differential MITSUBISHI ECLIPSE 1991 Workshop Manual

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 - General Information214
F5M22 (4G63 Engine)
Clutch housing
Bearrin
‘. ;
lg retainer
2nd speed gear
1st speedgear
1 st-2ndspeed
synchro-
I,
nizerassembly
3rd speed gear
3rd-4th speed synchronizer assembly4th speed gear
5th speed gear
5th speed
/
synchronizerassembly
Rear cover
,Reverse gear.norse-preventron
device
SpacerOutput shaft
Spacer‘Differential drive gear
SpacerDrain plug
TFMOOI 1

21-4MANUAL TRANSAXLE - General Information
F5M33Clutch housing
Bearing retainer
2nd
1st speed
sPteed gear
3rd speed gear
ge’-
l--z& , I ii’Input shaft
3rd-4th speed synchronizer assembly
4th speed gear
I5th speed gear
1 st-2nd
speed
synchro-
nizerassembly
I
5th speed
/
synchronizerassembly
cRear cover
Reverse gear
noise-prevention
deviceIntermediate gear
- Outputshaft
‘Differential drive gear
Spacer
Drain plug
/Differentral
TFMOO25

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)

21-8MANUAL TRANSAXLE - Specifications
Part name
Spacer
(For adjustment of output shaft preload)spacer(F5M33)
For adjustment of output shaft preload)
ipacer'or adjustment of differential case preload)Thickness mm (in.)
~dyemnt$j~at'on0.92
(0362)92
0.95
(0374)95
0.98 (.0386)98
1 .Ol t.0398)
011.04 (.0409)041.07 (.0421)071.10
(0433)101
.I3 (0445)13
1 .16 (0457)161
.I9 (0468)191.22 (.0480)22
1.25 (.0492)25
1.28
(0504)28
1.31
(0516)311.34 (.0527)34
0.83
(0327)83
0.86
(0338)86
0.89
(0350)89
0.92
(0362)92
0.95 (.0374)95
0.98
(0386)98
1 .Ol
l.0398)011.04 (.0409)041.07
(0421)07
1 . 10 (.0433)J1
.I3 (0445)D1.16 (.0457)
K1
.I9 (0468)L1.22 (.0480)
G1.25 (.0492)M
1.28 (.0504)
N1.31 (.0516)
E1.34 (.0527)0
0.80 (.0315)80
0.83 (.0327)83
0.86 (.0338)86
0.89
(0350)89
0.92 (.0362)92
0.95 (.0374)95
0.98 (.0394)98
1 .Ol t.0398)011.04
i.0409)041.07 (.0421)07
1
.I0 (0433)J1
.I3 (0445)D1
.I 6 (.0457)K
1 .19 (0468)LPart No.
MD720952
MD720953
MD720954
MD720955
MD720956
MD720957
MD720958
MD720959
MD720960M
D720961
MD720962
MD712346MD71 2347M
D7 12348MD71 2349
MD720937M
D720938
MD720939
MD720940MD720941
MD720942
MD720943M
D720944
MD720945
MD710454
MD700270MD71 0455
MD710456MD700271
MD710457
MD710458
MD706574
MD710459MD727661
MD720937
MD720938
MD720939M
D720940MD720941
MD720942
MD720943
MD720944
MD720945MD71 0454
MD700270
MD710455
MD710456

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

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 Asshmblv 21-23TFM0006
47./48. INSTALLATION OF SHIFT RAILS AND FORKS(1) Set the
lst-2nd speed shift sleeve at 2nd Speed.
(2) Set the
3rd-4th speed shift sleeve at 4th spe$d.(3) Fit the shift forks of shift rail assembly to groove of
sleeves.(4) Insert the shift rails into the shift rail holes of clutch
housing.(5) Turn the shift rails in the directions indicated by the
arrows in the order shown in the illustration, and
engage the shift lugs to control finger and interlock
plate.
45.146. INSTALLATION OF SPRING PINS
Install the spring pins using the special tool or a pin Punch.When installing, make sure that the slit of the spring pin is
aligned with the shift rail center line.
Caution
Do not reuse the spring pins.
35.137.139. SELECTION OF SPACERS
(1) Place two pieces of solder measuring about Ia mm (.4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races of intermediate
gear and differential.
(2) With a solder puddle measuring
10 mm (.39 in.) long
and 1.6 mm (.06 in.) across on the transaxle case at thelocation shown in the figure, install the
bearing outer
race of the shaft.
(3) Install the transaxle case and tighten the bolts to
specified torque.
(4) Remove the transaxle case.
(5) Remove the outer races and take out the crushed
solder.(6) If the solder is not broken, carry out the work in steps
(l)-(5) with large diameter solder.