oil MITSUBISHI ECLIPSE 1991 Workshop Manual

3-26REAR AXLE - Differential Carrier
REASSEMBLYN0311-40-60
Nm*B-43 ft.lbs.*
80-90 Nm*58-65 ft.lbs.*

11 BOO86Differential gear setFinal drive gear set
Reassembly steps
1. Gear carrierl * 2. Oil seale+3. Drive pinion rear bearing outer racel +4. Drive pinion front bearing outer race
l *Adjustment of pinion height
5. Drive pinion
6. Drive pinion rear shim
(for pinion height adjustment)
7. Drive pinion rear bearing inner race8. Drive pinion spacer
l 4Adjustment of drive pinion preload9. Drive pinion front shim
(for preload adjustment)10. Drive pinion assembly11. Drive pinion front bearing inner race
12. Oil seal
13. Companion flange
14. Washer
15. Self-locking nut
16. Differential casellA0260llA0290
17. Limited slip (viscous coupling) differential
case
l *Adjustment of differential gear backlash
18. Side gear spacers
19. Side gears20. Pinion washers
21. Pinion gears22. Pinion shaft
l * 23. Lock pin
l + 24. Drive gear
+4 25. Side bearing inner race
26. Side bearing outer race
l 4Adjustment of final drive gear backlash
27. Side bearing spacers28. Differential case assembly
29. Bearing capsl 30. Vent plug
l
31. Differential cover
NOTE(I) I)+ : Refer to “Service Points of Reassembly”.[Z!/ m : Non-reusable parts.*: Tightening torque with oil applied.

REAR AXLE - Differential Carrier3-27
llK010
71
llY181llY182
.MB990836(MB990835)
llrm3
V223
SERVICE POINTS OF REASSEMBLYNOJUBD2. PRESS FITTING OF OIL SEAL
(1) With the special tool, press fit the oil seal until it is flushwith the end of the gear carrier.
(2) Apply multipurpose grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
3. lNSTALLATlON OF DRIVE PINION REAR BEARING
OUTER RACE/4. DRIVE PINION FRONT BEARING
OUTER RACE
Press-fit the drive pinion rear and front bearing outer racesinto the gear carrier by using the special tools.
CautionBe careful not to press in the outer race at an angle.
l ADJUSTMENT OF PINION HEIGHT
Adjust the drive pinion height by the following procedures:
(1) Install special tools and drive pinion front and rear
bearing inner races on the gear carrier in the sequenceshown in the illustration.
NOTEApply a thin coat of multipurpose grease to the mating
face of the washer of the special tool.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
(2) Tighten the handle of the special tool until the standardvalue of drive pinion turning torque is obtained.
(3) Measure the drive pinion turning torque (without the oil
seal).Standard value:
Rotation torque
(starting friction torque)Nm
(in.lbs.)
I
NoneNew(with rust-I0.9-1.2 (8-10)prevention oil)New/reused Oil application
NOTE
0.4-0.5 (3-4)(I) Gradually tighten the nut of the special tool while
checking the drive pinion turning torque.
(2) Because the special tool cannot be turned one turn, turnit several times within the range that it can be turned;then, after fitting to the bearing, measure the rotation
torque.

3-28REAR AXLE - Differential Carrier
Y223
MB990031(4) Position the special tool in the side bearing seat of the
gear carrier, and then select a drive pinion rear shim of athickness which corresponds to the gap between the
special tools.
NOTE
Clean the side bearing seat thoroughly. When position-
ing the special tool, be sure that the cut-out sections ofthe special tool are in the position shown in the
illustration, and also confirm that the special tool is in
close contact with the side bearing seat.
When selecting the drive pinion rear shims, keep the
number of shims to a minimum.
(5) Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
race by using the special tool.
. ADJUSTMENT OF DRIVE PINION PRELOAD
Adjust the drive pinion turning torque by using the following
procedures:
(1) Fit the drive pinion front shim(s) between the drive
pinion spacer and the drive pinion front bearing inner
race.
(2) Tighten the companion flange to the specified torque byusing the special tools.
NOTEDo not install the oil seal.
(3) Measure the drive pinion turning torque (without the oil
seal) by using the special tools.
Standard value:
21
.;c
1 New
New/reused Oil application
0.4-0.5 (3-4)
(4) If the drive pinion turning torque is not within the range
of the standard value, adjust the turning torque by
replacing the drive pinion front shim(s) or the drive
pinion spacer.
NOTEWhen selecting the drive pinion front shims, if the
number of shims is large, reduce the number of shims
to a minimum by selecting the drive pinion spacers.

