1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Transaxle
4*
4*
30-35 Nm
22-25 ft.lbs.
\
/9-13 Nm7-10 ft.lbs.24-35 Nm
17-25
ftibs26-33 ft.lbs.
70-80 Nm r51-58 ft.lbs.09A013910. Under cover
11. Cotter pinI 2. Connection for tie rod end
13. Self-locking nut
14. Connection for lower arm ball joint
+e I)* 15. Connection for drive shaft
16. Circlip
::17. Front exhaust pipe
18. Transfer assembly
19. Bell housing cover
20. Right member
21. Gusset
22.
Lf:saxle assembly lower part coupling
~~ ~~ 23. Transaxle assemblyNOTE
(1) Reverse the removal procedures to reinstall.
(2) l * : Refer to “Service Points of Removal”.
(3) l 4 : Refer to “Service Points of Installation”.(4) m : Non-reusable parts

21-84MANUAL TRANSAXLE - Transaxle
r) ’TransaxlellKfil1
SERVICE POINTS OF REMOVALN21MBAV4. DISCONNECTION OF CLUTCH RELEASE CYLINDER/
12. TIE ROD
END/l4. LOWER ARM BALL JOINT
Refer to
P.21-21.15. DISCONNECTION OF DRIVE SHAFT
Insert a pry bar between the transaxle case and the drive
shaft, and then pry the drive shaft from the transaxle.
Caution
1.Do not pull on the drive shaft; doing so will damage
the inboard joint; be sure to use the pry bar.
2.Do not insert the pry bar so deep as to damaged theoil seal.

(1) Take out the drive shaft by lightly tapping the drive shaftT.J. case with a plastic hammer.
NOTERemove the drive shaft with the hub and knuckle, etc.,
as an assembly.
Caution
1. Removing the drive shaft from the,, outboa,rd
joint side can cause damage to the inboard joint.Always use a plastic hammer, etc., to remove
the drive shaft.
2. Tapping on the center bearing can damage it.
Never tap on the bearing.
(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.
17. REMOVAL OF FRONT EXHAUST PIPE
Refer to GROUP
1 l-Exhaust Pipe and Main Muffler.
18. REMOVAL OF TRANSFER ASSEMBLY
Refer to
P.21-85.23. REMOVAL OF TRANSAXLE ASSEMBLY
Refer to
P.21-22.
SERVICE POINTS OF INSTALLATION!’23. REMOVAL OF TRANSAXLE ASSEMBLY
Refer to
P.21-22.15. INSTALLATION OF DRIVE SHAFT
Refer to
P.21-22.7. INSTALLATION OF STARTER
Refer to
P.21-22.
NZlMDAQ

MANUAL TRANSAXLE - Transfer24-85
TRANSFER
--- REMOVAL AND INSTALLATION1NZlMAk
55-6040-43
Removal steps
1. Front exhaust pipe
2. Transfer assembly
NOTE(I) Reverse the removal procedures to reinstall.(2) +I) : Refer to “Service Points of Removal”.(3) q : Non-reusable parts.(4) If the grease has been wiped from the center shaft
spline or if the center shaft has been replaced, apply
special grease
(MOPAR Multi-mileage Lubricant PartNo.2525035 or equivalent) to the center shaft splrne.
ODA0027
B991193
oepoo44
SERVICE POINTS OF REMOVALNZlMBAU1. REMOVAL OF FRONT EXHAUST PIPE
Refer to GROUP 11 -Exhaust Pipe and Main Muffler.
2. REMOVAL OF TRANSFER ASSEMBLY
After moving the transfer assembly to the left and lowering,
the front side, then remove it from the propeller shaft.
Caution
1.Be cautious to avoid damaging the transfer oil seal
lip.2. The propeller shaft should be suspended so that it’
is not sharply bent.
3.Cover the transfer opening with the special tool to
prevent transaxle oil discharge and the entry of
foreign objects.

