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Chrysler 300 D C76-C300 1957, Service Manual, Page: 300 / 504

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Chrysler 300 D C76-C300 1957 Service Manual Download Page 300

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Summary of Contents for 300 D C76-C300 1957

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Page 2: ...enue Detroit 27 Michigan U S A unless otherwise specified Extra copies of this Manual are available at 4 00 each under Part Number D 16350 Order from Chrysler Division P O Box 1658 Detroit 31 Michigan CHRYSLER DIVISION Chrysler Corporation DETROIT 31 MICHIGAN Chrysler Corportion reserves the right to make changes in design or to make additions to or improvements in its product without imposing any...

Page 3: ...58x6 Fig 1 Model LC 1 Windsor Fig 2 Model LC 3 New Yorker 58x8 Fig 3 Model LY 1 Imperial MyMopar com ...

Page 4: ...one VAlley 2 4700 NOTE Please make certain to include the code WUX on all telegrams to either the Chrysler Division or Plymouth Division as this insures delivery direct to our Teleprint Room thus eliminating delay Letters or telegrams should be confined to one subject only and should include the fol lowing information Car Serial Number Owner s Name Date of Sale Mileage Complete description of diff...

Page 5: ...ts Books Bulletins etc should be forwarded direct to Chrysler Corporation Parts Division P O Box 1718 Detroit 31 Michigan Attention Parts Advertising Department Shortage of Accessories or Other Equipment on New Cars Before placing an order for missing accessories other parts or equipment on new cars received examine the vehicle for the presence of a back order notice which if present will be found...

Page 6: ...ised as follows Windsor Saratoga New Yorker L A Identification LC 1 L 1001 LC 2 L 1001 LC 3 L 1001 T The Engine number will be revised as fol lows Windsor Saratoga New Yorker Chrysler 300D Imperial Year Built Model 58 W 1001 58 S 1001 58 N 1001 58 N3 1001 58 C 1001 Serial Number Fig 4 Vehicle Number The vehicle number is stamped on a metal plate attached to the left front door body hinge post as s...

Page 7: ...ext highest Starting Vehicle Numbers Detroit Los Angeles LC 1 LC 1 1001 LC 1L1001 Windsor T P 9 inm T P 9T ioni T c i inni T t QT 1 om T v i 1 nri1 122 122 122 122 60 9 60 9 60 9 60 9 59 8 59 8 59 8 59 8 218 0 218 0 217 7 218 0 79 6 79 6 79 6 79 6 2 93 2 93 3 18 2 93 8 00x14 8 00x14 8 50x14 8 00x14 Ratio LC 2 Saratoga 126 126 126 60 9 60 9 60 9 59 8 59 8 59 8 220 2 220 2 220 2 79 6 79 6 79 6 2 93 ...

Page 8: ... Wheel Bearings 20 Service Diagnosis 21 DATA AND SPECIFICATIONS MANUAL STEERING Caster H W Camber 0 H right M l A left Steering Axis Inclination 5 to 7 At 0 Camber Toe In y w W Preferred WITH POWER STEERING Caster Camber 0 M right M M left Steering Axis Inclination 5 to 7 At 0 Camber Toe In Preferred SPECIAL TOOLS C 3553 Remover and Installer Shock Absorber Lower Bushing C 3557 Installer Lower Con...

Page 9: ...rol Arm Bushing Retainer Nut Inner 125 Upper Ball Joint Stud Nut 135 Lower Control Arm Shaft to Crossmember Mounting Nut 200 Upper Control Arm to Support Bracket Mounting Bolt Nuts 55 65 Control Arm Support Bracket to Frame Bolt 70 Steering Knuckle to Brake Support Bolt 55 Steering Knuckle to Steering Knuckle Arm Nut 50 UPPER CONTROL ARM BRACKET SHOCK ABSORBER TORSION BAR SPRINGS CAR HEIGHT MANUAL...

Page 10: ...at pressure is applied intermit tently Applying the grease in this manner will cause an up and down motion in the ball joint assembly to assist in thoroughly lubricating the joint It is also advisable to turn the steering gear to left and right to allow the grease to penetrate the whole assembly NOTE The upper ball joint cannot be un loaded but grease should be applied generously while turning the...

Page 11: ...R WASHER BUMPER BUSHING WASHER SHAFT LOCKWASHER NUT NUT BUSHING WASHER LINK SWAY BAR COTTERPIN NUT RETAINER WASHER NUT COTTERPIN BUSHING NUTS WASHER NUT STRUT RETAINER SEAL INNER SEAL OUTER RETAINER UMPER STEERING KNUCKLE FLAT WASHER NUT COTTERPIN UT T WASHER OTTERPIN BOLT SEAL LOWER CONTROL ARM LOCKWASHERS BALL JOINT LOWER LUBE FITTING 57x70A Fig 2 Front Suspension Disassembled View 57x81 Fig 3 L...

Page 12: ...HING x268 Fig 6 Lower Control Arm Strut and Sway Bar Assembly lower control arm as shown in Figure 6 The forward end of the struts are mounted in the front crossmember with replaceable rubber bushings as shown in Figure 9 The sway bar shaft is insulated and mounted to frame and the lower control arm Figs 6 and 10 The front end of the torsion bars are indexed with lower control arms at frame front ...

Page 13: ...e front sway bar is attached to frame and strut bars through insulated rubber mounting brackets To remove the sway bar proceed as follows Remove two sway bar link retaining nuts and concave washers Remove two sway bar cushion retaining nuts lockwashers and bolts one on each strut Slide sway bar out through control arm struts and away from vehicle The sway bar cushions are not serviced separately I...

Page 14: ...or Remove wheel and tire BUSHING 57x77 A Fig 13 Removing Upper Control Arm Bushing assembly Remove cotter pin nut and washer from upper ball joint stud Install tool and load studs Using a hammer remove ball joint stud from steering knuckle by striking the ball joint boss on knuckle sharply Do not hammer on threaded section of stud Remove upper control arm front and rear pivot bolt Remove control a...

Page 15: ...r to Paragraph 16 a Remove cotter pin nut and washer from lower control arm shaft assembly With washer removed reinstall nut to protect threads until it is flush with end of shaft The lower control arm shaft is a tapered fit in front crossmember Use a hammer and brass drift for loosening then remove nut from shaft Slide lower control arm and shaft assembly from rear of crossmember b Installation P...

Page 16: ...NTROL ARM Fig 17 Front Suspension Height and Level Gauge Installed b Assembly Position new bushing flanged end of bushing first on shaft and install washer and nut Tighten nut 100 to 150 foot pounds torque and install cotter pin With lower control arm supported install shaft and bushing assembly by using Tool C 3557 and pressing bushing into the lower con trol arm until flanged portion of bushing ...

Page 17: ...face of control arm bushing housing A I B 57x267 Fig 20 Measuring Front Suspension Height NOTE The measuring pins are spring loaded and scaled in inch increments These read ings are direct measurements and indicate the difference in height between the low point of the control arm ball joints and the lower sur face of the control arm housing These readings can be equalized or adjusted by raising or...

Page 18: ... NEGATIVE CASTER POSITIVE CASTER STEERING KNUCKLE Fig 21 Caster Angle VERTICAL LINE 57x199 A CAMBER ANGLE VERTICAL LINE AXIS ANGLE AXIS CENTER LINE 57x198 Fig 22 Camber Angle Axis Inclination NOTE Front suspension parts are heat treated if they are damaged or bent they should be replaced Under no circumstances should these parts be heated in order to straighten The method of checking front wheel a...

Page 19: ...ith only the weight of the vehicle on the springs Grasp the front bumper at the center and jounce the front of the car up and down sev eral times to place the front springs and shock absorbers in their normal position NOTE The car must remain in this normal position while checking all alignment settings 54x249 Fig 24 Checking Camber Tool C 3409 Check front suspension height by finding the differen...