REAR AXLE - Differential Carrier3-29
Y223(5) Remove the companion flange and drive pinion once
again.Drive the oil seal into the gear carrier front lip by using
the special tool.
Apply multipurpose grease to the oil seal lip.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
(6) Apply a thin coat of multipurpose grease to the
companion flange contacting surface of the washer
before installing drive pinion assembly.
Specified grease: MOPAR Multi-Mileage Lubricant
Part No.2525035 or equivalent
(7) Install the drive pinion assembly and companion flange
with mating marks properly aligned, and tighten the
companion flange self-locking nut to the specified
torque by using the special tools.
(8)Measure the drive pinion turning torque (with oil seal) toverify that the drive pinion turning torque complies with
the standard value.
Standard value:
Rotation torque
(starting friction torque)Nm
(in.lbs.)
IIIIIf there is a deviation from the standard value, check
whether or not there is incorrect tightening torque of
the companion flange tightening self-lock nut, or incor-
rect fitting of the oil seal.
. ADJUSTMENT OF DIFFERENTIAL GEAR BACKLASH
Adjust the differential gear backlash by the following
procedures:(1) Assemble the side gears, side gear spacers, pinion
gears, and pinion washers into the differential case.
(2) Temporarily install the pinion shaft.
NOTEDo not drive in the lock pin yet.
L-

3-34REAR AXLE - Differential Carrier (Limited Slip Differential)
DIFFERENTIAL CARRIER (LIMITED SLIP DIFFERENTIAL)
DISASSEMBLY AND REASSEMBLYNO31K--
Disassembly steps
1. Screwl + 2. Differential case A+e I)+ 3. Thrust washer (L.H.)4. Viscous unit
llP0127
I)+ 5. Pinion mate washer
M 6. Differential pinion mate
7. Differential pinion shaft
8. Differential side gear
(R.H.)
4+9. Thrust washer (R.H.)
l +
10. Differential case 6Feeler gauge-eeler gauge
\Feeler gauge/
’ IL4l\’IIDifferential sideThrkt washer
aear (riaht)(right)\llPO139
INSPECTION BEFORE DISASSEMBLYNO3IEBA1. CHECKING THE DIFFERENTIAL GEAR BACKLASH
(1) Secure the differential case assembly in a vise so that
the differential side gear (right) is facing upward.
Caution
When securing the vise, be sure not to hold the
differential case assembly too tightly.
(2) Insert a 0.03 mm (.0012 in.) feeler gauge at two places
(diagonally) between differential case
B and the thrust
washer (right).
CautionDo not insert a feeler gauge in the oil groove of
differential case B.

3-36REAR AXLE - Differential Carrier (Limited Slip Differential)Contact surface
with differential
viscous unit
llPO142
Mamaifferential case
BPinion mate
washer
bDifierential7-pinion matellPO134Feeler gauge
Feeler
gaugeFeeler gauge
lifferential gear (right)Thrust washer (right),\llPO130
1(5) Check the
spline part of the viscous unit for stepped
wear or damage, and check the contact surface with
differential case B.
45
(6)Check the side gear (left) of the viscous unit for unusualwear or damage.
SERVICE POINTS OF REASSEMBLYNOOINBE
10. INSTALLATION OF THE DIFFERENTIAL CASE B/2. DIFFERENTIAL CASE A
Align the mating marks of differential cases
B and A, and
assemble the cases.
6. INSTALLATION OF THE DIFFERENTIAL PINION
MATE/5. PINION MATE WASHER
With the washer in the position shown in the figure, install
to the differential pinion shaft, and then install to differentialM.case
B.3. SELECTION OF THE THRUST WASHER (LEFT)
(1) If the differential side gear and pinion mate gear have
been replaced, select the thrust washer (left) by
following the steps below.
@ Wash the differential side gear and pinion mate gear
in unleaded gasoline to remove all oil, grease, etc.
@ Install the previously used thrust washers (being
careful the left and right ones are used at the
correct side), together with the gears, viscous unit,
pinion mate washer and pinion shaft, to differential
cases A and
B, and then, using screws, secure
them temporarily.
@ Secure the differential case assembly in a vise so
that the differential side gear (right) is facing
upward.Caution
When securing in the vise, be sure not to hold the
differential case assembly too tightly.
@I Insert a 0.03 mm LOO12 in.) feeler gauge at two
places (diagonally) between differential case
B and
the thrust washer (right).
CautionDo not insert a feeler gauge in the oil groove of
rsrdifferential case B.

5-2BRAKES - SDecifications
SPECIFICATIONS
GENERAL SPECIFICATIONS

NO!iCA-- -
ItemsItems
NNVehicles without ABS Vehicles without ABSVehicles with ABS Vehicles with ABS
BIBI
PlPl
Fr Frlaster cylinder
TypeTandem typeTandem type
(with level sensor)(with level sensor)
I.D.mm (in.) 22.2 (7/8)23.8 (‘%6)rake booster
TypeVacuum typeVacuum type
Effective dia. of power cylinder
mm (in.) 230 (9.0)Front side: 180 (7.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.0 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]
.oportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
4,200 (597)
Decompression ratio
0.3
0.3ont brakes
TypeFloating caliper, single-piston,ventilated disc (M-R44V)Floating caliper, single-piston,ventilated disc (M-R44V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thicknessmm (in.) 16.0 (63)
16.0
(.63)Wheel cylinder I.D.
mm (in.) 53.9 (2
l/8)53.9 (2%)
Clearance adjustmentAutomaticAutomatic
3ar disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD30P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)
Disc thickness
mm (in.)
10 (39)10 i.39)Pad thickness
mm (in.) 14.5 (57)
14.5 (57)
Wheel cylinder I.D.
mm (in.) 30.1
(1 3/16)30.1 (1 346)Clearance adjustment
AutomaticAutomatic
)tor teeth
Front wheel side
-47Rear wheel side
-47
leed sensor-Magnet coil type
rking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever type
Lever type
Lever type
Cable arrangement
V-type
V-type
Rc Rc
SP SP
Pa Pa

