Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Eclipse & Spyder 2000-2006 Approved Mitsubishi Eclipse 2006 GR00003700-22A

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22A-1

GROUP 22A

MANUAL
TRANSAXLE
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 22A-2 TRANSAXLE CONTROL . . . . . . . . . . 22A-11
REMOVAL AND INSTALLATION . . . . . . . . 22A-11
MANUAL TRANSAXLE DIAGNOSIS 22A-5
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . 22A-5 TRANSAXLE ASSEMBLY . . . . . . . . . 22A-17
TROUBLESHOOTING STRATEGY . . . . . . 22A-5 REMOVAL AND INSTALLATION <5M/T> . 22A-17
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 22A-5 REMOVAL AND INSTALLATION <6M/T> . 22A-20
SYMPTOM PROCEDURES . . . . . . . . . . . . 22A-5
SPECIFICATIONS . . . . . . . . . . . . . . . 22A-24
SPECIAL TOOLS. . . . . . . . . . . . . . . . 22A-9 FASTENER TIGHTENING
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 22A-24
ON-VEHICLE SERVICE. . . . . . . . . . . 22A-10 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 22A-24
TRANSMISSION OIL LEVEL CHECK . . . . 22A-10
TRANSMISSION OIL REPLACEMENT . . . 22A-10
22A-2 MANUAL TRANSAXLE
GENERAL DESCRIPTION

GENERAL DESCRIPTION
M1221000100826

ITEM SPECIFICATION
Transaxle model F5M42 F6MBA
Engine model 2.4L Engine 3.8L Engine
Transaxle type 5-speed forward, 1-speed 6-speed forward, 1-speed
reverse constant mesh reverse constant mesh
Transaxle gear 1st 3.583 3.214
ratio 2nd 1.947 2.238
3rd 1.379 1.535
4th 1.030 1.171
5th 0.767 1.085
6th - 0.790
Reverse 3.363 3.456
Final reduction ratio 4.312 3.777 (1st, 2nd, 3rd, 4th)
3.238 (5th, 6th, Reverse)
Speedometer gear ratio 28/36 25/33

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MANUAL TRANSAXLE
GENERAL DESCRIPTION
22A-3
SECTIONAL VIEW <5M/T>

1 2 3 4 5

15 14 13 12 11
16 10

AC309077AC

1. 4TH SPEED GEAR 9. DIFFERENTIAL
2. 3RD- 4TH SPEED SYNCHRONIZER HUB 10. 1ST SPEED GEAR
3. 3RD SPEED GEAR 11. 1ST- 2ND SPEED SYNCHRONIZER HUB
4. TRANSAXLE CASE 12. 2ND SPEED GEAR
5. CLUTCH HOUSING 13. 5TH SPEED GEAR
6. REVERSE BEARING RETAINER 14. 5TH-REVERSE SPEED SYNCHRONIZER HUB
7. INPUT SHAFT 15. REVERSE GEAR
8. OUTPUT SHAFT 16. REVERSE IDLER GEAR

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22A-4 MANUAL TRANSAXLE
GENERAL DESCRIPTION

<6M/T>
6 7
5 8

3
2
1 4

18
17 14
15
16

AC500287AC

1. 6TH SPEED GEAR 10. INPUT SHAFT
2. 5TH- 6TH SPEED SYNCHRONIZER HUB 11. OUTPUT SHAFT NO.1
3. 5TH SPEED GEAR 12. DIFFERENTIAL
4. REVERSE SPEED SYNCHRONIZER HUB 13. 1ST SPEED GEAR
5. REVERSE SPEED GEAR 14. 1ST- 2ND SPEED SYNCHRONIZER HUB
6. REVERSE IDLER GEAR 15. 2ND SPEED GEAR
7. TRANSAXLE CASE 16. 4TH SPEED GEAR
8. CLUTCH HOUSING 17. 3RD- 4TH SPEED SYNCHRONIZER HUB
9. OUTPUT SHAFT NO.2 18. 3RD SPEED GEAR

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MANUAL TRANSAXLE
MANUAL TRANSAXLE DIAGNOSIS
22A-5
MANUAL TRANSAXLE DIAGNOSIS
INTRODUCTION
M1221006900756
The manual transaxle can exhibit any of the following The causes of these symptoms could come from:
symptoms: noise or vibration is generated, oil leaks, incorrect mounting, the oil level may be low, or a
shifting gears is hard or troublesome, or the tran- component of the transaxle may be faulty.
saxle jumps out of gear.
TROUBLESHOOTING STRATEGY
M1221007000671
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
manual transaxle fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1221007100667

