1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Transaxle Assemblv 21-27
206001E
47./48. REMOVAL OF SHIFT RAILS AND FORKS’(1) Shift the Ist-2nd speed shift fork to the
2nd speed.
(2) Shift the
3rd~4th speed shift fork to the 4th speed.
(3)Rotate the the shift controls in the direction of the arrowin numerical order. Remove the shift lugs from the
control finger and interlock plate.
(4) Raise each of the shift rails upward and remove them
from the clutch housing.
(5) Remove the all shift rails and forks.
52. REMOVAL OF INTERMEDIATE GEAR ASSEMBLYLift up the input shaft assembly and remove the intermedi-
ate gear assembly.
INSPECTION
BACKUP LIGHT SWITCH
N21MOdOperate the backup light switch to check continuity with a
circuit tester. If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLYN2mnGAU
61. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.

21-28MANUAL TRANSAXLE - Transaxle Assemblv
seal
201025Apply
adhesive
(.2 in.)TFMOO63
60. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
52. INSTALLATION OF INTERMEDIATE GEAR ASSEMBLY /
53. INPUT SHAFT ASSEMBLYLifting up the input shaft assembly, install it simultaneously
with the intermediate gear assembly.
49. APPLICATION OF ADHESIVE TO BOLTApply specified adhesive to the bolt threads.
CautionDo not apply to the bolt head.
Specified adhesive: MOPAR Part No.4318031or MOPAR Part
No.4318032
or equivalent

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%3T
IMD998245(5)
Insert a Phillips screwdriver [8 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
(8)
E$r& the reverse idle gear shaft bolt to specified
torque.
15./ 16. INSTALLATION OF LOCK NUTS(1) Install the special tool to the splined end of input shaft.
(2) Screw a bolt
(10 mm) into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(3) Shift the transmission in reverse using control lever andselect 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) Retighten 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.

21-32MANUAL TRANSAXLE - Transaxle Assembly
Slit
201034
2010043
APPLY a
TFM0041TFM0044
(2) When installing, make sure that the slit of the spring pin
is aligned with the shift rail center line.
fi
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
4. INSTALLATION OF SCREW BOLTSApply specified adhesive to screw bolts mounting portion.
Specified adhesive: 3M Stud Locking No.4170-
2. APPLICATION OF SEALANT TO REAR COVERApply specified sealant to the rear cover.
Specified sealant: MITSUBISHI Genuine Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly wlthout
excess or discontinuity.

MANUAL TRANSAXLE - Transaxle Assembly n-33
TRANSAXLE ASSEMBLY
3 DISASSEMBLY AND REASSEMBLYNZlME-6
--42 Nm
-30
ft.lbs.
\8I Q
30-35Nm
22-25ft.lbs.ml4
ff3d6 i
18
4.0-5.5Nm2.9-3.9ft.lbs.
-n
140-160 Nm102-115ft.&s.
3-5 Nm
16-22 Nm11-15 ft.lbs.1Disassembly steps
‘I. Bolt
l *2. Rear cover3.Wave springe4 4. Screw bolts5. Reverse brake cone6. Backup light switch
7.Gasket
8.Poppet plug9.Poppert spring
10.Poppet ball11.Bolt
12. Speedometer driven gear assembly
l 13. Air breather
4* l * 14. Spring pin
,I
2
TFMool6
4+ e4 15. Lock nut+e l 16. Lock nut17. 5th speed synchronizer assembly18. 5th speed shift fork19. Synchronizer ring20. 5th speed gear21. Needle bearing22.
5th speed intermediate gear.’
$?everse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly:.(3) l C : Refer to “Service Points of Reassembly(4) q : Non-reusable parts

21-34MANUAL TRANSAXLE - Transaxle Assembly
? ,‘,
30-35 Nm77-25 fLlbs.35-42 Nni26-30 ftlbs.
25
APi 77
--2lRl 26
\\15-22 Nm
---- -_ . .23
II-15 lt.lDS.
I
..d.. -Disassembly steps
23. Reverse idler gear shaft bolt24.Gasket
25.Bolt
l + 26. Transaxle case+4 ;I. ;$yrde
29:Springwasher30.Stopper bracket31. Restrict ball assembly
32.Gasketl 433.Oil seal34. Bearing outer racel * 35. Spacer
36. Bearing outer racel 437.Spacer38.Oil filter39. Bearing outer race32-39
ft.lbs.
TFMOlO9
l 4 40. Spacer41. Bearing outer race
I)* ;I. Sggcer
44: Reverse shift lever assembly
45. Reverse shift lever shoe
l + 46. Reverse idler gear shaft47. Reverse idler gear+e l + 48. Spring pinl * l + 49.Spring pin+I) l 50. Shift rail assembly
NOTE(I) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) e* : Refer to “Service Points of Reassembly”.(4) 19 : Non-reusable parts