1991 MITSUBISHI ECLIPSE Service Manual

STEERING - Power Steering Oil Pumt,DISASSEMBLY AND REASSEMBLY
137~.-
Oil pump seal kitOil pump cartridge kitOil pump pulley and shaft kit18-22 Nm
13-16
ft.lbs.50-70 Nm36-51 ft.lbs.
1
I\=--=x=-T--
6-10 Nm
4-7
ft.lbs.--
25-30 Nm ’16-22 ft.lbs.
\13A0351
25m29Disassembly steps
I)+1.Pumpcover
l + 2. O-ring
l 43.Cam ringl 44.Vanes
l + 5. Snap ring
l 46.Rotor
4*7. Pulley assembly
l 8. Side plate
I)+9.O-ringl a 10. O-ring11,Suction connectorl + 12. O-ring+4 13. Oil seal14.Connectorl + 15. O-ringl + 16. Flow control valve
17. Flow control spring
18.Terminal assembly
19.Snap ring
20.Terminal
21.Washer
22.Insulator
l + 23. O-ring24.Plug
l25.O-ring
l26.Spring
27.Plunger
28.Piston rod
29. Oil pump body
FyEeverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

19-42STEERING - Power Steering Oil Pump
13A0279SERVICE POINTS OF DISASSEMBLY
NleRFAM7. REMOVAL OF PULLEY ASSEMBLY
%
Tap the rotor side of the shaft lightly with a plastic hammer,,,~and take out the pulley assembly.
INSPECTION
NlSRGAK0 Check the flow control spring for wear.0 Check the shaft of the pulley for wear and bend.0 Check the groove of rotor vane for “stepped” wear.0 Check the contact surface of cam ring and vanes for
“stepped” wear.0 Check the vanes for breakage.
CHECK OF GAP BETWEEN VANE AND ROTOR GROOVE
Install vane to rotor groove as illustrated. Measure the gap
between vane and rotor groove with thickness gauge.
Limit: 0.06 mm
(.0024 in.)?ACHECK OF SHAFT BACKLASH OF PUMP BODY BUSHING
AND PULLEY ASSEMBLY
(1) Place a dial gauge at the end of the shaft of the pulley
assembly.
(2) Move the pulley assembly up and down, and measure theplay.
Limit: 0.1 mm
I.004 in.)
SERVICE POINTS OF REASSEMBLY
NlSRHBH26. INSTALLATION OF SPRING
Fit the spring to the oil pump body with the larger-diameter
end at the terminal assembly side.
A.

STEERING - Power Steering Oil Pump
Terminal assembly
13K753Mark
A,B or C-43Mark
A,B or C
13G0151
/Connector13K752
Suction-ring
25.123. INSTALLATION OF O-RINGSApply specified fluid on O-rings to install.
Specified fluid: MOPAR ATF PLUS (Automatic Transmis-sion Fluid Type 7176)/Automatic trans-
mission fluid “DEXRON” or “DGXRON II”
I No. II.D. x Widthmm (in.)1 Identification color 1
113x1.9t.51x.0748)Blue
23.8
x1.9l.15x.0748)-16. INSTALLATION OF FLOW CONTROL VALVE
(1) If the flow control valve is to be replaced, install the flowcontrol valve to the oil pump body corresponding with
the body identification mark (A,
6, C).
(2) Apply the specified fluid to the outside of the flow control
valve.
Specified fluid:MOPAR ATF PLUS (Automatic Trans-mission Fluid Type
7176)/htomatictransmission fluid “DEXRON” or
“DEXRON II”
15. INSTALLATION OF O-RINGS
Apply specified fluid on O-rings to install.
Specified fluid: MOPAR ATF PLUS (Automatic Transmis-sion Fluid Type 7176)/Automatic trans-
mission fluid “DEXRON” or “DlkXRON II”
No.I.D. x Widthmm (in.)
1I 1 x 1.9 t.43 x .0748)
213x 1.9 l.51 x .0748)
317.8 x 2.4 j.70 X .0945)
413.5 x 1.5 t.53 x .0590)
ldentificaqion color
Yelllow
Blue
-
Red13. INSTALLATION OF OIL SEAL
Drive the oil seal into the pump body.
12. INSTALLATION OF O-RING
Apply specified fluid on O-ring to install.
Specified fluid:MOPAR ATF PLUS (Automatib Transmis-sion Fluid Type 7176)/Autoniatic trans-
mission fluid “DEXRON” or “DEXRON II”I.D.
x Widthmm (in.)Identification color
I17.8 x 2.4 (.70 x .0945)-I
13A0277

