brake MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE - Transaxle Assembly n-33
TRANSAXLE ASSEMBLY
3 DISASSEMBLY AND REASSEMBLYNZlME-6
--42 Nm
-30
ft.lbs.
\8I Q
30-35Nm
22-25ft.lbs.ml4
ff3d6 i
18
4.0-5.5Nm2.9-3.9ft.lbs.
-n
140-160 Nm102-115ft.&s.
3-5 Nm
16-22 Nm11-15 ft.lbs.1Disassembly steps
‘I. Bolt
l *2. Rear cover3.Wave springe4 4. Screw bolts5. Reverse brake cone6. Backup light switch
7.Gasket
8.Poppet plug9.Poppert spring
10.Poppet ball11.Bolt
12. Speedometer driven gear assembly
l 13. Air breather
4* l * 14. Spring pin
,I
2
TFMool6
4+ e4 15. Lock nut+e l 16. Lock nut17. 5th speed synchronizer assembly18. 5th speed shift fork19. Synchronizer ring20. 5th speed gear21. Needle bearing22.
5th speed intermediate gear.’
$?everse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly:.(3) l C : Refer to “Service Points of Reassembly(4) q : Non-reusable parts

21-42MANUAL TRANSAXLE Transaxle Assembly /- 5th Speed Synchionizer AssemblyTFM0041
8” in.)TFM0044
4. INSTALLATION OF SCREW BOLTSApply specified adhesive to screw bolts mounting portion.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No. 4318032
or ‘equivalent
2. APPLICATION OF SEALANT TO THE REAR COVERApply specified sealant to the
rear cover.
Specified sealant: MITSUBISHI Genuine
Part No.
MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuity.
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
43
NZlMHAK
1Disassembly steps
1. Reverse brake ring (F5M22-2, F5M33)
2. Stop plate (F5M22-1)I)4 3. Synchronizer spring4. Synchronizer sleeveWI 5. Synchronizer key*+ 6. Synchronizer hubTFM0055
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Reassembly”.

MANUAL TRANSAXLE - Specifications21-75Items
Lower arm ball joint to knuckle
Center bearing bracket installation bolts
Right member installation bolt (front)
Right member installation bolt (rear)
Transfer assembly mounting bolt
Poppet plug
Backup light switch
Restrict ball
Speedometer mounting bolt
Oil filler plug
Oil drain plug
Input shaft lock nut
Intermediate shaft lock nut
Center differential drive gear mounting bolt
Front differential drive gear mounting bolt
Stopper bracket mounting bolt
Reverse idler gear shaft mounting bolt
Reverse shift lever mounting bolt
Bearing retainer mounting bolt
Interlock plate mounting bolt
Center member mounting bolt
Irive shaft center bearing mounting bolt
Iriven bevel lock nutgear
Select lever assembly mounting bolt
3everse brake cone screw boltsNm
ft.Ibs. ”
60-7243-52 “
36-4626-33
80-10058-72
70-8051-58
55-6040-43
30-4222-30
30-3522-25
30-3522-25
3-52.5-3.5
30-3522-25
30-3522-25
140-160102-I 15
140-160102-I 15
70-8051-57
130-14095-10115-22
11-1543-55
32-39
15-22
11-1515-22
11-15
20-2715-19
60-8043-58
36-46
26-33
140-160101-11515-22
11-15
4.0-5.52.9-3.9
TRANSFERItems
Transfer assembly mounting bolt
Cover mounting bolt
Extension housing mounting bolt
Transfer cover mounting bolt
Transfer case adapter mounting bolt
Driven bevel gear lock nut
Hanger bracket mounting boltNm
ft.lbs.
55-6040-43
8-106-7
15-22
II-1535-42
26-3035-42
26-30
140-160102-I 15
15-22
11-15
LUBRICANTSN21CD.BItems
Specified lubricantQuantity lit. (qts.)
I
ITransmission oil
MOPAR Hypoid gear oil or equivalent,2.3 (2.43)
API classification GL-4 or higherITransfer oil
MOPAR Hypoid gear oil or equivalent,
API classification
GL-4 or higher0.6 (.63)

21-76MANUAL TRANSAXLE -Specifications/Special Tools
SEALANTS AND ADHESIVESNZlCE-B
TransaxleH-
1
-/Items
Transaxle case-clutch housing mating surfaces
Transaxle case-adapter mating surfaces
Adapter-rear cover mating surfaces
Front differential drive gear bolts
Center differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
Air breatherSpecified sealants and adhesives
Mitsubishi genuine part
No.997740or equivalent
MOPAR part
No.4318031 or MOPAR part
No. 4318032 or equivalent
MOPAR part
No.4318025 or equivalent
TransferItems
Adapter-extension housing mating surfacesSpecified sealants and adhesives
Mitsubishi genuine part No.
MD997740or equivalent
Air breatherMOPAR part
No.4318025 or equivalent
SPECIAL TOOLSNZlDA-B AI
NllmherName
I Use,“I. .-. * ,--.
~ MD99801 9
.-...-Lock pin extractor---Removal of spring pin and lock pin
MD998245Lock pin installerInstallation of spring pin and lock pin
0
MD998304Oil seal installerInstallation of front output shaft bearing and
transfer extention housing oil seal
MD998320Bearing installer
Installation of input shaft bearing and input
shaft gear

