)-(5) with large diameter solder.

21-30MANUAL TRANSAXLE - Transaxle Assembly
2200048
IAmountl-2 mm(7) Measure the thickness of the crushed solder with a
micrometer and select a spacer of thickness that gives
standard
preload.,&
Standard value:
Intermediate shaft0.05-0.10 mm (.002-,004 in.)
Output shaft0.05-0.10 mm (.002-.004 in.)
Differential case0.05-0.10 mm (.002-,004 in.)
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outerrace and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear
shaft’s head is facing in the direction indicated in the
illustration.
NOTEIf there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of thetransaxle case.
Specified sealant: MITSUBISHI GenuinePart
No.MD997740 or
equivalent
CautionB
Squeeze out sealant from the tube uniformly with- -
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.

_-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

MANUAL TRANSAXLE - Transaxle Assembly Spring pin
/Shift rail
11-t201034er
2150008
220004E46./49.
INSTALLATION OF SPRING PINS(1) Install the spring pins using the special tool or a pin
punch.
Caution
Do not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
’
35. /37. /40./42. INSTALLATION OF SPACERS(1) Place two pieces of solder measuring about
10 mm (4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
’(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If the solder is not broken, carry out the work- in steps
(l)-(4) with large diameter solder.
(6) Measure the thickness of the crushed soid& with a
micrometer and select and install a spacer of thickness
that gives standard preload and end play.
Standard value:
Input shaft end play
O-0.05 mm (O-.002 in.)
Intermediate gear preload0.05-0.10 mm (.002-.004
in.)
Output shaft preload0.05-0.10 mm (.092-.004 in.)
Differential case preload
9.05-0.10 mm (.002-.004 in.)

21-40 MANUAL TRANSAXLE - Transaxle Assembly Amount
1-2 mm
J
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
.‘p,
/
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outerrace and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear
hshaft’s head is facing in the direction indicated in the
.-
illustration.
NOTEIf there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified sealant: MITSUBISHI Genuine
Part No.
MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
18 mm (32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
*
torque.,-(8) Tighten the reverse idler gear shaft bolt to specified
torque.

MANUAL TRANSAXLE 4WD> - Differential Assembly21-63
DIFFERENTIAL ASSEMBLYNZlMMAF.
DISASSEMBLY AND REASSEMBLYDisassembly steps
l
+ 1. Bolt2. Differential drive gear
l l a3. Taper roller bearing
+e l +4. Lock pin
M 5. Pinion shaft
l 6. Pinion
e+ 7. Washer
l + 8. Sidegear
l +9. Spacer (Select)10. Differential case
130-440 Nm94- 101 ft.lbs.
\6
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.
(3) ,+ : Refer to “Service Points of Reassembly”.
(4) p : Non-reusable parts
163025
Press
F+ Bearing
SERVICE POINTS OF DISASSEMBLY
3. REMOVAL OF TAPER ROLLER BEARING
Remove the taper roller bearing using the special tool as
illustrated.
Caution ’1. Do not reuse the bearing removed from the dif-
ferential case.
2.Replace the inner and outer races of the taper roller
bearing as a set.

21-64MANUAL TRANSAXLE - Differential Assembly2150020
Lock pin
Llla
Lock pinDifferen-tial case
alla-ctiol
ock pinendwith2150021
4. REMOVAL OF LOCK PINDrive out the lock pin from the hole A using a punch.
SERVICE POINTS OF REASSEMBLY9. INSTALLATION OF SPACER
/ 8. SIDE GEAR / 7.
WASHER
/ 6. PINION / 5. PINION SHAFT
(1) Install the spacer on the back of the side gear and then
install the gear in the differential case.
Caution
When installing a new side gear, use a spacer ofmedium thickness [0.93-1.00 mm (.36-.04 in.)].
(2) Set the washer on the back of each pinion and insert thetwo pinions to specified position while engaging
them
with the side gears and turning them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gears and
pinions.
Standard value:0.025-0.150 mm
LOO1 -.006 in.)
(5) If the backlash is out of specification, disassemble againand using correct spacer, reassemble and adjust.
Caution
Adjust for same backlash of both side gears.
4. INSTALLATION OF LOCK PINAlign the pinion shaft lock pin hole with the case lock pin
hole and insert the lock pin.
Caution1. Do not reuse the lock pin.
2. The lock pin head must be sunk from the flange
surface of the differential case.