differential MITSUBISHI ECLIPSE 1991 Repair Manual

21-72MANUAL TRANSAXLE - Specifications
Part nameThickness mm (in.)
Spacer
1.58
(.0622)(For adjustment of center differential casepreload)
1.61
(0634)1.64
(.0646)1.67
(0657)
1.70 (.0669)1.73
(.0681)1.76
i.0693)1.79
(.0705)Spacer
2.09-2.16 (.0823-.0850)(For adjustment of center differential pinion
2.17-2.24 (.0854-,0882)backlash-Front side)
2.25-2.32
(.0886-.0913)2.33-2.42
(.0917-.0953)
2.43-2.50 (.0957-.0984)
2.51-2.58 (.0988-.1016)2.59-2.66
(.1020-.1047)2.67-2.74
(.1051-.1079)2.75-2.82
(.1083-.I 110)
Spacer
0.59-0.66 (.0232-.0260)(For adjustment of center differential pinion
0.67-0.74 (,0264-.0291)backlash- Rear side)
0.75-0.82 (.0295-.0323)
0.83-0.92 (.0327-.0362)
0.93-I .OO (.0366-.0394)1
.01-l .08 (.0398-.0425)
1.09-I .I6 (.0429-.0457)1.17-1.24
(.0461-.0488)Spacer
0.56
(.0220)
6:;or)adjustment of front differential case end0.65 (,0256)0.74
(.0291)0.83
(.0327)0.92
(0362)1 .Ol
(.0398)
1.10 f.0433)1
.I9 (.0469)1.28
(.0504)1.37
(.0539)Spacer
0.75-0.82 (.0295-.0323)IFor adjustment of front differential pinionsacklash)
0.83-0.92 (.0327-.0362)
0.93-I .OO (.0366-.0394)1
.01-l .08 (.0398-.0425)
1.09-I .I6 (.0429-.0457)Identification
symbol
58
6164
67
70
73
76
79
0
9
8
7
6
5
4
3
2
74
50
80
79
78
76
77
49
56
65
74
83
92
01
J
LN
P
-
-
-
-
-Part No.
MD718527
MD71 8528
MD718529
MD71 8530
MD71 8531
MD721 959
MD721 960
MD721 961
M D730350
MD730349
M D730348
M D730347
M D730346
MD730345
M D730344
M D730343
M D730342
M D724974
M D724950
MD720680
MD720679
MD720678
MD720676
MD720677
M D724949
MD727658
MD727659
MD727660
MD720937
MD720940
MD720943
MD71 0454
MD71 0456
MD710458
MD71 0460
MA1 80862
MA1 80861
MA1 80860
MA1 80875
MA1 80876

MANUAL TRANSAXLE - Specifications21-75Items
Lower arm ball joint to knuckle
Center bearing bracket installation bolts
Right member installation bolt (front)
Right member installation bolt (rear)
Transfer assembly mounting bolt
Poppet plug
Backup light switch
Restrict ball
Speedometer mounting bolt
Oil filler plug
Oil drain plug
Input shaft lock nut
Intermediate shaft lock nut
Center differential drive gear mounting bolt
Front differential drive gear mounting bolt
Stopper bracket mounting bolt
Reverse idler gear shaft mounting bolt
Reverse shift lever mounting bolt
Bearing retainer mounting bolt
Interlock plate mounting bolt
Center member mounting bolt
Irive shaft center bearing mounting bolt
Iriven bevel lock nutgear
Select lever assembly mounting bolt
3everse brake cone screw boltsNm
ft.Ibs. ”
60-7243-52 “
36-4626-33
80-10058-72
70-8051-58
55-6040-43
30-4222-30
30-3522-25
30-3522-25
3-52.5-3.5
30-3522-25
30-3522-25
140-160102-I 15
140-160102-I 15
70-8051-57
130-14095-10115-22
11-1543-55
32-39
15-22
11-1515-22
11-15
20-2715-19
60-8043-58
36-46
26-33
140-160101-11515-22
11-15
4.0-5.52.9-3.9
TRANSFERItems
Transfer assembly mounting bolt
Cover mounting bolt
Extension housing mounting bolt
Transfer cover mounting bolt
Transfer case adapter mounting bolt
Driven bevel gear lock nut
Hanger bracket mounting boltNm
ft.lbs.
55-6040-43
8-106-7
15-22
II-1535-42
26-3035-42
26-30
140-160102-I 15
15-22
11-15
LUBRICANTSN21CD.BItems
Specified lubricantQuantity lit. (qts.)
I
ITransmission oil
MOPAR Hypoid gear oil or equivalent,2.3 (2.43)
API classification GL-4 or higherITransfer oil
MOPAR Hypoid gear oil or equivalent,
API classification
GL-4 or higher0.6 (.63)

