MITSUBISHI SPYDER 1990 Service Repair Manual

MANUAL TRANSAXLE Case
CASE REASSEMBLY
The sealant used to seal the transaxle case halves is Loctite
51617 or equivalent.
The sealant used for the bearing end plate cover is Loctite
18718 or equivalent.
(1)Verify bench fixture shims are removed from bench
Install output and input gear pallet
(2) Install shift rails and forks. into bench fixtu re.
(3) Install shift blocker assembly into bench
(4) gear case half over pallet fixture. shift
finger over
lug.
(5) Line up reverse brake friction cone lug to the slots in
the gear case. Verify reverse
is position.

MANUAL TRANSAXLE Case
End
Reverse
(6) Position input and output bearings on the shafts. Using
press input and bearings until’
they bottom into the case and
shafts:’ ,
(7) Install shaft snap rings at input and output be arings.
(8) Apply 18718 or equivalent to end cover outer
edge and around bolt holes. Install end cover onto gear
case. Tighten end cover bolts to torque.
(9) Remove gear case from bench fixture.
gear case in a holding fixture “facing
down.
(ll)Turn selector shaft into slot on shift, blocker assembly.
selector shaft spacer clip onto selector shaft. In stall
shift levers.
,
reverse idler gear and Install bolt into shaft.
Tighten bolt on shaft to 26

MANUAL TRANSAXLE Case-
Reverse idler
Screws (2)A
TSBRevision
reverse fork bracket and reverse cam lockout as-
sembly. Tighten screws to 11 Nm (9.6
torque.
differential into gear case.

TRANSAXLE
G E N E R A L R U L E S O N
(3)
(4)
Take extreme care when removing, and installing bearing
cups and cones. Use only
arbor for installation,
as a hammer may not properly* align the
or cone. Burrs or nicks on the bearing
give a end
play reading while gauging. for proper shims. Impro perly
seated bearing cups and cones are subject to low mi leage’
failure.
Bearing cups and ‘cones should be replaced if they
signs of pitting or heat distress., If distress seen on’
either the cup or bearing rollers, both cone must
be replaced.
Bearing preload and drag torque specifications
maintained to avoid premature’
(original) bearing may lose up to drag
torque offer break in. All bearing, adjustments
made with no other component
mesh.
Replace bearings as a pair. For
bearing is defective, replace both differential.
If one input shaft bearing is defective; ‘replace b oth input
s h a f t b e a r i n g s .
Bearing cones must not be reused if
Turning torque readings should be while smooth-
ly rotating in either direction,,
TSB Revision

Differential Bearing
MANUAL TRANSAXLE Preload Adjustment
DIFFERENTIAL BEARING
ADJUSTMENT
True bearing turning torque readings can only be obtained
with the gear train removed from the case.
(1) Remove bearing cup and existing shim from clutc h
housing case.
(2) Press in new bearing cup into bell housing case (or use
a cup that has been ground down on the outer edge
for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Lubricate differential bearings with SAE
engine
oil. Install differential assembly in transaxle gear case.
Install clutch bell housing over gear case.
and
torque case bolts to 29 Nm (21
(5) Position transaxle with bell housing facing dow n on work-
bench with C-clamps. Position dial indicator.
(6) Apply a medium load to differential with
and
a T-Handle, in the downward direction. Roll differe ntial
assembly back and forth many times. This will settl e the
bearings. Zero dial indicator. To obtain end play r eadings,
apply a medium load in the upward direction while r olling
differential assembly back and forth. Record end play.
(7) The shim required for proper bearing preload is total of
end play and (constant) preload of 0.18 mm
in.).
(8) Remove case bolts. Remove clutch bell housing d ifferen-
tial bearing cup. Install shim(s) selected in step (7). Then
press the bearing cup into clutch bell housing.
(9) Install and torque case bolts to 26 Nm (19
(lO)Using and an inch-pound torque wrench,
check turning torque of the differential assembly c lockwise
and counterclockwise. The turning torque should be 68
to 136 Ncm (6 to 12
If the turning torque is too
high, install a 0.5 mm in.) thinner shim. If the turning
torque is too low, install a 0.5 mm in.) thicker shim.
(11) Recheck turning torque. Repeat Step (10) until the proper
turning torque is obtained.
TSB Revision

. . ., ,

AUTOMATIC
TRANSAXLE
CONTENTS
AUTOMATIC TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSAXLE OVERHAUL . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSAXLE OVERHAUL . . . . . . . . .
AUTOMATIC TRANSAXLE OVERHAUL . . . . . . . . . . . . . . . .