Page 20: ...m y16 inch thick at each bracket will change camber approximately 6 The total thickness of each shim pack should not exceed e NOTE Should any front suspension parts be come bent they should be replaced Under no circumstances should these parts be heated to straighten or bend 12 ADJUSTING CASTER AND CAMBER WITH TORSION AIRE SHIM CHANGE CHART FIG 26 Both caster and camber can be adjusted at the same...

Page 21: ... 9 12 8 11 8 11 7 10 7 10 6 9 5 8 5 8 4 7 3 6 3 6 2 5 2 5 1 4 0 3 0 3 1 2 0 18 18 17 17 16 16 16 16 15 15 15 15 14 14 13 13 13 13 12 12 11 11 11 11 10 10 10 10 9 9 9 9 8 8 7 7 7 7 6 6 5 5 5 5 4 4 4 4 3 3 2 2 2 2 1 1 1 1 25 18 15 17 14 17 14 16 13 16 13 15 12 14 11 14 11 13 10 12 9 12 9 11 8 11 8 10 7 10 7 9 6 8 5 8 5 7 4 6 3 6 3 5 2 5 2 4 1 50 18 12 17 11 17 11 16 10 15 9 15 9 14 8 13 7 13 7 12 6 ...

Page 22: ...6 7 7 9 9 9 9 9 9 9 9 10 10 11 11 11 11 12 12 12 12 13 13 14 14 14 14 15 15 15 15 19 19 17 17 17 17 19 19 25 TO 1 1 3 3 1 2 1 3 3 0 3k 2 4 0 31 1 5 4 4 4 5 3 6 3 6 _ i 4I 1 5J 2 7 2 5 0 6 2 7 2 5 3 6 3 6 1 7 1 7 L 2 9 _ 4 7p 2 9 4 7 5 9 6 9 6 9 7 10 9 11 9 11 9 12 9 12 10 13 11 14 11 14 12 15 13 19 13 19 14 17 14 17 15 19 50 3 9 4 10 4 10 5 11 5 11 9 12 7 13 7 13 9 14 9 15 9 15 10 19 11 17 11 17 1...

Page 23: ...chart the alignment should be rechecked with the gauges to complete the operation 13 ADJUSTING FRONT WHEEL TOE IN Toe In means that wheels are closer together at front than they are at rear To measure spin front wheels and scribe a thin line in center of tread of each tire Fig 27 Jounce front end up and down several times and position wheels in straight ahead position Gauge and scriber t FRONT HUB...

Page 24: ...limits it is unnecessary to check steering axis inclina tion To check axis inclination refer to Figs 21 and 22 and proceed as follows Inflate tires to recommended pressure place front wheels in straight ahead position on turn tables and set foot brakes Grasp front bumper at center and move front end of car up and down several times to permit front suspension parts to settle in normal unloaded posi...

Page 25: ...e then slide steering arm over bolts Install lockwashers and nuts Tighten nuts evenly to 55 foot pounds torque Install cotter pins Remove covering from brake shoes replace wheel tire and drum assembly Adjust front wheel bearings as per Front Wheel Bear ing End Play Adjustment Paragraph 18 Re fer to Front Wheel Alignment Caster and Camber Paragraph 11 BALL JOINT STEERING KNUCKL Fig 32 Removing Uppe...

Page 26: ... squarely d Installation of Lower Ball Joint To reinstall screw ball joint into control arm as far as possible by hand Using Tool C 3561 tighten until ball joint housing is seated on control arm Slide seal and dust cover down into position over stud then position stud in steering knuckle Install washer and nut Tight en 135 foot pounds torque Install cotter pin lubricate fitting and lubricate ball ...

Page 27: ...GS FIGS 35 36 and 29 Remove hub cap and grease cap then jack up front of car Remove cotter pin that retains nut lock Remove nut lock Using an inch pound torque wrench tighten adjusting nut to 90 inch pounds while rotating wheel Remove torque wrench Selectively position the nut lock over adjust ing nut so that the spindle cotter pin hole is in approximate alignment with one set of slots in nut lock...

Page 28: ...or replace bushing or shock absorber as required Sway eliminator noisy Check attaching bolts for tightness and rubber bushings for wear If rubber bushings are worn replace sway eliminator assembly Worn or loose front wheel bearings Adjust or replace as required 20 BODY HAS TENDENCY TO PITCH AND ROLL Low or uneven tire pressures Inflate tires to proper pressure Shock absorber inoperativ quired Repl...

Page 29: ...arrier Installation 17 Axle Shaft End Play Adjustment 17 Axle Drive Shaft Bearing 18 Rear Axle Housing Alignment 18 Sure Grip Differential 19 Service Diagnosis 24 DATA AND SPECIFICATIONS Rear Axle Type Gear Type Ring Gear Diameter Pinion Bearing Type Adjustment Differential Bearings Type Adjustment LC 1 LC 2 LC 3 LY 1 Semi Floating Hypoid 8 75 Semi Floating Hypoid 8 75 Tapered Roller Shim Pack Tap...

Page 30: ...orque Flite No Drive Gear Teeth No Drive Pinion Teeth Type Recommended Summer Winter Extreme Cold Capacity Wheel Bearings Type Adjustment Axle End Play Road Clearance Full Load T C Wagon Sedan Tread Rear T C Wagon Sedan Matched Sets 005 Maximum 006 to 008 0 to 008 Matched Sets 005 Maximum 006 to 008 Standard 2 93 41 14 Multi Purpose Gear Lubricant 90 90 80 Pints Tapered Roller Select Shims 013 to ...

Page 31: ...Axle Shaft Inner Oil Seal C 845 or C 319 Puller Universal Wheel and Hub C 3565 Driver Axle Shaft Outer Seal C 3566 Driver Axle Shaft Outer Seal End Brake Support DD 996 or DD 955 Installing Sleeve Pinion Bearing DD 914 8 Ring Medium Reducer use with DD 914 89 DD 921 Wrench Differential Case Cap Remover and Installer DD 993 Puller Pinion Oil Seal DD 999 Installing Tool Companion Flange or Yoke DD 1...

Page 32: ...hould be carefully THRUST WASHER BOLT AND LOCKWASHER BEARING CONF SHAFT DIFFERENTIAL CASE PIN BEARING CONE CUP SPACER j SIDE GEAR THRUST WASHER PINION j SIDE GEAR THRUST WASHER DRIVE GEAR AND PINION BEARING CONE CUP SHIMS ADJUSTING WASHER BEARING CONE THRUST BLOCK THRUST WASHER BOLT AND LOCKWASHER 57x2 Fig 1 Rear Axle Exploded View LC 1 LC 2 SHAFT THRUST WASHER BEARING CONE BOLT AND LOCKWASHER LOC...

Page 33: ... PROCEDURES 2 REMOVAL OF DIFFERENTIAL CARRIER ASSEMBLY All models Raise car off floor and block the brake pedal PULLER TOOL 56x233A Fig 3 Removing Hub and Drum Assemblies SEAL PROTECTING SLEEVE TOOL OIL SEAL so pedal cannot be depressed Drain lubricant from housing Back off brake shoes with Tool C 845 Remove rear wheels hub and drum as semblies as shown in Figure 3 Disconnect the brake line at whe...

Page 34: ...r drive gear to pinion backlash before disassembly Fig 9 With carrier assembly mounted in REAR AXLE SHAFT INNER OIL SEAL 49x713 Fig 7 Removing Inner Oil Seal Using Tool C 637 DRIVER TOOL BRAKE SUPPORT 57x21 Fig 9 Checking Drive Gear and Pinion Backlash stand mark both differential bearing caps and adjusters if unit is to be checked for a specific noise condition as shown in Figure 10 before removi...

