oil MITSUBISHI ECLIPSE 1991 Service Manual

21-88MANUAL TRANSAXLE <AWD> - 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 <AWD>
- 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 <AWD> - 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 <AWD> 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.

MANUAL TRANSAXLE <AWD> - 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 <AWD> - 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.

21-100MANUAL TRANSAXLE <AWD> - Speedometer Gear Assembly
SPEEDOMETER GEAR ASSEMBLY
NZlMNAD
DISASSEMBLY AND REASSEMBLY
Disassembly steps
I. O-ringl *2. Spring pinl 3. Speedometer driven gear
4. Oil seal5. Sleeve
NOTE(1)Reverse the disassembly procedures to reassemble(2)**: Refer to “Service Poirits of Reassembly”.(3)q : Non-reusable parts.
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF SPEEDOMETER DRIVEN GEAR
Apply a small amount of gear oil to the speedometer drivengear shaft and insert the gear into position.
2. INSTALLATION OF SPRING PIN
lristall the spring pin so that its slit is not in contact with the
gear shaft.

21-102MANUAL TRANSAXLE <AWD>- 5th Speed Synchronizer Assembly
Oil groove
5thspeed +
$2
TFM0046
201001a,
SERVICE POINTS FOR REASSEMBLY5. INSTALLATION OF SYNCHRONIZER
tjyB.,/4. ,SYN- iic;
CHRONIZER KEY‘-a-/Install the synchronizer hub, and key in the directions as
shown.2. INSTALLATION OF SYNCHRONIZER SPRINGS
Install the synchronizer springs so that its protrusion fits
into the synchronizer key. Make sure that the protrusions inthe front and rear springs do not fit over the same key.
A

MANUAL TRANSAXLE <AWD> - Input Shaft Assemblylama
vear210018
Springprotrusion
Key
201001::
TFM0023
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
.6
wear.l Check the synchronizer cone for rough surfaces, damage,
-‘and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POlNTS OF REASSEMBLY18. INSTALLATION OF SUB
GEAR/17. CONE SPRING/16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, andthen install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing inthe correct direction.
10. INSTALLATION OF SYNCHRONIZER SPRINGS
(1) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
in,groove of the same key.
9. 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) Using the special tools, press-fit the
3rd-4th speed
synchronizer assembly over the input shaft.
Caution
1. When installing the synchronizer assembly,
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
h2. After installing the synchronizer assembly, --
check to see if the
3rd speed gear rotates
smoothly.

MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly21-121
CLUTCH HOUSING ASSEMBLY
-- DISASSEMBLY AND REASSEMBLY
NZlMPAH
-20-27 Nm
15-
19 ft.lbs.
15-22 Nm15 ft.lbs.18'
Disassembly steps
I, Bolt
2. Select lever assembly
3. Select lever shoe4. Interlock plate bolt
5.Gasket+* WC 6. Lock pinl * l *7. Spring pin
8. Neutral return spring
9.Stopper body10.Control finger11,Interlock plate
12. Neutral return spring assembly
13.Control shaft14. Control shaft boot
2210128
l * 15. Oil seal*I) l * 16. Needle bearing
a* l + 17. Needle bearing18. Clutch housing
19. Pin
20. Return spring21. Stopper plate
22. Spring pin
NOTE(1)Reverse the disassembly procedures to reassemble.(2)l +: Refer to “Service Points of Disassembly”.(3)l C: Refer to “Service Points of Reassembly”.(4) a: Non-reusable parts.