MITSUBISHI ECLIPSE 1991 Service Manual

MANUAL TRANSAXLE - Clutch Housing Assembly
SERVICE POINTS OF DISASSEMBLY
2f-67
MD998019
\
\
- Control
J$p--lever
201082
MD998\
w
-
20108:
Needle bearing’ ’
20601:
Socketwrench
I’ I20108!
6. REMOVAL OF LOCK PINDrive out the lock pin from the control finger using the
special tool.
Caution
When removing the lock pin, turn the control lever to,such position that the lock pin will not contact the
clutch housing.
7. REMOVAL OF SPRING PINDrive out the spring pin from the stopper body using the
special tool.
Caution
When removing the spring pin, pull the control shaft in
the direction illustrated so that the spring pin will not
contact the clutch housing.
SERVICE POINTS OF REASSEMBLY
17. / 16. INSTALLATION OF NEEDLE BEARINGSInstall the needle bearing flush with the surface A of the
clutch housing.
15. INSTALLATION OF OIL SEALInstall the control shaft oil seal using a socket wrench.7./6.
INSTALLATION OF SPRING PIN AND LOCK PIN
(1)Install new spring pin and lock pin using the special tool.
Caution
Do not reuse the spring pin and lock pin.
(2) install the spring pin with its slit at right angle to the
control shaft center.

21-68MANUAL TRANSAXLE - General Information
MANUAL TRANSAXLE

GENERAL INFORMATION
lnpu
Dnve bevel gearIClutch housing
1st speecBearing retainer
\
gear
;t-2ndspeed synchronizer assembly
2nd speed gear
3rd speed gear
3rd-4th speed synchronizer assembly
4th speed gear
I .
5th speed gear
intermediate gear
ii\IntermediategearCenter shaft
Viscous coupling
Front differential
\Cent& differential
Front output shaft
,&
--
APLTFM0014

MANUAL TRANSAXLE 2 S~ecifCca?io’iik
2f.46g
\ ,...,
,,, .,
SPECIFICATIONS
1 L,‘S. / ,‘; ,< ’,f. : ,: ; .>r
“. . ..&
. ’ GENERAL SPECIFICATIONSNZ1.pA.B’
Items
ModelApplicable engine
TypeGear ratio
1 st
2nd
3rd
4th
5th
ReverseReduction ratio
PrimaryFront differential
TransferSpeedometer gear ratio (driven/drive)
Oil quantity
Transaxle
TransferSpecifications
(I
W5M33-2-N PZV.,A I
4G63
5-speed transaxle floor shift
3.083
I .684
1.115
0.833
0.666
3.166
1.275
3.866
1.090
29136lit.
(qts.)2.3 (2.43)
0.6
l.63)
SERVICE SPECIFICATIONSN21CB-B
d-...
Items
Standard value
TransaxleInput shaft end play
Input shaft rear bearing end play
Intermediate gear preload
Intermediate gear bearing end play
Front output shaft preload
Center differential
Viscous coupling end play
Differential case preload
Differential pinion backlash
Front differential
Differential case end play
Differential pinion backlash
TransferBevel gear set backlash
Driven bevel gear turning drive torque
Drive bevel gear shaft turning drive torqueSpecifications
o-0.05 (O-.002)
0.01-0.09 (.0004-,004)
0.08-0.14 (.0031-,006)
0.01-0.11 (.0004-,004)
0.08-0.13 (.0031-,005)
0.1-0.26 (.0039-.OlO)0.08-O. 13
LOO31 - ,005)
0.025-0.150 LOO01 -.006)
0.05-0.17 (.0020-,007)
0.025-0.150 (.OOOl-,006)
0.08-0.13 (.0031-.005)
1
.O- 1.7 Nm (0.72- 1.23 ft.lbs.11.7-2.5 Nm (1.23-1.81
ft.lbs.1
mm,.(in.)

