oil MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE <AWD> - Specifications21-75Items
Lower arm ball joint to knuckle
Center bearing bracket installation bolts
Right member installation bolt (front)
Right member installation bolt (rear)
Transfer assembly mounting bolt
Poppet plug
Backup light switch
Restrict ball
Speedometer mounting bolt
Oil filler plug
Oil drain plug
Input shaft lock nut
Intermediate shaft lock nut
Center differential drive gear mounting bolt
Front differential drive gear mounting bolt
Stopper bracket mounting bolt
Reverse idler gear shaft mounting bolt
Reverse shift lever mounting bolt
Bearing retainer mounting bolt
Interlock plate mounting bolt
Center member mounting bolt
Irive shaft center bearing mounting bolt
Iriven bevel lock nutgear
Select lever assembly mounting bolt
3everse brake cone screw boltsNm
ft.Ibs. ”
60-7243-52 “
36-4626-33
80-10058-72
70-8051-58
55-6040-43
30-4222-30
30-3522-25
30-3522-25
3-52.5-3.5
30-3522-25
30-3522-25
140-160102-I 15
140-160102-I 15
70-8051-57
130-14095-10115-22
11-1543-55
32-39
15-22
11-1515-22
11-15
20-2715-19
60-8043-58
36-46
26-33
140-160101-11515-22
11-15
4.0-5.52.9-3.9
TRANSFERItems
Transfer assembly mounting bolt
Cover mounting bolt
Extension housing mounting bolt
Transfer cover mounting bolt
Transfer case adapter mounting bolt
Driven bevel gear lock nut
Hanger bracket mounting boltNm
ft.lbs.
55-6040-43
8-106-7
15-22
II-1535-42
26-3035-42
26-30
140-160102-I 15
15-22
11-15
LUBRICANTSN21CD.BItems
Specified lubricantQuantity lit. (qts.)
I
ITransmission oil
MOPAR Hypoid gear oil or equivalent,2.3 (2.43)
API classification GL-4 or higherITransfer oil
MOPAR Hypoid gear oil or equivalent,
API classification
GL-4 or higher0.6 (.63)

21-76MANUAL TRANSAXLE <AWD> -Specifications/Special Tools
SEALANTS AND ADHESIVESNZlCE-B
TransaxleH-
1
-/Items
Transaxle case-clutch housing mating surfaces
Transaxle case-adapter mating surfaces
Adapter-rear cover mating surfaces
Front differential drive gear bolts
Center differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
Air breatherSpecified sealants and adhesives
Mitsubishi genuine part
No.997740or equivalent
MOPAR part
No.4318031 or MOPAR part
No. 4318032 or equivalent
MOPAR part
No.4318025 or equivalent
TransferItems
Adapter-extension housing mating surfacesSpecified sealants and adhesives
Mitsubishi genuine part No.
MD997740or equivalent
Air breatherMOPAR part
No.4318025 or equivalent
SPECIAL TOOLSNZlDA-B AI
NllmherName
I Use,“I. .-. * ,--.
~ MD99801 9
.-...-Lock pin extractor---Removal of spring pin and lock pin
MD998245Lock pin installerInstallation of spring pin and lock pin
0
MD998304Oil seal installerInstallation of front output shaft bearing and
transfer extention housing oil seal
MD998320Bearing installer
Installation of input shaft bearing and input
shaft gear

MANUAL TRANSAXLE <AWD> - Special Tools21-77Tool
Number
Name
MD998321Oil seal installer
M D998323Bearing installer
MD998325Differential oil seal
installer
MD998350Bearing installer
MD998369Bearing installer
MD998806Wrench adapter
MD998801Bearing remover
MD998802Input shaft holder
M D998803Differential oil seal
installerUse
Installation of input shaft front oil seal
Installation of rear output shaft oil seal and
transfer case oil seal
Installation of differential oil seal
Installation of front output shaft, intermediate
gear, transfer drive bevel gear, and
intermediate gear
Installation of input shaft front bearing
Removal of input shaft, intermediate gear, ant
output shaft bearing and gears
nstallation and removal of input shaft and
Ttermediate gear lock nut
lstallation of differential oil seal
rdjustment of tooth contact and inspection ofJrning drive torquexstallation of input shaft rear snap ring

21-78MANUAL TRANSAXLE <AWD> - Special Tools
MD99881 9Installer adapter (40)Installation of front differential bearings
M D998820Installer adapter (42)Installation of center differential bearings and
driven bevel gear bearing
MD999566ClawRemoval of bearing outer race from
intermediate gear, front output shaft, and
center differential
MD998827Installer adapter (56)Installation of drive bevel gear bearing
MB990326Preload socketMeasurement of drive bevel gear shaft
rotating torque
M B990900(included in
MB990988)Side gear holding
Tool (A)Measurement of drive bevel gear shaft
rotating torque
MB991 013Special spannerInstallation and removal of driven bevel gear
lock nut
MB991 193PlugPrevention of transfer oil discharge and
foreign object entry