-.
BRAKES - Specifications5-3
ItemsFWDAWDMaster cylinder
TypeTandem type
(with level sensor)Tandem type
(with level sensor)
I.D.mm (in.) 23.8 (‘%a)25.4 (1)Brake booster
TypeVacuum type
Vacuum type
Effective dia. of power cylinder
mm (in.) Front side: 180 (7.0)
Front side: 180 (7.0)
Rear side: 205 (8.0)
Rear side: 205 (8.0)
Boosting ratio [Brake pedal depressing force]
5.5 [at 220
N (48 Ibs.)]5.5 [at 220 N (48 Ibs.)]Proportioning valve
TypeDual typeDual type
Split point
kPa (psi) 4,200 (597)
3,700 (526)
Decompression ratio
0.30.3Front brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (M-R44V)ventilated disc (M-R46V)Disc O.D.
mm (in.) 256 (10.1)256 (10.1)
Disc thickness
mm (in.) 24
(.94)24 (.94)Pad thickness
mm (in.) 16.0
(.63)16.0 (.63)Wheel cylinder I.D.
mm (in.)
53.9 (2 ‘16)60.3 (23%3)Clearance adjustment
AutomaticAutomatic
Rear disc brakes
TypeFloating caliper, single-piston,Floating caliper, single-piston,ventilated disc (AD30P)ventilated disc (AD35P)Disc
O.D.mm (in.) 265 (10.4)265 (10.4)Disc thicknessmm (in.) 10
(.39)10 f.39)Pad thicknessmm (in.) 14.5
(.57)14.5 (.57)Wheel cylinder I.D.mm (in.) 30.1 (1
3/16)34.9 (1 3h)Clearance adjustmentAutomaticAutomatic
qotor teeth*
Front wheel side
4747Rear wheel side
4747
speed sensor*Magnet coil typeMagnet coil type‘arking brakes
TypeMechanical brake actingMechanical brake acting
on rear wheelson rear wheels
Brake lever typeLever typeLever type
Cable arrangementV-typeV-type
NOTEThe *symbol indicates vehicles with ABS.

5-22BRAKES - Anti-lock Braking System Troubleshooting
1 E-4 1 Abnormality of solenoid valve drive circuit
[Explanation]
The ABS ECU normally monitors the solenoid valve
drive circuit.
If no current flows in the solenoid even if the ECU
when turned OFF, the ECU determines the solenoidcoil wire is broken/short circuited or the harness
isbroken short circuited and then warning light lights
turns the solenoid ON or if it continues to flow even
up.
J/B
HU
(
x:OMBINATION ME
:TER
MA0603
Is the resistance value for
the solenoid valve, that the
displayed trouble code indi-cates, within the range of
the standard values?
Standard value: 3.0-3.2 Q
Is the solenoid valve resist-
ance value, that the output
trouble code displays, withinthe range of the standard
values when measured at
the ECU connector?
Standard value: 3.0-3.2 B
nOrmll/
Solenoid valve drive circuit is
NoReplace HU.I
NoThe harness wire for thesolenoid valvecircuit
whose resistance value is
outside the range of the
standard value is broken
or short circuited.
I
1 Repair ABS harness.

5-38BRAKES - Anti-lock Braking System Troubleshooting
E-5Abnormality of solenoid valve drive circuit
[Explanation]*>The ABS ECU normally monitors the solenoid valve
when turned OFF, the ECU determines the solenoid%’ -’drive circuit.coil wire is broken/short circuited or the harness is
If no current flows in the solenoid even if the ECUbroken/short circuited and then the warning light
turns the solenoid ON or if it continues to flow evenlights up.
IGNITIONSWITCH(IGI)
7JIB------_-_tor and check with the
side connector.
Connect HU
1OP connec-
disconnect ECU con-
>Is the solenoid valve resis-
tance value within the range
of the standard values when
measured at the ECU con-
nector?Standard value:
3.0-3.2 Q
Yes1
II
I
Solenoid valve drive circuit isnormal.I
NoReplace HU.I
NoIs the resistance value for
the solenoid valve within the
range ofthe standard
values?Standard value:
3.0-3.2 Q, IYes ,
1
JThe harness wire for the
solenoidvalvecircuit
whose resistance value is
outside the range of the
standard value is broken
or short circuited.,-‘he-
-Repair