MITSUBISHI SPYDER 1990 Service Repair Manual

T R A N S A X L E
CONTENTS
CENTER DIFFERENTIAL . . . . . .60
CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . .65
DIFFERENTIAL. . . . . . . . . . . . . . . . . .57. . . . . . . .
DRIVE BEVEL GEAR
. . . . . . . . . . .76
DRIVEN BEVEL GEAR . . . . . . . . . .80
EXTENSION. . . . . . . . . .73
SYNCHRONIZER . . . . . . . . . . . . . .36
FRONT OUTPUT SHAFT . . . . . . . .56
GENERAL INFORMATION. . . . . . . . . . . . . . . . . .2
INPUT SHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . .38
INTERMEDIATE GEAR. . . . . . . . . . . . . . . . . . . .48
OUTPUT SHAFT . . . . . . . . .
55
SHIFT 3SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . . . . . .13
SPECIFICATIONS. . . . . . . . . . . . . . . . . ... . . . . . . .
G e a r R a t i o T a b l e . . .
...
. . . . . . . . . . . . . . . . . . . . . .5
Sealants and Adhesives . . . . . . . . . . . . . . . . . . . . .13
Service Specifications . . . . . . .6
Service Specifications . . . . .. . . . . . . .6
Snap Rings and Spacers for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . .12
Transaxle Model Table. . . . . . . . . . . . . .. . . . . . .5
SPEEDOMETER GEAR. . . . . . . . . . . . . . . . . . . .64
TRANSAXLE. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .17
TRANSFER . . . . . . . . . . . . . . . . . . . 68
TRANSFER CASE . . . . . . . . . . . . .
TRANSFER CASE ADAPTER .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .76

MANUAL. TRANSAXLE OVERHAUL General
GENERAL
ClutchBearing retainer
Input shaft
speed
synchro-
nizer
1 speed gear
22200010055
ed gear
speed gearI
speed gear
Rear cover
Reverse
brake device
speed
intermediate gear
Intermediate gear
spacer
Output shaft
Drain plug S p a c e r
Revision

MANUAL TRANSAXLE OVERHAUL Information
SECTIONAL VIEW
Clutch housingBearing retainer
speed gear
speed gear
1 speed gearI speed synchronizer assembly
Input shaft
1
I
Rear cover
Reverse
brake
gear
gear
S p a c e r
Output
Differentialdrive gear
Spacer
Drain plug Spacer
case
Differential
TSB Revision

MANUAL TRANSAXLE OVERHAUL Information
Clutch housing speed gear
I
speed synchronizer assembly
speed gear
Bearing retainerI
Sub gearIntermediate gear
Revision
speed gear
speed synchronizer assembly
speed gear
speed gear
speed
synchronizer
Center differential
Frontoutput shaft
Front differential
coupling

MANUAL TRANSAXLE OVERHAUL
SPECIFICATIONS
Transaxle modelGear ratioSpeedometer
gear ratio
A
Final gear ratio
3.625Vehicle model m o d e l ”
. .
4.153
Items
3.166 3.090
1.833 1.833.
1.240
1.217, ,
0.8960.888
0.731 0.741 0.666
Reverse
Transfer 3.1663.166
3.166
1.090
TSB Revision

MANUAL, TRANSAXLE OVERHAUL
Items
Differential case preload mm (in.)
Differential pinion backlash mm (in.)
Input shaft front bearing end play
mm (in.)
Input shaft end play
mm (in.)
Input shaft rear bearing end play mm (in.)
Intermediate gear bearing end play
mm (in.)
Intermediate gear bearing end play
mm (in.)
Intermediate gear preload mm (in.)
shaft preload mm (in.)
Standard value .
Center differential case end play mm (in.)
Center differential side gear end play mm (in.)
Front differential case end play mm (in.)
Front differential pinion backlash mm (in.)
Front output shaft preload mm (in.)
Input shaft end play mm (in.)
Input shaft front bearing end play mm (in.)
Input shaft rear bearing end play mm (in.) Intermediate gear bearing end play mrn (in.)
Intermediate gear preload mm (in.)
Transfer bevel gear set backlash mm (in.)
drive bevel gear rotating torque Nm
driven bevel gear rotating torque Nm
coupling end play mm (in.) Standard value
1.7-2.5
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Snap ring (For adjustment of input shaft front bearing end play)
Thickness mm (in.)identification symbolPart No.Thickness mm (in.) Identification symbolPart No.
2.24None 2 . 3 8 Brown
2.31Blue
Snap ring (For adjustment of input shaft rear beari ng end play)
Thickness mm (in.)Identification symbolPart No.Thickness mm (in.)
1.40
Blue 1 . 6 0
1.45Purple 1 . 6 5
1.50Red 1 . 7 0
1.55White 1 . 7 5
S p a c e r : (For adjustment of input shaft end play)
Thickness mm (in.)Identification symbol
0.8080
0.83
83
0.86
86
0.8989
0.92
92
0.9595
0.9898
1
1.0404
1.0707
1
1.13
Part No.
0454
Thickness mm (in.)
1.16
1.19
1.22
1.25
1.28
1.31
1.34
1.37
1.40
1.43
Identification symbol No.
Yellow
Brown
Green
Orange
Identification symbol
0
Snap ring: (For adjustment of intermediate rear front bearing end play)P a r t N o .
6457
Thickness mm (in.)Identification symbolPart No.Thickness mm (in.) Identification symbol Part
1.40None 1 . 6 0 Blue
1.50Brown
Snap ring: (For adjustment of intermediate gear front bearing
end play)
Thickness mm (in.) Identification symbol
1.40
1.50
Blue
RedPart No.
Thickness mm (in.) symbol No.
1 . 6 0 Yellow
1 . 7 0 Green
Revision

