MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE <AWD> - Input Shaft Assemblv214 IO
_.Damage, breakage
TFMO119Synchronizer ring
GearTFM0117
20104~
201045
1NEEDLE BEARING
lMate the needle bearing with the shaft or bearing sleeve
and gear, and check to see if rotation is smooth with no
binding, noise, or play.
l Check the needle bearing cage for possible
deformation.SYNCHRONIZER RING
l Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if the clearance is below the
limit.Limit: 0.5 mm
(.020 in.)
SYNCHRONIZER SLEEVE AND HUB
lMate the synchronizer sleeve with the hub and check to
see if they slide smoothly.
lCheck to see if the sleeve is free from damage at its inside
front and rear ends.
l Check the hub front and rear end faces (in contact with
each speed gear) for wear.
Caution
When replacement is necessary, replace the synchro-
nizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
l Check the synchronizer key center protrusion for wear.
lCheck the spring for proper tension, possible deformation
and breakage.

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> - Input Shaft Assembly21-l 19
MD998808-01
(Outer)
MD998808-0121500167. INSTALLATION OF BEARING SLEEVE
Using the special tool, press-fit the bearing sleeve.
4. INSTALLATION OF TAPER ROLLER BEARING
Using the special tools, press-fit the bearing over the input
shaft.Caution
Apply the special tool to the inner race only when
installing the bearing.
3. INSTALLATION OF SNAP RING
(1) Select the thickest snap ring that fits in the snap ring
groove.Standard value:
0.01-0.09 mm (.0004-.004 in.)
(2) Using the special tool, fit the snap ring to the input
shaft.
NOTE
(I) Do not reuse the snap ring.
(2) The use of snap ring plier can cause the snap ring toexpand too much, making correct installation of the
sleeve difficult.

21-120MANUAL TRANSAXLE <AWD> - Input Shaft Assembly
21500172. INSTALLATION OF BEARING SLEEVE
Using the special tool, install the bearing sleeve over the
,kinput shaft.
-‘d ’Caution
When the sleeve has been press-fitted over the input
shaft, make sure that the sleeve flange is in tight
contact with the bearing.
1. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the ball bearing over the
input shaft.
h

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.

MANUAL TRANSAXLE <AWD> - Clutch Housing Assembly21-12315. INSTALLATION OF OIL SEAL
Using a socket wrench, install the control shaft oil seal.
7. INSTALLATION OF SPRING PIN
/ 6. LOCK PIN
Using the special tool, drive a new spring pin and lock pin
into position.
Caution
1. Do not reuse the spring pin or lock pin.
2.Install the spring pin so that its slit will be at right
angles to the control shaft centerline.

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.

21-126MANUAL TRANSAXLE <AWD> - Transfer Assembly2210061
2210092
2210093
I
3.(4) Check to see if the backlash between the drive and
driven bevel gears is up to specification.
Standard value
Bevel gear set backlash:
0.08-0.13 mm (.0031-.005 in.)
INSTALLATION OF EXTENSION HOUSING
Apply sealant to the flange surface of the adapter and installthe housing.
Specified sealant: Mitsubishi genuine Part
CautionNo. 997740 or equivalent
Squeeze out the sealant from the tube uniformly
without excess or discontinuities.
TOOTH CONTACT ADJUSTMENT PROCEDURE
1. Standard tooth contact pattern
A: Small end
B: Drive side tooth surface
(The side receiving force in forward motion)
C: Big end
D: Coast side tooth surface
(The side receiving force in reverse motion)
2. Tooth contact pattern when driven bevel gear is too
highPossible cause:
The driven bevel gear is too close to the drive bevel gear.
Remedy:Use a thicker spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is further away
from the drive bevel gear.