lock MITSUBISHI ECLIPSE 1991 Service Manual

19-36STEERING - Power Steering Gear BoxMB991317
side
13A031fVinyl tape
APP~automatic
transmissionfluid
13POl44
IApprox. 1 mm
(Approx. ,040 in.)i, Tool
’ 13POO76
13A014:
End plug
Sealant
13K,30II
I
IEnd plug\ ,I
NOTE
Because the seal rings expand at the time of installation,use the special tool to compress the seal rings so that
-they are well seated.
L
(2) Apply multipurpose grease to pinion gear and housing
bearing.Grease: MOPAR Multi-mileage Lubricant
PartNo.2525035 or equivalent
(3) Wrap vinyl tape around the serrated part so that the oil
seal won’t be damaged when the pinion
and valveassembly is installed to the valve housing.
(4) Mount the pinion and valve assembly to the valve
housing.
18. INSTALLATION OF OIL SEAL
Using a tool, press the oil seal into the valve housing.
CautionIn order to eliminate a seal malfunction at the valve
-
housing alignment surface, the upper surface of -the oilseal should project outward
approximatelv 1 mm t.040in.) from the housing edge surface.
‘, I
16. INSTALLATION OF RACK SUPPORTApply multipurpose grease to the rack support surface in
contact with the rack bar.
Grease: MOPARMulti-mileage
LubricantPartNo. 2525035 or equivalent
14. INSTALLATION OF RACK SUPPORT COVER
Apply semi-drying sealant to rack support cover screw. Locktemporarily with locking nut.
11. INSTALLATION OF END PLUG
(1) Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No.6663 or equiva-
lent
rL-
(2) Secure the threaded portion of the end plug at two._places by using a punch.

STEERING - Power Steering Gear Box
13A017EI
\Silicon grease
Lip
Sealant131564-r-MB990776-A
13A0259l ADJUSTMENT OF TOTAL PINION TORQUE
(1) Position rack at its center. With special tool, tighten racksupport cover to 15 Nm (11
ftlbs.).(2) In neutral position, rotate pinion shaft clockwise one
turn/4-6 seconds with special tool. Return rack, support
cover
30°-60° and adjust torque to the stanoard,vaiue.Standard value:
0.6-l .3 Nm (5-l 1 in.lbs.1
Caution1. When adjusting, set the standard value at its
highest value.2. Assure no ratcheting or catching when operating
rack towards the shaft direction.
NOTEWhen it cannot be adjusted within the specified return
angle, check rack support cover components or replace.
(3) After adjusting, lock rack support cover with locking nut.8. INSTALLATION OF TIE ROD
After installing tie rod to rack, fold tab washe;, end (2
locations) to tie rod notch.
‘*,t, \
\6. APPLICATION OF GREASE TO BELLOWS
Pack tie rod bellows lock groove with specified grease.
Specified grease: Silicone grease3. INSTALLATION OF DUST COVER
(1) Pack dust cover interior and lip with multipurpose grease.Grease: MOPAR Multi-mileage Lubricant Part
No. 2525035 or equivalent
(2) Apply specified sealant to dust cover.
Specified sealant: 3M ATD Part
No.8663 or equiva-
lent
(3) Using the spcial tool, press dust cover to tie rod end.

STEERING - Power Steering Gear Box
I-
-l 183.4-185.4mm (7.22-7.30in.) 179.6-181.6mm (7.07-7.15in.)
13ElOO2. INSTALLATION OF TIE ROD END
Screw in tie rod end to have its right and left length as
-illustrated. Lock with locking nut.

