ESP MITSUBISHI SPYDER 1990 Service Manual PDF

AUTOMATIC TRANSAXLE
OVERHAUL. .
the thickness of the flattened” solder using a
micrometer.Add the measured ‘solder thickness to’
the value 0.38 mm
which corresponds the
gasket thickness.
Then subtract from that sum a corresponding to
the specified end play.
The result obtained is the thickness of the spacer to
selected..
Select a spacer whose thickness falls the range
determined by the formulas below:
[T 0.38 mm in.) 0.13 mm in.)] to
[T
0.38 mm in.) 0.08 mm in.)]
the spacer which was selected (60) and
the outer race on the
silicone grease to all gasket surfaces of the tran saxle
case.
a new gasket on the transaxle case.
Caution
Do not reuse the gasket which was previously re-
moved..
converter housing and tighten the 14 bolts indicat ed
by arrows to the specified torque.
Tightening torque: 21 Nm
the end clutch shaft, inserting the end that has
the longer splines first.
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AUTOMATIC TRANSAXLE
OVERHAUL
General
Precautions to be taken when disassembling and the
Because the automatic transaxle is of component parts of especially high degree of
precision, these parts should be very carefully han dled during disassembly and assembly so as not
to scar or scratch them.
A rubber mat should be placed on the and it should always be kept clean.
During disassembly, cloth gloves or shop towels, sh ould not be used.
such items must be used,
either use articles made of nylon, or use paper tow els.
All disassembled parts must be thoroughly cleaned.
Metal parts may be cleaned with ordinary but must thoroughly air dried.
Clean the clutch disc, resin thrust plate and rubbe r parts by using ATF (automatic transmission fluid) ,
being very careful that dust, dirt, etc. do not adhere to them.
Do not reuse gaskets, oil seals, or, rubber parts.
Replace such parts with new ones at every reassembl y. The oil’ gauge need not
be replaced.
Do not use grease other than petrolatum jelly.
Apply ATF to friction components, rotating
and sliding parts before installation.
A new clutch disc should be immersed in ATF for at least two hours before installation.
Do not apply sealer or adhesive to gaskets.
When a bushing must be replaced, replace the assemb ly in which it is incorporated:,
If the transaxle main unit is damaged, also disasse
mble and clean the ‘cooler system.,
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AUTOMATIC
OVERHAUL Transaxle
A
the oil temperature sensor into the
,
an O-ring in the O-ring groove at the top of ‘the
valve body assembly.
the solenoid valve harness grommet with
valve connector transaxle
case hole from the inside,
the solenoid valve harness the case
hole.
the knock pin of the valve body
keeping the detent plate pin in the manual groove.
Temporarily install the valve body,
the oil tempera-
ture sensor and holder; then tighten the
to the specified torque.
A 1 8
bolt: 40 mm (1.58 in.)
body assembly mounting 11
Caution
Firmly fasten the and temperature
sensor harness at the shown positions.
Especially, be sure to route the pressure
(PCSV) harness, which is separated from
other harness, as shown in the diagram and
the harness. Failure to fasten it may result in con tact
with the detent plate or parking rod.
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AUTOMATIC TRANSAXLE
OVERHAUL -Transaxle
the oil temperature sensor into the case.
an O-ring in the O-ring groove at the’ top of the
valve body assembly.
the solenoid valve harness grommet
a new one.
the solenoid valve connector through the transaxle
case hole from the inside.
the solenoid valve harness grommet into the case
hole.
the knock pin of the body, into case,
keeping the detent plate pin in the ‘manual valve g roove.
Temporarily install the valve body,
the oil’
ture sensor and holder; then tighten mounting bolts
to the specified torque.
A bolt: 18 mm
in.)
bolt: 25 mm in.)
bolt: 40 mm (1.57 in.)
Valve body assembly mounting bolts: 11 Nm (8
Caution
Firmly fasten the solenoid valve and oil temperatur e!
sensor harness at the shown positions.
Especially, be sure to route the pressure control
valve harness, which is separated from
other harness, as shown in the, diagram and clamp
the harness. Failure to fasten
‘may result in contact
with the detent plate or parking rod.
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FRONT AXLE Drive Shaft
B.J.Dynamicbamper
DYNAMIC DAMPER
Install the dynamic damper in the position shown in the illustra-
tion.
Items Engine Engine Engine
(Non-turbo) (Non-turbo) . .

A mm L.H.
(in.)
R.H.
SPIDER CASE
(1) Install the spider assembly to the shaft
of the spline section.
(2) After applying specified grease insert
the drive shaft and apply grease one
Specified grease: Repair grease
Engine (Non-turbo)> 105
Engine (Turbo) and
(4.23 oz.)
