MITSUBISHI SPYDER 1990 Service Repair Manual

MANUAL TRANSAXLE OVERHAUL
Spacer: (For adjustment of drive bevel gear mount)
Thickness mm (in.)Identification symbol Part No.Thickness mm (in.)Identification symbol Part No.
1.34341.5252
1.37371.5555
1.40401.5858
1.43431.6161
I 0575)46I64
1.4949I67 71
Spacer: (For adjustment of drive bevel gear preload)
Thickness mm (in.) symbol No.
Thickness mm (in.) Identification symbol Part
I 671.58
I 68I
69I
1.37I
I1.70
1.431.73
1.461.76
1.49
I
1.551.85
Spacer: (For adjustment of drive bevel gear mount)
Thickness mm (in.)Identification symbol
0.13
0.16
0.1919
0.2222
0.2525
0.28 IO)28
0.3131
Part No. Thickness mm (in.) Identification symbol No.
0.3434
0.3737
0.4040
0.4343
0.4646
0.4949
0.5252
Spacer: (For adjustment of driven bevel gear preload)
Thickness mm (in.)Identification symbol
119
I22
I25
1.28
28
I31
1.3434
1.37
37
1.40
40
1.4343
I46
1.49
49
I52
1.55
55
No.Thickness mm (in.)Identification symbol Part N O.
1.5858
1.6161
I64
1.6767
1.7070
1.7373
1.7676
1.7979
1.8282
I85 02
1.8888 03
1.9191 04
1.9494 05
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Items
Transaxle
Backup light switch
Bearing retainer bolt
Bell housing cover mounting bolt
Center differential lock actuator mou
Center differential lock indicator
Center differential shift lever
Differential drive gear bolt
Input shaft lock nut
Interlock plate bolt
Intermediate gear lock nut
3324
33
24
Output gear mounting bolt
Poppet plug
Rear cover bolt
Rear cover bolt
Restrict ball
Reverse brake cone machine screw
Reverse idler gear shaft bolt
Reverse shift lever assembly
Select lever mounting bolt
Shift cable bracket mounting bolt
Speedometer sleeve bolt
Starter motor mounting bolt
Stopper bracket bolt
Transaxle case tightening bolt
Transaxle mount bracket mounting
Transaxle mounting bolt mm
Transaxle mounting bolt mm diamet
Transaxle mounting bolt
mm diamet
Transaxle switch
Revision

MANUAL TRANSAXLE OVERHAUL Tools
Items Nm
Transfer
Cover mounting bolt
,
97
Driven bevel gear lock nut
Extension housing150109
Oil drain plug 3324
Oil filler plug3324
Transfer case adapter mounting bolt
Transfer cover mounting bolt
39 29
39
Transfer mounting bolt
5942
SEALANTS AND ADHESIVES
Items
Transaxle case rear cover mating surfacesSpecified sealants and adhesives
Mitsubishi genuine sealant
Part
or equivalent
Transaxle case clutch housing mating surfaces
Adapter-transaxle case mating surfaces
Adapter rear cover mating surfaces
Output gear bolt STUD Locking 70 or equivalent
Differential drive gear bolts
Bearing retainer bolt (Countersink head bolt only)
Air breather
SUPER WEATHERSTRIP or
equivalent
Transfer extension housing
adapter mating
surfaces
Transfer cover gasket Mitsubishi genuine sealant
Part
or equivalent
ATD Part or equivalent
SPECIAL TOOLS
Tool Tool number and Application
Oil seal installer
Oil seal installer
Quantity
As required
As.
As
Asrequired
As required
Installation of
extension
housing oil seal,
Installation of input seal
Revision

nber and nameApplication
General service tool Installation of input shaft
Differential oil seal
Installation of differential oil seal
Removal of gears and
of input shaft, intermediate
and output shaft
Installation and removal of inpu
shaft and intermediate gear
nut
General service tool Installation of differential oil seal
Adjustment of tooth contact and
inspection of turning drive torque
Installation of input shaft rear
snap ring
General service tool Use with installer and adapter
General service tool Use with installer cap and adapter
MANUAL TRANSAXLE OVERHAUL
Special Tools
I
Revision

MANUAL TRANSAXLE OVERHAUL
-Special Tools
Installer adapter (30)
Installer adapter
(38)
Installer adapter (46)
TSB Revision.I

6MANUAL TRANSAXLE OVERHAUL
Special Tools
Installer adapter (56)
ToolApplication
Installation of each bearing
Oil seal installer
Installation of transfer case oil
seal
Handle
Special spannerInstallation and removal of driver
gear lock nut
7
Bearing remover of intermediate
Claw of bearing outer race
General service tool
socket of drive bevel gear
haft rotating torque service tool
gear holding tool
Revision

MANUALTRANSAXLE OVERHAUL Transaxle
TRANSAXLE
DISASSEMBLY AND REASSEMBLY
33N m24
19 Nm14I
36
27Nm
Disassembly steps
1. Bolt 2. Rear cover
3. Reverse brake cone
41 Wave spring 5. Machine screw
6. Backup light switch
7.Gasket8.Poppetplug
9.Poppet spring10.Poppetball
11.Bolt
Lubricate all internaloil
12. Speedometer. driven gear assembly 13. Air breather 14. Spring
15. Lock nut 16. Lock nut17. speed synchronizer assembly
18.
speed shift fork .
19.Synchronizer ring
20. speed gear21.Needle bearing22. speed intermediate gear
TSB Revision

8MANUAL TRANSAXLE OVERHAUL
Transaxle
q 48
39 Nm33 Nm29
24
26
I
2 5
Revision
23
49 Nm36
Disassembly steps
23. Reverse idler gear shaft bolt24. Gasket25.Bolt 26. Transaxle case
27.Oil guide
28.Bolt
29.Spring washer
30.Stopper bracket31. Restrict ball assembly32.Gasket 33. Oil seal
34. Bearing outer race35.Spacer
2210010
36. Bearing outer race 37. Spacer
38. Bearing outer race
Reverse shift lever 42. Reverse shift lever shoe 43. Reverse idler gear shaft
44. Reverse idler gear
45. Spring pin 46. Spring pin 47. Shift rail assembly

MANUAL TRANSAXLE OVERHAUL
Transaxle
Lubricate all internalparts with oil during reassembly.
19 Nm19
54
58
Disassembly steps
Bearing retainer 51. Intermediate gear assembly
52. Input shaft assembly
53. Output shaft assembly
54. Differential gear assembly
55. Bearing outer race
56. Oil guide
57. Bearing outer race
58. Bearing outer race’ 59. Oil seal 60. Oil seal61. Clutch housing assembly
6 2 . M a g n e t
6 3 . M a g n e t h o l d e r
TSB Revision

MANUAL TRANSAXLE
. .
33N m24
19 Nm14
36
27
45
Disassembly steps
1.Bolt2.Rear cover3. Reverse brake cone 4. Wave spring 5. Machine
switch
Poppet plug9.
10.Poppet spring
Poppet ball
11.Bolt
Revision
12. Speedometer driven gear assembly 13. Air breather14.Spring pin
15. Lock nut 16. Lock nut
17. synchronizer assembly
1.8. fork 19.
20.gear bearing,:,22. gear