Page 35: ...e differential case assembly from car rier Use Tool C 293 in combination with 3 Number 18 adapter plates behind bearings to pull off the differential bearings from case as shown in Figure 12 If axle is equipped with a Sure Grip differential refer to Paragraph 23 for service procedure Remove differential pinion shaft lock pin by driving pin from case with a hammer and punch as shown in Figure 13 Dr...

Page 36: ...g Drive Pinion Bearing Oil Seal and blow dry with compressed air Remove any chips or foreign material from carrier Inspect all machined surfaces for nicks burrs or scratches including inner and outer thrust shoulders of differential case The thrust shoul der on adjusters must be free from burrs so that bearing cups will seat properly Check differential case for cracks fractures distor tion or dama...

Page 37: ...ughout the 360 degree revolution The clearance between each gear and case ranges from 001 to 012 inch This clearance has been established to ascertain free rotation TOOL BEARING 57x19 Fig 20 Checking Drive Gear Runout Install pinion shaft lock pin through hole in case from the pinion shaft side of the drive gear flange Position each differential bearing cone on hub of case Fig 19 taper away from d...

Page 38: ...mphasized The selection of adjusting washers to give the desired pre load should be carefully made When pinion DRIVE PINION REAR BEARING CONE SP 1730 SLEEVE COMPRESSION SLEEVE TOOL CENTRALIZING WASHER TOOL 57x12 Fig 23 Compression Sleeve and Centralizing Washer Positioned in Carrier bearings are installed without pre loading the cones are not drawn far enough into their cups to bring the rollers i...

Page 39: ...cor rect gear and pinion tooth contact NOTE If the differential assembly was satis factory from the standpoint of noise before be ing disassembled the drive pinion may be as sembled with the original adjusting washers A II PINION LOCATING WASHER OR SHIM SP 528 ASSEMBLY OF SP 526 CARRIER J SP 2919 v ASSEMBLY 57x152 SP 173O Used on Windsor PINION LOCATING WASHER NO WASHER OR SPACER x ASSEMBLY I OF S...

Page 40: ...rs in bearing cups Pre load torque required to rotate pinion shaft with bearings oiled should be 25 to 35 inch pounds torque Add shims to decrease torque or remove shims to increase torque After correct pinion setting and bearing preload has been obtained remove drive pinion flange install oil seal and tighten drive pinion flange washer and nut to proper torque Install drive gear with grease marki...

Page 41: ... be used for final assembly If spacer selected by the use of tool is 090 inch it is necessary to deduct 002 inch The correct washer therefore for final assembly would be 088 inch When correct washer has been selected for drive pinion disassemble tool from carrier Add washer selected to tool between spacer SP 2921 and pinion rear bearing Add spacer SP 2920 and the pinion bearing adjusting spac er t...

Page 42: ...S TOOL 3 32 INCH REAR BEARING CONE DRIVE PINION 52x382 Fig 30 Installing Pinion Bearing Cone on Pinion Shaft 58x187 Fig 31 Pinion Seal Installed With an inch pound torque wrench rotate wrench in a clockwise direction several revolu tions to seat bearings The correct torque read ing should be from 25 to 35 inch pounds If bearing preload is more than 35 inch pounds a thicker shim should be used unde...

Page 43: ...ash remains This will insure bearing cup alignment for final adjustment Turn drive gear a few times by hand to seat bearings With a dial indicator find point of least backlash on drive gear at 90 degree in tervals At least point of backlash screw in adjuster at back face of drive gear until 001 inch appears on indicator 57x20 Fig 33 Adjusting Differential Bearings Screw in adjuster on tooth side u...

Page 44: ...own in Figure 37 will result Notice that contact pattern is well centered on the drive and coast sides about 6 inch from edges of teeth When tooth marks are obtained by hand they are apt to be rather small Under an ac tual operating load however the contact area increases Figures 35 and 36 show improper or incorrect tooth contact To correct such conditions readjust drive gear and pinion as follows...

Page 45: ...nd in stall the dust shield lockwashers and nuts Tighten 30 35 foot pounds torque Working from the opposite end of the axle housing install the other axle shaft with bear ing until inner end of axle shaft contacts the axle shaft thrust block Lightly tap end of axle shaft with a fibre mallet to insure shaft is con tacting the thrust block this will force the Fig 38 lnstalling Axle Drive Shaft Beari...

Page 46: ... housing should be completely disas sembled if it is to be welded with arc welding equipment It is also possible to weld the as DRIVER TOOU 5ox234A BRAKE SUPPORT OIL SEAL _ 56x178 Fig 40 Removing Rear Axle Shaft Oil Seal from Brake Support with Tool C 839 sembled housing with gas welding equipment if precaution is taken to protect gaskets and heat treated parts 20 REAR AXLE HOUSING ALIGNMENT Rear ...

Page 47: ...a square against machined surface of housing end flange and surface plate as shown in Figure 45 Amount of housing misalignment will be indicated by thickness of feeler gauge between square and end flange at top or bot tom A housing that checks more than 007 inch should be replaced To determine amount that axle is misaligned multiply thickness of feeler stock used by the ratio of 4 7 to 1 SURE GRIP...

Page 48: ...al clearance in the case to permit a slight peripheral move ment of the ends of the pinion shafts within the case 22 OPERATION Fig 47 Torque delivered by the engine is transmitted to the rear wheels via the axle drive pinion PINION SHAFT DIFFERENTIAL PINION DIFFERENTIAL CASE CLUTCH PLATES AXLE SHAFT PINION THRUST MEMBER DIFFERENTIAL PINION PINION SHAFT 58x260 Fig 46 Sure Grip Differential Cut away...

Page 49: ...e clutch The other two friction plates of each clutch are attached to the differential case so that when they are en gaged both axles shafts become clutched to the case to a degree that varies with the amount of torque transmitted This in effect locks the axle shafts in nor mal straight ahead driving thus prevents momentary spinning of the wheels when en countering poor traction Refer to Figures 4...

Page 50: ...25 ASSEMBLY Clean all parts thoroughly Inspect all parts for wear nicks and burrs Replace worn cracked or distorted clutch plates If case is worn it will be necessary to replace both halves Install clutch plates alternately so that an external tanged plate approximately Vie inch thick is installed first followed by an internal CASE CAP CLUTCH PLATES SIDE GEAR RETAINER 58x719 Fig 51 Removing or Ins...

Page 51: ... inch should be installed so that it will be toward the case Install one side gear retainer Fig 57 en gaging splines of retainer with internal splined clutch plates Install one side gear Fig 56 Install a lock pin in one of the axle thrust spacers drive pin until pin appears at thrust end of spacer but does not extend beyond thrust face Align the pinion shafts and install spacer and pin through hol...

Page 52: ...LLATION Install drive gear and differential assembly in the same manner as outlined under the con ventional differential assembly LUBRICATION Fill Sure Grip Differential with 3 4 pints of special differential lubricant MOPAR 1879414 Check level of unit after filling SERVICE DIAGNOSIS 27 REAR WHEEL NOISE a Wheel loose on axle shaft b Worn drum or axle shaft keyways c Wheel hub bolts loose d Brinnel...

Page 53: ... housing d Vehicle overloaded 32 DIFFERENTIAL CASE BREAKAGE a Improper differential bearing adjustment b Abnormal clutch operation c Excessive drive gear clearance d Vehicle overloaded 33 DIFFERENTIAL SIDE GEAR BROKEN a Worn thrust washers b Misaligned or bent axle shaft c Overloading vehicle 34 TOOTH BREAKAGE Drive Gear and Pinion a Overloading and abnormal clutch opera tion b Improper gear adjus...