21-76MANUAL TRANSAXLE -Specifications/Special Tools
SEALANTS AND ADHESIVESNZlCE-B
TransaxleH-
1
-/Items
Transaxle case-clutch housing mating surfaces
Transaxle case-adapter mating surfaces
Adapter-rear cover mating surfaces
Front differential drive gear bolts
Center differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
Air breatherSpecified sealants and adhesives
Mitsubishi genuine part
No.997740or equivalent
MOPAR part
No.4318031 or MOPAR part
No. 4318032 or equivalent
MOPAR part
No.4318025 or equivalent
TransferItems
Adapter-extension housing mating surfacesSpecified sealants and adhesives
Mitsubishi genuine part No.
MD997740or equivalent
Air breatherMOPAR part
No.4318025 or equivalent
SPECIAL TOOLSNZlDA-B AI
NllmherName
I Use,“I. .-. * ,--.
~ MD99801 9
.-...-Lock pin extractor---Removal of spring pin and lock pin
MD998245Lock pin installerInstallation of spring pin and lock pin
0
MD998304Oil seal installerInstallation of front output shaft bearing and
transfer extention housing oil seal
MD998320Bearing installer
Installation of input shaft bearing and input
shaft gear

MANUAL TRANSAXLE - Special Tools21-77Tool
Number
Name
MD998321Oil seal installer
M D998323Bearing installer
MD998325Differential oil seal
installer
MD998350Bearing installer
MD998369Bearing installer
MD998806Wrench adapter
MD998801Bearing remover
MD998802Input shaft holder
M D998803Differential oil seal
installerUse
Installation of input shaft front oil seal
Installation of rear output shaft oil seal and
transfer case oil seal
Installation of differential oil seal
Installation of front output shaft, intermediate
gear, transfer drive bevel gear, and
intermediate gear
Installation of input shaft front bearing
Removal of input shaft, intermediate gear, ant
output shaft bearing and gears
nstallation and removal of input shaft and
Ttermediate gear lock nut
lstallation of differential oil seal
rdjustment of tooth contact and inspection ofJrning drive torquexstallation of input shaft rear snap ring

21-78MANUAL TRANSAXLE - Special Tools
MD99881 9Installer adapter (40)Installation of front differential bearings
M D998820Installer adapter (42)Installation of center differential bearings and
driven bevel gear bearing
MD999566ClawRemoval of bearing outer race from
intermediate gear, front output shaft, and
center differential
MD998827Installer adapter (56)Installation of drive bevel gear bearing
MB990326Preload socketMeasurement of drive bevel gear shaft
rotating torque
M B990900(included in
MB990988)Side gear holding
Tool (A)Measurement of drive bevel gear shaft
rotating torque
MB991 013Special spannerInstallation and removal of driven bevel gear
lock nut
MB991 193PlugPrevention of transfer oil discharge and
foreign object entry

--
MANUAL TRANSAXLE - Transaxle Assembly21-81
i5 r)
p$---al3743-55 Nm
3632-39 ft.lbs.
TFM0029Disassembly steps
I)+ 23. Snap ring
4*24. Viscous couplingl 4 25. Steel ball26. Center shaft
l 27. Transaxle case adapter
28. Outer race
l * 29. Spacer
30. Outer race
l 4 31. Spacer32. Outer race
l * 33. Spacer
34. Center differential
4*35. Outer race$?everse the disassembly procedures to reassemble.
Reverse idler gear shaft bolt(2) +I) : Refer to “Service Points of Disassembly”.l + 36.(3) l + : Refer to “Service Points of Reassembly”.
37. Gasket(4) m : Non-reusable parts.

