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

Transaxle

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REMOVAL & INSTALLATION



Front Wheel Drive, Except 4WD Vista


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Fig. Fig. 1 Cross-section of the 4 speed KM200 transaxle



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Fig. Fig. 2 Cross-section of the 5 speed KM201 transaxle



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Fig. Fig. 3 Cross-section of the 5 speed KM206 transaxle



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Fig. Fig. 4 Cross-section of the 5 speed KM210 transaxle

  1. Disconnect the negative battery cable and the positive cable. Remove the battery and battery tray.
  2.  
  3. Disconnect from the transaxle; the clutch cable or hydraulic line to slave cylinder, speedometer cable, back-up light harness, starter motor and the four upper bolts connecting the engine to the transaxle. On cars with a turbo-charger, remove the air cleaner case, the actuator mounting bolts, the pin coupling the actuator and shaft and remove the actuator. Discard the collar used with the pin and replace it with a new collar. On cars with a 5-speed transaxle, disconnect the selector control valve.
  4.  
  5. Jack up the car and support on jackstands.
  6.  
  7. Remove the front wheels. Remove the splash shield. Drain the transaxle fluid.
  8.  
  9. Remove the shift rod and extension. It may be necessary to remove any heat shields that can interfere with your progress.
  10.  
  11. On models equipped: Remove the stabilizer bar from the lower arm and disconnect the lower arm from the body side.
  12.  
  13. Remove the right and left halfshafts (driveshafts) from the transaxle case. Plug the transaxle holes to prevent dirt from entering. See Halfshaft Removal.
  14.  
  15. Disconnect the range selector cable (if equipped). Remove the engine rear cover.
  16.  
  17. Support the weight of the engine from above (chain hoist). Support the transaxle with a suitable floor or transmission jack and remove the remaining lower mounting bolts.
  18.  
  19. Remove the transaxle mount insulator bolt.
  20.  
  21. Remove (slide back and away from the engine) and lower the transaxle.
  22.  

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.  

4-WD Vista


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Fig. Fig. 5 Cross-section of the 4WD Vista Transaxle

  1. Disconnect the battery cables at the battery. Remove the coolant reserve tank.
  2.  
  3. Disconnect the speedometer cable, shift control cable and back-up light harness at the transaxle.
  4.  
  5. Remove the range select control valves and connectors.
  6.  
  7. Tag and disconnect all other wiring attached to the transaxle.
  8.  
  9. Remove the clutch slave cylinder.
  10.  
  11. Remove the vacuum reservoir tank.
  12.  
  13. Disconnect the starter wiring.
  14.  
  15. Remove the upper 5 engine-to-transaxle bolts.
  16.  
  17. Raise and support the car on jackstands.
  18.  
  19. Remove the front wheels, lower engine cover and skid plate.
  20.  
  21. Drain the transaxle and transfer case.
  22.  
  23. Remove the driveshaft.
  24.  
  25. Remove the transfer case extension housing.
  26.  
  27. Remove the left and right halfshafts.
  28.  
  29. Disconnect the right strut from the lower arm.
  30.  
  31. Remove the right fender liner.
  32.  
  33. Take up the weight of the transaxle with a floor jack.
  34.  

Use a wide board on the floor jack pedestal to help spread the weight over a large area of the transaxle.

  1. Remove the bell housing cover bolts and remove the cover.
  2.  
  3. Remove the remaining engine-to-transaxle bolts.
  4.  
  5. Remove the transaxle mount insulator bolt.
  6.  
  7. Remove the transaxle mounting bracket attaching bolts.
  8.  
  9. 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.
  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. Install the driveshaft, splash shield and skid plates after filling the transaxle and transfer case with lubricant.
  10.  
  11. Install the battery tray, the battery and connect the cables. Lower the vehicle if not already done.
  12.  
  13. Observe the following torques: Transaxle mount insulator nut: 55-58 ft. lbs. Transaxle mounting bracket bolts; 25-30 ft. lbs. Engine-to-transaxle bolts: 45 ft. lbs.
  14.  

 
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