21-86MANUAL TRANSAXLE - Transaxle AssemblyTRANSAXLE ASSEMBLY
DISASSEMBLY AND REASSEMBLY
30-35 Nm
22-25 ft.lbs.
\
30-35 Nm
22-25 Wbs.
4.0-5.5 Nm\62.9-3.9 ft.lbs.7-42 Nm
-30
ft.lbs.llI8-59
I21IDisassembly steps
l + 1. Rear cover
2. Wave spring
I)+ 3. Screw bolts
4. Reverse brake cone
;. E;zk;p light switch
7: Restrict ball assembly
8. Gasket
9. Poppet plug
.- ^1 U. Poppet spring11. Poppet ball
I 2. Speedometer driven gear assembly
l + 13. Air breather
l * l 4 14.Spring pin
140-160 Nm
w ”Y
102-115 ft.lbs.
16Bl/
22
++ I)+ 15. Lock nut+el 416.Lock nut
l + 17. 5th speed synchronizer assembly~~ 18. Shift fork
19.Synchronizer ring
20.
5th speed gear
21.Needle bearing
22.
5th speed intermediate gear35-42 Nm
26-30 ft.lbs.-1
TFMOOZSNOTE
(1) Revers_e the di?: ’(2) +-(3) +v : neler 10(4) IW : Non-reusat-yle parts.assembly
proceaures 10 reassemble.ry : KeTer to Service Points of Disassembly”.“-I-- I- “Service Points of Reassembly”.
’
i

MANUAL TRANSAXLE - 5th Speed Synchronizer Assembly2 q:-*t&f
5TH SPEED SYNCHRONIZER ASSEMBLY
/-- DISASSEMBLY AND REASSEMBLY
-Disassembly steps
1. Reverse brake ring
l 2. Synchronizer spring
3. Synchronizer sleeve
W 4. Synchronizer key
I)+ 5. Synchronizer hub
WlMHAL
. . I:,
TFMOO!56
NOTE(1)Reverse the disassembly procedures to reassemble(2)*a: Refer to “Service Points of Reassembly”.
INSPECTIONSYNCHRONIZER SLEEVE AND HUB
(1) Mate the synchronizer sleeve and hub and check to see if
they slide smoothly without binding.
(2) Make sure that the sleeve is free from damage at its inside
front and rear ends.
NOTEIf replacement is necessary, replace the synchronizer hub
and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
(1) Make sure that the center protrusion of the synchronizer
key is not worn.
(2) The spring must offer proper tension with no deformation
or damage.

AUTOMATIC TRANSAXLE - General Information21-141
ExFront clutchRear clutchLow-reverse
brake
Kickdown servo
End clutch
control solenoid
valve
To lubrvzatlon
(front)
-To lubrlcatlon +=(rear)
Shift control
valve
~~&-----~ Manual 1
( “,::mr JL-
mLine pressure
0Torque converter and lubncatlonpMSS”V2
= Reducing pressure
1 011 pump suction pressure
n Modulated line pressure
0 Damper clutch pressure
lmDamper clutch control solenoidvalve pressure
IPressure control solenoidvalve pressure
TFA0070

21-142AUTOMATIC TRANSAXLE - General Information

Klckdown servo
-,Low-reverse
brake
End clutch
Front clutch
FDamper clutch
control valve
Damper clutch
control
solenordTo lubrication
+_ifront)To lubncatlon CJIrear)
I I .“‘---Shaft control
114 !!. B ii IIII III/lII II.
TlPressure control
Pressure
\ \, Yal”eEm
0 011 pump suctton pressure
0 Modulated line pressure
m Damper clutch pressure
Damper clutch control
solenoidvalve pressure
-IPressure control solenoidvalve pressure
ILine pressure
xque converter and lubrlcatlonessure
Reducing pressure
TFA0071

AUTOMATIC TRANSAXLE - General Information21-145
Torque converter
Klckdown servo
Low reverse
brake
Front clutch
Rear clutch
End clutch
+Damper cluF:h
control
solenoidvalve
(front)
5%To lubrication cTo
lubrlcatlon cz(rear)
N-D control
valve
I,,--.- -InPressure controlI valve
Ahii
Pressure
1 Line relief
e
i ; valve
EX
011 pan
= Line pressure
0Torque converter and lubrlcatlonpressure
mRedumg pressure
011 pump suction pressure
Modulated
lane pressure
Pressure control
solenoidvalve pressure
mlDamper clutch pressure
Damper clutch control
solenoid1valve pressure
1 Drive (Second) 1
TFA0073

AUTOMATIC TRANSAXLE - General Information21-147
Torque converter
5-l
Klckdown servo
-,Low~reversebrake
\Front clutch
Rear clutchEnd clutchIexhaust valve exhaust valve
4
7-l’”Damper
clutcontrol solervalve
;k$icatton cTo
lubrlcatlon c=(rear)
1 ) Shift control ixvalve
v- 1.
I) I-
Pressure control
x-w
2 011pump
E Line reltef
11:: valve
EX
011 pan
0 011 pump suction pressure
unit
m Damper clutch pressurem Line pressure
Torque converter and
lubricationpressuren Modulated line pressureDamper clutch control solenoidvalve pressure
Pressure control
solenoidve pressure
TFA0075