Chrysler Colt/Vista 1990-1993 Repair Information

5-Speed Overhaul

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See Figures 1 through 13

The following procedures apply to all 5-speed transaxle. Differences among various years and model are noted where necessary.

DISASSEMBLY



  1. Place the transaxle assembly on a suitable work service. Remove the transaxle switch and gasket.
  2.  
  3. Remove the rear cover.
  4.  
  5. Remove the backup light switch, gasket and steel ball.
  6.  
  7. Remove the three poppet plugs, springs and balls.
  8.  
  9. Remove the speedometer driven gear assembly.
  10.  
  11. Remove the air breather.
  12.  
  13. Remove the spring pin using a pin punch.
  14.  
  15. Unstake the locknuts on the input and intermediate shafts. Shift the transaxle into reverse using the control and shift levers. Remove the locknuts.
  16.  
  17. Remove the fifth speed synchronizer assembly and shift fork.
  18.  
  19. Remove the synchronizer ring and fifth speed gear.
  20.  
  21. Remove the needle bearing and the bearing sleeve.
  22.  
  23. Remove the dished washer, roller bearing and the fifth speed intermediate gear.
  24.  
  25. Remove the idler gear shaft bolt.
  26.  
  27. Separate the transmission case from the clutch housing.
  28.  
  29. Remove the oil guide from the transmission case assembly.
  30.  
  31. Remove the bolt, spring washer and stopper bracket. Remove the restrictor ball assembly and gasket.
  32.  
  33. Remove the outer ring and oil seal from the transmission case.
  34.  
  35. Remove the three spacers. Remove the shift lever assembly and lever shoe.
  36.  
  37. Remove the reverse idler gear and shaft.
  38.  
  39. Remove the shift lever spring pins. Refer to the four speed transaxle procedures and remove the shift forks and rails. Remove the select spacer.
  40.  
  41. Remove the interlocking plungers from the clutch housing. Remove the fifth speed shift lug and select spacer.
  42.  
  43. Remove the output shaft assembly. Remove the deferential assembly.
  44.  
  45. Remove the poppet plug and the poppet spring and ball for the select shift rail.
  46.  
  47. Remove the input shaft front bearing retainer. Lift up the input shaft assembly together with the select shift fork and the intermediate shaft assembly.
  48.  
  49. Refer to the four speed procedures for component servicing and transaxle assembly.
  50.  

Input Shaft Disassembly
  1. Remove the front bearing snapring and press the bearing from the input shaft.
  2.  
  3. Straighten the lock tab, and remove the locknut at the rear of the input shaft.
  4.  
  5. Press the rear bearing from the shaft.
  6.  

Input Shaft Assembly
  1. Press the front bearing onto the input shaft.
  2.  
  3. Install the front bearing snapring into the retaining groove.
  4.  
  5. Install a spacer to the rear of the input shaft, with the stepped side toward the rear bearing.
  6.  
  7. Press the rear bearing on to the input shaft.
  8.  
  9. Tighten the locknut after installing the lock tab. Tighten the nut to 66-79 ft. lbs. Bend the locking tab and stake the plate into the notch provided on the shaft.
  10.  

Output Shaft Disassembly
  1. Unlock the rear nut lockplate and remove the nut.
  2.  
  3. Remove the front and rear tapered bearings from the output shaft, using a puller or press.
  4.  
  5. Press off the first speed gear, gear sleeve, first/second speed synchronizer and the second speed gear.
  6.  
  7. Press off the second speed gear sleeve, third speed gear and sleeve, third/fourth speed synchronizer assembly and the fourth speed gear.
  8.  

Output Shaft Assembly
  1. Press the fourth speed gear onto the shaft and install the synchronizer ring.
  2.  
  3. Lubricate the contact surfaces.
  4.  
  5. Press the third/fourth synchronizer unit to the output shaft with the oil grooves on the hub and the fork groove in the sleeve facing toward the engine side. Align the synchronizer ring keyway with the synchronizer ring key. After the installation, be sure the fourth gear rotates freely.
  6.  
  7. Install the third speed gear sleeve and third speed gear.
  8.  
  9. Install the second speed gear sleeve, be sure the third speed gear rotates freely.
  10.  
  11. Install the second speed gear and the first/second synchronizer ring.
  12.  
  13. Install the first/second speed synchronizer assembly onto the output shaft. Be sure the second speed gear rotates freely.
  14.  
  15. Install the first/second speed synchronizer ring with the keyways properly aligned.
  16.  
  17. Install the first gear to the gear sleeve and press the unit onto the shaft. Be sure the first speed gear rotates freely.
  18.  
  19. Install the front and rear tapered bearings.
  20.  
  21. Install the lock plate and nut. Tighten the nut to 66-79 ft. lbs. Bend the lock tab and stake the plate into the notch provided.
  22.  

Intermediate Shaft Disassembly
  1. Press off the front bearing.
  2.  
  3. Remove the sub-gear and the spring assembly.
  4.  
  5. Press off the rear bearing.
  6.  

