Dodge Colt/Challenger/Conquest/Vista 1971-1989 Repair Guide

4-Speed Overhaul

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DISASSEMBLY





Click image to see an enlarged view

Fig. Fig. 1 Exploded view of the 4 speed manual transaxle assembly

  1. Place the transaxle on a suitable work surface.
  2.  
  3. Remove the clutch cable operating bracket and the transaxle mounting bracket.
  4.  
  5. Remove the backup light switch and steel ball from the case.
  6.  
  7. Remove the rear cover from the transaxle case. Remove the spacers from the rear of the tapered roller bearings.
  8.  
  9. Remove the transaxle case from the clutch housing, exposing the gear train assembly.
  10.  
  11. Place all shift rails in the Neutral position.
  12.  

The shift rails would be locked if any one of the rails are in a position other than Neutral.

  1. Remove the three poppet plugs and remove the springs and balls, from the case.
  2.  
  3. Remove the reverse idler shaft and the reverse idler gear.
  4.  

The reverse idler shaft sometimes comes off with the removal of the transaxle case.

  1. Remove the reverse shift lever assembly.
  2.  
  3. Remove the reverse shift rail and the third/fourth shift rail spacer collar.
  4.  
  5. Remove the spring pins from the first/second and third/fourth shift forks using a punch and hammer. Support the shift forks before attempting to remove the spring pins.
  6.  
  7. Pull the first/second shift rail upwards from the case, sliding the rail through the shift fork. The shift rail cannot be removed until the completion of Step 13.
  8.  
  9. Pull the third/fourth shift rail from the case and remove the two shift rails and forks together.
  10.  
  11. Move the third/fourth speed synchronizer into the fourth speed position and remove the output shaft assembly.
  12.  
  13. Remove the differential assembly from the case.
  14.  
  15. On twin-stick models; Remove the plug, poppet and spring for the two-speed shift rail and fork.
  16.  
  17. Remove the bolts from the input shaft bearing retainer and remove the input shaft assembly.
  18.  
  19. On twin-stick models; remove the shift rail and fork along with the intermediate shaft assembly, when the input shaft is removed.
  20.  
  21. Remove the shift shaft spring retainer and pull the spring pin with pliers.
  22.  
  23. Move the shift shaft towards the outside of the case by using a pin punch in the pin hole. Pull the shaft from the case and remove the control finger, two springs, spacer collar poppet spring and ball.
  24.  

During removal of the shift shaft from the case, the poppet ball will jump out of the control finger hole. Close the hole with an object to prevent loss of the ball.

  1. Put an identifying mark on the tapered roller bearing outer race and remove it from the case.
  2.  
  3. Remove the lock and the speedometer driven gear assembly.
  4.  

Input Shaft Disassembly
MODELS WITHOUT TWIN-STICK


Click image to see an enlarged view

Fig. Fig. 2 Exploded view of the 4 speed input shaft assembly

  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.  

TWIN-STICK MODELS
  1. Remove the front bearing snapring and press off the front bearing.
  2.  
  3. Straighten the lock tab and remove the locknut at the rear of the input shaft.
  4.  
  5. Support the low gear of the input shaft, and press on the rear of the input shaft to remove the input high gear, gear sleeve, synchronizer assembly, input low gear and the rear bearing.
  6.  

Input Shaft Assembly
MODELS WITHOUT TWIN-STICK:
  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 install ing 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.  

TWIN-STICK MODELS:
  1. Press on the front bearing.
  2.  
  3. Install the front bearing snapring.
  4.  
  5. Install the synchronizer hub with the oil groove slot facing the engine side of the shaft.
  6.  
  7. The synchronizer sleeve must be installed with the thirty degree champfer facing the engine side. The other side of the sleeve is machined at a forty-five degree angle.
  8.  
  9. Install the synchronizer spring with its stepped part positioned on the synchronizer key. Alternate the stepped parts of the front and rear springs to avoid having the stepped parts on the same key.
  10.  
  11. Install the sub-gear to the input high gear and lubricate the entire surface.
  12.  
  13. Install the cone spring and install a new snapring, making sure the inner side of the cone spring is not in the snapring groove.
  14.  
  15. Install the input low gear and the needle bearing on the input shaft.
  16.  
  17. Install the synchronizer ring.
  18.  
  19. Press the synchronizer assembly onto the input shaft with the synchronizer key correctly aligned with the synchronizer ring keyway.
  20.  
  21. Press on the input high gear sleeve. The input low gear should rotate smoothly. Install the synchronizer ring, the input high gear and needle bearing.
  22.  
  23. Install the spacer with the stepprd side facing the rear bearing side.
  24.  
  25. Press on the rear bearing.
  26.  
  27. Install the lock tab and locknut. Tighten the nut to 66-79 ft. lbs. and bend the lock tab. The lock plate should be staked into the notch providedon the shaft.
  28.  

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


Click image to see an enlarged view

Fig. Fig. 3 Exploded view of the 4 speed intermediate gear assembly

  1. Press off the front bearing.
  2.  
  3. Remove the sub-gaer and the spring assembly.
  4.  
  5. Press off the rear bearing.
  6.  

Intermediate Shaft Assembly
  1. Assemble the sub-gaer 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





Click image to see an enlarged view

Fig. Fig. 4 Exploded view of the clutch housing 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. On the Twin-Stick; install an O-ring onto the selector shaft and lubricate the ring and the case bore. 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 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. On Twin-Stick models; install the selector shift rail and fork assembly at this time.
  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 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 reverse shift rail. Install the small diameter ends of the springs toward the balls.
  34.  
  35. Install the reverse shift lever assembly, the 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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