MITSUBISHI SPYDER 1990 Service Repair Manual

CONTENTS
CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . 8
CASE REASSEMBLY. . . . . . . . . . . . . . . . . . .31
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . .35
DIFFERENTIAL’ OVERHAUL. . . . . . . . . . . . .17
GEAR CASE OVERHAUL . . . . . . . . . . . . . . . 22
GENERAL INFORMATION
. . . . . . . . . . . . . . . .2
GENERAL SPECIFICATIONS. . . . . . . . . . . . .4
INPUT SHAFT DISASSEMBLY. . . . . . . . . . .13
INPUT SHAFT REASSEMBLY. . . . . . . . . . .28OUTPUT GEAR DISASSEMBLY
. . . . . . . . .16
SEALANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SERVICE SPECIFICATIONS. . . . . . . . . . . . . .4
SHIFTER RAILS OVERHAUL
. . . . . . . . . . . .22
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . .5
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . .4
SYNCHRONIZER OVERHAUL. . . . . . . . . . .20
TORQUE SPECIFICATIONS. . . . . . . . . . . . . .4
TRANSAXLE CLEANING AND CHECK .

MANUAL TRANSAXLE General Information
22210010018
The transaxle internal components can only
be serviced by separating the gear case from the
case. The transaxle output shaft is
as a unit, no, disassembly and reassembly
is possible. Damage to the transaxle may results.
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MANUAL TRANSAXLE General Information
SECTIONAL VIEW
speed gear
speed gear
synchronizer
IReverse idler gear
l
1 synchronizer
Differential
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MANUAL TRANSAXLE Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Applicable engine
Gear ratio1
Reverse
Final gear ratio
Speedometer gear ratio (driven/drive)
SERVICE SPECIFICATIONS
Differential side gear end playmm (in.)
Differential case preload mm (in.)
Specifications
-1
floor shift floor shift
3.54
3.54
2.132.13
1.36 1.36
1 . 0 3
3.94 ,
3.55
Specifications,
. 0.18
TORQUE SPECIFICATIONS22210040017
ItemsN m
Back-up light switch 2418
Differential ring boltgear81
End cover bolt2921
Output bearing race retainingstrap9.6
R e v e r s e i d l e r b o l tgear2619
Reverse fork bracket bolt119.6
Shift cable bracket-transaxle28 20
Transaxle case clutch housing bolt2921
SEALANTS22210050010
ItemsSpecified sealant
End cover and bolts
Clutch housing to transaxle case
Loctite 18718 or equivalent
Loctite 51817 or equivalent
As required
As required
Clutch housing to transaxle case bolts Loctite 51817 or equivalent
As requiredI
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MANUAL TRANSAXLE
SPECIAL TOOLS.
ToolTool number and name
Installer adapter
Installer adapter
Installer bar
Bearing remover
installer
Bearing remover
installer
Bearing remover
installer
Puller press
Puller blocks adapter
Dial indicator set
Removal of input.
and sleeve..
with
Installation and input
bear-
ing.
Removal of
of s i d e , ,
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MANUAL TRANSAXLE ,
ToolTool number and name
Removal of shifter rail bushing,Puller setshifter crossover bushing,
selector shaft.
Installation of input shaft bearing
Seal installer and sleeve.
Checking of different/al bearing
Differential bearing
end play, differential bearing torque tooling torque.
. .
.
Removal of differential bearing.
Adapter
Adjustment of differential side
gear end play.
,
6786 Removal of shifter bushing,
Bushing remover shifter selector shaft.
Removal of diffeiential bearing
Cup removerrace.
.
6787Removal of output bearing race.
Bearing race remover
6768Removal of input shaft bearing
Bearing remover and output shaft bearing.
installer
Bearing installer
Installation of input shaft bearing,
output bearing.
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Installation and of
Installer 100
tool
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MANUAL TRANSAXLE Case .
(1) Place transaxle on bench.
(2) Remove shift levers. bolts.’
(3) Place two screwdrivers in the slots provided in the case
halves near the dowels.
the case halves.’
(4) Remove bell housing case half, from
(5) Remove output shaft roller bearing from output shaft.
(6) Remove differential assembly.
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MANUAL TRANSAXLE
blockerassembly
Selector shaftspacer (Plastic)
( 7 ) R e m o v e r e v e r s e i d l e r s h a f t ,
Remove reverse idler gear.
(8) Remove two screws retaining
fork bracket.
Remove reverse fork bracket and reverse cam
assembly.
(9) Using snap ring pliers, remove shaft
. .
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MANUAL TRANSAXLE Case
Case
the selector shaft shift in theblocker,
assembly. Turn selector up out of the
(11) Remove transaxle end cover.
.
.
. . two snap rings retaining the output shaft and’
the input shaft to the bearing.
bench fixture and shims provided
transaxle over., Install trans-
axle onto bench fixture. Verify
are in
on bench fixture. Install transaxle into .
. .
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