1991 MITSUBISHI ECLIPSE Service Manual

_-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

IMD99801 9I
21-36MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF DISASSEMBLYNZlMFAS
14. REMOVAL OF SPRING PINRemove the spring pin using a special tool.
NOTEIf the spring pin interferes with the synchronizer ring or
cone gear, rotate the gear for dislocation and remove the
spring pin.
15. / 16. REMOVAL OF LOCK NUTS(1) Unstake lock nuts of the input shaft and intermediate
gear.
(2) Shift the transaxle in reverse using the control lever andselect lever.
(3) Install the special tool onto the input shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.
48.149. REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using a pin punch.

MANUAL TRANSAXLE - Transaxle Assemblv 21-37
18
50. REMOVAL OF SHIFT RAIL ASSEMBLY(1) Shift the
1st~2nd speed shift fork to the 2nd speed.
(2) Shift the
3rd4th speed shift fork to the 4th speed.
.”(3) Remove the shift rail assembly.
INSPECTIONNZlMOM
BACKUP LIGHT SWITCHOperate the backup light switch to check continuity with a
circuit tester.
If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLY64. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.
:

21-38 MANUAL TRANSAXLE - Transaxle Assembly
63. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
,,=
2010041
51. 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
50. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Set the lst-2nd speed shift sleeve at 2nd speed.
(2) Set the
3rd-4th speed shift sleeve at 4th speed.
(3) FJtt~~~shift forks of shift rail assembly to groove of
(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.A

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 - 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

21-42MANUAL TRANSAXLE Transaxle Assembly /- 5th Speed Synchionizer AssemblyTFM0041
8” in.)TFM0044
4. INSTALLATION OF SCREW BOLTSApply specified adhesive to screw bolts mounting portion.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No. 4318032
or ‘equivalent
2. APPLICATION OF SEALANT TO THE 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 without
excess or discontinuity.
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
43
NZlMHAK
1Disassembly steps
1. Reverse brake ring (F5M22-2, F5M33)
2. Stop plate (F5M22-1)I)4 3. Synchronizer spring4. Synchronizer sleeveWI 5. Synchronizer key*+ 6. Synchronizer hubTFM0055
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Reassembly”.