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Home >> Mitsubishi >> 1991 >> Eclipse L4-1997cc 2.0L DOHC Turbo >> Repair and Diagnosis >> Transmission and Drivetrain >> Manual Transmission/Transaxle >> Service and Repair >> Overhaul >> Unit Overhaul (F5M33)

Unit Overhaul (F5M33)

Part 1:




DISASSEMBLY AND REASSEMBLY

Part 2:




Part 3:




Part 4:




SEALING AND ADHESION POINTS

SERVICE POINTS OF DISASSEMBLY




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

NOTE: If the spring pin interferes with the synchronizer ring or cone gear, rotate the gear for dislocation and knock out the spring pin.

15./16. REMOVAL OF LOCK NUTS




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




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




3. Install the special tool onto the input shaft.
4. Screw a bolt [10 mm (.40 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.
5. Remove the lock nut, while using the bolt as a spinner handle stopper.




48./49. REMOVAL OF SPRING PINS
Remove the spring pins for 1st-2nd and 3rd-4th speed shift forks using a pin punch.

50. REMOVAL OF SHIFT RAIL ASSEMBLY




1. Shift the 1st-2nd speed shift fork to the 2nd speed.
2. Shift the 3rd-4th speed shift fork to the 4th speed.




3. Remove the shift rail assembly.

INSPECTION




BACKUP LIGHT SWITCH
Operate the backup light switch to check continuity with a circuit tester.
If without continuity replace the switch.

SERVICE POINTS OF REASSEMBLY







64. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.







63. INSTALLATION OF OIL SEAL
Install the input shaft front oil seal using the special tool.




50. INSTALLATION OF SHIFT RAIL ASSEMBLY
1. Set the 1st-2nd speed shift sleeve at 2nd speed.
2. Set the 3rd-4th speed shift sleeve at 4th speed.
3. Fit the shift forks of shift rail assembly to groove of sleeves.




4. Insert the shift rails into the shift 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.




48./49. INSTALLATION OF SPRING PINS
1. Install the spring pins using the special tool or a pin punch.

CAUTION: Do not reuse the spring pins.




2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.




46. INSTALLATION OF REVERSE IDLER GEAR SHAFT
Install in the direction illustrated.

35./37./40./42. INSTALLATION OF SPACERS




1. Place two pieces of solder measuring about 10 mm (.4 in.) in length and 1.6 mm (.06 in.) in diameter as illustrated and install the outer races.
2. Install the transaxle case and tighten the bolts to specified torque.
3. Remove the transaxle case.
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. Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard preload and end play.

Standard value:
Input shaft end play: 0 - 0.05 mm (0 - .002 in.)
Intermediate gear preload: 0.05 - 0.10 mm (.002 - .004 in.)
Output shaft preload: 0.05 - 0.10 mm (.002 - .004 in.)
Differential case preload: 0.05 - 0.10 mm (.002 - .004 in.)




33. INSTALLATION OF OIL SEAL
Install the drive shaft oil seal using the special tool.




27. INSTALLATION OF OIL GUIDE
Install the oil guide to the transaxle case as illustrated.




26. INSTALLATION OF TRANSAXLE CASE
1. Place the selected spacers on the intermediate gear and the differential's bearing outer race. Also insert the selected spacer between the output shaft bearing outer race and the transaxle case.
2. Set so that the threaded hole of the reverse idler gear shaft's head is facing in the direction indicated in the illustration.

NOTE: If there is a great deviation in the direction in which the threaded hole is facing, it will be impossible to align the threaded hole and the hole in the case after the transaxle case is installed.




3. Apply specified sealant to the clutch housing side of the transaxle case.

Specified sealant: MITSUBISHI Genuine Part No.MD997740 or equivalent

CAUTION: Squeeze out sealant from the tube uniformly without excess or discontinuity.

4. Install the transaxle case onto the clutch housing.
5. Insert a Phillips screwdriver [8 mm (.32 in.) shaft diameter] into the bolt hole in the case, as shown in the figure, and use it to align the threaded hole of the reverse idler gear shaft with the bolt hole in the transaxle case.




6. Install the reverse idler gear shaft bolt and tighten the bolt by fingers.
7. Tighten the all transaxle tightening bolts to specified torque.
8. Tighten the reverse idler gear shaft bolt to specified torque.




16./15. INSTALLATION OF LOCK NUTS
1. Install the special tool to the splined end of input shaft.
2. Screw a bolt [10 mm (.40 in.)] into the hole on the periphery of clutch housing and attach a spinner handle to the special tool.




3. Shift the transaxle in reverse using control lever and select lever.
4. Tighten the lock nut to specified torque, while using the bolt attached in the above step as a spinner handle stopper.
5. Loosen the lock nuts.
6. Retighten the lock nuts to the specified torque.
7. Stake the lock nut.




14. INSTALLATION OF SPRING PIN
1. Install the spring pin using the special tool or a pin punch.

CAUTION: Do not reuse the spring pins.




2. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.
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