service MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE -Front Output Shaft Assembly 9‘1.~105
FRONT OUTPUT SHAFT ASSEMBLY”,I N21MKAF
- DISASSEMBLY AND REASSEMBLY,’
2
Disassembly stepsl
*a1. Taper roller bearing+* l +2. Taper roller bearing
3. Front output shaftReverse thedisassemblyproceduresto reassemble.4*: Refer to “Service Points of Disassembly”.l 4: Refer to “Service Points of Reassembly”.2200075
SERVICE POINTS OF DISASSEMBLY
1./2. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearing.
Caution
1. Do not reuse the bearing if it has been,, removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
SERVICE POINTS OF REASSEMBLY
2. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, press-fit the taper
rbller bearing into
position.Caution
Apply the special tool to the inner race’ only when
installing the bearing.
1. INSTALLATION OF TAPER ROLLER BEARINGS
Using the special tool, press-fit the taper roller bearing into
position.Caution
Apply the special too! to the inner race only when
installing the bearing.

21-106MANUAL TRANSAXLE - Front Differential
FRONT DIFFERENTIAL
DISASSEMBLY AND REASSEMBLY
NZIMMAG
i;&
Disassembly stepsl + 1. Bolt
2. Differential drive gear
** l +3. Ball bearing+* l * 4. Lock pinI)+ 5. Pinion shaft
l * 6. Pinion
I)+ 7. Washer
l + 8. Sidegear
95-lOl ft.lbs.l * 9. Spacer10. Differential case
NOTE(I)Reverse the disassembly procedures to reassemble(2)C*: Refer to “Service Points of Disassembly”.(3)l +: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.
:&
-_-
160015
Press
teal case 2200095
SERVICE POINTS OF DISASSEMBLY3. REMOVAL OF BALL BEARING
Using the special tool, remove the ball bearing.
Caution
Do not reuse the bearing if it has been removed from
the differential case.
4. REMOVAL OF LOCK PIN
Drive out the lock pin from hole A using a punch.

MANUAL TRANSAXLE - Front Differential21-107SERVICE POINTS OF REASSEMBLY
9. INSTALLATION OF SPACER
! 8. SIDE GEAR / 7.
WASHER
/ 6. PINION / 5. PINION SHAFT
(1) Fit a spacer on to the back of the side gear and then
install the gear in the differential case.
Caution
When a new side gear is used, use a spacer of
intermediate thickness
[0.93-l .OO mm (.0366-
.0394 in.)]
160124Differential case
PinionshaftLot\ pin\-I\m Dir&ion ofInstallation
‘$ IS more chamtereXSide of lock pi? d,
II II2200096
MD99881 2
MD99881 9
TFMOOOE(2) Place a washer at the back of each of the two pinions
and insert the two pinions at the same time, meshing
them with the side gear and rotating them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gear and
pinion.Standard value: 0.025
- 0.150 mm (.OOOl - .0060 in.)
(5) If the backlash is out of specification, disassemble and
reassemble the gears with a new spacer.
Caution
Adjust to provide the same backlash for both side
gears.4. INSTALLATION OF LOCK PIN
Align the lock pin hole in the pinion shaft with that in the
case and press the lock pin into position.
Caution
1. Do not reuse the lock pin.
2.Make sure that the lock pin head is lower than the
differential case flange surface.
3. INSTALLATION OF BALL BEARINGS
Install the ball bearings in both sides of the differential case.

,-’ DISASSEMBLY AND REASSEMBLY
II-
Disassembly steps1.
3rd-4th speed shift fork
2.
1
st-2nd speed shift
fork
3.
1 st-2nd speed shiftrail4. 5th-Rev. speed shift raill 45.
interlock plunger
6.
3rd-4th speed shift railNOTE7. Reverse shift lug(1)Reverse the disassembly procedures to reassemble.(2)l 4: Refer to “Service Points of Reassembly”.-
\3rd-4th speed shift rail201088210027
SERVICE POINTS OF REASSEMBLY5. INSTALLATION OF INTERLOCK PLUNGER
Fit the interlock plunger into the position shown in
3rd-4thspeed shift rail.

21-I 10MANUAL TRANSAXLE - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLYNPlMJAR
DISASSEMBLY AND REASSEMBLY
j”r:
Disassembly steps
** 1. Snap ringl * l +2. Taper roller bearing
l * 3. Bearing sleeve
l *4. 1 st speed gear
5. Needle bearing
l a6. Synchronizer ringl +7. Synchronizer springl a8. 1 st-2nd speed synchronizer sleeve
l *9. Synchronizer keyw l a IO. 1 st-2nd speed synchronizer hub
l * II. Synchronizer ringa*12. 2nd speed gear
13. Needle bearing
l * l * 14. Taper roller bearing
15. Intermediate gearNOTE(I) Reverse the disassembly procedures to reassemble.Ah..(2)+*: Refer to “Service Points of Disassembly”.(3)l C: Refer to “Service Points of Reassembly”.(4)q : Non-reusable parts.