Page 54: ...D SPECIFICATIONS TOTAL CONTACT SERVICE BRAKES MODELS LCI LC2 LC3 LY1 TYPE Total Contact Floating Shoe Hydraulic DRUM DIAMETER 11 in 12 in LINING Type Moulded Asbestos Attachment Cyclebond Width 2Y2 in Thickness in BRAKE SHOE RETURN SPRING TENSION USING FISH SCALE HOOKED AT TOE OF SHOE 35 to 45 lbs required to break contact between shoe and push rod BRAKE PEDAL FREE PLAY in to V8 in WHEEL CYLINDER ...

Page 55: ...mber Tool Name C 3014 Installing Tool Hand Brake Adjusting Nut Spanner C 3015 Installing Tool Hand Brake Adjusting Nut Cable C 3080 Hone Brake Cylinder Surfacing C 3281 Wrench Brake Drum Holding C 3462 Wrench Brake Shoe Return Spring Remover and Installer C 3496 Tank Master Cylinder Refiller Air Pressure C 452 Puller Parking Brake Drum C 650 Hose Brake Bleeder C 757 Installing Sleeve Rear Axle Sha...

Page 56: ...cross width of lining The web of shoe is contoured in depth so when brakes are ap plied equal pressures are applied to brake drums along entire length of lining The shoes are held in position by brake shoe return springs One end of each spring is hooked in loop of return spring links The other end en gages the brake shoe An anchor pin in support plate assembly holds the spring link in a fixed posi...

Page 57: ...SHOE SCREW RETAINER SPRING SHOE TUBE RETAINER Fig 3 Front Brake Disassembled View BOLT CYLINDER 57x359 ROD SHIELD SEAL SCREW FACING SHOE ASSEMBLY SPRING WASHER SCREW SPRING RETAINER SPRING SUPPORT SHOE ASSEMBLY 57x360 Fig 4 Rear Brake Disassembled View MyMopar com ...

Page 58: ...th shoes pivot at the bottom of support plate and are actuated by wheel cylinder causing shoes to operate in opposition to each other Self ener gizing action is effective on rear brake front shoe when vehicle is traveling forward and ef fective on rear shoe when traveling in reverse BOOT SCREW CUP BOOT 57x358 A Fig 6 Rear Wheel Cylinder Exploded View SERVICE PROCEDURES 1 DISASSEMBLY OF FRONT BRAKE...

Page 59: ...e support plate with wheel cylinders and cylinder connector tube attached Fig 10 With assembly on bench remove cylinder connector tube and wheel cylinders NOTE Perform operations outlined in icing the Wheel Cylinders Serv 2 ASSEMBLY OF FRONT BRAKE Place wheel cylinders into position in support 57x50 Fig 9 Removing Front Brake Shoe From Support Plate 57x56 Fig 10 Removing or Installing Support Plat...

Page 60: ...BRAKE Block brake pedal in UP released position 58x744 Fig 15 Removing or Installing Rear Brake Support Shield with Tool C 745 Raise car and remove wheels Back off all ad justing cams Remove hub and drum assembly using puller Tool C 845 Insert wrench Tool C 3462 in inner support plate hole with tool cam slot engaging spring hook Fig 12 Turn tool handle to disengage spring from return spring link a...

Page 61: ...en between web of shoe and wheel cylinder push rod NOTE Long end of brake return springs must be hooked in shoes Otherwise brake noise will be encountered due to coil springs contacting shoes Install brake shoe guide springs making sure positioning lip of spring engages hole in support plate Fig 13 Loosen adjusting cams and install hub drum and wheel assem bly Bleed brake system refill master cyli...

Page 62: ...tches or show signs of corrosion can usually be cleaned up with crocus cloth Cylinders that have deep scratches or scoring may be honed however using Tool C 3080 providing diameter of cylinder bore is not increased more than 002 inch A cylinder that does not clean up at 002 inch should be discarded and new cylinder used Black stains RIGHT FRONT 55X708 Fig 19 Adjusting Front and Rear Brake Shoe Ori...

Page 63: ...and will do no harm CAUTION Use extreme care cleaning master cylinder af ter reconditioning Remove all dust or grit by flushing cylinder with alcohol Wipe dry with clean lintless cloth and clean second time with alcohol Dry master cylinder with air pressure and flush with clean brake fluid Be sure re lief port in master cylinder is open Before assembling piston cups and valve assembly should be di...

Page 64: ...remove flange and brake drum Remove brake adjusting screw cover and disengage ball end of cable from op erating lever Separate shoes at bottom allow ing brake shoe adjusting nut screw and sleeve to drop out and release shoes Remove brake shoe return spring Pry out brake shoe anchor washer and re move outer shoe guide Slide each shoe out from under brake support grease shield spring As shoes are re...

Page 65: ...ANCHOR WASHER BRAKE SUPPORT GREASE SHIELD BRAKE SHOE OPERATING LEVER LINK BRAKE SHOE ANCHOR BRAKE SHOE ANCHOR BRAKE SUPPORT BRAKE SHOE LINING ASSY SHAFT FLANGE BRAKE DRUM ASSY BRAKE SUPPORT SPACER BRAKE SUPPORT SPACER SLEEVE 1 SHAFT FLANGE WASHER SHAFT FLANGE NUT BRAKE SUPPORT GREASE SHIELD SPRING BRAKE SHOE RETURN SPRING BRAKE ADJUSTING SCREW COVER BRAKE ADJUSTING SCREW COVER SCREW BRAKE SHOE OPE...

Page 66: ...e b Installation Slide cable into guide Insert installer Tool C 3015 between spring retainer washer and ball on end of cable Hook cable into slot in oper ating lever with lever between ball and washer c Adjustment After installation has been completed adjust cable as follows The cable length adjusting nut should be positioned against cable housing so there is at least 005 inch but not more than 01...

Page 67: ...LVE VALVE HOUSING O RING SEAL BELLOWS RETAINER SPRING RETURN SPRING GUIDE BELLOWS SUPPORTS INNER MOUNTING PLATE OUTER MOUNTING COVER OPERATING ROD NUTS 4 STOP SEAL WASHER BUTTON O RING SET SCREW O RING SET SCREW YOKE 56x527A Fig 26 Bellows Type Power Brake Disassembled View MyMopar com ...

Page 68: ...ER BRAKE UNIT Use pedal depressor depress pedal to prevent trigger arm from extending beyond extremities of bracket NOTE If pedal linkage is allowed to extend through hole in dash panel trigger arm may be damaged Disconnect vacuum hose at power vent Re move master cylinder power unit and bracket assembly hex nuts and lockwashers Carefully withdraw unit from dash panel Fig 27 NOTE Use care to preve...

Page 69: ...pring retainer Place unit on its side and remove bolts and lockwashers that attach valve cover to valve Lift off cover Fig 33 If it is necessary use a flat blade to separate cover plate from bellows flange Extreme care should be taken to avoid marking or scratching inner face of plate where it clamps to bellows flange A scratch on this surface could cause a leak Remove 0 ring from valve cover and ...

Page 70: ...iscard valve housing to guide seal Invert valve housing and remove air valve seal from its groove in valve body Fig 38 CAUTION Work carefully to avoid marking or scratching inside diameter bore of valve housing The bellows type power brake now has been disassembled as much as necessary for cleaning and inspection Clean all parts except bellows bearing and air filter in solvent and blow dry with co...

Page 71: ... HOLDING FIXTURE 56x543 GUIDE 56x542 Fig 4 1 Installing the Vacuum Seal valve lining up bolt in guide with bolt holes in valve body Carefully lower guide down against valve body making certain tapered portion of vacuum valve enters seal evenly Press down on guide to seat and install bolts and lockwashers Tighten bolts evenly and se curely CAUTION Be sure countersunk holes at end of guide line up w...

