MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE - Intermediate Gear Assembly2MJ
Spline201065
10. REMOVAL OF lST-2ND SPEED SYNCHRONIZER HUB/12. 2ND SPEED GEAR
Remove the 1 st-2nd speed synchronizer assembly and 2nd
speed gear together using the special tool as illustrated.14. REMOVAL OF TAPER ROLLER BEARING
Use 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.
INSPECTION
INTERMEDIATE GEAR
lCheck the outer surface of the intermediate gear where the
needle bearing is mounted for damage, abnormal wear andseizure [portion
@.Il Check the
splines for damage and wear.
NEEDLE BEARING
l 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.

21-58MANUAL TRANSAXLE - Intermediate Gear Assembly
rDamage, breakage
Damage, wearl-FM0119
ISynchronizer ring
IGearTFM0117
SYNCHRONIZER RINGl Check the clutch gear teeth for damage and breakage.
l Check the cone inside paper lining for damage, wear or
~
peeling.
J
201045l 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 front-4rand 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 weakness, deformation and breakage.
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.
l Check the gear bore and front and rear ends for damage
kand wear.

MANUAL TRANSAXLE - Intermediate Gear AsOembly21 L59
.-_
Front +Identi-fication
mark
210031
Springprotrusion
Key2010018
SERVICE POINTS OF REASSElViBLY
14. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearing over the intermediate gear
using the special tool.
Caution
When installing the bearing, push the inner race only.
11. /6.
INSTALLATION OF SYNCHRONIZER RINGS
The 1 st speed synchronizer ring has an identification mark.
10. INSTALLATION OF lST-2ND SPEED SYNCHRONIZER
HUB/S. SYNCHRONIZER KEYi.8. IST-2ND SPEED
SYNCHRONIZER SLEEVE/7. SYNCHRONIZER SPRING(1) Combine the
lst-2nd speed synchronizer hub and
sleeve as illustrated.
(2) Assemble the synchronizer spring so that its projection
may be engaged in the groove of the synchronizer key.
NOTE
(1) Take care to prevent the projections of the front andrear spring from sitting in the groove of the same
key.(2) A synchronizer spring different from the one shown
in the figure may be used but the explanation is the
same.

21-60MANUAL TRANSAXLE - Intermediate Gear Assembly
MD998350
/
1 st-2ndspeedsynchronizerassembly
201069
. MD998350
I
3210024(2) install the Ist-2nd speed synchronizer assembly
overthe intermediate gear using the special tool.
,-
Caution1. When installing the synchronizer assembly,
-‘make sure that three
synchronizer keys are
seated correctly in respective grooves of the
synchronizer ring.2. After installation of synchronizer assembly,
check that the 3rd speed gear rotates smoothly.
3. INSTALLATlON OF BEARING SLEEVE
Install the 1 st speed gear and bearing sleeve together overthe intermediate gear using the special
-tool.
r%
-.
2. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearing over the intermediate using
the special tool.
Caution
When installing the bearing, push the inner race only.
1. INSTALLATION OF SNAP RINGSelect and install a snap ring that will result in an
intermediate gear bearing end play that is the standard
value.Standard value: 0.01-0.14 mm
(.0004-.OOS in.)h

MANUAL TRANSAXLE - Output Shaft Assembly21-61
OUTPUT SHAFT ASSEMBLYNZlMKAG
# - DISASSEMBLY AND REASSEMBLY
.C
Disassembly steps
+* .+1. Taper roller bearing
4* w2. Taper roller bearing
3. Output shaft
NOTE
(I) Reverse the disassembly procedures to reassemble(2) +e : Refer to “Service Points of Disassembly”.
(3) W : Refer to “Service Points of Reassemby”.
210028
PressSERVICE POINTS OF DISASSEMBLY
1./2. REMOVAL’ OF TAPER ROLLER BEARINGS
Remove the taper roller bearing using the special tool as
illustrated.
AD9d880.l
il7inn75
I-. ----
MD998350
210026Caution
1.Do not reuse the bearings removed from the shaft.
2.Replace the inner and outer races of the taper roller
bearing as a set.
SERVICE POINTS OF REASSEMBLY
1./2. REMOVAL OF TAPER ROLLER BEARINGS
install the taper roller bearing
using the special tool.
Caution
When installing the bearing, push the inner race only.

21-62MANUAL TRANSAXLE - Shift Rails and Forks
SHIFT RAILS AND FORKS
DISASSEMBLY AND REASSEMBLY
N21-
sbdisassembly steps
1, 1 st-2nd speed shift fork2. 1 st-2nd speed shift rail3. 3rd-4th speed shift fork
4. 5th-reverse speed shift rail** 5. Interlock plunger6.
3rd-4th speed shift rail
7. Reverse shift lug
NOTE(1)Reverse the disassembly procedures to reassemble.(2)l *: Refer to “Service Points of Reassembly”.
201073
InterlockReverse shift lugSERVICE POINTS OF REASSEMBLY
5. INSTALLATION OF INTERLOCK PLUNGERinsert the interlock plunger at illustrated position of the
3rd4th speed shift rail.
“r
3rd-4th speed shift rail2ojoaa

MANUAL TRANSAXLE 4WD> - Differential Assembly21-63
DIFFERENTIAL ASSEMBLYNZlMMAF.
DISASSEMBLY AND REASSEMBLYDisassembly steps
l
+ 1. Bolt2. Differential drive gear
l l a3. Taper roller bearing
+e l +4. Lock pin
M 5. Pinion shaft
l 6. Pinion
e+ 7. Washer
l + 8. Sidegear
l +9. Spacer (Select)10. Differential case
130-440 Nm94- 101 ft.lbs.
\6
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ~~ : Refer to “Service Points of Disassembly”.
(3) ,+ : Refer to “Service Points of Reassembly”.
(4) p : Non-reusable parts
163025
Press
F+ Bearing
SERVICE POINTS OF DISASSEMBLY
3. REMOVAL OF TAPER ROLLER BEARING
Remove the taper roller bearing using the special tool as
illustrated.
Caution ’1. Do not reuse the bearing removed from the dif-
ferential case.
2.Replace the inner and outer races of the taper roller
bearing as a set.

21-64MANUAL TRANSAXLE - Differential Assembly2150020
Lock pin
Llla
Lock pinDifferen-tial case
alla-ctiol
ock pinendwith2150021
4. REMOVAL OF LOCK PINDrive out the lock pin from the hole A using a punch.
SERVICE POINTS OF REASSEMBLY9. INSTALLATION OF SPACER
/ 8. SIDE GEAR / 7.
WASHER
/ 6. PINION / 5. PINION SHAFT
(1) Install the spacer on the back of the side gear and then
install the gear in the differential case.
Caution
When installing a new side gear, use a spacer ofmedium thickness [0.93-1.00 mm (.36-.04 in.)].
(2) Set the washer on the back of each pinion and insert thetwo pinions to specified position while engaging
them
with the side gears and turning them.
(3) Insert the pinion shaft.
(4) Measure the backlash between the side gears and
pinions.
Standard value:0.025-0.150 mm
LOO1 -.006 in.)
(5) If the backlash is out of specification, disassemble againand using correct spacer, reassemble and adjust.
Caution
Adjust for same backlash of both side gears.
4. INSTALLATION OF LOCK PINAlign the pinion shaft lock pin hole with the case lock pin
hole and insert the lock pin.
Caution1. Do not reuse the lock pin.
2. The lock pin head must be sunk from the flange
surface of the differential case.

bierential Assembl /MANUAL TRANSAXLE - SDeedometer Gear ksemblv
, .Bearing
TFYOOIO
The numerals 0 to (8 indicate1 the tiqhtening Gequeice.210029I
SPEEDOMETER GEAR ASSEMBLY
3. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearings on
bqth sides of the
differential case.
Caution
When press-fitting the bearings, push the inner race
only.
1. INSTALLATION OF BOLTSApply
spec.ified adhesive to the entire threads of the bolts
and quickly tighten in the order shown to specified torque.
Specified adhesive: MOPAR Part No.4318031or MOPAR Part
No.4318032
or equivalent
CautionIf a bolt is reused, remove traces of old adhesive
completely from the threads.
DISASSEMBLY AND REASSEMBLY
NZlMNABDisassembly steps
1.O-ring
l 42.Springpin
~4 3. Speedometer driven gear
4. Oil seal5. Sleeve
NOTE(1) Reverse the disassembly procedures to reassemble.(2) ,+ : Refer to “Service Points of Reassembly”.(3) q : Non-reusable parts201078
Slit
SERVICE POINTS OF REASSEMBLY
3. INSTALLATlON OF SPEEDOMETER DRIVEN GEARApply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft.
2. INSTALLATION OF SPRING PIN
Install the spring pin in such a way that its slit does not facethe gear shaft.

21-66MANUAL TRANSAXLE - Clutch Housing Assembly
CLUTCH HOUSING ASSEMBLYNZlMPAL
DISASSEMBLY AND REASSEMBLY
2=
-,_
1
L--15-22 Nm
11-15 ftlbs.
20-27 Nm15-19 ft.lbs.
Disassembly steps
1.Bolt2. Select lever assembly
3. Select lever shoe
4. Interlock place bolt
5.Gasket+e l *6. Lock pinj\l * l *7. Spring pin
8. Neutral return spring
9.Stopper body10.Control finger11.Interlock plate
12. Neutral return spring assembly
13.Control shaft14. Control shaft boot
l 415.Oil seal
2100019
l * 16. Needle bearing
l a 17. Needle bearing;EJ. Fil;tch housing
20: Return spring
21. Stopper plate
22. Spring pin
NOTE(1) Reverse the disassembl procedures to reassemble.(2)~~ : Refer to “Service ornts of Disassembly”.6.(3)l + : Refer to “Service Points of Reassembly”.(4) q : Non-reusable parts