service MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE <RND> - Clutch Housing Assembly
SERVICE POINTS OF DISASSEMBLY
2f-67
MD998019
\
\
- Control
J$p--lever
201082
MD998\
w
-
20108:
Needle bearing’ ’
20601:
Socketwrench
I’ I20108!
6. REMOVAL OF LOCK PINDrive out the lock pin from the control finger using the
special tool.
Caution
When removing the lock pin, turn the control lever to,such position that the lock pin will not contact the
clutch housing.
7. REMOVAL OF SPRING PINDrive out the spring pin from the stopper body using the
special tool.
Caution
When removing the spring pin, pull the control shaft in
the direction illustrated so that the spring pin will not
contact the clutch housing.
SERVICE POINTS OF REASSEMBLY
17. / 16. INSTALLATION OF NEEDLE BEARINGSInstall the needle bearing flush with the surface A of the
clutch housing.
15. INSTALLATION OF OIL SEALInstall the control shaft oil seal using a socket wrench.7./6.
INSTALLATION OF SPRING PIN AND LOCK PIN
(1)Install new spring pin and lock pin using the special tool.
Caution
Do not reuse the spring pin and lock pin.
(2) install the spring pin with its slit at right angle to the
control shaft center.

MANUAL TRANSAXLE <AWD> 2 S~ecifCca?io’iik
2f.46g
\ ,...,
,,, .,
SPECIFICATIONS
1 L,‘S. / ,‘; ,< ’,f. : ,: ; .>r
“. . ..&
. ’ GENERAL SPECIFICATIONSNZ1.pA.B’
Items
ModelApplicable engine
TypeGear ratio
1 st
2nd
3rd
4th
5th
ReverseReduction ratio
PrimaryFront differential
TransferSpeedometer gear ratio (driven/drive)
Oil quantity
Transaxle
TransferSpecifications
(I
W5M33-2-N PZV.,A I
4G63
5-speed transaxle floor shift
3.083
I .684
1.115
0.833
0.666
3.166
1.275
3.866
1.090
29136lit.
(qts.)2.3 (2.43)
0.6
l.63)
SERVICE SPECIFICATIONSN21CB-B
d-...
Items
Standard value
TransaxleInput shaft end play
Input shaft rear bearing end play
Intermediate gear preload
Intermediate gear bearing end play
Front output shaft preload
Center differential
Viscous coupling end play
Differential case preload
Differential pinion backlash
Front differential
Differential case end play
Differential pinion backlash
TransferBevel gear set backlash
Driven bevel gear turning drive torque
Drive bevel gear shaft turning drive torqueSpecifications
o-0.05 (O-.002)
0.01-0.09 (.0004-,004)
0.08-0.14 (.0031-,006)
0.01-0.11 (.0004-,004)
0.08-0.13 (.0031-,005)
0.1-0.26 (.0039-.OlO)0.08-O. 13
LOO31 - ,005)
0.025-0.150 LOO01 -.006)
0.05-0.17 (.0020-,007)
0.025-0.150 (.OOOl-,006)
0.08-0.13 (.0031-.005)
1
.O- 1.7 Nm (0.72- 1.23 ft.lbs.11.7-2.5 Nm (1.23-1.81
ft.lbs.1
mm,.(in.)

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.

MANUAL TRANSAXLE <AWD> - 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 <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.

21-86MANUAL TRANSAXLE <AWD> - 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