MITSUBISHI ECLIPSE 1991 Service Manual

STEERING - Power Steering Oil Pump
Terminal assembly
13K753Mark
A,B or C-43Mark
A,B or C
13G0151
/Connector13K752
Suction-ring
25.123. INSTALLATION OF O-RINGSApply specified fluid on O-rings to install.
Specified fluid: MOPAR ATF PLUS (Automatic Transmis-sion Fluid Type 7176)/Automatic trans-
mission fluid “DEXRON” or “DGXRON II”
I No. II.D. x Widthmm (in.)1 Identification color 1
113x1.9t.51x.0748)Blue
23.8
x1.9l.15x.0748)-16. INSTALLATION OF FLOW CONTROL VALVE
(1) If the flow control valve is to be replaced, install the flowcontrol valve to the oil pump body corresponding with
the body identification mark (A,
6, C).
(2) Apply the specified fluid to the outside of the flow control
valve.
Specified fluid:MOPAR ATF PLUS (Automatic Trans-mission Fluid Type
7176)/htomatictransmission fluid “DEXRON” or
“DEXRON II”
15. INSTALLATION OF O-RINGS
Apply specified fluid on O-rings to install.
Specified fluid: MOPAR ATF PLUS (Automatic Transmis-sion Fluid Type 7176)/Automatic trans-
mission fluid “DEXRON” or “DlkXRON II”
No.I.D. x Widthmm (in.)
1I 1 x 1.9 t.43 x .0748)
213x 1.9 l.51 x .0748)
317.8 x 2.4 j.70 X .0945)
413.5 x 1.5 t.53 x .0590)
ldentificaqion color
Yelllow
Blue
-
Red13. INSTALLATION OF OIL SEAL
Drive the oil seal into the pump body.
12. INSTALLATION OF O-RING
Apply specified fluid on O-ring to install.
Specified fluid:MOPAR ATF PLUS (Automatib Transmis-sion Fluid Type 7176)/Autoniatic trans-
mission fluid “DEXRON” or “DEXRON II”I.D.
x Widthmm (in.)Identification color
I17.8 x 2.4 (.70 x .0945)-I
13A0277

19-44STEERING - Power Steering Oil Pump
13AO350
13PO159
Punch mark
13c214 I
13W03ECutouts for
dowel pin
13PO16110. INSTALLATION OF
O-RING/S. O-RING
Apply specified fluid on O-ring to install.
-,Specified fluid: MOPAR ATF PLUS (Automatic
Trans- ”mission Fluid Type 7176)/Automatic
transmission fluid
“DEXRONY or “DE-XRON II”
1 No. 1I.D. x Widthmm (in.)Identification color
I2 1I47.2 16.8x x2.4 2.4(1.86 (.66x x.0945) .0945)- -8. INSTALLATION OF SIDE
PLATE
Align the dowel pin of the pump body with the dowel pin holeof the side plate to install the side plate.
6.
INSTALLATlON OF ROTOR
Install the rotor to the pulley assembly so that the rotor’s
punch mark is at the pump cover side.
s,5. INSTALLATION OF SNAP RING
Lift the rotor and check to be sure that the snap ring is in the
countersunk part.4.
INSTALLATlON OF VANE/3. CAM RING
(I1 Apply specified fluid to vane and cam ring friction
surface.
Specified fluid: MOPAR ATF PLUS (Automatic Trans-mission Fluid Type 7176)IAutomatic
Atransmission fluid “DEXRON” or
“DEXRON II”
(21 Align the dowel pins of the pump body with the dowel
holes of the cam ring, and then install so that the cam
ring’s punch mark is at the pump body side.

STEERING - Power Steering Oil Pump
Direct round edge
to the cam
ringCam ring13R0577
(3)Apply specified fluid to the vanes and instafl :lhe yaneson the rotor, paying close attention to the installation
direction.,L.,., ‘,, :.I
Specified fluid:MOPAR ATF PLUS (Automatic Trans-mission Fluid Type
7176)/Auto@tictransmission fluid
“DEXFhOW’ or
“DEXRON II”
2. INSTALLATION OF O-RING
Apply specified fluid to O-ring and install firmly on oil pump
body.
Specified fluid: MOPAR ATF PLUS (Automatic Trans-
mission Fluid Type 7176)/Automatic
transmission fluid “DEXRON” or
“DEdXRON II”.
1.
INSTALLATlON OF PUMP COVER
(1) Apply specified fluid to rotor friction surface of pump
cover.
Specified fluid:MOPAR ATF PLUS (Automatic Trans-
mission Fluid, Type
7176)/Automatictransmission fluid “DEXRON” or
“DEXRON II”.
(2) Align the dowel pin of the pump cover with the dowel pinhole in the cam ring to install the pump cover.

