MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE <FWD> - Transaxle Contid
erShift
lever
09A0159
09A016t16. INSTALLATION OF
SHIFT CABLE
(1) With the select lever in neutral, move the transaxle shift
lever (in the direction shown in the illustration) to set it
to
4th gear.
NOTE
If the shift lever does not move easily, depress and holdthe clutch pedal.
(2) Move the shift lever (at the vehicle interior side)
downward, in the direction
(4th gear position) shown in
the illustration until it contacts the stopper.
(3) Adjust, by using the adjuster, so that the end of the shiftcable is positioned as shown in the illustration relative
to the shift lever (interior side).
(4) The flange side of the resin bushing at the shift cable
end should be at the split pin side.
(5) Adjust the length of the shift cable, by using the
adjuster, so that the clearance (A) and
(B) between the
shift lever and the two stoppers are equal when the
shift lever is shifted to
3rd gear and 4th gear.
(6)Move the shift lever to each position and check that theshifting is smooth.

21-18MANUAL TRANSAXLE <FWD> - Shift Lever Assembly
SHIFT LEVER ASSEMBLYDISASSEMBLY AND REASSEMBLY
19-28
Nm14-20 ft.lbs.
Disassembly steps
1.Shift lever
e+2.Bushing
*q~ 3. Return spring
1)44.Bushing
5.Lever (A)
*47.;;;;;w
I)+8:Bushing9.Snap ring
10.Lever (B).+ 11. Bushing12.Bracket assembly17-26
09A0173
NOTE(1) Reverse the disassembly procedures to reassemble.
(2) l +
: Refer to “Service Points of Reassembly”.
: Non-reusable parts.
i%s.SERVICE POINTS OF REASSEMBLY
NZlGHAP
11./8./6./4,/3./2. APPLICATIONOF GREASE TO
BUSHINGS
Apply multi-purpose grease to the sliding part of the
bushings shown in the figure.
Grease: MOPAR Front Wheel Bearing
Grease Part No.3837794 or equivalent
3. INSTALLATION OF RETURN SPRING
Make sure that the end of the spring contacts the part
(shown in the illustration) of the bracket.

MANUAL TRANSAXLE <FWD> - Transaxle21-19
TRANSAXLE
- REMOVAL AND INSTALLATIONNZlMA-A
. .
,-27-34 Nm
20-25 ft.lbs.15-22 Nm
11-16
ft.lbs.43-55 Nm
32-39
ft.lbs.
\
60-80 Nm*43-58 ft.lbs.*60-80 Nm
/da-,, ft.lbs.
lo-12 NmI7-9
ft.lbs.I
15-2: Nm
11-16 ft.lbs.OOAOl~4
Pre-removal Operation@Removal of the Battery
rl Draining of the Transaxle Oil (Refer to
P.21-13.)l Removal of the Air Hose(Refer to GROUP 11-Air Cleaner.)
Post-installation 0erationl installation of theI!attery
l supplying of Transaxle Oil (Refer to P.21-13.)*Installation of the Air Hose
(Refer to GROUP 11 -Air Cleaner.)
l checking the Operation of the Shift Lever
l checkina the Ooeration of the Meters and Gauges
Removal steps
1. Cotter pin
2. Connection for select cable
3. Connection for shift cable
4*4. Connection for clutch release cylinder
5. Backup light switch connector
6. Connection for speedometer cable
I)* 7. Starter
8.
Lfrsaxle assembly upper part coupling
9. Transaxle mount bracket
ZKeverse the removal procedures to reinstall. ” ’(2) W : Refer to “Service Points of Removal”.
(3) ~~ : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts
(5)For tightening locations indicated by the * symbol, fjrst
tighten temporarily, and then make the final tightenrngwith the entire weight of the engine applied to the
vehicle body.
(6)If therease has been wiped from the input shaft spline
or if taeinput shaft has been replaced, apply specralgrease (MOPAR Multi-mileage Lubricant Part
No.2525035 or equivalent) to the input shaft Spline.

21-20MANUAL TRANSAXLE <FWD> - Transaxle
9-13 Nm7-10
ftlbs.
I
30-35 Nm
IO-12 Nm Ld7-9 ft.lbs.
60-72 Nm
,!24-35 Nm
17-25 ft.lbs.
+I)IO. Under cover11. Cotter pin
+I)12. Connection for tie rod end
13. Self-locking nut
**14. Connection for lower arm ball joint+I) l I 15. Connection for drive shaft
16.
Circlip17. Bell housing cover
18.
iT,nsaxle assembly lower part coupling
W e+ 19. Transaxle assembly
NOTE(1) Reverse the removal procedures to reinstall.(2) +e: Refer to “Service Points of Removal”.(3) ~~ : Refer to “Service Points of Installation”.(4) m : Non-reusable parts

MANUAL TRANSAXLE <FWD> - Transaxle’
---
-..
2) ’TransaxlellK611
SERVICE POINTS OF REMOVALNlZMBAR4. DISCONNECTION OF CLUTCH ‘RELEASE CYLINDER
FROM TRANSAXLE ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the
! body side
without disconnecting the oil line coupling.
”
10. REMOVAL OF UNDER COVER
Lift the vehicle before removing the under cover.
12. DISCONNECTION OF TIE ROD END FROM KNUCKLE
Using the special tool, disconnect the tie rod end from the
knuckle.Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
14. DISCONNECTION OF LOWER ARM BALL JOINT
Using the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
I15. DISCONNECTION OF DRIVE SHAFT
(1)
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
the oil seal.
(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.

