clutch MITSUBISHI ECLIPSE 1991 Workshop Manual

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

MANUAL TRANSAXLE - Transaxle Contid
erShift
lever
09A0159
09A016t16. INSTALLATION OF
SHIFT CABLE
(1) With the select lever in neutral, move the transaxle shift
lever (in the direction shown in the illustration) to set it
to
4th gear.
NOTE
If the shift lever does not move easily, depress and holdthe clutch pedal.
(2) Move the shift lever (at the vehicle interior side)
downward, in the direction
(4th gear position) shown in
the illustration until it contacts the stopper.
(3) Adjust, by using the adjuster, so that the end of the shiftcable is positioned as shown in the illustration relative
to the shift lever (interior side).
(4) The flange side of the resin bushing at the shift cable
end should be at the split pin side.
(5) Adjust the length of the shift cable, by using the
adjuster, so that the clearance (A) and
(B) between the
shift lever and the two stoppers are equal when the
shift lever is shifted to
3rd gear and 4th gear.
(6)Move the shift lever to each position and check that theshifting is smooth.

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.

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

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.

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.

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.

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.

MANUAL TRANSAXLE - Transaxle Assembly 2%3T
IMD998245(5)
Insert a Phillips screwdriver [8 mm (.32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt
hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten the
bolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
(8)
E$r& the reverse idle gear shaft bolt to specified
torque.
15./ 16. INSTALLATION OF LOCK NUTS(1) Install the special tool to the splined end of input shaft.
(2) Screw a bolt
(10 mm) into the hole on the periphery of
clutch housing and attach a spinner handle to the
special tool.
(3) Shift the transmission in reverse using control lever andselect lever.
(4) Tighten the lock
nut,to specified torque, while ‘using the
bolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
14. INSTALLATION OF SPRING PIN(1) Install the spring pin using the special tool or a pin
punch.
Caution
Do not reuse the spring pins.