SYMPTOM INSPECTION PROCEDURE REFERENCE PAGE
Noise, vibration 1 P.22A-5
Oil leaks 2 P.22A-7
Hard shifting 3 P.22A-7
Jumps out of gear 4 P.22A-8

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Noise, Vibration

DIAGNOSIS

STEP 1. Check the idle speed.
Q: Does the idle speed meet the standard values?
YES : Go to Step 2.
NO : Refer to GROUP 11A <2.4L Engine>, On-vehicle
Service -Curb Idle Speed Check P.11A-13 or
GROUP 11C <3.8L Engine>, On-vehicle Service -
Curb Idle Speed Check P.11C-15.

STEP 2. Check whether the transaxle and engine mount is
loose or damaged.
Q: Are the transaxle and engine mount loose or damaged?
YES : Tighten or replace the part. Then go to Step 7.
NO : Go to Step 3.

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22A-6 MANUAL TRANSAXLE
MANUAL TRANSAXLE DIAGNOSIS

STEP 3. Check that the oil level is up to the lower edge of
the filler plug hole.
Q: Is the oil level up to the lower edge of the filler plug
hole?
FILLER PLUG
HOLE YES : Go to Step 4.
NO : Refill DiaQueen NEW MULTI GEAR OIL 75W -80
(GL-3). Then go to Step 7 .

TRANSMISSION FILLER PLUG
OIL
AC102278AD

STEP 4. Check for the specified oil.
Q: Is the specified DiaQueen NEW MULTI GEAR OIL 75W -
80 (GL-3)?
YES : Go to Step 5.
NO : If in doubt, replace the oil (Refer to P.22A-10). Then
go to Step 7.

STEP 5. Remove the transaxle. Check the end play of the
input and output shafts.
Q: Does the end play of the input and output shafts meet
the standard value?
YES : Go to Step 6.
NO : Adjust the end play of the input and output shafts.
Then go to Step 7.

STEP 6. Disassemble the transaxle. Check the gears for
wear and damage.
Q: Are the gears worn or damaged?
YES : Replace the gears. Then go to Step 7.
NO : Go to Step 7.

STEP 7. Retest the system.
Q: Is the noise or vibration still there?
YES : Return to Step 1.
NO : The procedure is complete.

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MANUAL TRANSAXLE
MANUAL TRANSAXLE DIAGNOSIS
22A-7

INSPECTION PROCEDURE 2: Oil Leaks

DIAGNOSIS STEP 2. Visual check at the clutch housing.
Q: Do oil leaks appear around the joint between the
STEP 1. Visual check. engine and the clutch housing?
Raise the vehicle, and check for oil leaks. If the oil YES : Remove the transaxle. Check the input
leak is difficult to locate, steam clean the transaxle shaft oil seal, and replace if necessary.
and drive the vehicle for at 10 minutes. Then check Then go to Step 4.
the leak again. NO : Go to Step 3.
Q: Is the oil leak(s) found?
YES : Go to Step 2. STEP 3. Check the oil seal or O-ring for damage.
NO : Check for the oil leak(s) around the engine.
Q: Is the oil seal or O-ring damaged?
Then go to Step 4.
YES : Replace the oil seal or the O-ring. Then go
to Step 4.
NO : Go to Step 4.

STEP 4. Check trouble symptoms.
Q: Is the oil still leaking?
YES : Return to Step 1.
NO : This diagnosis is complete.

