service MITSUBISHI ECLIPSE 1991 Service Manual

STEERING - Power Steering Oil Pumt,DISASSEMBLY AND REASSEMBLY
137~.-
Oil pump seal kitOil pump cartridge kitOil pump pulley and shaft kit18-22 Nm
13-16
ft.lbs.50-70 Nm36-51 ft.lbs.
1
I\=--=x=-T--
6-10 Nm
4-7
ft.lbs.--
25-30 Nm ’16-22 ft.lbs.
\13A0351
25m29Disassembly steps
I)+1.Pumpcover
l + 2. O-ring
l 43.Cam ringl 44.Vanes
l + 5. Snap ring
l 46.Rotor
4*7. Pulley assembly
l 8. Side plate
I)+9.O-ringl a 10. O-ring11,Suction connectorl + 12. O-ring+4 13. Oil seal14.Connectorl + 15. O-ringl + 16. Flow control valve
17. Flow control spring
18.Terminal assembly
19.Snap ring
20.Terminal
21.Washer
22.Insulator
l + 23. O-ring24.Plug
l25.O-ring
l26.Spring
27.Plunger
28.Piston rod
29. Oil pump body
FyEeverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

19-42STEERING - Power Steering Oil Pump
13A0279SERVICE POINTS OF DISASSEMBLY
NleRFAM7. REMOVAL OF PULLEY ASSEMBLY
%
Tap the rotor side of the shaft lightly with a plastic hammer,,,~and take out the pulley assembly.
INSPECTION
NlSRGAK0 Check the flow control spring for wear.0 Check the shaft of the pulley for wear and bend.0 Check the groove of rotor vane for “stepped” wear.0 Check the contact surface of cam ring and vanes for
“stepped” wear.0 Check the vanes for breakage.
CHECK OF GAP BETWEEN VANE AND ROTOR GROOVE
Install vane to rotor groove as illustrated. Measure the gap
between vane and rotor groove with thickness gauge.
Limit: 0.06 mm
(.0024 in.)?ACHECK OF SHAFT BACKLASH OF PUMP BODY BUSHING
AND PULLEY ASSEMBLY
(1) Place a dial gauge at the end of the shaft of the pulley
assembly.
(2) Move the pulley assembly up and down, and measure theplay.
Limit: 0.1 mm
I.004 in.)
SERVICE POINTS OF REASSEMBLY
NlSRHBH26. INSTALLATION OF SPRING
Fit the spring to the oil pump body with the larger-diameter
end at the terminal assembly side.
A.

19-46STEERING - Power Steering Hoses
POWER STEERING HOSESREMOVAL AND INSTALLATIONNlSTA-
Pre-removal Operationl C+?ing of the Power Steering
,‘; ,L..,.,.):. ,4-14 NmwaI. . .-...5-10 ft.lbs.7
I9-14 NmI7 7-10 ft.lbs.
Post-installation Operationl Supplying of the Power Steering-.
1 Fluid
l Bleeding of the Power Steering
Fluid Line(Refer to P.19-13.1,621 N/-@b
K
2
3.0-4.5 Nm /2-3 ft.lbs.I/II z-”a.
413A0274
Removal steps
1.Returnhose2.Suctionhose
3.Returnhose4. Cooler tube
5. Return tube
6. Rubber hose
.a 7. Pressure hose
8.Pressure tube9.Return tube
10.O-ring
NOTE(1) Reverse the removal procedures to reinstall.
(2) l a : Refer to “Service Points of Installation”.(3) q : Non-reusable partsWhite lineUP0143SERVICE POINTS OF INSTALLATION
NlSTDAD7. INSTALLATION OF PRESSURE HOSE
(1) Connect the pressure hose so that its slit pat-t contacts
the oil pump’s guide bracket.
(2) When the pressure hose is installed, align the white line
on the pressure hose with the white line on the pressuretube so that together they form a straight line.

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
SPECIFICATIQNS
3ENERAL SPECIFICATIONS
ItemsModel
Applicable engine
TypeGear ratio
1 st2nd3rd
4th5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
SERVICE SPECIFICATIONShl22CBA
”
.,NZlCA-ASpecifications
1TF5M22-1
-VFWF5M22-2-VPZV
46374G63-DOHC
5-speed transaxle5-speed transaxle
floor shiftfloor shift
3.363
3.363
1.947
1.9471.285
1.285
0.9390.939
0.756
0.7563.0833.083
4.3224.322
29136291361.8 (1.9)1.8 (1.9)
F5M33-2-SPA!4G63-DOHC (Turbo)5-speed
trzinsaxlefloor shift.-~,3.090
1.833
1.217
0.888
0.7413.166
4.153
291362.2 (2.3)
ItemsStandard value
Transaxle
Input shaft end play
Input shaft front bearing end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
LimitSpecifications
o-0.05 (O-.002)
0.01-0.12 (.0004-.005)
0.01-0.09 (.0004-.004)
0.01-0.14 (.0004-,006)
0.05-0.10 (.002-.004)
0.05-0.10 (.002-.004)
0.05-0.10 (.002-.004)
0.025-0.150 LOO1 -.006)mm (in.)
Synchronizer ring and clutch gear clearance0.5 (.02)