21-70MANUAL TRANSAXLE - Specifications
SNAP RING (FOR ADJUSTMENT) AND SPACERPart nameThickness mm (in.)Identification
symbolPart No “Snap ring
0.80(.0315)80MD72766j
(For input shaft rear bearing end play)
0.83
(.0327)83MD720937
0.86
l.0339)86MD720938
0.89(.0350)89MD720939
0.92(.0362)92M D720940
0.95(0374)95MD720941
0.98
(.0386)98MD720942
1 .Ol(.0398)01MD720943
1.04(.0409)04M D720944
1.07(0421)07M D7209451
.lO (0433)JMD710454
1 .13(.0445)DMD700270
1.16(0457)KMD71 0455
1 .I9(0469)LMD71 04561.22 (0480)
GMD7002711.25
(.0492)MMD710457
1.28 (0504)
NMD7.10458,1.31
(.0516)EMD706574
1.34(.0528)0MD71 0459
1.37(.0539)PMD71 04601.40
(.0551)NoneMD706573
1.43(.0563)QMD71 0461
1.46(.0575)RMD71 0462
Spacer0.80(.0315)80MD720948
(For adjustment of intermediate gear preload)
0.83 (.0327)
83MD720949
0.86(.0339)86MD720950
0.89(0350)89MD726951
0.92(0362)
92MD720952
0.95(0.374)95MD720953
0.98(0386)98MD720954
1 .Ol(.0398)01MD720955
1.04(.0409)04MD720956
1.07(0421)07M D720.957
1.10(0433)10MD720958
1.13(0445)13MD720959
1.16(.0457)16MD720960
1.19i.0469)19MD726961
1.22(.0480)22MD720962
1.25(.0492)25M D7 12346
1.28
(.0504)28MD712347
‘I .31(.0516)31MD712348
1.34(0528)34MD712349
1.37(.0539)37MD712329
1.40(.0551)40MD712330
1.43(0563)43MD712331

MANUAL TRANSAXLE - Specificatihg21”;‘)r’ ”Part nameThickness mm (in.)Identification
symbolPart No.,Snap ring
1.40 (0551)NoneMD703779,:
(Fo; x&tment of intermediate gear bearing
1 .50 (6591)BrownMD703786,.r
1.60 (.0630)BlueMD703781
Spacer1.28(0504)B28MD7261 67(For adjustment of front output shaft preload)1 .31 (.05I6)B37MD7261 68
1.34(0528)B34MD7261 69
1.37 (.0539)B37M D724326
1.40 (0551)B40MD724327
1.43 (.0563)B43MD724328
1.46 (0575)B46MD724329,:,1.49 (.0587)B49M D724330
1.52 (.0598)B52MD7243311.55 (0610)
B55MD724332
1.58 (.0622)B58MD724333
1.61 (.0634)B61MD724334
1.64 (.0646)B64M D7243351.67
(.0657)B67MD7243361.70
(.0669)B70MD724337
1.73 (0681)B73M D7243381.76
(.0693)B76MD724339:1.79
(.0705)B79M D724340
1.82 (0717)B82M D7243411.85 (0728)
B85MD7243421.88 (0740)
B88M D724343
1.91 (0752)B91MD724344
Snap ring
1.30 (0512)OrangeMD727650(For adjustment of viscous coupling end play)
1
.40 (,055~)RedMD720686
1.50 (.0591)BlueMD720687
1.60 (0630)NoneM D720688
1.70 (.0670)WhiteMD720689
1.80 (.0709)YellowMD720690
1.90 (.0748)GreenMD727651
Spacer1 .I 3(.0445)13M D736928(For adjustment of center differential case
preload)I. 16(0457)16MD736929I
.I 9 (.0469)I9MD736751
1.22(0480)22MD736931
1.25(.0492)25MD7261 66
1.28(.0504)28MD718517’
1.31(.0516)31MD718518I
.34(.0528)34MD718519
1.37(.0539)37M D7 18520
1.40(.0551)40MD71 8521
1.43(.0563)43MD718522I
.46(.0575)46MD7 18523
1.49(.0587)49MD71 8524I
.52(.0598)52MD718525
1.55
(.0610)55MD718526

