1991 MITSUBISHI ECLIPSE clutch

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 - Transaxle Assembly ,214
10 mm (.40 in.)
16. / 15. INSTALLATION OF LOCK NUTS(1) install the special tool to the splined end of inputshaft.
(2) Screw a bolt [IO mm
(.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
MD998245\ISlit
,+i 1I I
r
Spring pin
, Shift rail(3) Shift the transaxle in reverse using control lever and
select lever.
(4) Tighten the lock nut to specified torque, while using the
bolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6)
&tighten the lock nuts to the specified torque.
(7) Stake the lock nut.
14. INSTALLATION OF SPRING PIN(1) Install the spring pin 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.
13. APPLICATION OF SEALANT TO AIR BREATHER
Apply specified sealant to air breather mounting portion andinstall to the clutch housing.
Specified sealant: MOPAR Part No.4318025
or equivalent

21-46MANUAL TRANSAXLE - Input Shaft Assembly
201051
TFMO119
Damage, breakage
/
Synchronizer ringGLarTFMOlli
NEEDLE BEARING3a Combine the needle bearing with the shaft or bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.
l Check the needle bearing cage for deformation.
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm
(.02 in.)
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check that
they slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear
ends.
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for deterioration, deformation and break-
age.

MANUAL TRANSAXLE -Input Shaft Assembly lamiNear20105:
Springprotrusion2010018TFM0021
MD998320/
SPEED GEARS
lCheck the bevel gear and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough
surface, damage
and wear.
lCheck the gear ‘bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
12. INSTALLATlON OF SYNCHRONIZER SPRING
Install the synchronizer spring so that its protrusion fits intothe groove in the synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
groove of the same key.
11. 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) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-rectly in respective grooves of the synchronizer
ring.(3) Check the
3rd speed gear rotates smoothly.
9. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.

21-52 MANUAL TRANSAXLE - Input Shaft Assembly
r
201051
Damage, breakage
Damage,TFMO119
ISynchronver ringGearTFM0117
2010441
NEEDLE BEARINGl Combine the needle bearing with the shaft or bearing
+,sleeve and gear and check that it rotates smoothly without
abnormal noise or play.
l Check the needle bearing cage for deformation.
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm
(.02 in.)
-z
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check that
they slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear ends.
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for deterioration, deformation and break-
age.

MANUAL TRANSAXLE -Incut Shaft Assembly Key
2010018
2ndgearTFM0024
MD998320
20105f
SPEED GEARS
lCheck the bevel gear and clutch gear teeth for damage andw.wear.l Check the synchronizer cone for rough surface, damage
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
13. INSTALLATION OF SYNCHRONIZER SPRINGAssemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
Take care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.
12. 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) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-rectly in respective grooves of the synchronizer
ring.(3) Check the
3rd speed gear rotates smoothly.
10. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.
j

21-58MANUAL TRANSAXLE - Intermediate Gear Assembly
rDamage, breakage
Damage, wearl-FM0119
ISynchronizer ring
IGearTFM0117
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
~
peeling.
J
201045l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit
:0.5 mm (.02 in.)
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check that
they slide smoothly.
lCheck that the sleeve is free from damage at its inside front-4rand rear ends.
-.--
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve
aS a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for weakness, deformation and breakage.
SPEED GEARS
lCheck the bevel gear and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough surface, damage
and wear.
l Check the gear bore and front and rear ends for damage
kand wear.

21-66MANUAL TRANSAXLE - Clutch Housing Assembly
CLUTCH HOUSING ASSEMBLYNZlMPAL
DISASSEMBLY AND REASSEMBLY
2=
-,_
1
L--15-22 Nm
11-15 ftlbs.
20-27 Nm15-19 ft.lbs.
Disassembly steps
1.Bolt2. Select lever assembly
3. Select lever shoe
4. Interlock place bolt
5.Gasket+e l *6. Lock pinj\l * 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
l 415.Oil seal
2100019
l * 16. Needle bearing
l a 17. Needle bearing;EJ. Fil;tch housing
20: Return spring
21. Stopper plate
22. Spring pin
NOTE(1) Reverse the disassembl procedures to reassemble.(2)~~ : Refer to “Service ornts of Disassembly”.6.(3)l + : Refer to “Service Points of Reassembly”.(4) q : Non-reusable parts