oil MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE - Transaxle21-19
TRANSAXLE
- REMOVAL AND INSTALLATIONNZlMA-A
. .
,-27-34 Nm
20-25 ft.lbs.15-22 Nm
11-16
ft.lbs.43-55 Nm
32-39
ft.lbs.
\
60-80 Nm*43-58 ft.lbs.*60-80 Nm
/da-,, ft.lbs.
lo-12 NmI7-9
ft.lbs.I
15-2: Nm
11-16 ft.lbs.OOAOl~4
Pre-removal Operation@Removal of the Battery
rl Draining of the Transaxle Oil (Refer to
P.21-13.)l Removal of the Air Hose(Refer to GROUP 11-Air Cleaner.)
Post-installation 0erationl installation of theI!attery
l supplying of Transaxle Oil (Refer to P.21-13.)*Installation of the Air Hose
(Refer to GROUP 11 -Air Cleaner.)
l checking the Operation of the Shift Lever
l checkina the Ooeration of the Meters and Gauges
Removal steps
1. Cotter pin
2. Connection for select cable
3. Connection for shift cable
4*4. Connection for clutch release cylinder
5. Backup light switch connector
6. Connection for speedometer cable
I)* 7. Starter
8.
Lfrsaxle assembly upper part coupling
9. Transaxle mount bracket
ZKeverse the removal procedures to reinstall. ” ’(2) W : Refer to “Service Points of Removal”.
(3) ~~ : Refer to “Service Points of Installation”.
(4) m : Non-reusable parts
(5)For tightening locations indicated by the * symbol, fjrst
tighten temporarily, and then make the final tightenrngwith the entire weight of the engine applied to the
vehicle body.
(6)If therease has been wiped from the input shaft spline
or if taeinput shaft has been replaced, apply specralgrease (MOPAR Multi-mileage Lubricant Part
No.2525035 or equivalent) to the input shaft Spline.

MANUAL TRANSAXLE - Transaxle’
---
-..
2) ’TransaxlellK611
SERVICE POINTS OF REMOVALNlZMBAR4. DISCONNECTION OF CLUTCH ‘RELEASE CYLINDER
FROM TRANSAXLE ASSEMBLY
Remove the clutch release cylinder and clutch oil line
bracket installation bolt, and then secure at the
! body side
without disconnecting the oil line coupling.
”
10. REMOVAL OF UNDER COVER
Lift the vehicle before removing the under cover.
12. DISCONNECTION OF TIE ROD END FROM KNUCKLE
Using the special tool, disconnect the tie rod end from the
knuckle.Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
14. DISCONNECTION OF LOWER ARM BALL JOINT
Using the special tool, disconnect the lower arm ball joint
from the knuckle.
Caution
1. Be sure to tie the cord of the special tool to the
nearby part.
2. Loose the nut but do not remove it.
I15. DISCONNECTION OF DRIVE SHAFT
(1)
Insert a pry bar between the transaxle case and the
drive shaft, and then pry the drive shaft
~from the
transaxle.Caution
1. Do not pull on the drive shaft; doing so will
damage the inboard joint; be sure to use the pry
bar.2. Do not insert the pry bar so deep as to damaged
the oil seal.
(2) Keep the removed drive shaft as far away from the
transaxle case as possible, and secure (by using rope,
etc.) the joints to the body so that it does not fall.

21-22MANUAL TRANSAXLE - Transaxle
1 Transaxleside1 Radiator lower hose
1 Transaxle side1 Radiator lower hosepart ofdrive shaft
I
-Transaxle
09LOO5819. REMOVAL OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
+Gthe lower hose of the radiator with the end of the
’transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
Support the transaxle assembly by using a transaxle jack;
then, after moving the transaxle assembly to the right,
lower it.
NOTEWhen supporting the transaxle assembly by the transaxle
jack, take care to be sure that the jack’s force is applied to awide area, not to only a small localized area.
SERVICE POINTS OF INSTALLATION
NZlMDAP19. INSTALLATION OF TRANSAXLE ASSEMBLY
Caution
On the turbo vehicle, take care to prevent damaging
Athe lower hose of the radiator with the end of the
-transaxle housing.
As a protective countermeasure, wind tape around the
lower hose and the transaxle housing at the positions
shown in the figure.
15. INSTALLATION OF DRIVE SHAFT
(1) Provisionally install the drive shaft so that the inboard
joint part of the drive shaft is straight, and not bent
relative to the transaxle.
Caution
Care must be taken to ensure that the oil seal lip
part of the transaxle is not damaged by the serratedpart of the drive shaft.
(2) Align the serrations and securely insert the drive shaft
into the transaxle.
7. INSTALLATION OF STARTER
Tighten the starter installation bolts with the wiring harness
clip and the ground cable.