21-22MANUAL TRANSAXLE <FM/D> - Transaxle
1 Transaxleside1 Radiator lower hose
1 Transaxle side1 Radiator lower hosepart ofdrive shaft
I
-Transaxle
09LOO5819. REMOVAL OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
+Gthe lower hose of the radiator with the end of the
’transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
Support the transaxle assembly by using a transaxle jack;
then, after moving the transaxle assembly to the right,
lower it.
NOTEWhen supporting the transaxle assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to awide area, not to only a small localized area.
SERVICE POINTS OF INSTALLATION
NZlMDAP19. INSTALLATION OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
Athe lower hose of the radiator with the end of the
-transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
15. INSTALLATION OF DRIVE SHAFT
(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bent
relative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serratedpart of the drive shaft.
(2) Align the serrations and securely insert the drive shaft
into the transaxle.
7. INSTALLATION OF STARTER
Tighten the starter installation bolts with the wiring harness
clip and the ground cable.

MANUAL TRANSAXLE <FWD>- Transaxle Assemblv <F5M22’>2743
TRANSAXLE ASSEMBLY <F5M22>
.._DISASSEMBLY AND REASSEMBLYN21ME-A
__
30-42 Nm22-30 ft.lbs.30-35 Nm22-25 ftlbs.q l4
ig5 !
----7m
IQ15-22 Nm
II-15 ft.lbs.
4.0-5.5 Nm2.9-3.9 ft.lbs.1I”I
a
140-160 Nmf
102-115 ft.lbs.
Disassembly steps
1. Bolt
l + 2. Rear cover
3. Wave spring
l 4. Screw bolts
5. Reverse brake cone
6. Backup light switch
7. Gasket
<F5M22-2>8. Poppet plug
9. Poppet spring
10. Poppet ball
11. Bolt
12. Speedometer driven gear assembly
l * 13. Air breather
*I) l * 14. Spring pin+I) l * 15. Lock nut
140-160102-115
TFMOOl6
+e I)+ 16. Lock nut
17. 5th speed synchronizer assembly
18. 5th speed shift fork
19. Synchronizer ring
20. 5th speed gear
21.Needle
bearing
22. 5th speed intermediate gear
NOTE(1) Reverse the disassembly procedures to reasseinble.
(2) ++ : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of ReaSsembly”:(4) m : Non-reusable parts

21-24MANUAL TRANSAXLE <FWD> - Transaxle Assemblv <F5M22>48
3e42 Nm22-30 ft.lbs.30-35
NmI
122-25 ft.lbs.26
2527
1!&22 Nm\
\
Disassembly steps23. Reverse idler gear shaft bolt
24.Gasket25.Bolt++ 26. Transaxle casel + 27. Oil guide
28.Bolt
29.Spring washer30.Stopper bracket
31. Restrict ball assembly
32.Gasketl 433.Oil seal
34. Bearing outer race
+*35.Spacer
36. Bearing outer race
l * 37. Spacer38. Bearing outer race
l + 39. Spacer40. Bolt41. Reverse shift lever assembly
42. Reverse shift lever shoe
43. Reverse idler gear shaft
44. Reverse idler gear
+I) l 4 45. Spring pin~~ ~~ 46. Spring pin+* l + 47. Shift rails and forks+* l 48. Shift rails and forks
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +* : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of Reassembly”y(4) m : Non-reusable parts

MANUAL TRANSAXLE <FWD>- Transaxle Assembly <F5M22>
2i &
15-22 Nm50 11-15 ft.lbs.
Disassembly steps
l +49. Bolt50. Screw
51. Bearing retainer
+e l + 52.Intermediate gear assemblyl + 53.Input shaft assembly54. Output shaft assembly
55. Differential gear assembly
56. Bearing outer race57. Oil guide
58. Bearing outer race
59. Bearing outer race
l 4 60. Oil seal
W 61. Oil seal
62. Magnet
63. Magnet holder
64. Clutch housing assembly
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.(3) e+ : Refer to “Service Points of Reassembly”.
(4) m : Non-reusable parts
21421

21-26 MANUAL TRANSAXLE <FWD>- Transaxle Assembly <F5M22>
SERVICE POINTS OF DISASSEMBLY
14. REMOVAL OF SPRING PINIMD99801 9\I
NZlMFARRemove the spring pin using the special tool.
Bolt10 mm
15.116. REMOVAL OF LOCK NUTS(1) Unstake lock nuts of the input shaft and intermediate
gear.(2) Shift the transmission in reverse using the control lever
and select lever.
(3) install the special tool onto the input shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.45./46.
REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using the pin punch.