21-88MANUAL TRANSAXLE - Transaxle Assembly15-22 Nm
11-15 ft.lbs.
-.@&35-42 Nm
26-30 ft.lbs.
\15-22 Nm
11-15 ft.lbs.
/4?2250013
Disassembly steps
38. Clutch oil line bracket
l + 39. Transaxle case
l + 40. Oil guide
l + 41. Oil guide
42. Outer race
l + 43. Spacer
l * 44. Spacer
45. Stopper bracket
l 46. Oil seal
47. Reverse shift lever assembly
48. Reverse shift lever shoe
49. Reverse idler gear shaft
50. Reverse idler gear
51. Front output shaft assembly
52. Needle bearing
53. Front differentialNOTE
(I) Reverse the disassembly procedures to reassemble.(2) l + : Refer to “Service Points of Reassembly”.(3) m : Non-reusable parts.

MANUAL TRANSAXLE - Transaxle Assembly23-95
46. INSTALLATION OF OIL SEALUsing the special tool, install the drive shaft oil seal.
I -.,44.143. INSTALLATION OF SPACER
(1) Place two pieces of approximately 10 mm (39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the transaxle case and install each outer race.
(2) Place two pieces of approximately
10 mm (.39 in.) long,
1.6 mm
(.06 in.) dia. solder at the locations shown on
the bearing outer race.
(3) Install the transaxle case, and tighten bolts to
specifiea-
tion.(4) Remove the transaxle case.
(5) Remove the outer races and remove the solder.
(6) If the solder is not broken, carry out the work in steps
(l)-(5) with large diameter solder.
(7) Using a micrometer, measure the thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Front output shaft preload
0.08-0.13 mm (.0031-.005 in.)
Front differential case end play
0.05-0.17 mm (.0020-.a07 in.)

MANUAL TRANSAXLE - Transaxle Assemblv
I-2mmml
,
Snap r
/ /221012:3(4) Remove the outer races and remove the
solder:(5) If the solder is not broken, carry out the work in steps,
(l)-(4) withlargediameter solder.
(6) Using a micrometer, measure ttie thickness of the
flattened solder and select a spacer of a thickness that
gives the specified end play and preload.
Standard values:
Input shaft end play
O-.0.05 mm (O-.0020 in.)
Intermediate gear preload
0.08-0.14 mm (.0031-.005 in.)
Center differential case preload
0.08-0.13 mm (.0031-,005 in.)
27. INSTALLATION OF TRANSAXLE CASE ADAPTER
Apply sealant (liquid gasket) to the transaxle case side of
the transaxle case adapter assembly.
Specified sealant: Mitsubishi genuine sealant Part
No. MD997740 or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuities.
25. INSTALLATION OF STEEL BALL
Move the center shaft so that the steel ball is seated
securely into the groove in center shaft.
23. INSTALLATION OF SNAP RING
Select the snap ring so that the end play in the viscous
coupling is up to specification.
Standard value:
0.1-0.26 mm (.0039-.OlO in.)
18. INSTALLATION OF SHIFT FORK/17.
5TH SPEED SYN-
CHRONIZER ASSEMBLY
Mate the
5th speed shift fork with the 5th gear synchroniz-
er assembly and install them simultaneously.

MANUAL TRANSAXLE - Center Differentid
CENTER DIFFERENTIAL
-4~ DISASSEMBLY AND REASSEMBLY
2210037
-
2250015
Disassembly steps
+* l +1. Taper roller bearing
l + 2. Bolt
l * l +3. Taper roller bearing
4. Output flange
I)* 5. Spacer
6. Side gear
7. Pinion shaft
8. Washer9. Pinion
10. Side gear
l + 11. Spacer
12. Center differential case
FJ)TEeverse the disassembly procedures to reassemble.(2)l *: Refer to “Service Points of Disassembly”.(3)l a: Refer to “Service Points of Reassembly”.
SERVICE POINTS OF DISASSEMBLY
1.13. REMOVAL OF TAPER ROLLER BEARINGS
Using the special tool, remove the taper roller bearings.
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.