NOTE
The grease in the repair kit be divided in. half
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses special Do not mix
old and new or different types of
T.J. BOOT BAND BOOT
(LARGE) INSTALLATION
Set the T.J. boot bands at the distance in order
to the of air inside the ‘boot, and tighten
the T.J. boot bands securely.
Standard value (A)
mm in.)
INSPECTION
l‘Check the drive shaft for damage, bending or corro sion.
lCheck the drive shaft spline part for wear or damage.
l Check the spider assembly for roller rotation, wear or
corrosion.
lCheck the groove inside T.J. case for wear of corro sion.
lCheck the dynamic damper for damage or cracking.
lCheck the boots for deterioration, damage or cracking.
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FRONT AXLE Drive Shaft
(4) Fill the specified grease to the T.J. case.
Specified grease: Repair kit grease 105 (3.70 oz.)
NOTE
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses special grease. Do not m ix
old and new or different types of grease.
BOOT BAND BOOT BAND
(LARGE) INSTALLATION
Set the T.J. boot bands at the specified distance in order
to adjust the amount of air inside the
boot, and then
tighten the T.J. boot band securely.
Standard value (A): 80
3 mm (3.15 in.)
INSPECTION26100280076
lCheck the drive shaft for damage, bending or corros ion.
lCheck the inner shaft for damage, bending or corros ion.
lCheck the drive shaft splines for wear or damage.
lCheck the inner shaft splines for wear or damage.
lCheck the spider assembly for roller rotation, wear or
corrosion.
lCheck the groove inside T.J. case for wear or corro sion.
Check the boots for deterioration, damage or cracking.
l Check the center bearing for seizure, discoloration or
roughness of rolling surface.
lCheck the dust cover for damage or deterioration.
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R E A R A X L E
(2) Remove the snap ring with ring
remove the spider assembly.
Caution
Do not disassemble the spider assembly.
(3) In case foreign objects such as water or dust i s mixed
in the grease, be sure to wash the spider assembly.
Caution
In case of having washed the spider assembly, when
assembling it, make sure to push enough grease be-
tween the spider axle and the roller so that grease may not run out.
T.J. BOOT REMOVAL
(1) Wipe the grease off of the spline portion.
(2) Remove the
boot and
N O T E
If the boots are reused, around the
drive shaft spline so that the boots
when they are removed. __
REASSEMBLY SERVICE
B.J. BOOTINSTALLATION
(1) Wrap plastic tape around the drive shaft spline .
(2) the drive shaft in’
. . .,
(3) the inside of the B.J. and B.J. boot with the specified
grease.
grease: Repair kit grease (2.66
NOTE
The grease in the repair kit should be divided in h alf
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses grease. DOnot mix
old and new or different types of grease.
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REAR AXLE Drive Shaft
Lever section.
BOOT BAND BOOT
(LARGE) INSTALLATION
Be careful that the drive shaft should be. straight when
tightening the B.J. boot bands.
Caution
Always check the identification numbers
boot band levers. Never the ‘bands;
section
I
T.J. BOOT/SPIDER CASE
I N S T A L L A T I O N
the drive shaft in T.J. boot.
(2) Install the spider assembly to the shaft from t he direction
, of the section.
(3) After applying specified grease to the T.J. cas e, insert
the drive shaft and apply grease one more time.
Specified grease:
Repair kit grease
95
(3.35
105 (3.70 oz.)
NOTE
The grease in the repair kit should be divided in h alf
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint use special grease. Do not
old and new or different types of grease.
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REAR AXLE Differential
2 0.05 mm in.) Thickness of the spacer on
one side
(2) Push the differential case to ‘one and measure the
clearance between the gear carrier and the bearing.
(3) Measure the thickness the side bearing on
one side, select two pairs of spacers which corresp ond
to that thickness plus one half of the clearance pl us 0.05
mm, and then install one pair each to the drive pin ion
side and the drive gear side.
(4) Install side bearing spacers and differential case as-
sembly, as shown in the illustration;’
the
, .
,.
(5) Tap the side bearing spacers with a brass bar t o fit them
to the side bearing outer race.
(6)Align the mating marks on the gear carrier and the bearing’:
cap, and then tighten the bearing cap.
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FRONT SUSPENSION Shock Absorber
Damper foinstallation
of the body
REASSEMBLY. SERVICE
COIL SPRING INSTALLATION
(1) Use the special tools to
the coil spring and
install it to the shock absorber.
Caution
Do not use an impact wrench to tighten the bolt of
the special tool.
(2) Align the edge of the coil spring to the steppe d part of
the shock
spring seat.
UPPER BRACKET ASSEMBLY
so that the position as’
in the illustration with respect the fork installation
bolt.
. SELF-LOCKING NUT . .
( 1 )
(2). the special tools and
tighten the
to- the ,
Caution
Do not use an impact wrench.
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