MANUAL TRANSAXLE OVERHAUL
Spacer: (For adjustment of intermediate gear end play)
Thickness mm (in.)Identification symbol Part No.Thickness mm (in.) Part
0.62621.0101 49
0.65
651.0404
0.68681.0707 51
0.71711.1010
0.74741.1313
0.77771.1616
0.80801.1919 55
0.83
83 431.2222
0.8686 441.2525
0.8989 451.2828 58
0.92
921.3131 59
0.95
951.3434 60
0.9898 481.3737
Spacer: (For adjustment of intermediate gear preload)
Thickness mm (in.) Identification syrnbol Part No.
Thickness mm (in.) Identification symbolPart No.
0.80801.1313
0.83831.1616
0.86861.19190.89891.22
22
0.92921.25252346’
0.95951.28282347
0.98981.3131 2348
1011.3434
1.04041.3737
1.07071.4040
1.10
101.4343
Spacer: (For adjustment of end play)
Revision
,Thickness mm (in.) Identification symbol
Part No.
Thickness mm (in.) Identification symbolPan No.
0.838310454
0.86
861
0.89891.16 0455
0.9292
0.95951.22
0.98981.25 0457
1011.280456
1.04041.31
1.07071.340 0459

MANUALTRANSAXLE OVERHAUL
Spacer: (For adjustment of fron
Identification symbol Thickness mm (in.)
0.56 56
0.6565
0.7474
0.8383
0.9292
differential case end play)
Part No.Thickness mm (in.) Identification symbolPart No.
101
1 . 1 0
1
1 . 2 8 0458
1 . 3 7 0460
Spacer: (For adjustment of front differential case end play)
Identification symbolThickness mm (in.)Identification symbolPart No.Thickness mm (in.)
0.80800.92
0.83830.95
0.86860.98
0.89891
1.04041
1.07071.19
1 04541.22
1.131.25
Part No.
P a r t N o .
80675
92
95
98
01
Spacer (For adjustment of front differential pinion backlash)
Identification symbolThickness mm (in.)Identification symbolThickness mm (in.) No.
80862
80861
80860
Spacer: (For adjustment of front output shaft preload)
Identification symbolPart No.Thickness mm (in.)Identification symbolPart No.
1.28
671.61
1.31 681.64
1.34 691.67
1.371.70
1.73
1.431.76
1.461.79
1.491.82
1.521.85
1.551.88
1.581.91
Thickness mm (in.)
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Snap ring: [For adjustment of viscous coupling end play (with VCU)]
Thickness mm (in.)Identification symbolPart No. Thickness mm (in.) Identification symbolPart No.
1.3
1.4
1.5
1.6
Orange
Red
Blue
None
1.7
1.8
1.9
White
Yellow
Green
Spacer: (For adjustment of center differential pinion back lash front side)
Thickness mm (in.)Identification symbolPart No.Thickness mm (in.)Identification symbolPart No.
2.25-2.32
2.33-2.42
412
410
409
2.59-2.66
2.67-2.74
2.75-2.82
4 3
2
408
407
405
Spacer: (For adjustment of center differential case preloa d)
Thickness mm (in.)Identification symbol
1.13
13
1.1616
1.1919
1.222 2
1.2525
1.2828
1.3131
1.3737
1.4040
1.43
43
1.4646 Part No.
66
8520
8522
8523
Revision
Thickness mm (in.)
Identification symbolPart No.
1.49
49 8524
1.5252 8525
1.5555 8526
1.5858 8527
1.6161 8528
1.6464 8529
1.6787 8530
1.7070 8531
1.73
73 959
1.7676 960
1.7979
Spacer: (For adjustment of center differential pinion back lash, rear side)
Thickness mm (in.)IdentificationPart No.Thickness mm (in.)Identification symbol No.
74 1 78
501 1.0876
8077
7949