MANUAL TRANSAXLE <AWD>- Troubleshooting/Service Adjustment Proceduresm-79
--/OQA0024
09FOll
TROUBLESHOOTINGRefer to
P.21-12.NIlEAAE
SERVICE ADJUSTMENT
PROCED’URES
TRANSAXLE OIL LEVEL INSPECTIONN2lFBAB1Refer to GROUP O-Maintenance Service.
TRANSAXLE OIL REPLACEMENTN2lFCAH(1) Position vehicle on a flat level and remove filler and drain
plugs to drain transaxle oil.
(2) Pour in fresh transaxle oil through filler port until it reaches
the bottom of filler port.
Transaxle oil: MOPAR Hypoid gear oil or equivalent,
API classification
GL-4 or higher.
Transaxle: 2.3 liters (2.4
qts.)Transfer: 0.6 liter
(.6 qt.)

21-80 MANUAL TRANSAXLE <AWD> -Service Adjustment Procedures
I I09K567
09K561
For L.H.For R.H.
DRIVE SHAFT OIL SEALS REPLACEMENTNZlFDAF(1) Disconnect the drive shaft from the transaxle.
(Refer to GROUP 2
- Drive Shaft.)Pas-(2) Remove the transfer assembly.
(3) Using a flat-tip
(-) screwdriver, remove the oil seal.
(4) Install the oil seals using the following procedure:
Using the special tool, tap the oil seal into the transaxle.
Note that there are two types of oil seals, one for
R.H. and
the other for L.H., and the shape of each type is different,
as shown.
-.
TRANSFER OIL SEAL REPLACEMENTN2lFGAF
(1) Pull out the propeller shaft from the transaxle. (Refer to
GROUP 16
- Propeller Shaft.)
(2) Using a flat-tip
(-) screwdriver, remove the oil seal.

Service Adjustment Procedures/Transaxle Control/
MANUAL TRANSAXLE <AWD> - SW Lever Assembly2%8T(3) Using the special tool, tap the drive shaft oil seal into
,the
transaxle.(4) Apply a coating of the transaxle.;Transaxle oil: MOPAR Hypoid gear oil or equivalent,
API classification
GL-4
SPEEDOMETER CABLE REPLACEMENTNZlFEAHRefer to
P.21-14.TRANSAXLE CONTROL
NZl JA-BRefer to
P.21-15.SHIFT LEVER ASSEMBLY
NZlGE-BRefer to
P.21-18.

21-82MANUAL TRANSAXLE <AWD> - Transaxle
TRANSAXLE
REMOVAL AND INSTALLATION
Pre-removal Operationl Removal of the Battery*Draining of the Transaxle Oil (Refer to P.Zl-13.)
@Removal of the Air Hose
(Refer to GROUP 11 -Air Cleaner.)IO-1
7-1111-16
ftlbs.
Post-installation Operation@Installation of the Battery
*Supplying of Transaxle Oil (Refer to P.21-13.)*Installation of the Air Hose
(Refer to GROUP II-Air Cleaner.)
*Checking the Operation of the Shift Lever
@Checking the Operation of the Meters and Gauges
27-34 Nm
60-60 Nm*60-80 Nm20-25 ft.lbs.
\
43-58/t.,b~43-58 ft.lbs.
15-22
6 Nm
ftlbs.
15-22 Nm
vt11-16
ft.lbs.Removal steps
1. Cotter pin
2. Connection for select cable
3. Connection for shift cable
*I)4. Connection for clutch release cylinder
5. Backup light switch connector
6. Connection for speedometer cable
l * 7. Starter
8.
A;;saxle assembly upper part coupling
9. Transaxle mount bracket
NZlMA-B -
,“rr,s.
09AOl44
NOTE(1) Reverse the removal procedures to reinstall.
(2)
+e : Refer to “Service Points of Removal”.
(3) I)+ : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts(5)For tightening locations indicated by the * symbol, first
tighten temporarily, and then make the final tightening
with the entire weight of the engine applied to the
(6)vehicle body.
If the grease has been wiped from the input shaft and
center shaft splines or if the input shaft and center shaft
have been replaced, apply special grease
(MOPARMulti-mileage Lubricant Part No. 2525035 or equivalent)
to the input shaft and center shaft splines.

21-84MANUAL TRANSAXLE <AWD> - 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
<R-H.>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.
<L.H.>
(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 <AWD> - 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.