Page 72: ...te inside of bearing and slide it over guide while compressing bel lows Fig 45 Bearing must be installed with lip of seal facing out Push bearing down over guide and into pocket of plate Release bellows and bearing will ride up guide with plate into position Install bearing to mounting plate 0 ring and lower outer mounting plate down on as sembly The notch on edge of plate must be in COVER RETURN ...

Page 73: ...ting screw Should pedal vibrate booster chatter turn adjusting screw in counter clock wise direction Fig 46 More likely cause of chatter is empty master cylinder or improp erly bled brake system Refill or bleed NOTE Rotation of adjustment screw should be limited to plus or minus 90 degrees about original setting 21 ASSEMBLY OF PEDAL LINKAGE IN PEDAL BRACKET CAUTION Use extreme care during assembly...

Page 74: ...on vehicle make following vacuum and hy draulic leakage test Operational test should also be made to determine that brake power unit and hydraulic brake system is operating up to standard Road test car and make brake applications at about 20 m p h If brake pedal has a spongy feel when brakes are applied air is present in hydraulic systems and lines must be bled Bleed brake system at each wheel cyl...

Page 75: ...essary 31 DRAGGING BRAKE a Excessive brake adjustment adjust to proper clearance b Check hand brake that it is fully released c Check wheel cylinders repair or replace as necessary d Check brake shoe return spring replace worn or broken springs e Brake pedal binding loosen pedal across shaft f Check master cylinder repair or replace Check for swollen cup g Check for lack of pedal free play adjust ...

Page 76: ...D BELT LC 1 80 25 35 40 LC 2 3 LY 1 75 35 40 NEW BELT LC 1 120 40 50 70 LC 2 3 LY 1 125 50 70 BELT DEFLECTION METHOD Deflection inches to be applied at midpoint of belt segment under a five pound load See Fig 3 ACCESSORY Power Steering Fan Belt Idler Generator Without Air Conditioning With Air Conditioning USED BELT LC 1 X Vs LC 2 3 LY 1 X Hi NEW BELT LC 1 Hi Hi Hi LC 2 3 LY 1 LC 1 with Air Condit...

Page 77: ...nsions can be properly established is as follows 1 TORQUE METHOD All generator and power steering pump belts can be tightened to the specified tension see specifications in this section by use of a torque wrench The generator belts are tensioned by using Tool C 3379 and torque Wrench as shown in Figure 1 The power steering belts are tight TORQUE WRENCH ened by inserting the torque wrench in the sq...

Page 78: ...r can be used if the accessory has a square hole Tighten the mounting bolts and check the deflection See tension specifica tions It may be necessary to repeat this pro cedure several times to establish the correct tension SERVICE DIAGNOSIS 3 INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE a Check belt tension and belt condition b If belt is excessively glazed or worn re place and tighten as spe...

Page 79: ... LC 3 LY 1 COOLING Type Pressure Vent Capacity With Heater 22 qts 25 qts Without Heater 21 qts 24 qts Radiator Cap Relief Valve Pressure psi 14 With Air Conditioning 14 WATER PUMP Type Centrifugal Bearing Type Ball Bearing THERMOSTAT Type Choke Starts to Open up to 158 to 162 F Air Cond 177 to 182 F Fully Open 185 F Air Cond 202 F FAN BELT Number Used Standard Steering one Power Steering two Type ...

Page 80: ...r Conditioning have ring shroud six blade Silent Flite fan with 2x i inch Fin and Tube LC 2 LC 3 LY 1 with Air Conditioning have a box type fan shroud five blade Silent Flite fan On LC 1 5 blade Silent Flite fan is not available SPECIAL TOOLS Tool Number C 311 Flushing Gun C 3208 Remover Water Pump Shaft Bushing C 3476 Puller Plastic Water Pump Impeller Insert C 3468 Sleeve Water Pump Bearing and ...

Page 81: ... NUT ixxmmm 58x180 Fig 1 Silent Flite Fluid 5 Blade Fan Drive Used On Air Conditioning Only Exploded View friction material has been applied to its faces in case of contact of these faces and the hous ing The housing is partially filled with a spe cial heavy fluid and the drag of the fluid between the housing and rotor provides the driving force rotating the fan The power required to rotate the fa...

Page 82: ...wer steering pump or idler pul ley generator and remove all belts Remove fan spacer and pulley On Air Conditioning Models remove the pulley from water pump fan hub loosen all nuts from fan to remove the fluid fan drive as shown in Figure 1 Remove bolts hold ing water pump body to housing and remove water pump WATER OUTLET ELBOW THERMOSTAT GASKET CYLINDER WATER OUTLET MANIFOLD SHAFT AND BEARING GAS...

Page 83: ...allation on Car Fig 7 Install water pump body on housing using new gasket Tighten bolts to 30 foot pounds torque Install pulley spacer and fan On Air Condi tioning Models assemble the fan to the fluid fan drive and pulley and attach the assembly to the water pump Tighten nuts to 15 foot pounds torque Install the upper half of fan shroud run the engine and check for leaks 3 RADIATOR The Torque Conv...

Page 84: ...o radiator may result Continue this procedure until water runs clean Refill cooling system Run engine and check for leaks a Cylinder Block Drain radiator and remove hoses at radiator Remove thermostat and reinstall thermostat housing Install flushing gun Tool C 311 or other suitable flushing gun to the inlet hose Connect water hose of gun to a pressure water source and the air hose of gun to a pre...

Page 85: ...RESSURE CAP Radiators are equipped with a 14 psi cap as shown in Figure 10 Always check identifica tion number on cap when replacing WARNING When removing pressure cap turn it counter clockwise to the stop permitting built up pres sure to escape through overflow tube This will prevent hot water from spraying out of radiator filler opening SERVICE DIAGNOSIS 8 POOR CIRCULATION a Check for low coolan...

Page 86: ...g the Regulator 17 Removal and Installation of Distributor 23 Checking Distributor Governor Advance 23 Servicing the Spark Plugs 26 Servicing the High Tension Cables 27 Headlight Aiming and Lighting System 28 Operation of Fuel Gauges 30 Ignition Starter Switch 33 Turn Signal Switch 34 Servicing the Horns 34 Servicing the Windshield Wipers 35 Servicing the Electric Window Lifts 37 Electric Locking ...

Page 87: ...Amps at 6 Volts Hold in Coil Draw 10 2 to 11 8 Amps at 6 Volts Pinion Adjustment Clearance Between Pinion and Stop with armature end play removed Hz W ELECTRICAL LIGHT BULBS Number Required Mazda Number C P or Watts Chrysler Part No Headlights Inner High Beam Only Headlights Outer High and Low Beam Headlight Beam Indicator Light Parking and Front Turn Signal Rear Tail Stop and Turn Signal Light Li...

Page 88: ...Air Conditioning Ground Polarity Poles Brushes Spring Tension Field Coil Draw Arm to Field Term Motorizing Draw Test Bench Output Test at 70 F GJC 7012A 1770754 GHM 6004C 1704264 GHM 6001E 1753265 Clockwise at Drive End 12 Controlled by Vibrating Regulator 30 Amperes Ball at drive end Bushing at opposite end Ball Both ends Negative 2 2 18 to 36 oz 1 2 to 1 3 amps at 10 volts 3 4 to 3 9 amps at 10 ...