Intermediate Shaft Assembly
  1. Assemble the sub-gear spring to the intermediate shaft gear with the longest end of the spring fitted in the hole.
  2.  
  3. Install the sub-gear and insert the remaining end of the spring into the hole in the sub-gear.
  4.  
  5. Press on the front and rear bearings.
  6.  

TRANSAXLE ASSEMBLY



  1. Lubricate all seals and O-rings during assembly. Prepare the transaxle case for component assembly by replacing all oil seals and case internal small parts that were removed.
  2.  
  3. Install the speedometer driven gear assembly in to the clutch housing. Install the locking plate into the grooves cot into the sleeve.
  4.  
  5. Install the shaft into the case and install the selector finger. Install the lock pin so that it is flush on the clutch housing side of the selector finger.
  6.  
  7. Install the poppet spring and steel ball into the control finger. Force the ball into the bore with a special tool and leave the tool in position securing the ball.
  8.  
  9. Install a new O-ring onto the shift shaft and install the shaft into the clutch housing. Engage the the 5th/reverse restrict spring and the control finger.
  10.  
  11. Press the shift shaft inward until the special tool holding the poppet ball is forced out. Remove the tool. Install the spacer collar and the neutral return spring. Force the shift shaft into its bore on the opposite side of the case.
  12.  
  13. Align the spring pin holes and install the spring pins
  14.  
  15. Install the spring retainer in place over the control finger assembly.
  16.  
  17. Install the differential gear assembly into the clutch housing.
  18.  
  19. Turn the intermediate shaft sub-gear in the direction of the embossed arrow, until the 8mm hole provided in the intermediate gear aligns with the hole in the sub-gear. Insert a snug fitting pin through the holes to hold the sub-gear in position.
  20.  
  21. Install the input shaft assembly and the intermediate shaft assembly into the clutch housing as a unit.
  22.  
  23. Install the selector shaft poppet ball. poppet spring and plug. Apply sealer to the plug and seat it flush with the housing surface.
  24.  
  25. Install the input shaft bearing retainer and remove the pin that secured the intermediate shaft sub-gear.
  26.  
  27. Install the output shaft assembly.
  28.  
  29. Install the interlocking plungers into the housing. Assemble the first/second and third/fourth shift rails and forks into position on the housing.
  30.  
  31. Install the spring pins with the split parallel with the center line of the rail.
  32.  
  33. Install the 5th/reverse shift rail and install the three poppet balls, springs and plugs. The poppet spring with the white paint ID must be installed in the poppet hole of the 5th/reverse shift rail. Install the small diameter ends of the springs toward the balls.
  34.  
  35. Install the 5th/reverse shift lever assembly, the 5th/reverse idler gear and shaft after lubricating them.
  36.  
  37. Apply sealer to a new gasket and install it on the clutch housing.
  38.  
  39. Install the spacer on the differential bearing and install the transaxle case. Tighten the bolts to 26-30 ft. lbs.
  40.  
  41. Install the intermediate and output shaft tapered bearing races and press them in by hand.
  42.  
  43. Install new halfshaft seals, if not already installed.
  44.  
  45. Apply sealer to the rear cover gasket and install the cover. Tighten the bolts to 14-16 ft. lbs.
  46.  



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Fig. Fig. 1: Transaxle disassembly/assembly - F4M21 4-speed and F5M21 5-speed - 1990-93 Colt hatchback and sedan



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Fig. Fig. 2: Transaxle disassembly/assembly - F4M21 4-speed and F5M21 5-speed - 1990-93 Colt hatchback and sedan



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Fig. Fig. 3: Transaxle disassembly/assembly - F4M21 4-speed and F5M21 5-speed - 1990-93 Colt hatchback and sedan



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Fig. Fig. 4: Transaxle disassembly/assembly - F5M22 5-speed - 1990-93 Colt hatchback, sedan, 2WD wagon and 2WD Vista



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Fig. Fig. 5: Transaxle disassembly/assembly - F5M22 5-speed - 1990-93 Colt hatchback, sedan, 2WD wagon and 2WD Vista



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Fig. Fig. 6: Transaxle disassembly/assembly - F5M22 5-speed - 1990-93 Colt hatchback, sedan, 2WD wagon and 2WD Vista



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Fig. Fig. 7: Transaxle disassembly/assembly - 1990 Colt 4WD wagon and 1992-93 4WD Vista



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Fig. Fig. 8: Transaxle disassembly/assembly - 1990 Colt 4WD wagon and 1992-93 4WD Vista



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Fig. Fig. 9: Transaxle disassembly/assembly - 1990 Colt 4WD wagon and 1992-93 4WD Vista



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Fig. Fig. 10: Transaxle disassembly/assembly - 1990 Colt 4WD wagon and 1992-93 4WD Vista



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Fig. Fig. 11: Transaxle disassembly/assembly - 1990-91 4WD Vista



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Fig. Fig. 12: Transaxle disassembly/assembly - 1990-91 4WD Vista



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Fig. Fig. 13: Transaxle disassembly/assembly - 1990-91 4WD Vista

 
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