MITSUBISHI SPYDER 1990 Service Repair Manual

MANUAL TRANSAXLE OVERHAUL,
Center
Side
DISASSEMBLY SERVICE
ROLLER REMOVAL
Remove-the taper roller bearings ‘using the special
NOTE
(1) Do not reuse the bearing removed from shaft.
(2) Replace the inner and
races the taperroller
bearing as a set.
REASSEMBLY SERVICE POINTS
I N S T A L L A T I O N
(1) Install the spacer, side gear, pinion gear,
and
pinion shaft to the center differential
(2) Holding down the pinion shaft, select the of maxi-
mum thickness that allows the pinion gear to
and install it to the shaft.
(3) Install the side gear, spacer and output gear
the bolt to the specified torque.
(4) Select the spacer of maximum thickness that all ows the
side gear to turn lightly and install it.
Check that both side gears turn lightly.
Standard,
Center differential side gear end play:
mm in.) .
TAPER ROLLER BEARINGS INSTALLATION
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Center Differential
TSB Revision
(1) Apply the specified sealant the threads.,
Specified sealant:
Stud Locking or equivalent,
Tighten to the specified torque following order
given in the illustration.
TAPER ROLLER BEARINGS
NOTE
Apply the special tool to the inner race
the bearing.

MANUAL TRANSAXLE OVERHAUL
Shift Fork
SHIFT FORK.
DISASSEMBLY AND REASSEMBLY
1
Disassembly steps
1. speed shift fork
2. speed shift fork
3. speed shift rail
4. speed shift rail
Reverse shift lug
, 0
speed shift rail
2201088
5. Interlock plunger 6. speed shift rail
7. Reverse shift lug
REASSEMBLY SERVICE POINT
INTERLOCK PLUNGER INSTALLATION

MANUAL TRANSAXLE OVERHAUL
Speedometer Gear .
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
,
Lubricate all internalparts with engine oil during reassembly.
Disassembly steps
1. e-clip driven gear
Sleeve
S E R V I C E
SPEEDOMETER DRIVEN GEAR
Apply gear oil sparingly to the speedometer gear shaft
and insert the shaft.
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Housing
CLUTCH HOUSING
DISASSEMBLY AND REASSEMBLY
19 Nm14
24 Nm
16
Lubricate all internalparts with engine oil
during reassembly.
22100019
Disassembly steps
1.Bolt2. Select lever assembly3.Select lever shoe4. Interlock plate bolt5.Gasket 6. Lock pin
7. Spring pin 8. Neutral return spring
9.Stopper body10.Controlfinger
1
Interlock plate
12. Neutral return spring assembly
13. Control shaft
14. Control shaft boot
15. Oil seal 16. Needle 17. Needle,
Return spring
21. plate
22. Spring pin
TSB Revision

MANUAL TRANSAXLE OVERHAUL Clutch Housing
2200064
Extension barsocket wrenchI
Needle bearing
DISASSEMBLY SERVICE
,
Caution
When removing the lock pin, turn the control lever to
such position that the lock pin will not contact the clutch
housing.
SPRING PIN REMOVAL
Caution
When spring pin, pull control shaft
the direction illustrated so that the pin will not
contact the clutch housing.
NEEDLE BEARING REMOVAL
REASSEMBLY SERVICE POINTS
NEEDLE
(1) Install the needle bearing flush surface A of
the
housing using a
(2) Install with the part type stamped the
A. . . .ii
TSB Revision

MANUAL TRANSAXLE OVERHAUL
Clutch Housina
bar socketwrench
Extension bar
socket wrench
SEAL INSTALLATION
PIN LOCK PIN
Caution
lDo not reuse the spring pin and lock pin.
lInstall the spring pin In such a way its will
at right angle to the control shaft center.
TSB RevisionI

M A N U A L T R A N S A X L E .
TRANSFER
DISASSEMBLY AND REASSEMBLY
I
39Nm28
I
Lubricate all internal
, with engine oil
during reassembly.. .
Disassembly steps
1. Cover 2. Cover gasket 3. Extension housing assembly
4. Transfer case subassembly
5. Spacer
6. O-ring7. Transfer case adapter sub-assembly
T S B R e v i s i o n

MANUAL TRANSAXLE OVERHAUL
R E A S S E M B L Y
B A C K L A S H A D J U S T M E N T ,
(1) a light and uniform coat
lead to the driven bevel gear teeth
brush.
using.
,
.
(2) install the spacer that has
., ,,
,
.
(3)Align the transfer drive bevel gear mating
, ,
(4) Align the transfer case adapter and drive bevel gear mating
marks.
(5) Assemble the transfer case and transfer case ad apter
and tighten to the specified torque.
(6) With the mating marks” aligned as in
that the transfer case and gear mating marks
are matched looking from the cover.’

22
MANUAL TRANSAXLE
(7) Turn the drive bevel gear shaft (one. forward turn,
reverse turn) using the special
NOTE.
Do not turn the drive bevel shaft more than one
turn in either direction as this will ‘cause an unclear tooth
contact pattern.
(8) Check to see if the drive tooth contact is normal.
NOTE
Refer to the TOOTH CONTACT
PROCE-
DURES on page for the standard tooth contact.
(9) Check to see if the drive bevel gear and driven bevel
backlash is as specified.
Standard value: Bevel gear set
mm
O-RING INSTALLATION’
Caution
Apply oil to the Q-ring,
H O U S I N G .
Apply sealant to the adapter flange surface and
the
extension housing.
Specified sealant: Mitsubishi genuine Sealant
or
equivalent
NOTE
Squeeze out sealant from the ‘tube uniformly and
continuously in adequate amount.
TSB Revision