Page 89: ...e in degrees F Current at Specific Temperature 40 31 35 60 29 33 70 28 32 80 27 31 100 25 29 40 41 45 60 39 43 70 38 42 80 37 41 100 35 39 Cut Out Relay Voltage Winding Resistance Air Gap Contacts Open Measure Gap as near hinge as possible Contact Gap Minimum Contacts Close Volts Contacts Open After a charge of 10 amperes Discharge Amperes Volts 107 to 121 ohms 031 to 034 inch 015 inch 13 0 to 13 ...

Page 90: ...0 to 80 F 665 to 735 HORNS All Models Make Auto Lite Spartan Jubilee Current draw at 12 4 volts 9 to 10 amps ELECTRIC WINDSHIELD WIPER All Models Variable Speed Motor Rated Volts 12 Resistor ohms Variable speed wiper 17 40 Field Current Draw at 13 5 volts V z to 2 amps Motor Current Draw with dry glass High Speed 1J4 amps at 66 to 75 rpm Low Speed 3 amps at 35 to 40 rpm POWER SEAT LIFTS All Models...

Page 91: ... of 1 225 or less in cold temperature or 1 210 in warm temperature and all cells reading even ly within 15 specific gravity points 015 of each other requires recharging A battery that has a specific gravity reading which varies more than 15 points between any two cells should be recharged and high rate discharge tester or other suitable method used to check battery before discarding battery as uns...

Page 92: ...h 6 and 12 volt batteries on the same circuit Each 12 volt unit must be considered as equal to two 6 volt batteries and charging rate must be ad justed to suit the smallest 12 volt battery on the line Safe slow charging rates are deter mined by allowing one ampere per positive plate per cell The proper slow charging rate for an 11 plate battery is five amperes Connect positive charger lead to posi...

Page 93: ...hen open circuit voltage drops to 2 05 volts per cell Battery should be fully charged when installed WARNING When batteries are being charged an explosive gas mixture forms beneath cover of each cell Do not smoke near batteries on charge or which have recently been charged Do not break live circuits at terminals of batteries on charge A spark will occur where the live circuit is brok Keep all open...

Page 94: ...CHRYSLER SERVICE MANUAL CTRICAL SYSTEM 9 CN MyMopar com ...

Page 95: ...b Stall Test Install starter motor in test bench Follow in structions of equipment manufacturer and check stall torque of starter against following specifications With applied battery voltage ad justed to 4 volts stall torque should be 8 5 foot pounds minimum with a current draw of 350 amperes 6 DISASSEMBLING THE STARTER TIG 4 Remove clevis pin from solenoid plunger link age Remove thru bolts and ...

Page 96: ...ease starter efficiency and damage the armature core and windings 12 SERVICING THE BUSHINGS Inspect armature shaft bearing surfaces and bearings for wear by placing core in vise equipped with soft jaws Do not squeeze tightly Try commutator end plate and the drive end nose casting by placing them on shafts and checking for side play Replace commutator end plate assembly if bearing is worn Also repl...

Page 97: ...wheel mounting surfaces are free of dirt and oil These surfaces must be clean to make good electrical contact Install starter from beneath car Draw attaching bolts up tight and attach wires to solenoid switch Lower car to floor install battery cable and test operation of starter for proper engine cranking GENERATORS 17 REMOVAL The generator is mounted on a bracket at tached to engine and held in p...

Page 98: ...or brushes for excessive arcing and or bounce while high output is being de livered A rough burned or dirty commutator will cause arcing and bouncing at brushes 20 DISASSEMBLY To disassemble a standard type generator Fig 7 remove through bolts and pull end plate from field frame Slide armature and drive end frame assembly from generator field frame Place armature core in vise equipped with soft ja...

Page 99: ...14 ELECTRICAL SYSTEM CHRYSLER SERVICE MANUAL MyMopar com ...

Page 100: ...D COILS ARMATURE RETAINER SNAP RING SCREW WASHER INSULATOR TERMINAL SPRING BRUSH ARM SCREW AND LOCKWASHER BRUSH ARM BEARING SPRING WASHER SCREW AND LOCKWASHER Fig 8 1 2 Volt Generator Air Conditioning Models COVER 56x40A CO en MyMopar com ...

Page 101: ...al post and field frame If lamp lights it indicates that either terminal post or brush holder is grounded Remove terminal post and retest brush holder If lamp lights brush holder is grounded Replace defective parts It is necessary to replace field frame if insulated brush holder is grounded d Testing Field Current Draw Fig 9 Test field coils for short circuits between wind ings high resistance con...

Page 102: ...d plate and through bolts Place felt and shield in commutator end plate and press bear ing on shaft applying pressure to inner race Install shield c Testing After Assembly The generator should be tested before it is in stalled on car If proper bench test equipment is not available it is possible to motor test generator A generator that will motor freely with specified voltage applied will in most ...

Page 103: ...ize regulator temperature REGULATOR 31 TESTING REGULATOR TEMPERATURE When testing regulator keep cover in place and make sure temperature at regulator is known The regulator armature hinges are temperature compensated and control will vary with temper ature changes To measure temperature at regulator hold an accurate Fahrenheit thermometer two inches from cover The correct voltage setting of regul...

Page 104: ... ulator immediately follows voltage regulator test generator should be run at its rated out put of 30 amperes for 15 minutes in addition to voltage regulator 15 minute run before checking or adjusting current regulator Test as follows Install test equipment Fig 12 start en gine and increase speed to 2 000 r p m Adjust variable resistance across battery until current settles to steady ampere output...

Page 105: ...ntrol knob to full resistance position Slowly rotate variable re sistance control knob toward no resistance position while carefully observing voltmeter Increase engine speed slowly The relay con tacts close when voltmeter hand jumps back slightly The closing voltage is highest reading in volts reached before hand jumps back and should be 13 to 13 75 volts Rotate variable re sistance control knob ...

Page 106: ...ct point file Do not remove too much material Never use sandpaper emery ADJUSTING SCREW 51x624 cloth or dirty file to clean contact points as foreign material may become embedded in con tacts and result in arcing or burning The filing should be done parallel to length of armatures Cross filing will form grooves and result in contacts sticking and faulty op eration After contacts are clean and smoo...

Page 107: ...ainst upper stop 031 inch gauge should slide in freely but 034 inch gauge should be too tight Adjust air gap by bending upper stop up to increase air gap or down to decrease it d Cut Out Relay Contact Clearance Adjust contact clearance by expanding or con ARMATURE STOP STATIONARY CONTACT BRIDGE e 51x621 Fig 17 Adjusting Cut Out Relay Contact Clearance tracting bridge Fig 17 The proper clearance is...

Page 108: ...iming indicator pointer Rotate distributor until contacts are just opening and tighten hold down plate In stall vacuum tube primary lead and distributor cap 38 IGNITION TIMING FIG 19 Make certain distributor is properly installed in engine Install timing light and start engine Allow engine to warm up sufficiently to enable carburetor fast idle mechanism to position for ATTACH TO NO l SPARK PLUG WI...

Page 109: ...WASHER FELT WASHER BREAKER PLATE CAM SLEEVE WICK SNAP RING CAM ANTI RATTLE SPRING SPACER SHAFT THRUST WASHERS BUSHING PRIMARY LEAD SPRING CLIP AND BRACKET SCREW LOCKWASHER SPRING CLIP AND BRACKET VACUUM CHAMBER ASSEMBLY GOVERNOR WEIGHT SPRING SET WASHERS GASKET GOVERNOR WEIGHTS PLUG 57x315 Fig 21 Single Point LC 1 LC 2 Distributor Disassembled MyMopar com ...

Page 110: ...t of contacts readjust clearance 015 to 018 inch 42 ADIUSTING CONTACT POINT CLEARANCE Measure clearance with feeler gauge dial in dicator or with a dwell meter 015 to 018 inch New contacts should always be adjusted to 018 inch This will allow rubbing block to wear into cam contour and still provides specified clear ance when shaped Where dwell meter is used to check clearance it is essential to ad...

