MITSUBISHI ECLIPSE 1991 Service Manual

AUTOMATIC TRANSAXLE - Valve Body21-327
SERVICE POINTS OF REASSEMBLY42./33.
LOCATION OF STOPPER PLATES/SO. N-D PLATE/
19. TEFLON BALL/18. STEEL BALL
Install the stopper plates, N-D plate, teflon ball and steel
ball in the upper valve body in the positions shown in the
figure.
17. INSTALLATION OF UPPER VALVE BODY SUB ASSEM-
BLYInstall the special tool, then, after securing the upper
separating plate and the intermediate plate by the eight
installation bolts, remove the special tool.
MD998226
18. INSTALLATION OF OIL FILTER/IS. STEEL BALL/
14. RELIEF SPRINGInstall, to the intermediate plate, the oil filter, the two steel
balls, and the spring.
10. INSTALLATION OF LOWER VALVE BODY SUB ASSEM-
BLY(1) Install the special tool to the intermediate plate.
(2) Install the separating plate.

21-328AUTOMATIC TRANSAXLE - Valve Bodv
XSV-ASkV-Brj,,SV (FJA22)TFAM80(3) After securing the lower valve body by
the installationbolt, remove the special tool.
Sk
5./4./3./2. INSTALLATION OF SOLENOID VALVE ASSEM-
BLYInstall each solenoid valve in the position shown in the
figure.
Solenoid valveWiring colorI
Shift control solenoid valve “A”
Shift control solenoid valve “B”
Damper clutch control solenoid valve
Yellow
Red
Pressure control solenoid valveBlue

AUTOMATIC TRANSAXLE - Center Differential
CENTER DIFFERENTIAL
- DISASSEMBLY AND REASSEMBLY
21-329
NZlLWM
TEA0261
Disassembly steps
l *1. Transfer driven gear
+e l 2. Taper roller bearing
l * :zi. poy;r roller beanng
5: Center differential flange
l + 6. Spacer
7. Side gear (front)
8. Pinion shaft
9. Pinion
10. Washer
11. Side gear (rear)
12. Clip
l * 13. Spacer14. Center differential case
FEeverse the disassembly procedures to reassemble.(2) +e : Refer to ZServjce Pojnts of Disassembly’:‘.1::4 : Refer to Serwce Points of Reassembly&I: Non-reusable parts
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF TRANSFER DRIVEN GEAR
Remove the transfer driven gear.
NOTEIf it is hard to remove, use the special tool to remove it.

21-330AUTOMATIC TRANSAXLE - Center Differential
2. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing from/icthe transfer driven gear.
‘;-
3. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing fromthe center differential flange.
SERVICE POINTS OF REASSEMBLY
13.16. SELECTION OF SPACERS(1) Install the spacer, side gear (rear), pinion, washer and
pinion shaft in the center differential case.
rs,(2) While pressing the pinion shaft, select the thickest
-m ,-’spacer to gently rotate the pinion.
(3) Install the side gear (front), spacer and center differen-
tial flange and tighten the bolts with the specified
torque.Center differential
drive gear bolt:
70-80 Nm (51-57 ft.lbs.)(4) Using the front output shaft, rotate the side gear front
and select the thickest spacer to gently rotate the side
gear front.
4.INSTALLATION OF BOLTFirst apply sealant to the end
[5 mm (2 in.)] of the bolt
threads and then tighten to the specified torque in the ordershown in the figure.Center differential
drive gear bolt:
70-80 Nm (51-57 ft.lbs.) *
Specified adhesive: MOPAR Part No.4318031 or +’MOPAR
Part No.4318032 orequivalent

AUTOMATIC TRANSAXLE - Center Differential 21-331
3. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, install the taper roller bearing on thecenter differential flange.
2. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, install the taper roller bearing on thetransfer driven gear.

