service MITSUBISHI ECLIPSE 1991 Service Manual

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.

21-122MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly
SERVICE POINTS OF DISASSEMBLY
6. REMOVAL OF LOCK PIN
Drive out the lock pin from the control finger using the
special tool or a pin punch.
Caution
When removing the lock pin, turn the control lever to a
position so that the lock pin will not contact the clutch
housing.13mm
socket wrench
A
Needle bearingII2010847. REMOVAL OF SPRING PIN
Using the special tool or a pin punch, drive out the spring
pin from the stopper body.
Caution
When removing the spring pin, pull the control shaft in
the direction shown so that the spring pin will not
contact the clutch housing.
16.7 17. REMOVAL OF NEEDLE BEARING
Drive out the needle bearing using a socket wrench.
SERVICE POINTS OF REASSEMBLY17.
/ 16. INSTALLATION OF NEEDLE BEARINGS
(1) Using a socket wrench, press-fit the needle bearing
flush with surface A in the clutch housing.
(2) Make sure that the side of the bearing with a stamped
type number faces surface A.

21-124MANUAL TRANSAXLE <AWD> - Transfer Assembly
TRANSFER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
8-10Nm
6-7ft.‘bs.Y15-22Nm
2210130
Disassembly steps
1. Cover
2. Cover gasket
l *3. Extension housing assembly
l *4. Transfer case sub assembly
l * 5. Spacer
6. O-ring
l *7. Transfer case adapter sub assembly
NOTE(I)Reverse the disassembly proceduresto reassemble
(2)l +: Refer to “Service Points of Reassembly”.(3) a: Non-reusable parts.

MANUAL TRANSAXLE <AWD> - Transfer Assembly22100507
P
MB990900
TFMOOIP
SERVICE POINTS OF REASSEMBLY7. INSTALLATION OF TRANSFER CASE ADAPTER SUB-
ASSEMBLY
Using a brush, apply a thin even coat of machine blue or
minium to both tooth surfaces of the driven bevel gear.
5. INSTALLATION OF SPACER
Install the spacer which has been used so far.
4. INSTALLATION OF TRANSFER CASE SUBASSEMBLY
(1) Tighten the transfer case adapter subassembly on the
transfer case subassembly to the specified torque.
(2) Using the special tool, turn the drive bevel gear shaft
one turn each in the direction of normal and reverse
rotation.Caution
Do not rotate the drive bevel gear shaft more thanone turn as it cause a blurred tooth contact pattern.
(3) Make sure that the contact pattern of the driven bevel
gear teeth is correct.
NOTE
See Tooth Contact Adjustment Procedure on next pagefor the standard tooth contact pattern.

21-128MANUAL TRANSAXLE <AWD> - Extension Housing Assembly
EXTENSION HOUSING ASSEMBLYN21MTAA
DISASSEMBLY AND REASSEMBLY
TFM0039
Disassembly steps
6+ 1. Air breather
2. Dust seal guardI)+ 3. Oil seal
4. Extension housing
NOTE(I)(2)Reverse the disassembly procedures to reassemble.(3)l *: Refer to “Service Points of Reassembly”.q : Non-reusable parts.
.
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF OIL SEAL
Using the special tool, install the oil seal.
1. INSTALLATION OF AIR BREATHER
Apply sealant to the air breather port and fit the air breatherin position.
Specified sealant: MOPAR Part No.4318025
or equivalent

MANUAL TRANSAXLE <AWD> - Transfer Case Sub Assembly21;129
TRANSFER CASE SUB ASSEMBLYN21MUAA
- DISASSEMBLY AND REASSEMBLY
I-
-2210079
‘35-42Nm26 - 30 ft.lbs.
Disassembly steps
I. Transfer cover
2. O-ring
l a 3. Spacer
4. Outer race
5. Drive bevel gear assembly6. Outer race
*a 7. Spacer
l *8. Oil seal
9. Transfer case
NOTE(1)Reverse the disassembly procedures to reassemble(2)*a: Refer to “Service Points of Reassembly”.(3)q : Non-reusable parts.

21-130MANUAL TRANSAXLE <AWD> - Transfer Case Sub Assembly
SERVICE POINTS OF REASSEMBLY8. INSTALLATION OF OIL SEAL
Using the special tool, install the oil sea
jP,
II..-67. INSTALLATION OF SPACER
Install the spacer which has been used so far
3. INSTALLATION OF SPACER
Install the spacer which has been used so far
INSPECTIONDRIVE BEVEL GEAR ASSEMBLY
Using the special tools, check to see if the turning drive torque
of the drive bevel gear is up to specification.
Standard value: 1.7
- 2.5 Nm (1.23 - 1.81 ft.lbs.)Caution
1.If the turning drive torque is out of specification, adjust
by using adjusting spacers.
2.Select spacers of nearly same thickness on both sides.
h

MANUAL TRANSAXLE <AWD>- Transfer Case Adapter Sub Assembly
TRANSFER CASE ADAPTER SUB ASSEMBLY
1’” DISASSEMBLY AND REASSEMBLY
2143’1
N2lhlVAS.-
Disassembly steps
w l a 1. Locknuta*2. Driven bevel gear assemblyl *3. Taper roller bearing
l * 4. Spacer
5. Collar
l *6. Outer racel *7. Outer race
8. Transfer case adapter
I2210133
140 - 160 Nm102-115ft.lbs.
NOTE(1)Reverse the disassembly procedures to reassemble.(2)+*: Refer to “Service Points of Disassembly”.(3)*+: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.

21-132MANUAL TRANSAXLE <AWD>- Transfer Case Adapter Sub Assembly
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF LOCK NUT
(1) Unstake the lock nut.
(2) Remove the driven bevel gear’s lock nut by using the
special tool.
2. REMOVAL OF DRIVEN BEVEL GEAR ASSEMBLY
Using a press, remove the driven bevel
‘gear assembly.6.17. REMOVAL OF OUTER RACE
Apply a screwdriver to the outer race and tap it to remove
the outer race.
SERVICE POINTS OF REASSEMBLY4. INSTALLATION OF SPACER
Install the spacer which has been used so far.

21-134MANUAL TRANSAXLE <AWD> - Drive Bevel Gear Assembly
DRIVE BEVEL GEAR ASSEMBLYNZlMWAA
DISASSEMBLY AND REASSEMBLY
Disassembly steps
4~ WI1. Taper roller bearing+* l 42. Taper roller bearing
3. Drive bevel gearl *4. Drive bevel gear shaft
TFM0053
NOTE(I)Reverse the disassembly procedures to reassemble.(2)**: Refer to “Service Points of Disassembly”.(3)*a: Refer to “Service Points of Reassembly”.
22100851
SERVICE POINTS OF DISASSEMBLY
1.12. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing.