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

Transmission

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REMOVAL & INSTALLATION



Rear Wheel Drive, Except Conquest

The clutch housing and transmission are removed as a unit.

  1. Disconnect the battery cables, negative cable first.
  2.  
  3. Remove the battery cable from the starter and fasten it away from the transmission.
  4.  
  5. Remove the starter.
  6.  
  7. Remove the top two clutch housing bolts.
  8.  
  9. From inside the passenger compartment: Untie the leather or rubber shift boot and pull the rug back over the shift lever. If the car is equipped with a console it is necessary to remove same for access to the shift lever retaining plate etc.
  10.  
  11. Place the four speed transmission in second gear and the five speed transmission in first gear. Unscrew the four retaining bolts and remove the gearshift lever from the tailshaft housing.
  12.  
  13. From underneath the vehicle: Jack up the front of the car and support it on stands.
  14.  
  15. Drain the transmission oil.
  16.  
  17. Disconnect the transmission back-up light switch and the speedometer cable.
  18.  
  19. Remove the driveshaft.
  20.  
  21. Disconnect the exhaust pipe at the manifold and the engine side bracket. Drop the pipe down and out of the way.
  22.  
  23. Disconnect the clutch cable.
  24.  
  25. Position a jack under the transmission cover to support it when the crossmember is removed. Use a board between the cover and the jack.
  26.  
  27. Remove the two attaching bolts from the transmission-to-crossmember mount.
  28.  
  29. Unscrew the two bolts at each side of the crossmember and remove the crossmember.
  30.  
  31. Remove the remaining bolts from the clutch housing.
  32.  
  33. Pull the transmission rearward and lower it to the floor.
  34.  

When removing the transmission, pull it straight back so as not to damage the pilot bearing, clutch disc, or pressure plate.

  1. Lube the mainshaft splines with white lube. Raise the transmission on the floor jack until the mainshaft is level with the clutch disc, and at the same degree of engine slant.
  2.  
  3. Push the jack and transmission forward until the mainshaft enters the clutch disc. Wiggle the transmission to align the splines and push the transmission forward until it is in position against the engine. When wiggling the transmission, do not knock it off of the jack.
  4.  
  5. Secure the transmission to the engine with the mounting bolts. Install the crossmember and lower the transmission. Secure the transmission to the crossmember. Install the driveshaft.
  6.  
  7. Connect the clutch cable, the exhaust pipe, speedometer cable and back-up light switch.
  8.  
  9. Install the gearshift lever and console. Install the upper bell housing bolts. Install the starter motor. Fill the transmission with lubricant. Adjust the clutch. Lower the vehicle and connect the battery cables.
  10.  
  11. When installing the gearshift assembly, position the lever in First gear so that the nylon bushing is vertical. Make sure that no dirt enters the transmission housing during the installation of the shifter.
  12.  

Conquest
  1. Remove the console, place the shift lever in Neutral and remove the gearshift lever. Raise and support the front and rear of the car on jackstands.
  2.  
  3. Remove the driveshaft.
  4.  
  5. Drain the transmission.
  6.  
  7. Disconnect the speedometer cable and switch at the transmission.
  8.  
  9. Remove the clutch slave cylinder.
  10.  
  11. Remove the lower bell housing cover.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the two upper transmission mounting bolts.
  16.  
  17. Support the transmission with a floor jack.
  18.  
  19. Remove the remaining transmission mounting bolts.
  20.  
  21. Remove the engine support bracket, insulator assembly and ground strap.
  22.  
  23. Place the shift lever in the NEUTRAL position. Remove the trim plate and unbolt the shifter assembly, removing it and the stopper plate underneath it.
  24.  
  25. Cover the rear of the cylinder head with a heavy cloth to prevent damage from contact with the firewall.
  26.  
  27. Slowly lower the jack, pull it rearward to disengage the transmission from the clutch.
  28.  
  29. Raise the transmission on the jack until the mainshaft is level with the clutch disc. Push the transmission forward until the mainshaft enters the clutch. Raise or lower the jack as required and push the transmission into position against the engine. Secure it with the mounting bolts.
  30.  
  31. Install the mount and support bracket, then secure the transmission. Remove the jack. Install the starter and lower bell housing shield. Attach the speedometer cable and switch connector. Install the driveshaft and fill the transmission with lubricant. Install the clutch slave cylinder. Install the gearshift lever (in Neutral) and the console. Bleed the clutch if necessary.
  32.  
  33. Tighten the transmission mounting bolts to 35 ft. lbs.; the starter bolts to 20 ft. lbs. Lower the vehicle.
  34.  

