MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE <Fwb - Specifications,nj-r.
Part name
Spacer (F5M22)
(For adjustment of intermediate gear preload)
Spacer (F5M33)
:For adjustment
ofintermediate
gearpreload)
ipacer
=or adjustment of output shaft preload)Thickness mm (in.)
~ye~~~~tionPart No.
0.68 t.0268)68
MD735663 ’
0.71(.0280)71MD7356640.74(.0291)
74
MD7356650.77(.0303)
77MD7356660.80
LO31 5)80M D723307
0.83f.0327)
83M
D723308
0.86
i.0338)86MD7233090.89
i.0350)89MD72331 00.92
i.0362)92MD72331 10.95(.0374)
95MD72331
20.98
i.0394)98MD72331 3
1 .Ol(.0398)01MD7233141.04(.0409)
04MD72331
51.07(.0421)
07MD72331
6
1 .I0(.0433)10MD72331 71.13(.0445)
13MD72331 8
1 .16i.0457)16MD72331 91.19(.0468)
19MD7233201.22(.0480)
22MD723321
1.25t.0492)
25M
D723322
1.28(.0504)
28
MD723323
1.31(.0516)31MD7233241.34(.0527)
34
MD7233251.37(.0539)
37M
D723326
0.80
LO31 5)80MD7241 420.83(.0327)83MD7241
430.86t.0338)
86MD7241 44
0.89(.0350)
89MD7241
450.92(.0362)
92MD7241 46
0.95f.0374)
95MD7241
470.98
i.0386)98MD7241 48
1 .Ol(.0398)01MD7241 491.04(.0409)
04MD7241
501.07
i.0421)07MD7241 511.10
l.0433)10MD7241 52
1 .I3i.0445)13MD7241 531.16(.0457)
16MD7241 54
1.19
l.0468)19MD7241 551.22
i.0480)22MD7241 56
1.25(.0492)
25MD7241
571.28(.0504)
28MD7241 58
1.31LO51 6)31MD7241 591.34(.0527)
34MD7241
601.37
i.0539)37MD7241 610.83(.0327)
83
MD7209490.86
i.0338)86M D720950
0.89
i.0350)89MD720951

21-8MANUAL TRANSAXLE <FWD> - Specifications
Part name
Spacer
(For adjustment of output shaft preload)spacer(F5M33)
For adjustment of output shaft preload)
ipacer'or adjustment of differential case preload)Thickness mm (in.)
~dyemnt$j~at'on0.92
(0362)92
0.95
(0374)95
0.98 (.0386)98
1 .Ol t.0398)
011.04 (.0409)041.07 (.0421)071.10
(0433)101
.I3 (0445)13
1 .16 (0457)161
.I9 (0468)191.22 (.0480)22
1.25 (.0492)25
1.28
(0504)28
1.31
(0516)311.34 (.0527)34
0.83
(0327)83
0.86
(0338)86
0.89
(0350)89
0.92
(0362)92
0.95 (.0374)95
0.98
(0386)98
1 .Ol
l.0398)011.04 (.0409)041.07
(0421)07
1 . 10 (.0433)J1
.I3 (0445)D1.16 (.0457)
K1
.I9 (0468)L1.22 (.0480)
G1.25 (.0492)M
1.28 (.0504)
N1.31 (.0516)
E1.34 (.0527)0
0.80 (.0315)80
0.83 (.0327)83
0.86 (.0338)86
0.89
(0350)89
0.92 (.0362)92
0.95 (.0374)95
0.98 (.0394)98
1 .Ol t.0398)011.04
i.0409)041.07 (.0421)07
1
.I0 (0433)J1
.I3 (0445)D1
.I 6 (.0457)K
1 .19 (0468)LPart No.
MD720952
MD720953
MD720954
MD720955
MD720956
MD720957
MD720958
MD720959
MD720960M
D720961
MD720962
MD712346MD71 2347M
D7 12348MD71 2349
MD720937M
D720938
MD720939
MD720940MD720941
MD720942
MD720943M
D720944
MD720945
MD710454
MD700270MD71 0455
MD710456MD700271
MD710457
MD710458
MD706574
MD710459MD727661
MD720937
MD720938
MD720939M
D720940MD720941
MD720942
MD720943
MD720944
MD720945MD71 0454
MD700270
MD710455
MD710456

