1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Special Tools ’2149
SPECIAL TOOLS
”
N?/bA-A

21-12 MANUAL TRANSAXLE - Special Tools/Troubleshooting
I
IICPintermediate shaft lock nut
MD998819Installer adapterInstallation of differential case bearing
TROUBLESHOOTINGNZlEAABsSymptomVibration, noise
3il leakage
Hard shift
Jumps out of gearProbable causeRemedy
a. Loose or damaged transaxle anda. Tighten or replace mounts
engine mounts
b. Inadequate shaft end playb. Correct end play
c. Worn of damaged gears
c. Replace gears
d. Use of inadequate grade of oild. Replace with specified oil
e. Low oil level
e. Replenish
f. Inadequate engine idle speed
f. Adjust idle speed
a. Broken or damaged, oil seal or O-ringa. Replace oil seal or O-ring
a. Faulty control cable
a. Replace control cable
b. Poor contact or wear of synchronizer ring
and gear coneb. Correct or replace
c. Weakened synchronizer springc. Replace synchronizer spring
d. Use of inadequate grade of oil
d. Replace with specified oil
a. Worn gear shift fork or broken poppet
springa. Replace shift fork or poppet spring
b. Synchronizer hub to sleeve spline
clear-ante too largeb. Replace synchronizer hub and sleeve

MANUAL TRANSAXLE - Service Adjustment Procedures21-13
II
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I09K56i
09K56f
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SERVICE ADJUSTMENT PROCEDURESN21FBABlTRANSAXLE OIL LEVEL INSPECTION
Refer to GROUP O-Maintenance Service.
TRANSAXLE OIL REPLACEMENT
NZlFCADa(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transaxle oil to
drain.(3) Refill the transaxle to the proper level with specified
transaxle oil. The oil level should be the bottom of the oil
filler hole.
Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or hiqher
1.8 liters (1.9 qts.)
2.2 liters ‘(2.3 qts.)DRIVE SHAFT OIL SEALS REPLACEMENT
NZlFDACa
(1) Disconnect the drive shaft from the transaxle.
(Refer to GROUP
2-Drive Shaft.)
(2) Using a flat-tip
(-) screwdriver, remove the oil seal.
(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
(4) Apply a coating of the transaxle oil to the lip of the oil seal.Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or higher

21-14 MANUAL TRANSAXLE -Service Adjustment Procedures
I-Adapter%A0905SPEEDOMETER CABLE REPLACEMENT
NZlFEAKl
1.Correctly insert the adapter into the instrument panel, andS.
fasten the new speedometer cable.1-
2.Install the grommet so that, as shown in the illustration, the
cable attachment is positioned upward.Caution
1.The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2.The arrangement of the speedometer cable should
be such that it does not interfere with other
parts.
3. At the transaxle end of the speedometer cable, the key
joint should be inserted into the transaxle, and the nut
should be securely tightened.Caution
lllcIf the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.

MANUAL TRANSAXLE - Transaxle Control2M5
TRANSAXLE CONTROL
-^ REMOVAL AND INSTALLATION
Removal steps1. Plug
2. Side cover (A)
3. Side cover(B)
4. Cover(B)
N21JA-A
919AO349
9-14 Nm .
+-
0
0OQA017412. Cotter pin
13. Retainer
14. Retainer
15. Cotter pin
9-14 Nm7- 10 ftlbs.5. Manual transaxle shift lever knob
6. Cup holder
7. Carpet
8. Connection for floor console wiring
I)4 16. Shift cable
I)+ 17. Select cable
18. Shift lever assembly
harness
9. Guide ring
10. Shoulder belt
11. Floor console
NOTE(1) Reverse the removal procedures to reinstall.(2) *a : Refer to “Service Points of Installation”.(3) m : Non-reusable parts

21-16MANUAL TRANSAXLE - Transaxle Control
INSPECTIONN21JcAD
ICBA0160 1Incorrect
5I,I
-ri
IIIncorrect
1,-I I,,1 :
Sele’ctcableFlange side
yof the resin LbushingLever
&OSAOl72l Check the select
cable for funct,ion and for damage.
l Check the shift cable for function and for damage.
l Check the boot for damage.
l Check each bushing for wear or abrasion, sticking,
impeded action, and damage.
l Check the spring for deteriorated strength.
SERVICE POINTS OF INSTALLATION
NZlJDAK17. INSTALLATION OF SELECT CABLE
(1) Move the transaxle shift lever to the neutral position.
NOTEThe select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral
position.(2) Move lever
(6) to the neutral position.
(3) Adjust, by using the adjuster, so that the end of the
select cable is positioned as shown in the illustration
relative to lever
(B).
k,I.,,(4) The flange side of the resin bushing at the select cable
end should be at the lever
(B) end surface.
A.

MANUAL TRANSAXLE - Transaxle Contid
erShift
lever
09A0159
09A016t16. INSTALLATION OF
SHIFT CABLE
(1) With the select lever in neutral, move the transaxle shift
lever (in the direction shown in the illustration) to set it
to
4th gear.
NOTE
If the shift lever does not move easily, depress and holdthe clutch pedal.
(2) Move the shift lever (at the vehicle interior side)
downward, in the direction
(4th gear position) shown in
the illustration until it contacts the stopper.
(3) Adjust, by using the adjuster, so that the end of the shiftcable is positioned as shown in the illustration relative
to the shift lever (interior side).
(4) The flange side of the resin bushing at the shift cable
end should be at the split pin side.
(5) Adjust the length of the shift cable, by using the
adjuster, so that the clearance (A) and
(B) between the
shift lever and the two stoppers are equal when the
shift lever is shifted to
3rd gear and 4th gear.
(6)Move the shift lever to each position and check that theshifting is smooth.

21-18MANUAL TRANSAXLE - Shift Lever Assembly
SHIFT LEVER ASSEMBLYDISASSEMBLY AND REASSEMBLY
19-28
Nm14-20 ft.lbs.
Disassembly steps
1.Shift lever
e+2.Bushing
*q~ 3. Return spring
1)44.Bushing
5.Lever (A)
*47.;;;;;w
I)+8:Bushing9.Snap ring
10.Lever (B).+ 11. Bushing12.Bracket assembly17-26
09A0173
NOTE(1) Reverse the disassembly procedures to reassemble.
(2) l +
: Refer to “Service Points of Reassembly”.
: Non-reusable parts.
i%s.SERVICE POINTS OF REASSEMBLY
NZlGHAP
11./8./6./4,/3./2. APPLICATIONOF GREASE TO
BUSHINGS
Apply multi-purpose grease to the sliding part of the
bushings shown in the figure.
Grease: MOPAR Front Wheel Bearing
Grease Part No.3837794 or equivalent
3. INSTALLATION OF RETURN SPRING
Make sure that the end of the spring contacts the part
(shown in the illustration) of the bracket.