OVERHAUL



4-Speed KM110


Click image to see an enlarged view

Fig. Fig. 1 Cross-section of the KM110 4 speed transmission

  1. Remove the clutch control lever shaft and arm.
  2.  
  3. Remove the speedometer driven gear.
  4.  
  5. Remove the backup light switch.
  6.  
  7. Remove the extension housing. It may be necessary to tap it with a soft mallet to break it loose.
  8.  
  9. Turn the transmission upside down (on its top) and remove the bottom cover.
  10.  
  11. Remove the snapring and take out the speedometer drive gear.
  12.  
  13. Tap off the main drive gear bearing retainer.
  14.  
  15. Remove the countershaft retainer.
  16.  
  17. Remove the countershaft from the rear of the case. Remove the forty needle bearings, both front and rear spacers and the front and rear thrust washers also.
  18.  
  19. Remove the reverse idler gear, needle bearings, spacer and front thrust washer from the idler gear shaft.
  20.  
  21. Remove the reverse idler gear shaft locking bolt and pull the idler gear shaft from the rear of the case.
  22.  
  23. Remove the three plugs on the right side of the case, then the poppet spring and balls.
  24.  
  25. Remove the reverse gear, reverse shift rail and fork.
  26.  
  27. Drive the shift rail and fork springs off with a 3 / 16 in. punch.
  28.  
  29. Remove each shift rail and selector out of the rear of the case and then remove the shift fork.
  30.  
  31. Pull the mainshaft assembly rearward and off of the bearing retainer.
  32.  
  33. Remove the main drive gear synchronizer ring and pilot needle bearing.
  34.  
  35. Remove the snapring and pull the mainshaft rear bearing retainer off of the bearing.
  36.  
  37. Remove the locknut.
  38.  
  39. Hold the mainshaft with the forward end down and strike it against a wooden block to make the bearing fall off.
  40.  
  41. Remove the spacer, first gear needle bearing, spacer bushing, synchronizer ring, first-second speed synchronizer assembly, synchronizer ring, second speed gear and the needle bearing.
  42.  
  43. Remove the snapring from the front end of the mainshaft and then remove the third-fourth speed synchronizer assembly, synchronizer ring, third speed gear and the needle bearing.
  44.  
  45. Remove the main drive gear assembly from the front of the case.
  46.  
  47. Remove the snapring(s) and remove the bearing using an appropriate puller.
  48.  
  49. Remove the shifter and control shaft lock pin with a punch.
  50.  
  51. Remove the return spring and pull off the control shaft. Inspect all of the disassembled parts. Replace as necessary.
  52.  

To assemble:
  1. Press the main drive gear bearing into place and install a select fitted snapring to bring the end-play down to 0-0.05mm.
  2.  
  3. Assemble the synchronizers. Install the needle bearings and third speed gear onto the mainshaft from the front. Install the synchronizer ring and the third-fourth synchronizer assembly.
  4.  
  5. Install the first-second speed synchronizer.
  6.  
  7. Install a snapring to bring the the synchronizer end-play down to 0-0.08mm. Third gear end-play should be 0.025-0.200mm.
  8.  
  9. Install the needle bearing, second speed gear, synchronizer ring and first-second speed synchronizer assembly onto the mainshaft.
  10.  
  11. Force the synchronizer assembly forward and check the second speed gear end-play. Play should be 0.025-0.200mm.
  12.  
  13. Install the first gear spacer ring, needle bearing, synchronizer ring, first speed gear and spacer. Force these parts forward and check the end-play. Play should be 0.025-0.200mm.
  14.  
  15. Press on the mainshaft bearing. Tighten the locknut to 72. ft. lbs. and install the locking key.
  16.  
  17. Install the snapring on the rear bearing retainer and install the retainer. A snapring should be selected that will give an end-play of 0-0.15mm.
  18.  
  19. Temporarily install the counter gear, front and rear thrust washers and shaft. Measure the end-play of the counter gear. If the end-play is not between 0.05-0.20mm, correct it by selecting a suitable rear thrust washer of correct thickness. Make certain that the thrust washer tongue fits properly in the slot made into the transmission case.
  20.  
  21. Install the needle rollers and the bearing spacers in the front and rear bores of the counter gear. Apply grease to the rollers to prevent them from falling out of position. Install the spacers on the outside of the rollers.
  22.  
  23. Attach the front thrust washer and the rear thrust washer that have been selected to provide proper end-play. Hold them in place with grease. Install the counter gear into the case.
  24.  
  25. Secure the counter gear by tightening the stopper plate. Install the reverse idler shaft and gear. Install the shift forks and rails.
  26.  
  27. Fill the front bearing oil seal lip with grease. Apply sealant to the packing. Install the seal.
  28.  
  29. When installing the front bearing retainer, check the thickness of the packing. Thickness, top and bottom, should be 0.3mm. Adjust bearing clearance with the proper thickness shim.
  30.  
  31. Install the speedometer driven gear onto the mainshaft.
  32.  
  33. Apply sealant to the packing and lockbolts and install the extension housing to the transmission case.
  34.  
  35. Install the backup light switch and ball.
  36.  
  37. Install the speedometer driven gear and lockplate.
  38.  
  39. Install the bottom cover. Tighten the bolts in a criss-cross pattern to 6-7 ft. lbs.
  40.  
  41. Install the control lever assembly, with the shifter in the second speed position, and the nylon bushing in the vertical position.
  42.  

