MITSUBISHI SPYDER 1990 Service Repair Manual

MANUAL TRANSAXLE
SleeveASSEMBLY
(1) Position synchronizer hub onto a suitable holding fixture
(input shaft). The synchronizer hubs are directiona l. The
hubs must be installed with the facing upward.
(2) Install springs into hub slot
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
balls
into each key.
(5)Slide sleeve over the hub and depress balls as you careful-
ly slip the sleeve into position.
(6) Line up stop ring tang over the keys in the hub . Install‘
stop rings. Center the keys and balls by pushing on both
stop rings.
.INSPECT
Proper inspections of components involved:
Teeth, for wear, scuffed, nicked, burred or broken teeth keys,
for wear or distortion.
Balls and springs, for distortion, cracks or wear’
If any of these conditions exists in these replace
as necessary.
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Shifter Rails Overhaul/
MANUAL
SHIFTER
Disassemble the transaxle case using the procedures’
provided in this group.
(2) Remove shifter rails from the
(3) To service the shift rail, remove the retaining
the reverse shift lever arm. Remove the
“shift fork
roll pin and remove the
shift fork.
Remove the shift lug roll pin and remove the shift lug.’
Replace parts as necessary.
(4) To service the
shift rail, remove the roll pin retaining’
the
shift fork. Remove the shift fork.,, Remove the
shift lug roll pin and remove shift lug. Replace pa rts as,
necessary.
(5) To service the shift rail, remove roll pin retaining,
the shift fork. Remove the shift replace parts
as necessary.
GEAR CASE
The sealant used to seal the transaxle case halves is Loctite
51817 or equivalent. The sealant used for the bearing end
plate cover is Loctite
or equivalent.
The components that are left in the gear cases when the
gear train is pulled out are the:
Axle shaft seals
Output bearing race and retainer Input bearing and sleeve
Differential bearing cones
Shifter rail bushings ,
Shifter shafts
Shifter shaft seals
Shifter shaft bushings
Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
a flat blade pry tool at outer axle shaft
seal.
(2) Tap on the pry tool with a small and
axle shaft seal.
INSTALLATION
Clean axle shaft seal bore of any excess sealant.
(2) Align axle shaft seal with axle shaft seal bore .
(3) Install axle seal on tool and insert
shaft seal bore.
(4) Tap seal into position.
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MANUAL TRANSAXLE Case Overhaul
outputbearing
Bearing
Input shaftb e a r i n g .
REMOVAL
(1) Note the position of the output shaft
The bearing is not identical to end.
Remove caged roller bearing from output bearing “race.
(2) Remove screws at output bearing strap.
(3) Install tool tool to
bearing race.
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MANUAL TRANSAXLE Case
I \Differential
ing
(1) Line up bearing race race bore.
(2) tool into output bearing
race. Tap race into bore.
Tighten bolts to’ 11 Nm
__
,
INPUT BEARING AND SLEEVE
The input bearing is a one-piece bearing and sleeve
The sleeve is the slide point for the clutch release bearing
and lever.
__
R E M O V A L
tool over input bearing on.
the gear case side of the transaxle clutch housing.
(2) Tap the input bearing out housing.’
INSTALLATION.
(1)Apply coating of Loctite sealant
Position sleeve and bearing
bore.
(2) Install tool input
.
.
,
(3)Using the spacer tool and shop press, install input bearing
into bore until it is fully seated.
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MANUAL TRANSAXLE Case
Gear case
REMOVAL
(1) Install into the differential bearing cup.
(2) Install the tool cup over the tool.
(3) Tighten the tool until the race is removed from the case.
INSTALLATION
(1) Position the bearing cup into case.
(2) Install the bearing cup onto
(3) Using driver, install differential
bearing cup into the transaxle
,
REMOVAL
(1) Thread tool into shifter rail bushing.
(2) Install
onto tool.
(3) Remove bushing using slide hammer and tool asse mbly.
bearing
INSTALLATION
(1) Line up replacement bushing in bore.
(2) Using tool
tap bushing into bore until flush
with the chamfer in the case.
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MANUAL TRANSAXLE Gear Case
SHAFT SEALS
It is not necessary to remove the shifter the trans-
axle to service the shifter shaft seals.
REMOVAL
(1) Using a pick tool, pry up the shifter seal and
remove seal from bore.
INSTALLATION
(1) Position new shifter shaft seal in bore.
(2) Install shifter shaft seal
bore using an
size deep well socket.
REMOVAL
(1) With the transaxle disassembled, remove the sel ector
shaft by pushing on the shaft from the outside and pulling
shaft out from the inside.
Reverse removal procedure to install selector shaft .
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REMOVAL
(1) With the transaxle disassembled, remove the crossover
shaft seal.
(2) Using snap ring pliers, remove the snap ring at the cross-
over shaft bore.
(3) Push the crossover shaft in the case and remove the
crossover assembly.
Reverse removal procedure to install crossover shaft.

MANUAL TRANSAXLE Gear Case Overhaul
SHIFTER SELECTOR SHAFT
REMOVAL
(1) Thread into bushing.
(2) Install
onto tool and remove bushing using
slide hammer.
INSTALLATION
(1) Position replacement over selector shaft bore.
(2)Using an appropriate size deep well socket, install bushing
in selector shaft bore.
SHIFTER CROSSOVER
REMOVAL
(1) Install through the crossover bushing.
(2) Thread nut and washer onto
(3) Using the remove the crossover shaft bush-
ing.
INSTALLATION
(1 Position the replacement crossover shaft bushing o ver
the crossover shaft bushing bore.
(2) Using an appropriate size deep
socket, install the
crossover shaft bushing into the bushing bore.
.
REAR BEARING OIL FEED TROUGH
REMOVAL
The bearing oil feed trough is retained in the case by a pin
that is molded into the case and clips that are par t of the
trough.
(1) Using light plier pressure, squeeze the clips together at
the rear of the trough.
Slide the trough over the retaining’ pin that locates the
trough in the case.
Reverse removal procedure to
feed
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MANUAL TRANSAXLE Shaft Reassembly
Input shaft
Input shaft
input shaft
gear cagedneedle bearing
gear
INPUT SHAFT REASSEMBLY
The snap rings that are used the input available
in select fit sizes. Use the thicknest that will fit
in each ‘snap ring groove.
(1) Place input shaft into shop press. (2) Install
gear caged needle on input shaft.
(3) Install gear and synchronizer onto input shaft.
Install 3, shaft
and press on synchronizer hub
gear. The
nizer hub has the letter the top
of the hub.
This designates that the hub
be installed with the
“U” facing upward.
(4) Install synchronizer snap ring into input shaft.
(5) Install blocking ring into synchronizer. gear
caged needle bearing.
(6) Install
gear onto input shaft.
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Separation pinInput shaft
Input shaft
InputCagedneedle
bearing
(7) split thrust washer pin.
. .,
.
, ,.
(8) Install split thrust washer onto input shaft.
(9) Install split thrust washer retaining ring.
gear caged needle bearing.
(11) Using 2, install speed gear and
synchronizer. The
gear synchronizer hub has the letter
stamped on the top face of the hub. This designate s
that hub must be installed with the facing upward.

MANUAL TRANSAXLE Shaft Reassembly
gear synchronizer snap ririg.
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