MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE -Input Shaft Assembly lamiNear20105:
Springprotrusion2010018TFM0021
MD998320/
SPEED GEARS
lCheck the bevel gear and clutch gear teeth for damage and
wear.l Check the synchronizer cone for rough
surface, damage
and wear.
lCheck the gear ‘bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
12. INSTALLATlON OF SYNCHRONIZER SPRING
Install the synchronizer spring so that its protrusion fits intothe groove in the synchronizer key. Make sure that the
protrusions in the front and rear springs are not in the
groove of the same key.
11. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTEIf the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter
spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-rectly in respective grooves of the synchronizer
ring.(3) Check the
3rd speed gear rotates smoothly.
9. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.

21-48 MANUAL TRANSAXLE -lntwt Shaft Assemblv
4th speedgear sideTFM004:
2060006
6. INSTALLATION OF SPACERSome spacers have an inscribed identification mark. For
_
such spacers, installation should be so that the surface that.-has no mark is facing toward the
4th gear side. Spacers -without identification mark may be installed” in either
direction.
5. INSTALLATION OF BALL BEARING
Install the ball bearing over the input shaft using the special
tool.
4. INSTALLATION OF SNAP RINGInstall a snap ring so that the input shaft rear bearing end
play will be the standard value.
Standard value: 0.01-0.09 mm
(.0004-.004 in.)
3. INSTALLATION OF BEARING SLEEVEUsing the special tool, attach the bearing sleeve on the
input shaft.
Caution
When press-fitting the sleeve on the input shaft, verify
that the flange of the sleeve fits closely on the bearing.
h

MANUAL TRANSAXLE -Input Shaft Assemblv 21-49
20105t
2. INSTALLATION OF BALL BEARING
Install the ball bearing over the input shaft using the sdecial
tool..e,*
1.INSTALLATION OF SNAP RINGSnap rings are available in three different thickness. Select
the thickest one that fits in the snap ring groove.
CautionDo not cause damage to the input shaft oil seal
contacting portion.Standard value: 0.01-0.12 mm
(.0004-,005 in.)

21-50MANUAL TRANSAXLE - Input Shaft Assembly
INPUT SHAFT ASSEMBLY NZlMIAUa
DISASSEMBLY AND REASSEMBLYDisassembly steps
+* l +1. Taper roller bearing++ ~~ 2. Bearing sleeve*+ 3. Snap ring++ I)+ 4. Taper roller bearingl + 5. Snap ringI)+ 6. Cone spring
~~ 7. Subgear8. 4th speed gear9. Needle bearing~~ 10. Bearing sleeve11. Synchronizer ringl + 12. 3rd-4th speed synchronizer assemblyl * 13. Synchronizer spring
2150009
14.Synchronizer sleeve
15.Synchronizer key16.Synchronizer hub17.Synchronizer ring
18. 3rd
speed gear
19.Needle bearing20.Input shaft
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ++ : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.(4) m : Non-reusable parts

MANUAL TRANSAXLE -lnwt Shaft Assembly 21-51
I
2010x-
I. .I
SERVICE POINTS OF DISASSEMBLY
1. REMOVAL OF TAPER ROLLER BEARINGRemove the front bearing using the special tool as
illustrated.
2. REMOVAL OF BEARING SLEEVERemove the bearing sleeve using the special tool as
illustrated.
4. REMOVAL OF TAPER ROLLER BEARINGRemove the taper roller bearing together using the special
tool as illustrated.
18. 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 SHAFTl Check the outer surface of the input shaft where the
needle bearing is mounted for damage; abnormal wear andseizure [portion
@I.l Check the splines for damage and wear.

21-52 MANUAL TRANSAXLE - Input Shaft Assembly
r
201051
Damage, breakage
Damage,TFMO119
ISynchronver ringGearTFM0117
2010441
NEEDLE BEARINGl 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.)
-z
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.

MANUAL TRANSAXLE -Incut Shaft Assembly Key
2010018
2ndgearTFM0024
MD998320
20105f
SPEED GEARS
lCheck the bevel gear and clutch gear teeth for damage andw.wear.l Check the synchronizer cone for rough surface, damage
and wear.
lCheck the gear bore and front and rear ends for damage
and wear.
SERVICE POINTS OF REASSEMBLY
13. INSTALLATION OF SYNCHRONIZER SPRINGAssemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
Take care to prevent the projections of the front and rear
spring from sitting in the groove of the same key.
12. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER
ASSEMBLY
(1) Install the synchronizer assembly so that the part that
has the small round indentation is in the oil groove at
the hub end.
NOTEIf the installation is in the opposite way, press-in might
not be possible. This is because the edge of the hub
inner diameter spline at the part that has the small
round indentation is made to facilitate pressing in.
(2) Press the
3rd-4th speed synchronizer assembly onto
the input shaft using the special tool as illustrated.
Caution
When installing the synchronizer assembly, make
sure that three synchronizer keys are seated cor-rectly in respective grooves of the synchronizer
ring.(3) Check the
3rd speed gear rotates smoothly.
10. INSTALLATION OF BEARING SLEEVEUse the special tool as illustrated.
j

21-54MANUAL TRANSAXLE - Input Shaft Assembly
2nd speed
MD998808(inner)7. INSTALLATION OF SUB GEAR/G. CONE
SPRINGI
5. SNAP RING
install the sub gear and cone spring to 4th gear, and then-install the snap ring.
NOTE
Be sure that the cone spring is installed so that it is facing inthe correct direction.
4. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using thespecial tool.
3. REASSEMBLY OF SNAP RING(1) Select the thickest possible snap ring which can enter
the snap ring groove.
Standard value: 0.01-0.09 mm
(.0004--004 in.)
(2) Using a special tool, attach the snap ring to the input
shaft.
Caution1. Don’t reuse the old snap ring.
2. If snap ring pliers are used, the snap ring may
sometimes be expanded excessively. This will
h
prevent proper mounting of the sleeve.

MANUAL TRANSAXLE -Input Shaft AsSe’mbly gq-86
2. REASSEMBLY OF BEARING SLEEVE
(1) Using a special tool, fit the begring sleeye to t$?i~nputshaft._ ., .L)
Caution
After fitting, check that the sleeve flange is closelyfit to the bearing.
1. INSTALLATION OF TAPER ROLLER BEARING
Install the taper roller bearing over the input shaft using the
special tool.

21-56MANUAL TRANSAXLE - Intermediate Gear Assembly
INTERMEDIATE GEAR ASSEMBLYNZlhlJAd
DISASSEMBLY AND REASSEMBLYDisassembly steps
l *1. Snap ring
w *+ 2. Taper roller bearing
w 3. Bearing sleeve
4*4.1 st speed gear
5.Needle bearing
l +6. Synchronizer ring
ea 7. Synchronizer spring
w8.1 st-2nd speed synchronizersleeve
l *9. Synchronizer key
+* ~~ 10. 1 st-2nd speed synchronizer hub
l a 11. Synchronizer ring
l *12. 2nd speed gear
13.Needle bearing
+* ,* 14. Taper roller bearing
15.Intermediategear
NOTE(1) Reverse the disassembly procedures to reassemble.(2) +e : Refer to “Service Points of Disassembly”.(3) l + : Refer to “Service Points of Reassembly”.
(4) III : Non-reusable parts
MD998801SERVICE POINTS OF DISASSEMBLY
2. REMOVAL OF TAPER ROLLER BEARING/Q. 1ST SPEED
GEAR
Remove the taper roller bearing, 1 st speed gear and bearing
sleeve using the special tool as illustrated.
Caution
1. Do not reuse the bearing removed from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.