19-44STEERING - Power Steering Oil Pump
13AO350
13PO159
Punch mark
13c214 I
13W03ECutouts for
dowel pin
13PO16110. INSTALLATION OF
O-RING/S. O-RING
Apply specified fluid on O-ring to install.
-,Specified fluid: MOPAR ATF PLUS (Automatic
Trans- ”mission Fluid Type 7176)/Automatic
transmission fluid
“DEXRONY or “DE-XRON II”
1 No. 1I.D. x Widthmm (in.)Identification color
I2 1I47.2 16.8x x2.4 2.4(1.86 (.66x x.0945) .0945)- -8. INSTALLATION OF SIDE
PLATE
Align the dowel pin of the pump body with the dowel pin holeof the side plate to install the side plate.
6.
INSTALLATlON OF ROTOR
Install the rotor to the pulley assembly so that the rotor’s
punch mark is at the pump cover side.
s,5. INSTALLATION OF SNAP RING
Lift the rotor and check to be sure that the snap ring is in the
countersunk part.4.
INSTALLATlON OF VANE/3. CAM RING
(I1 Apply specified fluid to vane and cam ring friction
surface.
Specified fluid: MOPAR ATF PLUS (Automatic Trans-mission Fluid Type 7176)IAutomatic
Atransmission fluid “DEXRON” or
“DEXRON II”
(21 Align the dowel pins of the pump body with the dowel
holes of the cam ring, and then install so that the cam
ring’s punch mark is at the pump body side.

STEERING - Power Steering Oil Pump
Direct round edge
to the cam
ringCam ring13R0577
(3)Apply specified fluid to the vanes and instafl :lhe yaneson the rotor, paying close attention to the installation
direction.,L.,., ‘,, :.I
Specified fluid:MOPAR ATF PLUS (Automatic Trans-mission Fluid Type
7176)/Auto@tictransmission fluid
“DEXFhOW’ or
“DEXRON II”
2. INSTALLATION OF O-RING
Apply specified fluid to O-ring and install firmly on oil pump
body.
Specified fluid: MOPAR ATF PLUS (Automatic Trans-
mission Fluid Type 7176)/Automatic
transmission fluid “DEXRON” or
“DEdXRON II”.
1.
INSTALLATlON OF PUMP COVER
(1) Apply specified fluid to rotor friction surface of pump
cover.
Specified fluid:MOPAR ATF PLUS (Automatic Trans-
mission Fluid, Type
7176)/Automatictransmission fluid “DEXRON” or
“DEXRON II”.
(2) Align the dowel pin of the pump cover with the dowel pinhole in the cam ring to install the pump cover.