MANUAL TRANSAXLE - Service Adjustment Procedures21-13
II
\
;‘:,
\;
\
\I00”011009FOli
I
I09K56i
09K56f
,
SERVICE ADJUSTMENT PROCEDURESN21FBABlTRANSAXLE OIL LEVEL INSPECTION
Refer to GROUP O-Maintenance Service.
TRANSAXLE OIL REPLACEMENT
NZlFCADa(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transaxle oil to
drain.(3) Refill the transaxle to the proper level with specified
transaxle oil. The oil level should be the bottom of the oil
filler hole.
Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or hiqher
1.8 liters (1.9 qts.)
2.2 liters ‘(2.3 qts.)DRIVE SHAFT OIL SEALS REPLACEMENT
NZlFDACa
(1) Disconnect the drive shaft from the transaxle.
(Refer to GROUP
2-Drive Shaft.)
(2) Using a flat-tip
(-) screwdriver, remove the oil seal.
(3) Using the special tool, tap the drive shaft oil seal into the
transaxle.
(4) Apply a coating of the transaxle oil to the lip of the oil seal.Transaxle oil: MOPAR Hypoid gear oil or equivalent
API classification
GL-4 or higher

21-14 MANUAL TRANSAXLE -Service Adjustment Procedures
I-Adapter%A0905SPEEDOMETER CABLE REPLACEMENT
NZlFEAKl
1.Correctly insert the adapter into the instrument panel, andS.
fasten the new speedometer cable.1-
2.Install the grommet so that, as shown in the illustration, the
cable attachment is positioned upward.Caution
1.The cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
2.The arrangement of the speedometer cable should
be such that it does not interfere with other
parts.
3. At the transaxle end of the speedometer cable, the key
joint should be inserted into the transaxle, and the nut
should be securely tightened.Caution
lllcIf the cable is not correctly and securely connected, it
may cause incorrect indication by the speedometer, or
abnormal noise. Be sure to connect it correctly.

MANUAL TRANSAXLE - Transaxle Control2M5
TRANSAXLE CONTROL
-^ REMOVAL AND INSTALLATION
Removal steps1. Plug
2. Side cover (A)
3. Side cover(B)
4. Cover(B)
N21JA-A
919AO349
9-14 Nm .
+-
0
0OQA017412. Cotter pin
13. Retainer
14. Retainer
15. Cotter pin
9-14 Nm7- 10 ftlbs.5. Manual transaxle shift lever knob
6. Cup holder
7. Carpet
8. Connection for floor console wiring
I)4 16. Shift cable
I)+ 17. Select cable
18. Shift lever assembly
harness
9. Guide ring
10. Shoulder belt
11. Floor console
NOTE(1) Reverse the removal procedures to reinstall.(2) *a : Refer to “Service Points of Installation”.(3) m : Non-reusable parts

21-16MANUAL TRANSAXLE - Transaxle Control
INSPECTIONN21JcAD
ICBA0160 1Incorrect
5I,I
-ri
IIIncorrect
1,-I I,,1 :
Sele’ctcableFlange side
yof the resin LbushingLever
&OSAOl72l Check the select
cable for funct,ion and for damage.
l Check the shift cable for function and for damage.
l Check the boot for damage.
l Check each bushing for wear or abrasion, sticking,
impeded action, and damage.
l Check the spring for deteriorated strength.
SERVICE POINTS OF INSTALLATION
NZlJDAK17. INSTALLATION OF SELECT CABLE
(1) Move the transaxle shift lever to the neutral position.
NOTEThe select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral
position.(2) Move lever
(6) to the neutral position.
(3) Adjust, by using the adjuster, so that the end of the
select cable is positioned as shown in the illustration
relative to lever
(B).
k,I.,,(4) The flange side of the resin bushing at the select cable
end should be at the lever
(B) end surface.
A.

21-18MANUAL TRANSAXLE - Shift Lever Assembly
SHIFT LEVER ASSEMBLYDISASSEMBLY AND REASSEMBLY
19-28
Nm14-20 ft.lbs.
Disassembly steps
1.Shift lever
e+2.Bushing
*q~ 3. Return spring
1)44.Bushing
5.Lever (A)
*47.;;;;;w
I)+8:Bushing9.Snap ring
10.Lever (B).+ 11. Bushing12.Bracket assembly17-26
09A0173
NOTE(1) Reverse the disassembly procedures to reassemble.
(2) l +
: Refer to “Service Points of Reassembly”.
: Non-reusable parts.
i%s.SERVICE POINTS OF REASSEMBLY
NZlGHAP
11./8./6./4,/3./2. APPLICATIONOF GREASE TO
BUSHINGS
Apply multi-purpose grease to the sliding part of the
bushings shown in the figure.
Grease: MOPAR Front Wheel Bearing
Grease Part No.3837794 or equivalent
3. INSTALLATION OF RETURN SPRING
Make sure that the end of the spring contacts the part
(shown in the illustration) of the bracket.