MANUAL TRANSAXLE - intermediate Gear Assembly21’-111
MD998801
I
70106:
Sphnes201065
SERVICE POINTS OF DISASSEMBLY
2.REMOVAL OF TAPER ROLLER BEARING / 4. IST SPEED
GEARUsing the special tool, remove the taper roller bearing, the
1st speed gear, and the bearing sleeve.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
10. REMOVAL OF
IST-2ND SPEED SYNCHRONIZER HUB /12. 2ND SPEED GEAR
Using the special tool, remove the lst-2nd speed synchro-
nizer assembly and
2nd speed gear.
14. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing.
Caution
1. Do not reuse the bearing if it has been removed
from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
INSPECTIONINTERMEDIATE GEAR
l
Check the outer surface of the intermediate gear where the
needle bearing is mounted for damage; abnormal wear, andseizure (portion
@I.l Check splines for damage and wear.

-.
MANUAL TRANSAXLE - Intermediate Gear Assemblv21-113
D99835021002:
r$J$ch housingc
prorruslon
Sprinprotrusion
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough surface, damage,
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY14. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the taper roller bearing overthe intermediate gear.
Caution
Apply pressure with the special tool only to the inner
race when installing the bearing.
11. / 6. INSTALLATION OF SYNCHRONIZER RINGNote the identification mark made on the
1st speed
synchronizer ring.
10. INSTALLATION OF lST-2ND SYNCHRONIZER HUB / 9.
SYNCHRONIZER KEY
/ 8. lST-2ND SYNCHRONIZER
SLEEVE
/ 7. SYNCHRONIZER SPRING
(1) Mate the 1 st-2nd speed synchronizer hub and sleeve asshown.
(2) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key.
Caution-Make sure that the protrusions in the front and rear
springs are not in the groove of the same key.
NOTEA synchronizer spring different from the one shown in
the figure may be used but the explanation is the same.

MANUAL TRANSAXLE - Input Shaft Assembly21-115
INPUT SHAFT ASSEMBLY-- DISASSEMBLY AND REASSEMBLYNZlMlASa
18
Disassembly steps
+e I)+I. Taper roller bearing~~ I)4 2. Bearing sleeve
*4 3. Snap ring
+e I)+ 4. Taper roller bearing
5.
4th speed gear
6. Needle bearing
I)+ 7. Bearing sleeve
8. Synchronizer ring
I)+ 9. 3rd-4th speed synchronizer assembly++ IO. Synchronizer spring11. 3rd4th speed synchronizer assembly
12. Synchronizer key
13.
3rd-4th speed synchronizer hub
14.Synchronizer ring
4*15. 3rd speed gear++ 16. Snap ring
+* 17. Cone spring+4 18. Sub gear19.Needle bearing
20.
Input shaft
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) +* : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts.

21-116MANUAL TRANSAXLE - Input Shaft Assembly
c
SERVICE POINTS OF DISASSEMBLY1. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the front bearing.
2. REMOVAL OF BEARING SLEEVE
Remove the bearing sleeve using the special tool as
illustrated.4. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the bearing sleeve and rear
bearing.15. REMOVAL OF
3RD SPEED GEAR;;c.Using the special tool, remove the bearing sleeve,
3rd-4thi”-speed synchronizer assembly, and
3rd speed gear.
INSPECTIONINPUT SHAFT
l
Check the outer surface of the input shaft where the needlebearing is mounted for damage, abnormal wear, and
seizure (portion
&I).l Check the splines for damage and wear.h
4

MANUAL TRANSAXLE - Input Shaft Assemblylama
vear210018
Springprotrusion
Key
201001::
TFM0023
SPEED GEARSl Check the bevel and clutch gear teeth for damage and
.6
wear.l Check the synchronizer cone for rough surfaces, damage,
-‘and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POlNTS OF REASSEMBLY18. INSTALLATION OF SUB
GEAR/17. CONE SPRING/16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, andthen install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing inthe correct direction.
10. INSTALLATION OF SYNCHRONIZER SPRINGS
(1) Install the synchronizer spring so that its protrusion fits
into the groove in synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
in,groove of the same key.
9. INSTALLATION OF
3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTEIf the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter
spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Using the special tools, press-fit the
3rd-4th speed
synchronizer assembly over the input shaft.
Caution
1. When installing the synchronizer assembly,
make sure that the three synchronizer keys are
seated correctly in their respective grooves in
the synchronizer ring.
h2. After installing the synchronizer assembly, --
check to see if the
3rd speed gear rotates
smoothly.