MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE - Transaxle Assemblv 21-37
18
50. REMOVAL OF SHIFT RAIL ASSEMBLY(1) Shift the
1st~2nd speed shift fork to the 2nd speed.
(2) Shift the
3rd4th speed shift fork to the 4th speed.
.”(3) Remove the shift rail assembly.
INSPECTIONNZlMOM
BACKUP LIGHT SWITCHOperate the backup light switch to check continuity with a
circuit tester.
If without continuity, replace the switch.
SERVICE POINTS OF REASSEMBLY64. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.
:

21-38 MANUAL TRANSAXLE - Transaxle Assembly
63. INSTALLATION OF OIL SEALInstall the input shaft front oil seal using the special tool.
,,=
2010041
51. APPLICATION OF ADHESIVE TO BOLTApply specified adhesive to the bolt threads.
CautionDo not apply to the bolt head.
Specified adhesive: MOPAR Part No.4318031or MOPAR Part
No.4318032
or equivalent
50. INSTALLATION OF SHIFT RAIL ASSEMBLY
(1) Set the lst-2nd speed shift sleeve at 2nd speed.
(2) Set the
3rd-4th speed shift sleeve at 4th speed.
(3) FJtt~~~shift forks of shift rail assembly to groove of
(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.A

MANUAL TRANSAXLE - Transaxle Assembly Spring pin
/Shift rail
11-t201034er
2150008
220004E46./49.
INSTALLATION OF SPRING PINS(1) Install the spring pins using the special tool or a pin
punch.
Caution
Do not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
’
35. /37. /40./42. INSTALLATION OF SPACERS(1) Place two pieces of solder measuring about
10 mm (4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
’(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If the solder is not broken, carry out the work- in steps
(l)-(4) with large diameter solder.
(6) Measure the thickness of the crushed soid& with a
micrometer and select and install a spacer of thickness
that gives standard preload and end play.
Standard value:
Input shaft end play
O-0.05 mm (O-.002 in.)
Intermediate gear preload0.05-0.10 mm (.002-.004
in.)
Output shaft preload0.05-0.10 mm (.092-.004 in.)
Differential case preload
9.05-0.10 mm (.002-.004 in.)

21-40 MANUAL TRANSAXLE - Transaxle Assembly Amount
1-2 mm
J
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
.‘p,
/
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
hshaft’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 the
transaxle case.
Specified sealant: MITSUBISHI Genuine
Part No.
MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
18 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
*
torque.,-(8) Tighten the reverse idler gear shaft bolt to specified
torque.

MANUAL TRANSAXLE - Transaxle Assembly ,214
10 mm (.40 in.)
16. / 15. INSTALLATION OF LOCK NUTS(1) install the special tool to the splined end of inputshaft.
(2) Screw a bolt [IO mm
(.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
MD998245\ISlit
,+i 1I I
r
Spring pin
, Shift rail(3) Shift the transaxle in reverse using control lever and
select 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)
&tighten 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.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
13. APPLICATION OF SEALANT TO AIR BREATHER
Apply specified sealant to air breather mounting portion andinstall to the clutch housing.
Specified sealant: MOPAR Part No.4318025
or equivalent

21-42MANUAL TRANSAXLE Transaxle Assembly /- 5th Speed Synchionizer AssemblyTFM0041
8” in.)TFM0044
4. INSTALLATION OF SCREW BOLTSApply specified adhesive to screw bolts mounting portion.
Specified adhesive: MOPAR Part No.4318031
or MOPAR Part No. 4318032
or ‘equivalent
2. APPLICATION OF SEALANT TO THE REAR COVERApply specified sealant to the
rear cover.
Specified sealant: MITSUBISHI Genuine
Part No.
MD997740
or equivalent
Caution
Squeeze out sealant from the tube uniformly without
excess or discontinuity.
5TH SPEED SYNCHRONIZER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
43
NZlMHAK
1Disassembly steps
1. Reverse brake ring (F5M22-2, F5M33)
2. Stop plate (F5M22-1)I)4 3. Synchronizer spring4. Synchronizer sleeveWI 5. Synchronizer key*+ 6. Synchronizer hubTFM0055
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Reassembly”.

