Chrysler Colt/Vista 1990-1993 Repair Information

REMOVAL AND INSTALLATION

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Colt and 2WD Colt Wagon

See Figures 1 through 11

  1. Disconnect the battery ground (negative) cable and the positive cable. Remove the battery and battery tray.
  2.  



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Fig. Fig. 1: Remove these parts prior to transaxle removal - 1990-92 Colt hatchback or sedan



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Fig. Fig. 2: Transaxle removal/installation - 1990-92 Colt hatchback or sedan



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Fig. Fig. 3: Transaxle removal/installation - 1990 2WD Colt wagon

  1. Disconnect from the transaxle:
    1. The clutch cable or hydraulic line to slave cylinder.
    2.  
    3. The speedometer cable.
    4.  
    5. The back-up light harness.
    6.  
    7. The starter motor.
    8.  
    9. The the 4 upper bolts connecting the engine to the transaxle.
    10.  
    11. On cars with a 5-speed transaxle, disconnect the selector control valve.
    12.  

  2.  



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Fig. Fig. 4: Transaxle removal/installation - 1993 Colt hatchback or sedan



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Fig. Fig. 5: Transaxle removal/installation - 1990-91 2WD Vista

  1. Jack up the car and support on jackstands.
  2.  
  3. Remove the front wheels. Remove the splash shield. Drain the transaxle fluid.
  4.  



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Fig. Fig. 6: Remove these parts prior to transaxle removal - 1992-93 2WD Vista



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Fig. Fig. 7: Transaxle removal/installation - 1992-93 2WD Vista



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Fig. Fig. 8: Remove these parts prior to transaxle removal - 1990 4WD Colt wagon



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Fig. Fig. 9: Transaxle removal/installation - 1990 4WD Colt wagon

  1. Remove the shift rod and extension. It may be necessary to remove any heat shields that can interfere with your progress.
  2.  
  3. Remove the stabilizer bar from the lower arm and disconnect the lower arm from the body side.
  4.  

  1. Remove the right and left halfshafts from the transaxle case. Plug the transaxle holes to prevent dirt from entering. See Halfshaft Removal.
  2.  
  3. Remove the engine rear cover.
  4.  
  5. Support the weight of the engine from above with an engine crane. Support the transaxle with a suitable floor jack or transmission jack and remove the remaining lower mounting bolts.
  6.  
  7. Remove the transaxle mount insulator bolt.
  8.  
  9. Slide the transaxle back and away from the engine, and lower the transaxle.
  10.  

To install:
  1. Position the transaxle on a suitable floor or transmission jack and raise it into position under the vehicle.
  2.  
  3. Push the transaxle towards the rear of the engine and align the mainshaft with the clutch disc. Push the transaxle into position against the engine, take care not to knock the transaxle off of the jack.
  4.  
  5. Install and tighten the transaxle to engine lower mounting bolts. Install the transaxle mount through bolt. Disconnect the chain hoist from the engine.
  6.  
  7. Install the halfshafts. Use new retaining ring circlips when installing the halfshafts. Connect the range selector cable. Connect the engine roll control bar, the lower bell housing shield, the lower arms and stabilizer bar.
  8.  
  9. Install the upper transaxle to engine mounting bolts, the starter motor, speedometer cable, ground cable, back-up light harness, select cable, shift cable, clutch linkage or hydraulic connection, and install the splash shield after filling the transaxle with lubricant.
  10.  
  11. Install the battery tray, the battery and connect the cables. Lower the vehicle if not already done.
  12.  

2WD Vista
  1. Disconnect the battery cables, negative cable first. Remove the battery and tray.
  2.  
  3. Remove the coolant reservoir.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Disconnect the clutch cable, speedometer cable and backup light wiring from the transaxle.
  8.  
  9. Remove the upper engine-to-transaxle bolts.
  10.  
  11. Disconnect the select control lever and switch harness.
  12.  
  13. Remove the starter.
  14.  
  15. Disconnect and tag all wiring from the transaxle.
  16.  
  17. Raise and support the vehicle safely.
  18.  
  19. Remove the front wheels.
  20.  
  21. Drain the transaxle fluid.
  22.  
  23. Remove the extension and shift rod from the engine compartment.
  24.  
  25. Remove the stabilizer and strut bar from the lower control arm.
  26.  
  27. Remove the left and right halfshafts.
  28.  
  29. Support the transaxle with a suitable floor jack, taking care to avoid damaging the pan.
  30.  
  31. Remove the bell housing cover.
  32.  
  33. Remove the remaining transaxle-to-engine bolts.
  34.  
  35. Remove the transaxle mounting bolt.
  36.  
  37. Lower the jack and slide the transaxle from under the car.
  38.  