Page 111: ...into position The bushing when properly in stalled will measure 094 inch below top of bore Place adapter over driver with shoulder down and slide new upper bushing over driver and down on adapter shoulder Insert bushing and driver into bore Fig 24 and press bushing into position The bushing when properly in stalled will measure 094 inch below top of bore Invert distributor housing reverse adaptor ...

Page 112: ...n installed Terminal clips should fit tight in cap towers TUBE Fig 26 Spark Plugs a Spitfire b Firepower 56x321A R51x394B Fig 27 Removing and Installing Spark Plugs b Distributor Cap and Rotor Inspect cap for cracks and clean corrosion from towers Inspect electrodes for excessive burning Inspect rotor for cracks and burned tip Inspect brush spring for distortion and be sure carbon brush moves free...

Page 113: ...the center line of the car with the cen ter vertical line of the screen By measuring from the floor to the center of the head lamps determine the horizontal center line of the lamps Transfer this measurement to the screen then locate the horizontal aiming line two 2 inches below the head lamp horizontal center line See Fig 28 c Vertical Alignment It will be necessary to determine vertical center l...

Page 114: ...is still inserted in connector socket With Sealed Beam unit in its correct position top prong supplies current for low traffic beam One of the side prongs sup plies current for high beam and the other is ground connection With only lights burning engine warmed up and running at speed equivalent to car speed of about 20 m p h voltage at headlights should be not less than 13 25 volts or more than 14...

Page 115: ... one wire of test lamp to SW ter minal on panel unit and connect other wire to a ground If lamp lights when ignition switch is turned on this circuit is in good condition b Testing Panel and Tank Units for Ground The panel unit and tank unit must have good grounds to operate properly Use jumper wire to temporarily ground each unit at case If gauge reading changes when temporary ground CONSTANT FIE...

Page 116: ...Fig 35 When in stalling unit in tank do not bend float arm Make sure that gasket is properly positioned and tighten lock ring 54 ELECTRIC TEMPERATURE GAUGE The electric or magnetic temperature gauge consists of two units dash unit and engine TANK RETAINER TERMINAL VARIABLE FIELD POLE SHOES V GAUGE UNIT SUCTION TUBE Fig 35 Removing and Installing Fuel Gauge Tank Unit AMMETER ENGINE UNIT 53x527A Fig...

Page 117: ...e result of leak in oil gauge tube or due to improper installation To correct this condition disconnect tubing at gauge and engine block and drain out oil Con nect tubing at gauge first and then at block Test for possible plugging by breaking con nection at gauge Hold gauge end of line over an empty clean container and start engine The oil should flow at a steady rate If it does not flow steadily ...

Page 118: ... push button b Vacuum Switch is located on Engine In take Manifold c Neutral Switch is located on outside of Torque Flite transmission 60 REMOVAL AND INSTALLATION OF IGNITION LOCK CYLINDER NOTE Remove battery ground cable before removing ignition lock cylinder To remove ignition lockcylinder turn ignition key clockwise to on position and loosen set screw holding switch in instrument panel Pull swi...

Page 119: ...he instrument panel The relay is mounted at the top of the left cowl side panel It contains the latching relays which hold the circuits closed until they are broken either by the automatic or manual can celing switches HORNS Three makes of horns are used Sparton Au to Lite and Jubilee The horn circuits are 57x319 Fig 38 Adjusting Sparton Horn CONTACTS ADJUSTING SCREW LOCK NUT DO NOT DISTURB THIS N...

Page 120: ...ED OFF GLASS PARKING WINDSHIELD WIPERS Refer to Figure 44 The variable speed motor is a compound wound reversible type unit which makes possible off glass parking feature The wiper also contains a Geneva Wheel in gear box for actuating off glass parking switch and an eccentric in connecting link at wiper crank pivot which automatically lengthens links mak ing off glass parking position possible 67...

Page 121: ...tain ing nut To replace wiper switch or Geneva Wheel remove switch plate c Assembly of Motor Switch Make sure gear box contains lubricant Install switch plate Be sure Geneva Wheel follower pin engages smoothly with top of gear d Assembly of Windshield Wiper Link Install spring washer with concave surface toward crank arm Expand ends of crank pin coil spring and install on crank pin Install spring ...

Page 122: ...nd an individual door switch for each of other doors The individual switch feeds are brought out to circuit breaker on cowl side The harness for right door is car ried across upper firewall The motors require no lubrication When operating a window normal amperage draw is 12 to 16 amperes for all cars except rear doors of four door Nassau Newport and St Regis models which draw approximately 18 to 2...

Page 123: ...ing the lock slide member into the lock or unlock position Fig 48 All doors may be locked or unlocked either mechanically or electrically To lock mechan ically push the front door handle to the for ward position and depress the rear door lock ing button To lock electrically depress the switch to lock or lift upward to unlock the doors 71 REMOVAL AND INSTALLATION OF SOLENOID a Removal Remove the do...

Page 124: ...vel is 2 inches at front and 2 inches at rear Available tilt is iy de grees forward and 8 degrees rearward from neutral 72 REMOVAL AND INSTALLATION OF FRONT SEAT ASSEMBLY AND ADJUSTER a Removal Remove front seat cushion four door only and disconnect battery Remove control wires from switch Remove front seat assembly On Hard Top Models remove front seat and cush ion as an assembly Remove nuts from ...

Page 125: ...e inside and longest on the outside Install the flexible ca bles in the tubes Make sure the cables seat in the slave unit Position drive unit on left side tubes Make Sul e flexible cables seat in slot in drive unit Bolt drive unit to guide bracket Place the right side flexible cables in the right side tubes Position left guide and drive assembly on the right side tubes Make sure the cables seat in...

Page 126: ...URN SIGNAL LIGHT LEFT FRONT DOOR AUTOMATIC SWITCH QT 9 FUEL GAUGE r 18 YELLOW RIGHT REAR DOOR AUTOMATIC SWITCH RIGHT TAIL STOP AND TURN SIGNAL LIGHT I 18 BROWN LUSTER LIGHT RIGHT SPEEDOMETER LIGHT CLOCK LIGHT 18 LIGHT BLUE 4S RED TURN SIGNAL SWITCH CABLE CONNECTOR TURN SIGNAL FLASHER DOME LIGHT 4 DOOR SEDAN 18 PINK 18 WHITE HAND BRAKE LIGHT GREEN INDICATOR LIGHT 18 WHITE 18 BLACK D 9 D 8 D 7 YELLO...

Page 127: ... SPEEDOMETER LIGHTS LEFT TURN SIGNAL INDICATOR LIGHT PUSH BUTTON GEARSHIFT INDICATOR LIGHT TRUNK LIGHT AND SWITCH li8ORANGE 12RED WHiTE STARTER RELAY LEFT BACK UP LIGHT TURN SIGNAL RELAY 16 LIGHT GREEN FOOT DIMMER SWITCH _ 1 6 CJ BLACK I WHITE J 16RED WHITE HEADLIGHT SWITCH INDICATOR LIGHT 18 WHITE HAND BRAKE LIGHT SWITCH 18 YELLOW BODY HARNESS CABLE CONNECTOR LEFT TAIL STOP AND TURN SIGNAL LIGHT ...

Page 128: ...DARK GREEN WHITE STRIPE REAR WINDOW DEFROSTER MOTOR C3 18 BLACK TOP UFT MOTOR CONVERTIBLE ONLY IGNITION REAR WINDOW DEFROSTER SWITCH VARIABLE SPEED WINDSHIELD 1 6 WIPER SWITCH BLACK i 16 BLUE VARIABLE SPEED I k 1 6 Y E U 0 W W NDSHIELD WIPER _ P 6 R E O YELLOW WHITE STRIPE 12 RED WHITE STRIPE 16 BLACK 4 B BLACK TO BATTERY OO STARTER RELAY TERMINAL BLOCK 10 RED DARK GO TOP LIFT SWITCH AND 25 AMPERE...

