1991 MITSUBISHI ECLIPSE Service Manual

..-MANUAL TRANSAXLE
-5th Speed Synchr’onizer Assembly tq-43
201044
201045TFM0046
Springprotrusion
Key
2010018
INSPECTION_ -.‘-
SYNCHRONIZER SLEEVE AND HUB-_
lCombine the synchronizer sleeve and hub and check thatthey slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear ends.
lCheck for wear of the hub front end (surface in contact withthe
5th 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.
SERVICE POINTS OF REASSEMBLY6. INSTALLATION OF SYNCHRONIZER HUB/5. SYN-
CHRONIZER KEY.Assemble the synchronizer hub, and key noting their
direction.
NOTEOnly the direction of the keys for the
F5M22-1 has to be
observed.3. INSTALLATION OF
SYNCHRONliER $PRlNGAssemble the synchronizer spring so that
:its projection
may be engaged in the groove of the synchronizer key.
NOTETake care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.

21-44 MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY N2tMW
DISASSEMBLY AND REASSEMBLY
18
16
17 IDisassembly steps
*+ 1. Snap ring+1)1)+ 2. Ball bearing
+I) I)+ 3. Bearing sleevel + 4. Snap ring4+*+ 5. Ball bearingl + 6. Spacer
7.
4th speed gear8.Needle bearing~~ 9. Bearing sleeve10.Synchronizer ringl + 11. 3rd-4th speed synchronizer assemblyl + 12. Synchronizer spring2060019
l *
13.Synchronizer sleeve14.Synchronizer key15.Synchronizer hub16.Synchronizer ring
17. 3rd speed gear18.Needle bearing19.Input shaft
NOTE(I) Reverse the disassembly procedures to reassemble(2) l * : Refer to “Service Points of Disassembly”.(3) +* : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

MANUAL TRANSAXLE -Input Shaft Assemblir 2145
MD998801
201048SERVICE POINTS OF DISASSEMBLY
2. REMOVAL OF BALL BEARINGRemove the front bearing using the special tool
as
illustrated.:
j, /I’ ’:”VI
3. REMOVAL OF BEARING SLEEVERemove the bearing sleeve using the special tool as
illustrated.
5. REMOVAL OF BALL BEARING
Remove the ball -bearing together using the special tool as
illustrated.
17. REMOVAL OF 3RD SPEED GEARRemove the bearing sleeve,
3rd-4th speed synchronizer
assembly and
3rd speed gear together using the special
tool as illustrated.
INSPECTION
INPUT SHAFT
lCheck the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear and seizure[portion
@I.l Check the
splines for damage and wear.

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.

21-48 MANUAL TRANSAXLE -lntwt Shaft Assemblv
4th speedgear sideTFM004:
2060006
6. INSTALLATION OF SPACERSome spacers have an inscribed identification mark. For
_
such spacers, installation should be so that the surface that.-has no mark is facing toward the
4th gear side. Spacers -without identification mark may be installed” in either
direction.
5. INSTALLATION OF BALL BEARING
Install the ball bearing over the input shaft using the special
tool.
4. INSTALLATION OF SNAP RINGInstall a snap ring so that the input shaft rear bearing end
play will be the standard value.
Standard value: 0.01-0.09 mm
(.0004-.004 in.)
3. INSTALLATION OF BEARING SLEEVEUsing the special tool, attach the bearing sleeve on the
input shaft.
Caution
When press-fitting the sleeve on the input shaft, verify
that the flange of the sleeve fits closely on the bearing.
h

MANUAL TRANSAXLE -Input Shaft Assemblv 21-49
20105t
2. INSTALLATION OF BALL BEARING
Install the ball bearing over the input shaft using the sdecial
tool..e,*
1.INSTALLATION OF SNAP RINGSnap rings are available in three different thickness. Select
the thickest one that fits in the snap ring groove.
CautionDo not cause damage to the input shaft oil seal
contacting portion.Standard value: 0.01-0.12 mm
(.0004-,005 in.)

21-50MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY NZlMIAUa
DISASSEMBLY AND REASSEMBLYDisassembly steps
+* l +1. Taper roller bearing++ ~~ 2. Bearing sleeve*+ 3. Snap ring++ I)+ 4. Taper roller bearingl + 5. Snap ringI)+ 6. Cone spring
~~ 7. Subgear8. 4th speed gear9. Needle bearing~~ 10. Bearing sleeve11. Synchronizer ringl + 12. 3rd-4th speed synchronizer assemblyl * 13. Synchronizer spring
2150009
14.Synchronizer sleeve
15.Synchronizer key16.Synchronizer hub17.Synchronizer ring
18. 3rd
speed gear
19.Needle bearing20.Input shaft
NOTE(1) Reverse 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