To install:
  1. Secure the transaxle on a transaxle jack and position it to the engine.
  2.  
  3. Carefully guide the transaxle input shaft into the clutch assembly. Make sure the transaxle is seated properly and is flush to the engine flange. Install 2 transaxle-to-engine bolts.
  4.  
  5. Install the transaxle mounting bolt. Torque the bolt to 29-36 ft. lbs. (40-50 Nm).
  6.  
  7. Install the lower transaxle-to-engine bolts. Torque the bolts to 32-39 ft. lbs. (43-53 Nm).
  8.  
  9. Remove the floor jack from the transaxle.
  10.  
  11. Install the left and right halfshafts.
  12.  
  13. Install the stabilizer and strut bar to the lower control arm.
  14.  
  15. Install the extension and shift rod.
  16.  
  17. Refill the transaxle with an approved gear oil.
  18.  
  19. Install the front wheels and lower the vehicle.
  20.  
  21. Connect all wiring to the transaxle.
  22.  
  23. Install the starter and mounting bolts. Torque the mounting bolts to 20-24 ft. lbs. (27-34 Nm).
  24.  
  25. Connect the select control lever and switch harness.
  26.  
  27. Install the upper engine-to-transaxle bolts. Torque the bolts to 32-39 ft. lbs. (43-53 Nm).
  28.  
  29. Connect the clutch cable, speedometer cable and backup light wiring to the transaxle.
  30.  
  31. Install the air cleaner.
  32.  
  33. Install the coolant reservoir and refill with coolant.
  34.  
  35. Install the battery tray and battery. Connect the battery cables, positive cable first.
  36.  

4WD Colt Wagon

See Figures 8 and 9

  1. Disconnect the negative battery cable, drain the transaxle fluid and remove the under cover.
  2.  
  3. Remove the air cleaner, battery and battery tray.
  4.  
  5. Remove the split pin and disconnect the shift and select cables.
  6.  
  7. Disconnect the clutch cylinder line, backup light switch and speedometer cable.
  8.  
  9. Disconnect the stabilizer bar, tie rod ends, lower ball joint and driveshaft from the control arm and strut.
  10.  
  11. Remove the starter motor.
  12.  
  13. Place a jack under the transaxle and support the engine from above.
  14.  
  15. Remove the center crossmember with roll stopper bracket.
  16.  
  17. Remove the rear driveshaft and transfer case.
  18.  
  19. Remove the transaxle mount bracket and bell housing bolts.
  20.  
  21. Using the jack, lower the transaxle and check for interference.
  22.  

To install:
  1. Using the jack, raise the transaxle and check for interference.
  2.  
  3. Install the transaxle mount bracket and bell housing bolts. Torque the bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Install the rear driveshaft and transfer case. Torque the transfer bolts to 30 ft. lbs. (41 Nm).
  6.  
  7. Install the center crossmember with roll stopper bracket.
  8.  
  9. Remove the jack and engine support.
  10.  
  11. Install the starter motor and torque the bolts to 35 ft. lbs. (41 Nm).
  12.  
  13. Connect the stabilizer bar, tie rod ends, lower ball joint and driveshaft to the control arm and strut.
  14.  
  15. Connect the clutch cylinder line, backup light switch and speedometer cable.
  16.  
  17. Install the split pin and connect the shift and select cables.
  18.  
  19. Install the air cleaner, battery and battery tray.
  20.  
  21. Connect the negative battery cable, refill the transaxle fluid and install the under cover.
  22.  

4WD Vista

See Figures 10 and 11

  1. Disconnect the battery cables, negative cable first. Remove the battery.
  2.  
  3. Remove the coolant reserve tank.
  4.  