INSPECTION PROCEDURE 3: Hard Shifting

DIAGNOSIS STEP 4. Remove and disassemble the transaxle.
Check the control housing <5M/T> or selecting
STEP 1. Check the transaxle control bell-crank assembly and control bell-crank dust
cover and the shift and select lever shaft <6M/T>.
Q: Are the shift cable and the select cable in good
condition? Q: Is the control housing in good condition?
YES : Go to Step 2. YES : Go to Step 5.
NO : Repair or replace the shift cable and the NO : Repair or replace the control housing (Refer
select cable (Refer to P.22A-11). Then go to to GROUP 22B, Transaxle P.22B-6)
Step 7. <5M/T> or the selecting bell-crank assembly
and control bell-crank dust cover and the
shift and select lever shaft (Refer to GROUP
STEP 2. Check the transaxle oil.
22C, Transaxle P.22C-6) <6M/T>. Then go
Q: Is the oil dirty? to Step 7.
YES : Replace the oil (Refer to P.22A-10). Then
go to Step 7 .
STEP 5. Check for poor meshing of worn
NO : Go to Step 3.
synchronizer ring and gear cone.
Q: Is poor meshing or worn synchronizer ring and
STEP 3. Check the clutch system.
gear cone found?
Q: Is the clutch system normal? YES : Repair or replace the synchronizer ring and
YES : Go to Step 4. gear cone. Then go to Step 7.
NO : Repair or replace the clutch system (Refer NO : Go to Step 6.
to GROUP 21A P.21A-3). Then go to Step
7.

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22A-8 MANUAL TRANSAXLE
MANUAL TRANSAXLE DIAGNOSIS

STEP 6. Check the synchronizer spring for STEP 7. Retest the system.
weakness. Q: Is the shifting of the gears still hard?
Q: Is the synchronizer spring weak? YES : Return to Step 1.
YES : Replace the synchronizer spring. Then go NO : The procedure is complete.
to Step 7.
NO : Go to Step 7.

INSPECTION PROCEDURE 4: Jumps Out of Gear

DIAGNOSIS STEP 4. Check the gear shift forks for wear.
Q: Is the gear shift forks worn?
STEP 1. Check the transaxle control YES : Replace the gear shift fork (Refer to
Q: Are the shift cable and the select cable in good GROUP 22B, Transaxle P.22B-6 <5M/T> or
condition? GROUP 22C, Transaxle P.22C-6 <6M/T>).
YES : Go to Step 2. Then go to Step 6 .
NO : Repair or replace the shift cable and the NO : Go to Step 5.
select cable (Refer to P.22A-11). Then go to
Step 6. STEP 5. Check the clearance.
Q: Is the clearance between the synchronizer hub and
STEP 2. Remove and disassemble the transaxle. sleeve excessive?
Check the poppet spring <5M/T> or lock ball YES : Replace the synchronizer hub or sleeve
assembly <6M/T> for breakage. (Refer to GROUP 22B, Input Shaft
Q: Is the poppet spring or lock ball assembly broken? P.22B-16, Output Shaft P.22B-24 <5M/T>
YES : Replace the poppet spring (Refer to or GROUP 22C, Output Shaft P.22C-28,
GROUP 22B, Transaxle P.22B-6) <5M/T> P.22C-38 <6M/T>). Then go to Step 6.
or the lock ball assembly (Refer to GROUP NO : Go to Step 6.
22C, Transaxle P.22C-6) <6M/T>. Then go
to Step 6. STEP 6. Check trouble symptoms.
NO : Go to Step 3.
Q: Does the transaxle still jumps out of gear?
YES : Return to Step 1.
STEP 3. Check the control housing <5M/T> or NO : This diagnosis is complete.
selecting bell-crank assembly and control
bell-crank dust cover and the shift and select
lever shaft <6M/T>.
Q: Is the control housing in good condition?
YES : Go to Step 4.
NO : Repair or replace the control housing (Refer
to GROUP 22B, Transaxle P.22B-6)
<5M/T> or the selecting bell-crank assembly
and control bell-crank dust cover and the
shift and select lever shaft (Refer to GROUP
22C, Transaxle P.22C-6) <6M/T>. Then go
to Step 6.

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MANUAL TRANSAXLE
SPECIAL TOOLS
22A-9
SPECIAL TOOLS
M1221000600791

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION
NAME
MB992012 General service Supporting the engine assembly
Engine hanger plate A tool during removal and installation of the
transaxle assembly
MB992012

MB992013 General service
Engine hanger plate B tool

MB992013

MB991454 MZ203827-01 When the engine hanger is used:
Engine hanger Supporting the engine assembly
balancer during removal and installation of the
transaxle assembly
B991454 NOTE: Special tool MB991454 is a
part of engine hanger attachment set
MB991527 Tool not available MB991453.
Hanger

B991527

MB991895 Tool not available
Engine hanger

MB991895

MB991928 Tool not available
SLIDE BRACKET (HI) Engine hanger
A: MB991929
E Joint (50)

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