5-Speed KM119

Special tools are needed, the are: Rear Stopper Plate MD998244, Front Stopper Plate MD998243 and Mainshaft Support MD998241, or equivalent.

  1. Remove the inspection cover.
  2.  
  3. Remove the backup light switch and ball.
  4.  
  5. Loosen the extension housing bolts, but do not remove them.
  6.  
  7. Loosen the plunger plug and place the shift lever in reverse. Remove the bolts and pull off the extension housing.
  8.  
  9. Remove the snapring, speedometer drive gear and ball.
  10.  
  11. Remove the snapring, mainshaft rear bearing, and bearing front snapring.
  12.  
  13. Remove the reverse idler gear and related parts.
  14.  
  15. Loosen and remove the mainshaft intermediate locknut and countershaft gear rear end locknut.
  16.  
  17. Remove the three poppet spring covers, springs and balls from the right side of the case.
  18.  
  19. Use a punch and drive the split pin retainers from the first-second and third-fourth shift forks.
  20.  
  21. Pull the first-second shift rail toward the rear of the case. Remove the counter fifth gear and ball bearing with the rail.
  22.  
  23. Pull the third-fourth shift rail toward the rear of the case.
  24.  
  25. Remove the mainshaft nut.
  26.  
  27. Remove the fifth-reverse synchronizer assembly, the fifth gear and the fifth-reverse shift rail and fork.
  28.  
  29. Remove the two interlock plungers.
  30.  
  31. Remove the spacer and reverse counter gear.
  32.  
  33. Remove the rear retainer.
  34.  
  35. Remove the front bearing retainer and spacer.
  36.  
  37. At this point, the special tools MD998244 and MD998243, the front and rear stopper plates are needed.
  38.  
  39. Insert the rear stopper plate tool between the clutch gear and synchronizer ring of the third speed gear, and the front stopper plate tool between the clutch gear and the synchronizer ring of the maindrive gear.
  40.  
  41. Remove the mainshaft bearing snapring and bearing. Slide the mainshaft support tool in place over the mainshaft to support it.
  42.  
  43. Remove the main drive gear bearing snaprings. Remove the bearing using an appropriate puller.
  44.  
  45. Remove the front and rear stopper plate tools.
  46.  
  47. Remove the countershaft gear front bearing snapring. Remove the front bearing using a puller.
  48.  
  49. Remove the countershaft gear rear bearing snapring. Remove the bearing with a puller.
  50.  
  51. Remove the mainshaft support tool. Lower the mainshaft and take the first speed gear rear spacer out of the case.
  52.  
  53. Shift the third-fourth synchronizer sleeve to the third speed side to permit easy removal of the countershaft gear.
  54.  
  55. Remove the countershaft gear.
  56.  
  57. Remove the first-second and third-fourth shift forks.
  58.  
  59. Remove the main drive gear.
  60.  
  61. Remove the mainshaft assembly and disassemble it into its component parts.
  62.  