23-2
NOTES
. .
.
,.

CONTENTS
AUTOMATIC TRANSAXLE
ENGINE (NON-TURBO)> . . . . . 115
AUTOMATIC TRANSAXLE KEY INTERLOCK
AND SHIFT LOCK MECHANISMS* . . . . . . . . 192
GENERAL INFORMATION
. . . . . . . . . . . . . . . . 115
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . .117
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 159
Automatic Transaxle Control Component
Oil Temperature Sensor Continuity Check . . . . 160
Pinion Factor Writing Procedure After
TCM Replacement or Tire Size Change
. . . 159
Selector Level Operation Check . . . . . . . . . . . . . . ,166
Shift Lock Mechanism Check. . . . . . . . . . . . . . .
1 8 6
TCM Resetting Procedure . . . . . . . . . . . . .
..159
Torque Converter Stall Testing. . . . . . . . . . . . . .166
Transaxle Fluid Level Check . . . . . . . . . . .. . .159
Transaxle Fluid Replacement. . . . . . . . . . . . . . .
Transaxle Range Sensor Continuity . . .
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163SERVICE SPECIFICATIONS.. . . .. . .Automatic Transaxle Control Component Layout
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . .117Clutch Air Pressure Tests . . . . . . . . . . . . . . . . . . .168
Fluid Leakage-Torque Converter Housing Area
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Hydraulic Pressure Tests. . . . . . . . . . . . . . . . . . .169
Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . .173
TRANSAXLE ASSEMBLY. . . . . . . . . . . . . . . .
TRANSAXLE CONTROL*. . . . . . . . . . . . . . . . .187
Selector Lever Assembly. . . . . . . . . . . . . . . . . . .189
Key Interlock Mechanism Check . . . . . . . . . . .
. 186CONTINUED ON NEXT PAGE
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL EQUIPPED VEHICLES
WARNING! (1) Improper service or maintenance of any componen t of the
or any component, can lead to personal
injuryordeath inadvertent the inoperative).
(2) Service or maintenance of any component or SRS-related component must be perform ed only at an authorized
MITSUBISHI dealer.
(3)MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP Supplemental Re-
straint System (SRS) and GROUP 00 -Maintenance Serv ice before beginning any service or maintenance of any com-
ponent of the
or any component.
NOTEThe SRS includes the following components: SRS-ECU, SRS warning light, air bag module, clockspring and inte rconnecting wiring.Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indi-cated in the table of contents by an asterisk

TRANSAXLE OIL COOLER. . . . . . . . . . . . . . .198
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSAXLE KEY INTERLOCK
AND SHIFT LOCK MECHANISMS*
. . . . . . . .
GENERAL INFORMATION. . . . . . . . . . . . . . . . . .3
LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ON-VEHICLE SERVICE. . . . . . . . . . . . . . . . . . . .55
Control Component Check. . . . . . . . .61
Automatic Transaxle Control
Component Layout. . . . . . . . . . . . . . . . . . . . . . . . . .58
Hydraulic Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Hydraulic Pressure Test. . . . . . . . . . . . . . . . . . . . .65
Key Interlock Mechanism Check . . . . . . . . . . . . .91
Servo Adjustment. . . . . . . . . . . . . . . . .84
Line Pressure Adjustment
. . . . . . . . . . . . . . . . . . .67
Park/Neutral Position Switch and Control Cable
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Park/Neutral Position Switch Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
, . .
Selector Lever Operation Check . . . . . . . . . . . . . 91
Lock Mechanism Check . . . . . . . . . . . . . . . . 92
Throttle Position Adjustment . . . . 57
Torque Converter . . . . . . . . . . . . . . . . .64
Transaxle Fluid Level Check . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . .55
Transfer Level Check . . . . . . . . . . . . . . . . . .55
Transfer Oil Replacement . . . . . . . . . . . . . . . . . .55
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . .9
T R A N S A X L E
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
TRANSAXLE
Selector Lever Assembly . . . . . . . . .95
TRANSAXLE OIL COOLER . . . . . . . . . . . . . .
TRANSFER ASSEMBLY . . . . . . .
TROUBLESHOOTING . . . . . . . . , . . . . . . . . . . 11
,
.
, . .