TRANSAXLE ’
MANUAL AND AUTOMATICCONTENTS
;-AUTOMATICTRANSAXLE
.....................................................137ANNULUS GEAR AND TRANSFER DRIVE GEAR SET (F4A22)..........315ANNULUS GEAR AND TRANSFER DRIVE GEAR SET(F4A33.W4A33)...........................................................................................317CENTERDIFFERENTIAL(W4A33).............................................................329DIFFERENTIAL............................................................................................319ENDCLUTCHASSEMBLY.........................................................................309EXTENSIONHOUSINGASSEMBLY(W4A33).........................................337FRONTCLUTCHASSEMBLY....................................................................302FRONTOUTPUTSHAFT(W4A33)...........................................................332GENERALINFORMATION.........................................................................137KICKDOWNSERVO....................................................................................322LOW-REVERSEBRAKE..............................................................................323OILPUMP...................................................................................................299PLANETARYGEARSET............................................................................311PLANETARYGEARSET............................................................................313REARCLUTCHASSEMBLY(F4A22)........................................................304REARCLUTCHASSEMBLY(FQA33sW4A33)............................................307SERVICEADJUSTMENTPROCEDURES..................................................Drive
Shaft,OilSealsReplacement....................................................;;;
InhibitorSwtchAdjustment................................................................21 1KeyInterlockMechanismCheck.....................................................KrckdownServoAdjustment..................................zii..............................
LinePressureAdjustment...................................................................213
ReducingPressureAdjustment.........................................................214Selector Lever Operation Check........................................................210ShiftLockMechanismCheck...............................................................21 1SpeedometerCableReplacement.........................................................Throttle-posltipn Sensor Adjustment.................................................z2:
TransaxleFluIdLevelInspectIon......................................................209
TransaxleFluidReplacement.............................................................209
SPECIALTOOLS.........................................................................................SPECIFICATIONS........................................................................................;“5”9
GeneralSpeclficatlons..................................................................1%Lubricants..................................................................................Sealants and Adhesives..............................................................izi
Serwce Speclflcatlons..................................................159...............Spacer andSnapRing.,.,.............................................................Spacer Set..................................................................1::Torque Speclflcatlons...........................................166Valve Body Spring Identification Chart.....................
.................160
SPEEDOMETERGEARASSEMBLY..........................................................TRANSAXLEASSEMBLY(WA22)............................................................zTRANSAXLE
ASSEMBLY(F4A33.W4A33)................................................TRANSAXLECONTROL.............................................................................;;;TRANSAXLE
OILCOOLER........................................................................TRANSFER..................................................................................................fg
TRANSFERASSEMBLY.............................................................................333TRANSFERCASEADAPTERSUBASSEMBLY(W4A33).......................339TRANSFER CASE SUB ASSEMBLY (W4A33)341TRANSFER SHAFT (F4A33)TROUBLESHOOTING..................................................................................................................................................................................................f;;VALVE
BODY.............................................................................................324
MANUAL TRANSAXLE .......................................2CLUTCHHOUSINGASSEMBLY...............................................................DIFFERENTIAL ASSEMBLY ,....._................................................................E
5TH-SPEEDSYNCHRONIZERASSEMBLY...............................................42GENERALINFORMATION.........................................................................2.-.INPUTfj,-,A,TASSEMBLY.....................................................INPUTSHAFTASSEMBLY.....................................................;
INTERMEDIATE GEAR ASSEMBLY..........................................................56OUTPUT
SHAFT ASSEMBLY....................................................................61SERVICEADJUSTMENTPROCEDURES..................................................DriveShaftOilSealsReplacement......................................................;;Speedometer Cable Replacement.........................................................
Transaxle Oil Level
InspectIon..............................................................‘liTransaxle Oil Replacement....................................................................
I3
SHIFTLEVERASSEMBLY.........................................................................SHIFTRAILSANDFORKS........................................................................g
SPECIALTOOLS.........................................................................................SPECIFICATIONS........................................................................................1:
General Specifications5Lubricants..........................................................................................................................................................................10Sealants and Adhesives
Service Specifications
....................................................................................................................................................1:Snap Ring (for Adjustment) and Spacer...............................................
Torque Specifications.............................................................................
i
SPEEDOMETERGEARASSEMBLY..........................................................TRANS&G.E................................................................................................zTRANSAXLEA!jSEMBLY
........................................................i?3TFlANSAXLEASSEMBLY........................................................TRANSAXLECONTROL.............................................................................g
TROUBLESHOOTING..................................................................................12
MANUAL TRANSAXLE ......................................BACKUPLIGHTSWITCH...........................................................................g
CENTERDIFFERENTIAL.............................................................................103CLUTCHHOUSINGASSEMBLY...............................................................DRIVE BEVEL GEAR ASSEMBLY;g
...... .......................................................DRIVENBEVELGEARASSEMBLY...................................a......................EXTENSIONHOUSINGASSEMBLY.........................................................;g
5Tf.jSPEEDSYNCHRONIZERASSEMBLY...............................................101
FRONTDlFFERENTlAL...............................................................................106
FRONTOUTPUTSHAFTASSEMBLY......................................................106
GENERALI~~~~MATN)N...............................................................,.,.......66INPUTSHAFTASSEMBLY........................................................................l~ER,“,EDlATEGEARASSMBLY..........................................................;;i
SERVICEADJUSTMENTPROCEDURES..................................................Drive Shaft Oil Seals Replacement......................................................;;Speedometer Cable Replacement.........................................................
Transaxle
Ojl Level lnspectlon..............................................................;l
Transaxle 011 R~pb33ment....................................................................79Transfer
OilSealReplacement.............................................................80
SHIFTLEVERASSEMBLY.........................................................................SHIFTRAILASSEMBLY............................................................................,z
SPECIALTOOLS.........................................................................................76
SPECIFICATIONS........................................................................................6g
GeneralSpecifications...........................................................................6g
Lubricants...............................................................................................75
SealantsandAdhesives........................................................................76
ServiceSpecifications............................................................................6gSnap Ring (for Adjustment) and Spacer...............................................7 o
TorqueSpecifications.............................................................................74
SPEEDOMETERGEARASSEMBLY..........................................................TRANSAXLE................................................................................................1:TRANSAXLEASSEMBLY...........................................................................86TRANSAXLE
CONTROL
.............................................................................TRANSFER...............................................................................................
g.._TRANSFERA!333lBLY.............................................................................,24
TRANSFERCASEADAPTERSUBASSEMBLY.......................................131TRANSFERCASESUBASSEMBLY.........................................................TR,,UBLES,,OO,,NG..................................................................................1;;