To assemble:
  1. Inspect all parts, replace as necessary. Assemble the mainshaft components onto the mainshaft.
  2.  
  3. Insert the mainshaft into the case.
  4.  
  5. Install the synchronizer ring and needle bearing on the main drive gear and insert it into the case from the front.
  6.  
  7. Install the first-second and third-fourth shift forks, the third-fourth synchronizer sleeve and the countershaft.
  8.  
  9. Install the countershaft gear.
  10.  
  11. Support the countershaft gear, install the snapring and press on the bearing.
  12.  
  13. Install the countershaft front bearing outer race into the case first, the the needle bearing.
  14.  
  15. Drive the bearing into place using a soft drift and hammer.
  16.  
  17. Support the mainshaft rear end.
  18.  
  19. Insert the front stopper plate tool between the maindrive gear and the synchronizer ring. Install the rear stopper plate tool between the third speed gear and the synchronizer ring.
  20.  
  21. Install the main drive gear bearing snapring and drive the bearing into position. Install the select fit snapring onto the main drive gear to maintain a clearance, between the bearing inner race and the snapring of 0.05mm.
  22.  
  23. Remove the mainshaft support tool and install the snapring on the mainshaft bearing. Drive the bearing into position and remove the front and rear stopper plates.
  24.  
  25. Apply grease to the front bearing oil seal lip and drive the seal into place in the front bearing retainer.
  26.  
  27. Check the clearance between the front bearing retainer and the maindrive gear. Select and install a spacer to provide a clearance of 0-0.1mm.
  28.  
  29. Install the front bearing retainer.
  30.  
  31. Install the rear retainer.
  32.  
  33. Install the counter reverse gear and spacer.
  34.  
  35. Install the two interlock plungers.
  36.  
  37. Assemble the fifth-reverse synchronizer.
  38.  
  39. Install the spacer on the mainshaft.
  40.  
  41. Install the synchronizer ring, fifth gear, needle bearing and sleeve to the synchronizer.
  42.  
  43. Install the synchronizer assembly and the fifth-reverse shift rod and fork on the mainshaft.
  44.  
  45. Install the mainshaft locknut.
  46.  
  47. Insert the third-fourth shift rail into the rear of the case and into the shift forks.
  48.  
  49. Insert the first-second shift rail in the same way.
  50.  
  51. Align the fifth countergear with the relieved portion of the shift rail and install both parts simultaneously. Install the bearing.
  52.  
  53. Align the spring pin holes of the shift forks and rails. Install the spring pins The pins must not project out of the forks and the split of the pin must be parallel with the rail.
  54.  
  55. Install the poppet balls and springs. Install the plugs until the heads are flush with the case surface. The springs must be installed with the tapered ends inside the balls. The first-second spring is longest.
  56.  
  57. Tighten the mainshaft locknut to 70-90 ft. lbs. and the countershaft locknut to 50-70 ft. lbs.
  58.  
  59. Insert the reverse idler shaft into the case.
  60.  
  61. Install the spacer bushing, gear, needle bearing and thrust washer. Tighten the nut to 20-40 ft. lbs. Align the split of the nut with the cotter pin hole and install a cotter pin.
  62.  
  63. Install the rear bearing on the mainshaft. Install a select fit snapring to provide the clearance of 0-0.2mm between the bearing inner race and the snapring.
  64.  
  65. Install the speedometer drive gear and snapring.
  66.  
  67. Assemble the extension housing components.
  68.  
  69. Install the extension housing to the case. When installing, tilt the shifter down and to the left and fit the lever in the grooves provided in the selector.
  70.  
  71. Install the neutral return plungers and ball, screw in the plugs until they are flush with the case.
  72.  
  73. Install the backup light switch and ball.
  74.  
  75. Install the bottom cover and tighten the bolts to 6-7 ft. lbs.
  76.  
  77. Install the control lever assembly.
  78.  

5-Speed KM132


Click image to see an enlarged view

Fig. Fig. 2 Exploded view of the KM132 transmission



Click image to see an enlarged view

Fig. Fig. 3 Back off the neutral return plunger B, then turn the change shifter down to the left



Click image to see an enlarged view

Fig. Fig. 4 Using a punch, remove the 3-4 and 1-2 shift fork spring pins



Click image to see an enlarged view

Fig. Fig. 5 With the same punch, remove the overtop and reverse shift forks spring pins



Click image to see an enlarged view

Fig. Fig. 6 Bend the lockwasher back, then loosen the locknuts on the main and countershaft rear ends



Click image to see an enlarged view

Fig. Fig. 7 Using a gear puller, remove the overtop gear and sleeve from the mainshaft



Click image to see an enlarged view

Fig. Fig. 8 Remove the rear bearing retainer



Click image to see an enlarged view

Fig. Fig. 9 Drive the reverse idler gear shaft from inside the case



Click image to see an enlarged view

Fig. Fig. 10 Using a bearing puller, remove the counter rear bearing



Click image to see an enlarged view

Fig. Fig. 11 Remove the snapring, then pull off the counter front bearing with a puller