MANUAL TRANSAXLE <FWD> - Specifications
Part name
Spacer
(For adjustment of differential case preload)
Spacer
(For adjustment of differential pinion backlash)
TORQUE SPECIFICATIONSThickness mm (in.)
1.22 f.0480)
1.25 (.0492)
0.75-0.82
(.0295-.0323)
0.83-0.92
(.0327-.0362)
0.93- 1 .oo
(.0366-.0394)
1.01-1.08
(.0398-.0425)
1.09-1.16
(.0429-.0457)Identification
symbol
GM
-
-
-
-Part No.
MA180862MA1
80866MA1 80875MA1 86876
Items
Nm
Shift lever to lever (A)
19-28
Lever (A) to bracket assembly
17-26
Drain plug
30-35Filler plug
30-35Starter motor mounting bolt
27-34
Transaxle bracket
60-80Shift lever knob
4.5-7.5
Shift cable and select cable to body9-14
Shift lever assembly to body
9-14
Automatic seat belt guide ring attaching bolt17-26
Clutch release cylinder mounting bolt
15-22
Clutch tube to transaxle assembly
15-22
Transaxle mount bracket to transaxle
60-80Shift cable and select cable to transaxle15-22
Under cover
9-13
Transaxle mounting bolt [12 mm (.47 in.) diameter
bolt143-55
Transaxle mounting bolt [IO mm (.40 in.) diameter
bolt130-35Transaxle mounting bolt
[8 mm (.31 in.) diameter bolt]IO-12Tie rod end to knuckle
24-35
Lower arm ball joint to knuckle
60-72Bell housing cover
IO-123ear cover bolt
15-223ackup light switch
30-35
loppet plug30-42
jpeedometer sleeve bolt3.0-5.0nput shaft lock nut
140-160ntermediate lock nut
gear
140-160
3everse idler gear shaft bolt
43-55
rransaxle case tightening bolt
35-42
stopper bracket bolt
15-22
qestrict ball assembly30-35
ft.lbs.
13-2012-18
22-25
22-25
20-2543-58
3-5
7-10
7-1012-19
11-16
11-1643-58
11-16
7-1032-39
22-25
7-9
17-25
43-52
7-9
11-1522-25
22-302.5-3.5
102-I 15
102-11532-39
26-3011-15
22-25

MANUAL TRANSAXLE <FWD> - Specifications
ItemsNm
ftlbs.Reverse shift lever assembly attaching bolt
15-2211-15
Bearing retainer bolt15-2211-15
Differential drivegear
bolt
130-14094-101Interlock plate bolt
20-2715-19
Select lever assemblymountingbolt15-2211-15
LUBRICANTS
NZlCD-A
ItemsManual transaxle oil
Drive shaft oil seal lipSpecified lubricant
MOPAR Hypoid gear oil or equivalent
API classification GL-4 or higher
MOPAR Hypoid gear oil or equivalent
API classification GL-4 or higherQuantity lit. (qts.)
<F5M22> 1.8 (1.9)<F5M33> 2.2 (2.3)’
As required
Shift lever bushingMOPAR Front Wheel Bearing Grease
Part No. 3837794 or equivalentAs required
SEALANTS AND ADHESIVES
NZlCE-A
IItemsSpecified sealants and adhesivesITransaxle case-clutch housing mating surfacesMitsubishi genuine Part No.
MD997740 or equivalent
Transaxle case-rear cover mating surfaces
Differential drive gear bolts
Bearing retainer screw (flush head screw)MOPAR Part
No.4318031 or MOPAR Part No.4318032or equivalent
Air breather
IMOPAR Part
No.4318025 or equivalent