MANUAL TRANSAXLE - Specifications
Part name
Spacer
(For adjustment of differential case preload)
Spacer
(For adjustment of differential pinion backlash)
TORQUE SPECIFICATIONSThickness mm (in.)
1.22 f.0480)
1.25 (.0492)
0.75-0.82
(.0295-.0323)
0.83-0.92
(.0327-.0362)
0.93- 1 .oo
(.0366-.0394)
1.01-1.08
(.0398-.0425)
1.09-1.16
(.0429-.0457)Identification
symbol
GM
-
-
-
-Part No.
MA180862MA1
80866MA1 80875MA1 86876
Items
Nm
Shift lever to lever (A)
19-28
Lever (A) to bracket assembly
17-26
Drain plug
30-35Filler plug
30-35Starter motor mounting bolt
27-34
Transaxle bracket
60-80Shift lever knob
4.5-7.5
Shift cable and select cable to body9-14
Shift lever assembly to body
9-14
Automatic seat belt guide ring attaching bolt17-26
Clutch release cylinder mounting bolt
15-22
Clutch tube to transaxle assembly
15-22
Transaxle mount bracket to transaxle
60-80Shift cable and select cable to transaxle15-22
Under cover
9-13
Transaxle mounting bolt [12 mm (.47 in.) diameter
bolt143-55
Transaxle mounting bolt [IO mm (.40 in.) diameter
bolt130-35Transaxle mounting bolt
[8 mm (.31 in.) diameter bolt]IO-12Tie rod end to knuckle
24-35
Lower arm ball joint to knuckle
60-72Bell housing cover
IO-123ear cover bolt
15-223ackup light switch
30-35
loppet plug30-42
jpeedometer sleeve bolt3.0-5.0nput shaft lock nut
140-160ntermediate lock nut
gear
140-160
3everse idler gear shaft bolt
43-55
rransaxle case tightening bolt
35-42
stopper bracket bolt
15-22
qestrict ball assembly30-35
ft.lbs.
13-2012-18
22-25
22-25
20-2543-58
3-5
7-10
7-1012-19
11-16
11-1643-58
11-16
7-1032-39
22-25
7-9
17-25
43-52
7-9
11-1522-25
22-302.5-3.5
102-I 15
102-11532-39
26-3011-15
22-25

MANUAL TRANSAXLE - Specifications
ItemsNm
ftlbs.Reverse shift lever assembly attaching bolt
15-2211-15
Bearing retainer bolt15-2211-15
Differential drivegear
bolt
130-14094-101Interlock plate bolt
20-2715-19
Select lever assemblymountingbolt15-2211-15
LUBRICANTS
NZlCD-A
ItemsManual transaxle oil
Drive shaft oil seal lipSpecified lubricant
MOPAR Hypoid gear oil or equivalent
API classification GL-4 or higher
MOPAR Hypoid gear oil or equivalent
API classification GL-4 or higherQuantity lit. (qts.)
1.8 (1.9) 2.2 (2.3)’
As required
Shift lever bushingMOPAR Front Wheel Bearing Grease
Part No. 3837794 or equivalentAs required
SEALANTS AND ADHESIVES
NZlCE-A
IItemsSpecified sealants and adhesivesITransaxle case-clutch housing mating surfacesMitsubishi genuine Part No.
MD997740 or equivalent
Transaxle case-rear cover mating surfaces
Differential drive gear bolts
Bearing retainer screw (flush head screw)MOPAR Part
No.4318031 or MOPAR Part No.4318032or equivalent
Air breather
IMOPAR Part
No.4318025 or equivalent