Click image to see an enlarged view

Fig. Fig. 12 With a bearing puller, remove the main drive gear bearing



Click image to see an enlarged view

Fig. Fig. 13 Remove the mainshaft bearing snapring, then remove the ball bearing



Click image to see an enlarged view

Fig. Fig. 14 Draw the mainshaft assembly out of the case



Click image to see an enlarged view

Fig. Fig. 15 Exploded view of the neutral return plunger components

  1. Remove the cover plate.
  2.  
  3. Remove the backup light switch and ball.
  4.  
  5. Remove the extension housing attaching bolts. Back off the neutral return plunger plug, turn the shift lever down to the left and pull off the extension housing.
  6.  
  7. Remove the snapring and speedometer drive gear.
  8.  
  9. Remove the snapring and the mainshaft rear bearing.
  10.  
  11. Remove the three plugs, and remove the poppet springs and balls.
  12.  
  13. Remove the first-second and third-fourth shift fork pins using a punch. Pull each rail toward the rear of the case and remove the forks and interlock plunger.
  14.  
  15. In the same manner, remove the fifth-reverse forks.
  16.  
  17. Engage the reverse and second gears, remove the mainshaft and countershaft locknuts.
  18.  
  19. Remove the fifth counter gear and bearing using a puller. Remove the spacer and reverse counter gear.
  20.  
  21. Remove the fifth gear and sleeve from the mainshaft. Remove the fifth synchronizer and spacer.
  22.  
  23. Remove the cotter pin, nut and reverse idler gear.
  24.  
  25. Remove the rear bearing retainer.
  26.  
  27. Drive the reverse idler gear shaft from the case.
  28.  
  29. Remove the front bearing retainer.
  30.  
  31. Press the counter gear to the rear and remove the bearing snapring.
  32.  
  33. Use a puller, and remove the counter rear bearing.
  34.  
  35. Remove the snapring and pull the counter front bearing. Remove the counter gear from the case.
  36.  
  37. Remove the main drive pinion from the case.
  38.  
  39. Remove the two snaprings and pull the bearing.
  40.  
  41. Remove the snapring and pull the mainshaft bearing.
  42.  
  43. Remove the mainshaft from the case.
  44.  
  45. Disassemble the mainshaft.
  46.  
  47. Disassemble the extension housing.
  48.  

To assemble:
  1. Inspect all of the transmission components, replace as necessary. Install the bearing on the maindrive pinion and select a snapring which will give a clearance of 0-0.06mm between the snapring and the bearing.
  2.  
  3. Assemble the mainshaft. Use a spacer which will give the third-fourth synchronizer an end-play of 0-0.08mm. Use a snapring that will give the first-second gear end-play of 0.05-0.20mm.
  4.  
  5. Insert the mainshaft into the case and drive in the center bearing.
  6.  
  7. Install the needle bearing and synchronizer ring, then insert the main drive pinion into the case from the front.
  8.  
  9. Insert the countergear into the case.
  10.  
  11. Install the snapring on the countershaft front bearing and drive the bearing into the case carefully.
  12.  
  13. Install the snapring on the countershaft rear bearing and install it in place.
  14.  
  15. Install the front bearing retainer using a spacer that will give a clearance of 0-0.1mm between the retainer and bearing.
  16.  
  17. Install the front retainer oil seal.
  18.  
  19. Install the rear retainer.
  20.  
  21. Install the reverse idler shaft.
  22.  
  23. Install the needle bearing, reverse idler gear, and thrust washer. Tighten the locknut and install the cotter pin. Idler gear end-play should be 0.12-0.28mm. If not replace the thrust washer.
  24.  
  25. Assemble the fifth gear synchronizer.
  26.  
  27. Install the spacer, stop plate and fifth synchronizer assembly, the fifth gear bearing sleeve and needle bearing, the synchronizer ring and fifth gear, in that order, to the mainshaft from the rear. Fifth gear end-play should be 0.10-0.25mm.
  28.  
  29. Install the spacer, counter reverse gear, counter fifth gear and the ball bearing onto the countershaft gear from the rear. Tighten and lock the nut.
  30.  
  31. Insert the third-fourth and the first-second forks into their synchronizer sleeves. Insert each shift rail from the rear of the case. Install the spring pins, with the split of the pins parallel with the rail. Install the interlock plunger.
  32.  
  33. Insert the ball and poppet spring into each shift rail. Tighten the plugs flush with the transmission case.
  34.  
  35. Install the ball bearing on the rear of the mainshaft.
  36.  
  37. Install the speedometer drive gear.
  38.  
  39. Turn the shifter down and to the left and install the extension housing.
  40.  
  41. Install the neutral return plungers, spring, and resistance spring and ball. Tighten the plug flush with the case.
  42.  
  43. Install the speedometer driven gear.
  44.  
  45. Install the backup light switch and ball.
  46.  
  47. Install the bottom cover and torque the bolts to 6-7 ft. lbs.
  48.  
  49. Install the control lever assembly.
  50.  

 
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