21-332AUTOMATIC TRANSAXLE - Front Output Shaft
FRONT OUTPUT SHAFT 2
DISASSEMBLY AND REASSEMBLY
II
NZlLXAA
Disassembly steps
*I) l 1. Taper roller bearing+e l 42. Taper roller bearing
3. Front output shaft
NOTE(I) Reverse the disassembly procedures to reassemble.(2) +I) : Refer to “Service Points of Disassembly”.
(3) l 4 : Refer to “Service Points of Reassembly”.
SERVICE POINTS OF DISASSEMBLY1./2. REMOVAL
OF TAPER ROLLER BEARINGSUsing the special tool, remove the taper roller bearings on
both ends of the front output shaft.
MD998822
SERVICE POINTS OF REASSEMBLY
2./l. INSTALLATION OF TAPER ROLLER BEARINGSUsing the special tool, press-fit the taper roller bearings on
both ends of the front output shaft.

AUTOMATIC TRANSAXLE - Transfer Assembly
TRANSFER ASSEMBLY
- DISASSEMBLY AND REASSEMBLY
21-333
NElVE-35-42
Nm26-30 ft.lbs.
TFAO601
Disassembly steps
1. Cover
2. Cover gasket
3. Extension housing assembly
4. Oil guide
l I5. Transfer case sub assemblyl 6. Spacer7. O-ring
l +8. Transfer case adapter sub assembly
$?everse the disassembly procedures to reassemble.(2) l 4 : Refer to “Service Points of Reassembly”.
(3) m : Non-reusable parts

21-334AUTOMATIC TRANSAXLE - Transfer Assemblv
2210050
-TifAO315
SERVICE POINTS OF REASSEMBLYWmnAE
8. INSTALLATION OF TRANSFER CASE ADAPTER SUB +=GASSEMBLY
-Using a brush, apply a thin even coat of machine blue orminium to both tooth surfaces of the driven bevel gear.
6. INSTALLATION OF SPACERInstall the spacer which has been used so far.
5. INSTALLATION OF TRANSFER CASE SUB ASSEMBLY
(1) Tighten the transfer case adapter sub assembly on the
transfer case sub assembly 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.
MB991144(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.
4
-am--

AUTOMATIC TRANSAXLE - Transfer Assembly 21-335(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.)
22100612210092
2210093
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
high
Possible 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.
3. INSTALLATlON OF EXTENSION HOUSING ASSEMBLY
Apply sealant to the flange surface of the adapter and installthe housing.
Specified sealant: Mitsubishi genuine Part No.997740Caution
or equivalentSqueeze out
the sealant from the tube uniformly
without excess or discontinuities.

21-336AUTOMATIC TRANSAXLE - Transfer Assembly 2210094
2210095
Spacer for
adiustina drivebekel gear mount
\Spacer for
bevel gear preloacSpacer for
adjusting/ driven bevel
gear mount
Spacer for
, adjusting
driven bevel
gear preload
2210129
3. Tooth contact pattern when driven bevel gear is too
low
Possible cause:A-kThe driven bevel gear is further away from the drive bevel
~gear than necessary.
Remedy:Use a thinner spacer for the driven bevel gear mount
adjustment so that the driven bevel gear is closer to the
drive bevel gear.
NOTE(1) If correct tooth contact cannot be obtained by replace-
ment of spacer for adjusting driven bevel gear mount,
change the spacers for adjustment of drive bevel gear
preload and drive bevel gear mount adjustment to those4of appropriate thickness as described below and adjust
-.’the tooth contact again.
lIf the driven bevel gear height is still too small whenthe thinnest spacer for driven bevel gear mount
adjustment
[0.13 mm (.005 in.)] is used;
Change the spacer for drive bevel gear mount
adjustment to the next thicker one and change the
spacer for drive bevel gear preload adjustment to
the next thinner one.
lIf the driven bevel gear height is still too large whenthe thickest spacer for driven bevel gear mount
adjustment
[0.52 mm (021 in.)] is used;
Change the spacer for drive bevel gear mount
adjustment to the next thinner one and change the
spacer for drive bevel gear preload adjustment to
the next thicker one.
Repeat above steps until standard tooth contact
pattern is obtained.
(2) If the tooth contact pattern cannot be brought close to
the standard pattern by the adjustment described
above, replace the drive bevel gear and driven bevel
gear as a set and adjust the tooth contact again.