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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 >> Transaxle Assembly

Transaxle Assembly

Part 1:




DISASSEMBLY AND REASSEMBLY

Part 2:




Part 3:




Part 4:




Part 5:




SEALING AND ADHESION POINTS




ADHESION POINT

SERVICE POINTS OF DISASSEMBLY




14. REMOVAL OF SPRING PIN
Remove the spring pin using the pin punch.

15./16. REMOVAL OF LOCK NUTS




1. Unstake lock nuts of the input shaft and intermediate gear.




2. Shift the transaxle into reverse using the control lever and select lever.




3. Install the special tool on the input shaft.
4. Install the spinner handle and 10 mm (.039 in.) bolt.




5. Remove the lock nuts.




24. REMOVAL OF VISCOUS COUPLING
Using a flat-blade screwdriver, pry off the viscous coupling little by little.




35. REMOVAL OF OUTER RACE
Using the special tool, remove the outer race.




54./55. REMOVAL OF SPRING PINS
Remove the spring pins using the pin punch.




56. REMOVAL OF SHIFT RAIL ASSEMBLY
1. Shift the 1st-2nd speed shift fork into 2nd speed.
2. Shift the 3rd-4th speed shift fork into 4th speed.




3. Rotate the shift controls in the direction of the arrow in numerical order. Remove the shift lugs from the control finger and interlock plate.
4. Raise each of the shift rails upward and remove them from the clutch housing.
5. Remove the all shift rails and forks.




59. REMOVAL OF INTERMEDIATE GEAR ASSEMBLY/60. INPUT SHAFT ASSEMBLY
Lift up the input shaft assembly and remove the intermediate gear assembly.




61./62./64. REMOVAL OF OUTER RACE
Using the special tool, remove the outer race.

SERVICE POINTS OF REASSEMBLY




69. INSTALLATION OF MAGNET HOLDER/68. MAGNET
Install the magnet and magnet holder, ensuring they are installed in the correct direction.




67. INSTALLATION OF OIL SEAL
Using the special tool, install the rear output shaft oil seal.










66. INSTALLATION OF OIL SEAL
Using the special tool, Install the drive shaft oil seals, making sure that the seal for each side is in its proper location.

CAUTION: Make sure that the notch in the L.H. oil seal flange is on the up side where it is installed.




65. INSTALLATION OF OIL SEAL
Using the special tool, install the input shaft front oil seal.




60. INSTALLATION OF INPUT SHAFT ASSEMBLY/59. INTERMEDIATE GEAR ASSEMBLY
Lifting up the input shaft assembly, install it together with the intermediate gear assembly.




56. INSTALLATION OF SHIFT RAIL ASSEMBLY
1. Shift the 1st-2nd synchronizer sleeve into 2nd speed.
2. Shift the 3rd-4th synchronizer sleeve into 4th speed.
3. Fit the shift forks of shift rail assembly to their groove of sleeves.




4. Install the shift rails, rail holes of clutch housing.
5. Turn the shift rails in the directions indicated by the arrows in the order shown in the illustration, and engage the shift lugs. to control finger and interlock plate.




55./54. INSTALLATION OF SPRING PINS
Using the special tool, drive the spring pins into position. Make sure that the slit in the spring pin is aligned with the shift rail centerline.

CAUTION: Do not reuse the spring pins.




46. INSTALLATION OF OIL SEAL
Using the special tool, install the drive shaft oil seal.




44./43. INSTALLATION OF SPACER
1. Place two pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.06 in.) dia. solder at the locations shown on the transaxle case and install each outer race.




2. Place two pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.06 in.) dia. solder at the locations shown on the bearing outer race.
3. Install the transaxle case, and tighten bolts to specification.
4. Remove the transaxle case.
5. Remove the outer races and remove the solder.
6. If the solder is not broken, carry out the work in steps (1)-(5) with large diameter solder.




7. Using a micrometer, measure the thickness of the flattened solder and select a spacer of a thickness that gives the specified end play and preload.

Standard values:
Front output shaft preload: 0.08 - 0.13 mm (0.0031 - 0.005 in.)
Front differential case end play: 0.05 - 0.17 mm (0.0020 - 0.007 in.)







41./40. INSTALLATION OF OIL GUIDE
Install the oil guide or the transaxle case.




36. INSTALLATION OF REVERSE IDLER GEAR SHAFT BOLT
1. Center the shaft with a screwdriver [shaft diameter 8 mm (.31 in.) or similar object].
2. Tighten the reverse idler gear shaft bolt to specification.




33./31./29 INSTALLATION: OF SPACER
1. Place two pieces of approximately 10 mm (0.39 in.) long, 1.6 mm (0.06 in.) dia. solder at the locations shown on the transaxle case adapter assembly and install each outer race.
2. Install the transaxle case adapter assembly and rear cover, and tighten bolts to specification.
3. Remove the transaxle case adapter assembly and rear cover.




4. Remove the outer races and remove the solder.
5. If the solder is not broken, carry out the work in steps (1)-(4) with large diameter solder.
6. Using a micrometer, measure the thickness of the flattened solder and select a spacer of a thickness that gives the specified end play and preload.

Standard values:
Input shaft end play: 0 - 0.05 mm (0 - 0.0020 in.)
Intermediate gear preload: 0.08 - 0.14 mm (0.0031 - 0.0055 in.)
Center differential case preload: 0.08 - 0.13 mm (0.0031 - 0.005 in.)




25. INSTALLATION OF STEEL BALL
Move the center shaft so that the steel ball is seated securely into the groove in center shaft.




23. INSTALLATION OF SNAP RING
Select the snap ring so that the end play in the viscous coupling is up to specification.

Standard value: 0.1 to 0.26 mm (0.0039 to 0.0102 in.)




18. INSTALLATION OF SHIFT FORK/17. 5TH SPEED SYNCHRONIZER ASSEMBLY
Mate the 5th speed shift fork with the 5th gear synchronizer assembly and install them simultaneously.




16./15. INSTALLATION OF LOCK NUTS
1. Shift the transaxle into reverse using the control lever and select lever.




2. Install the special tool on the input shaft.
3. Fit on the spinner handle and bolt.




4. Tighten the lock nut to specification and then loosen it completely before tightening it again to the specified torque.




5. Punch the lock nut into locked position.
(Punch two places on the lock nut of the input shaft and one place on the lock nut of the intermediate gear.)




14. INSTALLATION OF SPRING PIN
1. Using the special tool, drive the spring pin into position.
2. Make sure that the slit in the spring pin is aligned with the shift rail centerline.

CAUTION: Do not reuse the spring pin.
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