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Fig. Fig. 10: Remove these parts prior to transaxle removal - 1992-93 4WD Vista



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Fig. Fig. 11: Transaxle removal/installation - 1992-93 4WD Vista

  1. Disconnect the speedometer cable, shift control cable and back-up light harness at the transaxle.
  2.  
  3. Remove the range select control valves and connectors.
  4.  
  5. Tag and disconnect all other wiring attached to the transaxle.
  6.  
  7. Remove the clutch slave cylinder.
  8.  
  9. Remove the vacuum reservoir tank.
  10.  
  11. Disconnect the starter wiring and remove.
  12.  
  13. Remove the upper engine-to-transaxle bolts.
  14.  
  15. Raise and support the vehicle safely.
  16.  
  17. Remove the front wheels, lower engine cover and skid plate.
  18.  
  19. Drain the transaxle and transfer case.
  20.  
  21. Remove the driveshaft.
  22.  
  23. Remove the transfer case extension housing.
  24.  
  25. Remove the left and right halfshafts.
  26.  
  27. Disconnect the right strut from the lower arm.
  28.  
  29. Remove the right fender liner.
  30.  
  31. Take up the weight of the transaxle with a suitable floor jack.
  32.  
  33. Remove the bell housing cover bolts and remove the cover.
  34.  
  35. Remove the remaining engine-to-transaxle bolts.
  36.  
  37. Remove the transaxle mount insulator bolt.
  38.  
  39. Remove the transaxle mounting bracket attaching bolts.
  40.  
  41. Move the transaxle/transfer case assembly to the right. Tilt the right side of the transaxle down, until the transfer case is about level with the upper part of the steering rack tube, then turn it to the left and lower the assembly.
  42.  

To install:
  1. Secure the transaxle/transfer case assembly to a transaxle jack.
  2.  
  3. Raise the assembly in position to the engine. It may be necessary to tilt or angle the assembly in and around the steering rack tube.
  4.  
  5. Once the transaxle/transfer assembly is positioned to the engine, carefully guide the input shaft into the clutch assembly.
  6.  
  7. Install the transaxle mounting bracket attaching bolts. Torque the bolts to 40-43 ft. lbs. (55-60 Nm).
  8.  
  9. Install the transaxle mount insulator bolt. Torque to 40-43 ft. lbs. (55-60 Nm).
  10.  
  11. Install the lower engine-to-transaxle bolts. Torque to 31-40 ft. lbs. (43-55 Nm).
  12.  
  13. Install the bell housing cover bolts and install the cover.
  14.  
  15. Remove the the floor jack from the transaxle.
  16.  
  17. Install the right fender liner.
  18.  
  19. Connect the right strut to the lower arm.
  20.  
  21. Install the left and right halfshafts.
  22.  
  23. Install the transfer case extension housing and the driveshaft.
  24.  
  25. Refill the transaxle and transfer case with an approved gear oil.
  26.  
  27. Install the front wheels, lower engine cover and skid plate.
  28.  
  29. Lower the vehicle.
  30.  
  31. Install the upper engine-to-transaxle bolts. Torque the bolts to 40-43 ft. lbs. (55-60 Nm).
  32.  
  33. Install the starter motor and mounting bolts. Torque the bolts to 22-25 ft. lbs. (30-35 Nm). Connect the starter wiring.
  34.  
  35. Install the vacuum reservoir tank.
  36.  
  37. Install the clutch slave cylinder.
  38.  
  39. Connect all other wiring to the transaxle, as tagged.
  40.  
  41. Install the range select control valves and connectors.
  42.  
  43. Connect the speedometer cable, shift control cable and back-up light harness at the transaxle.
  44.  
  45. Remove the coolant reserve tank.
  46.  
  47. Install the battery. Connect the battery cables, positive cable first.
  48.  

LINKAGE ADJUSTMENT



4WD Vista
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the console assembly from the vehicle.
  4.  
  5. At the shift selector assembly, remove the shift cable-to-shift selector cotter pins and disconnect the shift cables from the shift selector assembly.
  6.  
  7. Move the transaxle shift selector and shift selector into the N positions.
  8.  
  9. If necessary, turn the shift cable adjuster to adjust the cables length to align with shift lever in the N position. Connect the shift cable, flange side of the resin bushing should face cotter pin side of the shift lever, with lever Band install a new cotter pin.
  10.  
  11. At the shift selector, make sure dimensions A and B are equal; if they are not, turn the cable adjuster to make the necessary adjustment.
  12.  
  13. Adjust the other cable in the same fashion.
  14.  
  15. Move the shift selector into each position to make sure it is shifting smoothly.
  16.  

 
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