1991 MITSUBISHI ECLIPSE Service Manual

MANUAL TRANSAXLE - Transaxle Assembly21-91,
24. REMOVAL OF VISCOUS COUPLINGUsing a flat-blade screwdriver, pry off the viscous coupling
little by little.
35. REMOVAL OF OUTER RACEUsing the special tool, remove the outer
race.
54.155. REMOVAL OF SPRING PINSRemove the spring pins using the special tool.
56. REMOVAL OF SHIFT RAIL ASSEMBLY(1) Shift the Ist-2nd speed shift fork into
2nd speed.
(2) Shift the
3rd-4th speed shift fork into 4th speed.

MANUAL TRANSAXLE - Transaxle Assembly(3) Rotate the shift controls in the direction of the arrow in
numerical order. Remove the shift lugs from the controlfinger 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.
59. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY/
60. INPUT SHAFT ASSEMBLY
Lift up the input shaft assembly and remove the intermedi-
ate gear assembly.
61./62./64. REMOVAL OF OUTER RACE
Using the special tool, remove the outer race.
SERVICE POINTS OF REASSEMBLYN21MGAPa69. INSTALLATION OF MAGNET HOLDER/68. MAGNET
Install the magnet and magnet holder, ensuring they are
installed in the correct direction.
67. INSTALLATION OF OIL SEAL
Using the special tool, install the rear output shaft oil seal.

MANUAL TRANSAXLE L Transaxle Assenibty21-93
For L.H.For R.H.
Dust66. INSTALLATION OF OIL SEAL
Using the special tool, install the drive shaft oil seals,
making sure that the seal for each side is in its proper
location.Caution
Make sure that the notch in the L.H. oil seal flange is onthe up side where it is installed.
,’ *65. INSTALLATION OF OIL SEAL
Using the special tool, install the input shaft front oil seal.
60. INSTALLATION OF INPUT SHAFT ASSEMBLY/
59. INTERMEDIATE GEAR ASSEMBLY
Lifting up the input shaft assembly, install it together with
the intermediate gear assembly.

21-94MANUAL TRANSAXLE - Transaxle Assembly
5mm(.21 in.)TFM006357. INSTALLATION OF BOLT
Apply adhesive to the bolt threads.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No.4318032
or equivalent
Caution
Be careful not to apply to adhesive to the bold head.
56. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Shift the Ist-2nd synchronizer sleeve into 2nd speed.
(2) Shift the
3rd-4th synchronizer sleeve into 4th speed.
(3)Fit the shift forks of shift rail assembly to their groove of
sleeves.
(4) Install the shift rails, 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.
55./54. INSTALLATION OF SPRING PINS
Using the special tool, drive the spring pins into position.
Make sure that the slit in the spring pin is aligned with the
shift rail centerline.
Caution
Do not reuse the spring pins.

MANUAL TRANSAXLE - Transaxle Assembly23-95
46. INSTALLATION OF OIL SEALUsing the special tool, install the drive shaft oil seal.
I -.,44.143. INSTALLATION OF SPACER
(1) Place two pieces of approximately 10 mm (39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the transaxle case and install each outer race.
(2) Place two pieces of approximately
10 mm (.39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the bearing outer race.
(3) Install the transaxle case, and tighten bolts to
specifiea-
tion.(4) Remove the transaxle case.
(5) Remove the outer races and remove the solder.
(6) If the solder is not broken, carry out the work in steps
(l)-(5) with large diameter solder.
(7) Using a micrometer, measure the thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Front output shaft preload
0.08-0.13 mm (.0031-.005 in.)
Front differential case end play
0.05-0.17 mm (.0020-.a07 in.)

21-96MANUAL TRANSAXLE - Transaxle Assembly
/._~~1 - 2 mm l.039 - ,078 in.)2200051
41./40. INSTALLATION OF OIL GUIDE
Install the oil guide or the transaxle case.
39. INSTALLATION OF TRANSAXLE CASE
Apply sealant (liquid gasket) to the clutch housing side of
the transaxle case.
Specified sealant: Mitsubishi genuine Part
No. 997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
36. INSTALLATION OF REVERSE IDLER GEAR SHAFT BOLT(1) Center the shaft with a screwdriver [shaft diameter 8
mm
(.31 in.) or similar object].
(2) Tighten the reverse idler gear shaft bolt to specification.33.131.129 INSTALLATION OF SPACER
(1) Place four pieces of approximately 10 mm (.39 in.) long,
1.6 mm
(06 in.) dia. solder at the locations shown on
the transaxle case adapter assembly and install each
outer race.
(2) Install the transaxle case adapter assembly and rear
Acover, and tighten bolts to specification.
(3) Remove the transaxle case adapter assembly and rear
cover.

MANUAL TRANSAXLE - Transaxle Assemblv
I-2mmml
,
Snap r
/ /221012:3(4) Remove the outer races and remove the
solder:(5) If the solder is not broken, carry out the work in steps,
(l)-(4) withlargediameter solder.
(6) Using a micrometer, measure ttie thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Input shaft end play
O-.0.05 mm (O-.0020 in.)
Intermediate gear preload
0.08-0.14 mm (.0031-.005 in.)
Center differential case preload
0.08-0.13 mm (.0031-,005 in.)
27. INSTALLATION OF TRANSAXLE CASE ADAPTER
Apply sealant (liquid gasket) to the transaxle case side of
the transaxle case adapter assembly.
Specified sealant: Mitsubishi genuine sealant Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
25. INSTALLATION OF STEEL BALL
Move the center shaft so that the steel ball is seated
securely into the groove in center shaft.
23. INSTALLATION OF SNAP RING
Select the snap ring so that the end play in the viscous
coupling is up to specification.
Standard value:
0.1-0.26 mm (.0039-.OlO in.)
18. INSTALLATION OF SHIFT FORK/17.
5TH SPEED SYN-
CHRONIZER ASSEMBLY
Mate the
5th speed shift fork with the 5th gear synchroniz-
er assembly and install them simultaneously.

21-98MANUAL TRANSAXLE - Transaxle Assembly
16.115. INSTALLATION OF LOCK NUTS
(1) Shift the transaxle into reverse using the control lever
,+and select lever.
.,./(2) Install the special tool on the input shaft.
(3) Fit on the spinner handle and bolt.
(4) Tighten the lock nut to specification and then loosen it
completely before tightening it again to the specified
torque.
i;(5) Punch the lock nut into locked position.
(Punch two places on the lock nut of the input shaft andone place on the lock nut of the intermediate gear.)
14. INSTALLATION OF SPRING PIN
(1) Using the special tool, drive the spring pin into position.(2) Make sure that the slit in the spring pin is aligned with
the shift rail center line.
CautionDo not reuse the spring pin.A