19-46STEERING - Power Steering Hoses
POWER STEERING HOSESREMOVAL AND INSTALLATIONNlSTA-
Pre-removal Operationl C+?ing of the Power Steering
,‘; ,L..,.,.):. ,4-14 NmwaI. . .-...5-10 ft.lbs.7
I9-14 NmI7 7-10 ft.lbs.
Post-installation Operationl Supplying of the Power Steering-.
1 Fluid
l Bleeding of the Power Steering
Fluid Line(Refer to P.19-13.1,621 N/-@b
K
2
3.0-4.5 Nm /2-3 ft.lbs.I/II z-”a.
413A0274
Removal steps
1.Returnhose2.Suctionhose
3.Returnhose4. Cooler tube
5. Return tube
6. Rubber hose
.a 7. Pressure hose
8.Pressure tube9.Return tube
10.O-ring
NOTE(1) Reverse the removal procedures to reinstall.
(2) l a : Refer to “Service Points of Installation”.(3) q : Non-reusable partsWhite lineUP0143SERVICE POINTS OF INSTALLATION
NlSTDAD7. INSTALLATION OF PRESSURE HOSE
(1) Connect the pressure hose so that its slit pat-t contacts
the oil pump’s guide bracket.
(2) When the pressure hose is installed, align the white line
on the pressure hose with the white line on the pressuretube so that together they form a straight line.