19-46STEERING - Power Steering Hoses
POWER STEERING HOSESREMOVAL AND INSTALLATIONNlSTA-
Pre-removal Operationl C+?ing of the Power Steering
,‘; ,L..,.,.):. ,4-14 NmwaI. . .-...5-10 ft.lbs.7
I9-14 NmI7 7-10 ft.lbs.
Post-installation Operationl Supplying of the Power Steering-.
1 Fluid
l Bleeding of the Power Steering
Fluid Line(Refer to P.19-13.1,621 N/-@b
K
2
3.0-4.5 Nm /2-3 ft.lbs.I/II z-”a.
413A0274
Removal steps
1.Returnhose2.Suctionhose
3.Returnhose4. Cooler tube
5. Return tube
6. Rubber hose
.a 7. Pressure hose
8.Pressure tube9.Return tube
10.O-ring
NOTE(1) Reverse the removal procedures to reinstall.
(2) l a : Refer to “Service Points of Installation”.(3) q : Non-reusable partsWhite lineUP0143SERVICE POINTS OF INSTALLATION
NlSTDAD7. INSTALLATION OF PRESSURE HOSE
(1) Connect the pressure hose so that its slit pat-t contacts
the oil pump’s guide bracket.
(2) When the pressure hose is installed, align the white line
on the pressure hose with the white line on the pressuretube so that together they form a straight line.

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;;

21-2MANUAL TRANSAXLE - General Information
MANUAL TRANSAXLE
GENERAL INFORMATION
NZlBAAP
F5M22 (4637 Engine)
Clutch housing
Bearing retainer
2nd speed gear
3rd soeedaear
5th speedsynchronizerassemblv
-----..-.IRear cover
5th speed inter-
mediate gear
Intermediate gear
SpacerOutput shaft
SpacerTransaxle case
\Dif ferential drive gear
Diffelential
Spacer
#&---- Drain plug
2060020

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)

21-6MANUAL TRANSAXLE - SDecificationsSNAP RING (FOR ADJUSTMENT) AND SPACER
Part name
Snap ring (F5M22)
(For adjustment of input shaft front bearing
end play)
Snap ring (F5M22)
(For adjustment of input shaft rear bearing
end play)
Snap ring (F5M33)
IFor adjustment ,of input shaft rear bearing
and play)
jpacer (F5M33)
For adjustment of input shaft end play)
nap ring
‘or adjustment of intermediate gear front bearing
nd play). . .
Thickness mm (in.)
‘~y~f$~t’onPart N;: :,‘.I2.24
1.0882)NoneM D706537
2.31 (.0909)BlueM
D706538
2.38 (.0937)BrownMD706539.f.1.80 (.0709)Blue
MD7307851.87 t.0736)White
MD7307861.94 t.0764)None
MD7307872.01 (.0791)Green
MD7307882.08
LO81 9)YellowM D730834
2.15 (.0846)Brown
MD7308351.40 (.0551)Blue
MD7232761.45 (.0571)PurpleM
D7308891.50 (.0591)Red
MD7232771.55 (.0610)WhiteM
D7308901.60 (.0630)Yellow
MD7232781.65 (.0650)BrownMD730891
1.70 (.0670)Green
MD7232791.75 f.0689)Orange
MD7308920.80 I.031 5)80MD727661
0.83 (.0327)83
MD7209370.86
i.0338)86M D720938
0.89
i.0350)89MD7209390.92 t.0362)92
MD7209400.95
l.0374)95MD720941
0.98
l.0386)98MD7209421 .Ol
i.0398)01MD7209431.04 (.0409)04
MD7209441.07 (.0421)07
MD720945
1 .lO (.0433)JMD71 0454
1
.I3 i.0445)DMD7002701.16 (.0457)
KMD71 0455
1.19 (.0468)
LMD71 0456
1.22 (.0480)
GMD700271
1.25
l.0492)MMD71 0457
1.28 t.0504)
NMD71 0458
1.31 f.0516)
EMD7065741.34 (.0527)
0
MD7104591.37 (.0539)
PMD7104601.40 (.0551)
-MD7065731.43
i.0563)QMD710461
1.46 t.0575)
RM D7 10462None 1.4 (.0551)
MD7037791.5 (.0591)Brown
MD7037801.6
(0630)BlueMD703781