21-12 MANUAL TRANSAXLE - Special Tools/Troubleshooting
I
IICPintermediate shaft lock nut
MD998819Installer adapterInstallation of differential case bearing
TROUBLESHOOTINGNZlEAABsSymptomVibration, noise
3il leakage
Hard shift
Jumps out of gearProbable causeRemedy
a. Loose or damaged transaxle anda. Tighten or replace mounts
engine mounts
b. Inadequate shaft end playb. Correct end play
c. Worn of damaged gears
c. Replace gears
d. Use of inadequate grade of oild. Replace with specified oil
e. Low oil level
e. Replenish
f. Inadequate engine idle speed
f. Adjust idle speed
a. Broken or damaged, oil seal or O-ringa. Replace oil seal or O-ring
a. Faulty control cable
a. Replace control cable
b. Poor contact or wear of synchronizer ring
and gear coneb. Correct or replace
c. Weakened synchronizer springc. Replace synchronizer spring
d. Use of inadequate grade of oil
d. Replace with specified oil
a. Worn gear shift fork or broken poppet
springa. Replace shift fork or poppet spring
b. Synchronizer hub to sleeve spline
clear-ante too largeb. Replace synchronizer hub and sleeve

21-20MANUAL TRANSAXLE - Transaxle
9-13 Nm7-10
ftlbs.
I
30-35 Nm
IO-12 Nm Ld7-9 ft.lbs.
60-72 Nm
,!24-35 Nm
17-25 ft.lbs.
+I)IO. Under cover11. Cotter pin
+I)12. Connection for tie rod end
13. Self-locking nut
**14. Connection for lower arm ball joint+I) l I 15. Connection for drive shaft
16.
Circlip17. Bell housing cover
18.
iT,nsaxle assembly lower part coupling
W e+ 19. Transaxle assembly
NOTE(1) Reverse the removal procedures to reinstall.(2) +e: Refer to “Service Points of Removal”.(3) ~~ : Refer to “Service Points of Installation”.(4) m : Non-reusable parts

MANUAL TRANSAXLE - Transaxle Assemblv 2743
TRANSAXLE ASSEMBLY
.._DISASSEMBLY AND REASSEMBLYN21ME-A
__
30-42 Nm22-30 ft.lbs.30-35 Nm22-25 ftlbs.q l4
ig5 !
----7m
IQ15-22 Nm
II-15 ft.lbs.
4.0-5.5 Nm2.9-3.9 ft.lbs.1I”I
a
140-160 Nmf
102-115 ft.lbs.
Disassembly steps
1. Bolt
l + 2. Rear cover
3. Wave spring
l 4. Screw bolts
5. Reverse brake cone
6. Backup light switch
7. Gasket
8. Poppet plug
9. Poppet spring
10. Poppet ball
11. Bolt
12. Speedometer driven gear assembly
l * 13. Air breather
*I) l * 14. Spring pin+I) l * 15. Lock nut
140-160102-115
TFMOOl6
+e I)+ 16. Lock nut
17. 5th speed synchronizer assembly
18. 5th speed shift fork
19. Synchronizer ring
20. 5th speed gear
21.Needle
bearing
22. 5th speed intermediate gear
NOTE(1) Reverse the disassembly procedures to reasseinble.
(2) ++ : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of ReaSsembly”:(4) m : Non-reusable parts

21-26 MANUAL TRANSAXLE - Transaxle Assembly
SERVICE POINTS OF DISASSEMBLY
14. REMOVAL OF SPRING PINIMD99801 9\I
NZlMFARRemove the spring pin using the special tool.
Bolt10 mm
15.116. REMOVAL OF LOCK NUTS(1) Unstake lock nuts of the input shaft and intermediate
gear.(2) Shift the transmission in reverse using the control lever
and select lever.
(3) install the special tool onto the input shaft.
(4) Screw a bolt [IO mm] into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(5) Remove the lock nut, while using the bolt as a spinner
handle stopper.45./46.
REMOVAL OF SPRING PINS
Remove the spring pins for 1 st-2nd and 3rd-4th speed shiftforks using the pin punch.