21-86MANUAL TRANSAXLE - Transaxle AssemblyTRANSAXLE ASSEMBLY
DISASSEMBLY AND REASSEMBLY
30-35 Nm
22-25 ft.lbs.
\
30-35 Nm
22-25 Wbs.
4.0-5.5 Nm\62.9-3.9 ft.lbs.7-42 Nm
-30
ft.lbs.llI8-59
I21IDisassembly steps
l + 1. Rear cover
2. Wave spring
I)+ 3. Screw bolts
4. Reverse brake cone
;. E;zk;p light switch
7: Restrict ball assembly
8. Gasket
9. Poppet plug
.- ^1 U. Poppet spring11. Poppet ball
I 2. Speedometer driven gear assembly
l + 13. Air breather
l * l 4 14.Spring pin
140-160 Nm
w ”Y
102-115 ft.lbs.
16Bl/
22
++ I)+ 15. Lock nut+el 416.Lock nut
l + 17. 5th speed synchronizer assembly~~ 18. Shift fork
19.Synchronizer ring
20.
5th speed gear
21.Needle bearing
22.
5th speed intermediate gear35-42 Nm
26-30 ft.lbs.-1
TFMOOZSNOTE
(1) Revers_e the di?: ’(2) +-(3) +v : neler 10(4) IW : Non-reusat-yle parts.assembly
proceaures 10 reassemble.ry : KeTer to Service Points of Disassembly”.“-I-- I- “Service Points of Reassembly”.
’
i

--
MANUAL TRANSAXLE - Transaxle Assembly21-81
i5 r)
p$---al3743-55 Nm
3632-39 ft.lbs.
TFM0029Disassembly steps
I)+ 23. Snap ring
4*24. Viscous couplingl 4 25. Steel ball26. Center shaft
l 27. Transaxle case adapter
28. Outer race
l * 29. Spacer
30. Outer race
l 4 31. Spacer32. Outer race
l * 33. Spacer
34. Center differential
4*35. Outer race$?everse the disassembly procedures to reassemble.
Reverse idler gear shaft bolt(2) +I) : Refer to “Service Points of Disassembly”.l + 36.(3) l + : Refer to “Service Points of Reassembly”.
37. Gasket(4) m : Non-reusable parts.

21-88MANUAL TRANSAXLE - Transaxle Assembly15-22 Nm
11-15 ft.lbs.
-.@&35-42 Nm
26-30 ft.lbs.
\15-22 Nm
11-15 ft.lbs.
/4?2250013
Disassembly steps
38. Clutch oil line bracket
l + 39. Transaxle case
l + 40. Oil guide
l + 41. Oil guide
42. Outer race
l + 43. Spacer
l * 44. Spacer
45. Stopper bracket
l 46. Oil seal
47. Reverse shift lever assembly
48. Reverse shift lever shoe
49. Reverse idler gear shaft
50. Reverse idler gear
51. Front output shaft assembly
52. Needle bearing
53. Front differentialNOTE
(I) Reverse the disassembly procedures to reassemble.(2) l + : Refer to “Service Points of Reassembly”.(3) m : Non-reusable parts.

--MANUAL TRANSAXLE
- Transaxle Assembly6?
Disassembly steps
*I) l + 54. Spring pin+I) l + 55. Spring pin+e e+ 56. Shift rail assemblyl + 57. Bolt58. Bearing retainer
+e l + 59.Intermediate gear assembly
s: W 60. Input shaft assembly
61. Outer racel 4 66. Oil seal
l 4 67. Oil seal
l + 68. Magnet
W 69. Magnet holder
70. Clutch housing assembly
NOTE
TFM0666
4*62. Outer race
63. Oil guide(1) Reverse the disassembly procedures to reassemble.(2) +I) : Refer to “Service Points of Disassembly”.4*64. Outer race
(3) ~~ : Refer to “Service Points of Reassembly”.
l 4 65. Oil seal(4) m : Non-reusable parts.

MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF DISASSEMBLYNZlMFAT
14. REMOVAL OF SPRING PINriiRemove the spring pin using the special tool.
.,
15.116. REMOVAL OF LOCK NUTS
(1) Unstake lock nuts of the input shaft and intermediate
gear.(2) Shift the transaxle into reverse using the control lever
and select lever.
(3) Install the special tool on the input shaft.
(4) Install the spinner handle and 10 mm
(.039 in.) bolt.
(5) Remove the lock nuts.
A