MANUAL TRANSAXLE <FWD> - Special Tools ’2149
SPECIAL TOOLS
”
N?/bA-A

21-12 MANUAL TRANSAXLE <FWD>- Special Tools/Troubleshooting
I
IICPintermediate shaft lock nut
MD998819Installer adapterInstallation of differential case bearing
TROUBLESHOOTINGNZlEAABsSymptomVibration, noise
3il leakage
Hard shift
Jumps out of gearProbable causeRemedy
a. Loose or damaged transaxle anda. Tighten or replace mounts
engine mounts
b. Inadequate shaft end playb. Correct end play
c. Worn of damaged gears
c. Replace gears
d. Use of inadequate grade of oild. Replace with specified oil
e. Low oil level
e. Replenish
f. Inadequate engine idle speed
f. Adjust idle speed
a. Broken or damaged, oil seal or O-ringa. Replace oil seal or O-ring
a. Faulty control cable
a. Replace control cable
b. Poor contact or wear of synchronizer ring
and gear coneb. Correct or replace
c. Weakened synchronizer springc. Replace synchronizer spring
d. Use of inadequate grade of oil
d. Replace with specified oil
a. Worn gear shift fork or broken poppet
springa. Replace shift fork or poppet spring
b. Synchronizer hub to sleeve spline
clear-ante too largeb. Replace synchronizer hub and sleeve

MANUAL TRANSAXLE <FWD>- Service Adjustment Procedures21-13
II
\
;‘:,
\;
\
\I00”011009FOli
I
I09K56i
09K56f
,
SERVICE ADJUSTMENT PROCEDURESN21FBABlTRANSAXLE OIL LEVEL INSPECTION
Refer to GROUP O-Maintenance Service.
TRANSAXLE OIL REPLACEMENT
NZlFCADa(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transaxle oil to
drain.(3) Refill the transaxle to the proper level with specified
transaxle oil. The oil level should be the bottom of the oil
filler hole.
Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or hiqher
<F5M22>1.8 liters (1.9 qts.)
<F5M33>2.2 liters ‘(2.3 qts.)DRIVE SHAFT OIL SEALS REPLACEMENT
NZlFDACa
(1) Disconnect the drive shaft from the transaxle.
(Refer to GROUP
2-Drive Shaft.)
(2) Using a flat-tip
(-) screwdriver, remove the oil seal.
(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
(4) Apply a coating of the transaxle oil to the lip of the oil seal.Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or higher

21-14 MANUAL TRANSAXLE <FWD> -Service Adjustment Procedures
I-Adapter%A0905SPEEDOMETER CABLE REPLACEMENT
NZlFEAKl
1.Correctly insert the adapter into the instrument panel, andS.
fasten the new speedometer cable.1-
2.Install the grommet so that, as shown in the illustration, the
cable attachment is positioned upward.Caution
1.The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2.The arrangement of the speedometer cable should
be such that it does not interfere with other
parts.
3. At the transaxle end of the speedometer cable, the key
joint should be inserted into the transaxle, and the nut
should be securely tightened.Caution
lllcIf the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.

MANUAL TRANSAXLE <FWD> - Transaxle Control2M5
TRANSAXLE CONTROL
-^ REMOVAL AND INSTALLATION
Removal steps1. Plug
2. Side cover (A)
3. Side cover(B)
4. Cover(B)
N21JA-A
919AO349
9-14 Nm .
+-
0
0OQA017412. Cotter pin
13. Retainer
14. Retainer
15. Cotter pin
9-14 Nm7- 10 ftlbs.5. Manual transaxle shift lever knob
6. Cup holder
7. Carpet
8. Connection for floor console wiring
I)4 16. Shift cable
I)+ 17. Select cable
18. Shift lever assembly
harness
9. Guide ring
10. Shoulder belt
11. Floor console
NOTE(1) Reverse the removal procedures to reinstall.(2) *a : Refer to “Service Points of Installation”.(3) m : Non-reusable parts

21-16MANUAL TRANSAXLE <FWD> - Transaxle Control
INSPECTIONN21JcAD
ICBA0160 1Incorrect
5I,I
-ri
IIIncorrect
1,-I I,,1 :
Sele’ctcableFlange side
yof the resin LbushingLever
&OSAOl72l Check the select
cable for funct,ion and for damage.
l Check the shift cable for function and for damage.
l Check the boot for damage.
l Check each bushing for wear or abrasion, sticking,
impeded action, and damage.
l Check the spring for deteriorated strength.
SERVICE POINTS OF INSTALLATION
NZlJDAK17. INSTALLATION OF SELECT CABLE
(1) Move the transaxle shift lever to the neutral position.
NOTEThe select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral
position.(2) Move lever
(6) to the neutral position.
(3) Adjust, by using the adjuster, so that the end of the
select cable is positioned as shown in the illustration
relative to lever
(B).
k,I.,,(4) The flange side of the resin bushing at the select cable
end should be at the lever
(B) end surface.
A.