21-24MANUAL TRANSAXLE - Transaxle Assemblv 48
3e42 Nm22-30 ft.lbs.30-35
NmI
122-25 ft.lbs.26
2527
1!&22 Nm\
\
Disassembly steps23. Reverse idler gear shaft bolt
24.Gasket25.Bolt++ 26. Transaxle casel + 27. Oil guide
28.Bolt
29.Spring washer30.Stopper bracket
31. Restrict ball assembly
32.Gasketl 433.Oil seal
34. Bearing outer race
+*35.Spacer
36. Bearing outer race
l * 37. Spacer38. Bearing outer race
l + 39. Spacer40. Bolt41. Reverse shift lever assembly
42. Reverse shift lever shoe
43. Reverse idler gear shaft
44. Reverse idler gear
+I) l 4 45. Spring pin~~ ~~ 46. Spring pin+* l + 47. Shift rails and forks+* l 48. Shift rails and forks
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +* : Refer to “Service Points of Disassembly”.(3) l * : Refer to “Service Points of Reassembly”y(4) m : Non-reusable parts

MANUAL TRANSAXLE - Transaxle Assembly
2i &
15-22 Nm50 11-15 ft.lbs.
Disassembly steps
l +49. Bolt50. Screw
51. Bearing retainer
+e l + 52.Intermediate gear assemblyl + 53.Input shaft assembly54. Output shaft assembly
55. Differential gear assembly
56. Bearing outer race57. Oil guide
58. Bearing outer race
59. Bearing outer race
l 4 60. Oil seal
W 61. Oil seal
62. Magnet
63. Magnet holder
64. Clutch housing assembly
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.(3) e+ : Refer to “Service Points of Reassembly”.
(4) m : Non-reusable parts
21421

MANUAL TRANSAXLE - Transaxle Assemblv 21-27
206001E
47./48. REMOVAL OF SHIFT RAILS AND FORKS’(1) Shift the Ist-2nd speed shift fork to the
2nd speed.
(2) Shift the
3rd~4th speed shift fork to the 4th speed.
(3)Rotate the the shift controls in the direction of the arrowin numerical order. Remove the shift lugs from the
control finger and interlock plate.
(4) Raise each of the shift rails upward and remove them
from the clutch housing.
(5) Remove the all shift rails and forks.
52. REMOVAL OF INTERMEDIATE GEAR ASSEMBLYLift up the input shaft assembly and remove the intermedi-
ate gear assembly.
INSPECTION
BACKUP LIGHT SWITCH
N21MOdOperate the backup light switch to check continuity with a
circuit tester. If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLYN2mnGAU
61. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.

21-28MANUAL TRANSAXLE - Transaxle Assemblv
seal
201025Apply
adhesive
(.2 in.)TFMOO63
60. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
52. INSTALLATION OF INTERMEDIATE GEAR ASSEMBLY /
53. INPUT SHAFT ASSEMBLYLifting up the input shaft assembly, install it simultaneously
with the intermediate gear assembly.
49. APPLICATION OF ADHESIVE TO BOLTApply specified adhesive to the bolt threads.
CautionDo not apply to the bolt head.
Specified adhesive: MOPAR Part No.4318031or MOPAR Part
No.4318032
or equivalent

21-30MANUAL TRANSAXLE - Transaxle Assembly
2200048
IAmountl-2 mm(7) Measure the thickness of the crushed solder with a
micrometer and select a spacer of thickness that gives
standard
preload.,&
Standard value:
Intermediate shaft0.05-0.10 mm (.002-,004 in.)
Output shaft0.05-0.10 mm (.002-.004 in.)
Differential case0.05-0.10 mm (.002-,004 in.)
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and the differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outerrace and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gear
shaft’s head is facing in the direction indicated in the
illustration.
NOTEIf there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of thetransaxle case.
Specified sealant: MITSUBISHI GenuinePart
No.MD997740 or
equivalent
CautionB
Squeeze out sealant from the tube uniformly with- -
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.

21-34MANUAL TRANSAXLE - Transaxle Assembly
? ,‘,
30-35 Nm77-25 fLlbs.35-42 Nni26-30 ftlbs.
25
APi 77
--2lRl 26
\\15-22 Nm
---- -_ . .23
II-15 lt.lDS.
I
..d.. -Disassembly steps
23. Reverse idler gear shaft bolt24.Gasket
25.Bolt
l + 26. Transaxle case+4 ;I. ;$yrde
29:Springwasher30.Stopper bracket31. Restrict ball assembly
32.Gasketl 433.Oil seal34. Bearing outer racel * 35. Spacer
36. Bearing outer racel 437.Spacer38.Oil filter39. Bearing outer race32-39
ft.lbs.
TFMOlO9
l 4 40. Spacer41. Bearing outer race
I)* ;I. Sggcer
44: Reverse shift lever assembly
45. Reverse shift lever shoe
l + 46. Reverse idler gear shaft47. Reverse idler gear+e l + 48. Spring pinl * l + 49.Spring pin+I) l 50. Shift rail assembly
NOTE(I) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) e* : Refer to “Service Points of Reassembly”.(4) 19 : Non-reusable parts

_-MANUAL TRANSAXLE
- Transaxle Assembly 2%35
11-15 ftlbs.
5115-22 Nm
11-15
ftlbs.
l,451.Bolt
52.Bolt
53.Bearing retainer54.Intermediate gearassembly
55. Input shaft assembly
56. Output shaft assembly
57. Differential gear assembly
58. Bearing outer race
59. Bearing outer race60. Oil guide
61. Bearing outer race62. Bearing outer race
/’
62
+463.Oil seal+464.Oil seal
65.Magnet
66.Magnetholder67. Clutch housing assembly
; .,
FFkeverse the disassembly procedures to rdassembte.(2) ++ : Refer to “Service Points of Reassem’bly”.(3) m : Non-reusable parts