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 - Specifications2’7 -73Part nameThickness mm (in.)Identification
symbolPart No.
Spacer
1.34
(.0528)34MD723600(For adjustment of drive bevel gear mount)
1,37 (.0539)37MD723601,1.40
(.0551)40MD723602
1.43(.0563)43MD723603
1.46(.0575)46MD7236041.49
(.0587)49M D7236051.52
l.0598)52MD723606
1.55(0610)55M D7236071.58
(0622)58M D7236081.61
(.0634)61M D7236091.64
(.0646)64MD7261 70
1.67
(0657)67MD7261 71Spacer
1.28
(.0504)628MD7261 67
(For adjustment of drive bevel gear train
preload)1.31
(.0516)631MD7261 68
1.34
(0528)B34MD7261 69
1.37 (.0539)B37MD724326
1.40 (.0551)B40MD724327
1.43 (.0563)B43MD7243281.46
(.0575)B46MD7243291.49
(.0587)B49M D7243301.52
(.0598)B52MD724331
1.55 (0610)B55MD7243321.58
(.0622)B58M D7243331.61
(.0634)B61M D7243341.64
(0646)B64MD7243351.67
(0657)B67MD724336
1.70 1.0669)B70MD7243371.73
(.0681)B73MD7243381.761.0693)
B76MD724339 :.1.79
(0705)879M D724340
.1.82(.0717)B82MD7243411.85
(0728)B85M D724342 1Spacer
1 .I9l.0469)19MD726172(For adjustment of driven bevel gear train
preload)
1.22
(.0480)22MD722081
1.25(.0492)25MD722682:
1.28(0504)28MD7226831.31
(.0516)31MD722084 i_1.34
(.0528)34MD722085.
1.37(.0539)37MD722086
1.40(.0551)40MD722087
1.43(.0563)43MD7220881.46
(.0575)46M D7220891.49
(.0587)49MD7220901.52
i.0598)52MD722091
1.55(.0610)55MD722692
1.58(.0622)58M D722093

21-74MANUAL TRANSAXLE - Specifications
Part nameThickness mm (in.)Identification
symbolPart No.
Spacer
1.61
(.0634)61MD722094(For adjustment of driven bevel gear trainpreload)
1.64
(.0646)64MD7220951.67
(0657)67MD722096
1.70(.0669)70MD7220971.73
(0681)73MD7220981.76
(.0693)76M D7220991.79
(0705)79MD7221 00
1.82
(0717)82MD7221 011.85
(.0328)85MD7221 02
1.88
(.0740)88MD7221 03
1.91
(.0752)91MD7221 04
1.94
(0764)94MD722105Spacer
0.13
(0051)13MD720353(For adjustment Of driven bevel gear
mOWIt)o,16 ( 0063)16M D7203540.19
(0075)19MD7203550.22
(.0087)22MD7203560.25
(.0098)25MD7203570.28(.Ol
IO)28MD7203580.31
(0122)31MD7203590.34
(0134)34MD7203600.37
(0146)37MD7203610.40
(0517)40M D7203620.43
(.0169)43MD7203630.46
(0181)46MD7203640.49
(.0193)49MD7203650.52
(0205)52MD720366
TORQUE SPECIFICATIONSNZlCC-B
TRANSAXLEItems
Bell housing cover mounting bolt
Starter motor mounting bolt
Transaxle mount bracket mounting bolt
Shift cable and select cable bracket mounting bolt
Rear cover mounting bolt
Transaxle case mounting bolt
Clutch release cylinder mounting bolt
Clutch tube to transaxle assembly
Under cover
Transaxle mounting bolt
[I2 mm (47 in.) diameter bolt]
Transaxle mounting bolt [IO mm
(40 in.) diameter bolt]
Transaxle mounting bolt [8 mm (.31 in.) diameter bolt]
Tie rod end to knuckleNm
ft.lbs.
IO-127-9
27-34
20-25
60-8043-58
15-22
11-1635-42
26-3035-42
26-3015-22
11-1615-22
11-169-13
7-1043-55
32-39
30-3522-25
IO-127-9
24-3517-25

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