TRANSAXLE ’
MANUAL AND AUTOMATICCONTENTS
;-AUTOMATICTRANSAXLE
.....................................................137ANNULUS GEAR AND TRANSFER DRIVE GEAR SET (F4A22)..........315ANNULUS GEAR AND TRANSFER DRIVE GEAR SET(F4A33.W4A33)...........................................................................................317CENTERDIFFERENTIAL(W4A33).............................................................329DIFFERENTIAL............................................................................................319ENDCLUTCHASSEMBLY.........................................................................309EXTENSIONHOUSINGASSEMBLY(W4A33).........................................337FRONTCLUTCHASSEMBLY....................................................................302FRONTOUTPUTSHAFT(W4A33)...........................................................332GENERALINFORMATION.........................................................................137KICKDOWNSERVO....................................................................................322LOW-REVERSEBRAKE..............................................................................323OILPUMP...................................................................................................299PLANETARYGEARSET............................................................................311PLANETARYGEARSET............................................................................313REARCLUTCHASSEMBLY(F4A22)........................................................304REARCLUTCHASSEMBLY(FQA33sW4A33)............................................307SERVICEADJUSTMENTPROCEDURES..................................................Drive
Shaft,OilSealsReplacement....................................................;;;
InhibitorSwtchAdjustment................................................................21 1KeyInterlockMechanismCheck.....................................................KrckdownServoAdjustment..................................zii..............................
LinePressureAdjustment...................................................................213
ReducingPressureAdjustment.........................................................214Selector Lever Operation Check........................................................210ShiftLockMechanismCheck...............................................................21 1SpeedometerCableReplacement.........................................................Throttle-posltipn Sensor Adjustment.................................................z2:
TransaxleFluIdLevelInspectIon......................................................209
TransaxleFluidReplacement.............................................................209
SPECIALTOOLS.........................................................................................SPECIFICATIONS........................................................................................;“5”9
GeneralSpeclficatlons..................................................................1%Lubricants..................................................................................Sealants and Adhesives..............................................................izi
Serwce Speclflcatlons..................................................159...............Spacer andSnapRing.,.,.............................................................Spacer Set..................................................................1::Torque Speclflcatlons...........................................166Valve Body Spring Identification Chart.....................
.................160
SPEEDOMETERGEARASSEMBLY..........................................................TRANSAXLEASSEMBLY(WA22)............................................................zTRANSAXLE
ASSEMBLY(F4A33.W4A33)................................................TRANSAXLECONTROL.............................................................................;;;TRANSAXLE
OILCOOLER........................................................................TRANSFER..................................................................................................fg
TRANSFERASSEMBLY.............................................................................333TRANSFERCASEADAPTERSUBASSEMBLY(W4A33).......................339TRANSFER CASE SUB ASSEMBLY (W4A33)341TRANSFER SHAFT (F4A33)TROUBLESHOOTING..................................................................................................................................................................................................f;;VALVE
BODY.............................................................................................324
MANUAL TRANSAXLE .......................................2CLUTCHHOUSINGASSEMBLY...............................................................DIFFERENTIAL ASSEMBLY ,....._................................................................E
5TH-SPEEDSYNCHRONIZERASSEMBLY...............................................42GENERALINFORMATION.........................................................................2.-.INPUTfj,-,A,TASSEMBLY.....................................................INPUTSHAFTASSEMBLY.....................................................;
INTERMEDIATE GEAR ASSEMBLY..........................................................56OUTPUT
SHAFT ASSEMBLY....................................................................61SERVICEADJUSTMENTPROCEDURES..................................................DriveShaftOilSealsReplacement......................................................;;Speedometer Cable Replacement.........................................................
Transaxle Oil Level
InspectIon..............................................................‘liTransaxle Oil Replacement....................................................................
I3
SHIFTLEVERASSEMBLY.........................................................................SHIFTRAILSANDFORKS........................................................................g
SPECIALTOOLS.........................................................................................SPECIFICATIONS........................................................................................1:
General Specifications5Lubricants..........................................................................................................................................................................10Sealants and Adhesives
Service Specifications
....................................................................................................................................................1:Snap Ring (for Adjustment) and Spacer...............................................
Torque Specifications.............................................................................
i
SPEEDOMETERGEARASSEMBLY..........................................................TRANS&G.E................................................................................................zTRANSAXLEA!jSEMBLY
........................................................i?3TFlANSAXLEASSEMBLY........................................................TRANSAXLECONTROL.............................................................................g
TROUBLESHOOTING..................................................................................12
MANUAL TRANSAXLE ......................................BACKUPLIGHTSWITCH...........................................................................g
CENTERDIFFERENTIAL.............................................................................103CLUTCHHOUSINGASSEMBLY...............................................................DRIVE BEVEL GEAR ASSEMBLY;g
...... .......................................................DRIVENBEVELGEARASSEMBLY...................................a......................EXTENSIONHOUSINGASSEMBLY.........................................................;g
5Tf.jSPEEDSYNCHRONIZERASSEMBLY...............................................101
FRONTDlFFERENTlAL...............................................................................106
FRONTOUTPUTSHAFTASSEMBLY......................................................106
GENERALI~~~~MATN)N...............................................................,.,.......66INPUTSHAFTASSEMBLY........................................................................l~ER,“,EDlATEGEARASSMBLY..........................................................;;i
SERVICEADJUSTMENTPROCEDURES..................................................Drive Shaft Oil Seals Replacement......................................................;;Speedometer Cable Replacement.........................................................
Transaxle
Ojl Level lnspectlon..............................................................;l
Transaxle 011 R~pb33ment....................................................................79Transfer
OilSealReplacement.............................................................80
SHIFTLEVERASSEMBLY.........................................................................SHIFTRAILASSEMBLY............................................................................,z
SPECIALTOOLS.........................................................................................76
SPECIFICATIONS........................................................................................6g
GeneralSpecifications...........................................................................6g
Lubricants...............................................................................................75
SealantsandAdhesives........................................................................76
ServiceSpecifications............................................................................6gSnap Ring (for Adjustment) and Spacer...............................................7 o
TorqueSpecifications.............................................................................74
SPEEDOMETERGEARASSEMBLY..........................................................TRANSAXLE................................................................................................1:TRANSAXLEASSEMBLY...........................................................................86TRANSAXLE
CONTROL
.............................................................................TRANSFER...............................................................................................
g.._TRANSFERA!333lBLY.............................................................................,24
TRANSFERCASEADAPTERSUBASSEMBLY.......................................131TRANSFERCASESUBASSEMBLY.........................................................TR,,UBLES,,OO,,NG..................................................................................1;;

21-2MANUAL TRANSAXLE - General Information
MANUAL TRANSAXLE
GENERAL INFORMATION
NZlBAAP
F5M22 (4637 Engine)
Clutch housing
Bearing retainer
2nd speed gear
3rd soeedaear
5th speedsynchronizerassemblv
-----..-.IRear cover
5th speed inter-
mediate gear
Intermediate gear
SpacerOutput shaft
SpacerTransaxle case
\Dif ferential drive gear
Diffelential
Spacer
#&---- Drain plug
2060020