..-MANUAL TRANSAXLE
-5th Speed Synchr’onizer Assembly tq-43
201044
201045TFM0046
Springprotrusion
Key
2010018
INSPECTION_ -.‘-
SYNCHRONIZER SLEEVE AND HUB-_
lCombine the synchronizer sleeve and hub and check thatthey slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear ends.
lCheck for wear of the hub front end (surface in contact withthe
5th speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for weakness, deformation and breakage.
SERVICE POINTS OF REASSEMBLY6. INSTALLATION OF SYNCHRONIZER HUB/5. SYN-
CHRONIZER KEY.Assemble the synchronizer hub, and key noting their
direction.
NOTEOnly the direction of the keys for the
F5M22-1 has to be
observed.3. INSTALLATION OF
SYNCHRONliER $PRlNGAssemble the synchronizer spring so that
:its projection
may be engaged in the groove of the synchronizer key.
NOTETake care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.

21-44 MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY N2tMW
DISASSEMBLY AND REASSEMBLY
18
16
17 IDisassembly steps
*+ 1. Snap ring+1)1)+ 2. Ball bearing
+I) I)+ 3. Bearing sleevel + 4. Snap ring4+*+ 5. Ball bearingl + 6. Spacer
7.
4th speed gear8.Needle bearing~~ 9. Bearing sleeve10.Synchronizer ringl + 11. 3rd-4th speed synchronizer assemblyl + 12. Synchronizer spring2060019
l *
13.Synchronizer sleeve14.Synchronizer key15.Synchronizer hub16.Synchronizer ring
17. 3rd speed gear18.Needle bearing19.Input shaft
NOTE(I) Reverse the disassembly procedures to reassemble(2) l * : Refer to “Service Points of Disassembly”.(3) +* : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

MANUAL TRANSAXLE -Input Shaft Assemblir 2145
MD998801
201048SERVICE POINTS OF DISASSEMBLY
2. REMOVAL OF BALL BEARINGRemove the front bearing using the special tool
as
illustrated.:
j, /I’ ’:”VI
3. REMOVAL OF BEARING SLEEVERemove the bearing sleeve using the special tool as
illustrated.
5. REMOVAL OF BALL BEARING
Remove the ball -bearing together using the special tool as
illustrated.
17. REMOVAL OF 3RD SPEED GEARRemove the bearing sleeve,
3rd-4th speed synchronizer
assembly and
3rd speed gear together using the special
tool as illustrated.
INSPECTION
INPUT SHAFT
lCheck the outer surface of the input shaft where the needle
bearing is mounted for damage, abnormal wear and seizure[portion
@I.l Check the
splines for damage and wear.

21-46MANUAL TRANSAXLE - Input Shaft Assembly
201051
TFMO119
Damage, breakage
/
Synchronizer ringGLarTFMOlli
NEEDLE BEARING3a Combine the needle bearing with the shaft or bearing
sleeve and gear and check that it rotates smoothly without
abnormal noise or play.
l Check the needle bearing cage for deformation.
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
peeling.l Force the synchronizer ring toward the clutch gear and
check clearance “A”. Replace if it is out of specification.
Limit: 0.5 mm
(.02 in.)
SYNCHRONIZER SLEEVE AND HUB
lCombine the synchronizer sleeve and hub and check that
they slide smoothly.
lCheck that the sleeve is free from damage at its inside frontand rear
ends.
lCheck for wear of the hub end surfaces (in contact with
each speed gear).
CautionWhen replacing, replace the synchronizer hub and
sleeve as a set.
SYNCHRONIZER KEY AND SPRING
lCheck for wear of the synchronizer key center protrusion.
lCheck the spring for deterioration, deformation and break-
age.