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Home >> Mitsubishi >> 1991 >> Eclipse AWD L4-1997cc 2.0L DOHC Turbo >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul >> Input Shaft Assembly

Input Shaft Assembly




DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY




1. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the front bearing.




2. REMOVAL OF BEARING SLEEVE
Remove the bearing sleeve using the special tool as illustrated.




4. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the bearing sleeve and rear bearing.
15. REMOVAL OF 3RD SPEED GEAR
Using the special tool, remove the bearing sleeve, 3rd-4th speed synchronizer assembly, and 3rd speed gear.

INSPECTION




INPUT SHAFT
- Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear, and seizure (portion (A)).
- Check the splines for damage and wear.




NEEDLE BEARING
- Mate the needle bearing with the shaft or bearing sleeve and gear, and check to see if rotation is smooth with no binding, noise, or play.
- Check the needle bearing cage for possible deformation.




SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check the cone inside paper lining for damage, wear or peeling.




- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if the clearance is below the limit.

Limit: 0.5 mm (.020 in.)




SYNCHRONIZER SLEEVE AND HUB
- Mate the synchronizer sleeve with the hub and check to see if they slide smoothly.
- Check to see if the sleeve is free from damage at its inside front and rear ends.
- Check the hub front and rear end faces (in contact with each speed gear) for wear.

CAUTION: When replacement is necessary, replace the synchronizer hub and sleeve as a set.




SYNCHRONIZER KEY AND SPRING
- Check the synchronizer key center protrusion for wear.
- Check the spring for proper tension, possible deformation and breakage.




SPEED GEARS
- Check the bevel and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surfaces, damage, and wear.
- Check the gear bore and front and rear ends for damage and wear.

SERVICE POINTS OF REASSEMBLY




18. INSTALLATION OF SUB GEAR/17. CONE SPRING/16. SNAP RING
Install the sub gear and cone spring to 3rd speed gear, and then install the snap ring.

NOTE: Be sure that the cone spring is installed so that it is facing in the correct direction.




10. INSTALLATION OF SYNCHRONIZER SPRINGS
1. Install the synchronizer spring so that its protrusion fits into the groove in synchronizer key. Make sure that the protrusions in the front and rear springs are not in the groove of the same key.




9. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER ASSEMBLY
1. Install the synchronizer assembly so that the part that has the small round indentation is in the oil groove at the hub end.

NOTE: If the installation is in the opposite way, press-in might not be possible. This is because the edge of the hub inner diameter spline at the part that has the small round indentation is made to facilitate pressing in.

2. Using the special tools, press-fit the 3rd-4th speed synchronizer assembly over the input shaft.

CAUTION:
1. When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves in the synchronizer ring.
2. After installing the synchronizer assembly, check to see if the 3rd speed gear rotates smoothly.




7. INSTALLATION OF BEARING SLEEVE
Using the special tool, press-fit the bearing sleeve.




4. INSTALLATION OF TAPER ROLLER BEARING
Using the special tools, press-fit the bearing over the input shaft.

CAUTION: Apply the special tool to the inner race only when installing the bearing.




3. INSTALLATION OF SNAP RING
1. Select the thickest snap ring that fits in the snap ring groove.

Standard value: 0.01 - 0.09 mm (.0004 - .0035 in.)




2. Using the special tool, fit the snap ring to the input shaft.

NOTE:
1. Do not reuse the snap ring.
2. The use of snap ring plier can cause the snap ring to expand too much, making correct installation of the sleeve difficult.




2. INSTALLATION OF BEARING SLEEVE
Using the special tool, install the bearing sleeve over the input shaft.

CAUTION: When the sleeve has been press-fitted over the input shaft, make sure that the sleeve flange is in tight contact with the bearing.




1. INSTALLATION OF BALL BEARING
Using the special tool, press-fit the ball bearing over the input shaft.
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