Page 129: ... BLAl R HEADLIGHT SWITCH TO BATTERY STARTER RELAY TOP LIFT SWITCH AND 25 AMPERE CIRCUIT BREAKER CONVERTIBLE ONLY 57x731 A Fig 53 Windshield Wipers Heater and Convertible Top Imperial Wiring Diagram TEMPERATURE GAUGE SENDING UNIT TEMPERATURE GAUGE 1POWER llh W ANTENNA fft UP RED 1 BLACK 41 D O W N _ J irVJ DnA A ki 18 BLACK 12 BATTERY STARTER RELAY RED WHITE AMMETER THRU LOOPS 12 RED WHITE AUXILIAR...

Page 130: ... SIZE 4D SED 12 12 12 14 14 14 14 12 14 14 14 14 12 14 14 14 12 SIZE 4D SUB 12 12 12 14 14 12 12 14 14 12 12 14 12 SIZE 4D H T 12 _ _ 14 14 12 14 14 14 12 14 14 14 12 12 SIZE 2D H T CV CPE RT FRONT DOOR W LIFT MOTOR TAILGATE LOCK SW TAIL GATE W LIFT SW FEED o DOWN I DOWN W I N D O W LIFT 30 AMP C B REAR TAIL GATE W LIFT MOTOR LEFT FRONT DOOR W LIFT MASTER SWITCH LF LEFT REAR DOOR OR QUARTER W LIFT...

Page 131: ... PANEL LAMPS A POST AUTOMATIC DOOR SWITCH FOUR DOOR SEDAN MAP LAMP BATTERY WITH MANUAL A POST 4 lililil r INTEGRAL WITCH jip isv i B POST AUTOMATIC DOOR SWITCH i A POST I AUTOMATIC DOOR j SWITCH B POST AUTOMATIC DOOR SWITCH CENTER DOME LAMP WITH INTEGRAL MANUAL SWITCH Fig 56 Interior Lamps and Switches Wiring Diagram Chrysler FOUR DOOR SEDAN SUBURBAN BATTERY MAP LAMP WITH INTEGRAL MANUAL SWITCH A ...

Page 132: ... terminal on starter relay c Replace neutral switch TF trans only d Replace starter relay e Replace ignition starter switch f Recharge battery 78 RELAY OPERATES BUT SOLENOID DOES NOT a Replace open circuit wire between starter relay solenoid terminal and solenoid actuating terminal post b Check and clean up solenoid switch con tacts c Clean and tighten terminal connections on terminal bus bar betw...

Page 133: ...ed armature lead from generator to regulator 86 LOW UNSTEADY CHARGING RATE a Adjust or replace drive belt b Test charging circuit resistance cleaning and tightening all loose connections c Inspect generator brushes and commuta tor for wear grease or commutator out of round d Test car ammeter 87 EXCESSIVE CHARGING RATE a Check regulator contacts for sticking and for high setting of voltage regulato...

Page 134: ...ITION 95 BURNED CONTACTS a File contacts that are not excessively burned Align contacts and adjust gap to speci fications Adjust breaker arm spring tension b Replace contacts that are badly burned Check for presence of oil or grease on and around contacts eliminate cause if present Check voltage regulator Check condenser 98 PITTED CONTACTS a Replace condenser with one of proper capacity 97 FOULED ...

Page 135: ... frame ground connection d Check tank unit for open coil Replace tank unit e Replace dash unit 107 GAUGE POINTER FUCKERS a Clean and tighten all loose connections including ground b Check tank unit arm contact to rheostat 108 GAUGE POINTER STAYS AT FULL a Check both dash and tank units for short circuit HORNS 109 HORNS DO NOT BLOW a Short from relay SW terminal to ground IGN SW ON If horns now blo...

Page 136: ...ontrol switch b Replace master control switch c Replace broken wire at door containing master switch group 117 WINDOW DOES NOT OPERATE FROM EITHER MASTER OR INDIVIDUAL a Replace burned out motor and check for grounded sticking or defective switch b Check voltage of circuit for broken wiring between circuit breaker and motor terminals c Replace circuit breaker if voltage is pres ent at terminal opp...

Page 137: ...UNIT INOPERATIVE Remove all wires from seat switch and con nect together as shown for the six various con trol operations if operation is normal by con necting wires as shown Replace switch For Forward Horizontal Red Connects White Green For Rearward Horizontal Red Connects Blue Green For Forward Tilt Red Connect White Yellow For Rearward Tilt Red Connect White Brown For StraightUp Red Connect Whi...

Page 138: ...ll peen hammer CAUTION Do not run motor with drive cables and tubes disassembled or unit will be placed out of synchronization c Remove seat support B d Remove seat slave unit from seat track slide C e Remove horizontal stops located on slide at D f Separate seat slice C from base N by pressing slide rearward which will allow rollers A to jump retaining rivets E F G H thereby separating slide from...

Page 139: ...alves and Valve Springs 14 Removal and Installation of Valve Guides 15 Testing Valve Springs 16 Hydraulic Tappets 17 Checking Valve Timing 19 Removal and Installation of Timing Gears and Chain 20 Camshaft Removal 23 Distributor Basic Timing 23 Removal and Installation of Camshaft Bearings 24 Cylinder Block 24 Connecting Rods 26 Crankshaft 27 Removal and Installation of Oil Pan 29 Oil Pump 29 Remov...

Page 140: ...able in Standard and the Following Undersizes CONNECTING RODS AND BEARINGS Type Length Center to Center Weight less bearings shells V90 8 3 94 3 63 354 cu in 10 0 to 1 150 to 200 lbs 20 lbs l_8 4 3 6 5 7 2 1 3 5 7 2 4 6 8 Fully Counter Balanced Steel Backed Babbitt 2 4995 to 2 5005 2 249 to 2 250 001 5 005 to 0015 002 to 007 No 3 Main Bearing Diagonal Knurling Upper and Lower Nos 1 2 4 Upper and L...

Page 141: ...2 3 and 4 No 5 TIMING CHAIN Adjustment Number of Links Pitch Width Steel Backed Babbitt 2 2507 to 2 2512 x 2 0005 to 0015 0025 006 to 014 Standard 001 002 003 010 012 US Steel Backed Bronze 8 9843 to 9846 x l All 0001 to 0004 Selective Chain Steel Backed Babbitt 5 Thrust Plate 002 to 006 010 001 to 003 005 1 998 to 1 999 x 1 998 to 1 999 x 1 4355 to 1 4365x2 Steel Backed Babbitt 2 375 x 2 0005 to ...

Page 142: ...NG SIDE CLEARANCE Compression Upper Hydraulic 0005 to 0015 9040 to 9045 Dry Lash 060 to 210 Horizontal Slot w steel strut Aluminum Alloy Tin Coated 028 to 033 from Bottom of Skirt 0005 to 0015 646 gm 3 99 in 200 200 194 Std 005 020 040 060 OS Full Floating 9841 to 9843 x 3 140 to 3 150 0000 to 0005 004 to 026 0001 to 0004 Std 003 008 OS Toward Right Side of Engine 3 2 1 0775 to 0780 1860 to 1865 0...

Page 143: ...d When Compressed to valve open Valve Springs I D CYLINDER HEAD Number Used Combustion Chamber Valve Seat Runout maximum Intake Valve Seat Angle Seat Width finished Exhaust Valve Seat Angle Seat Width finished 002 to 0035 001 to 0025 Silicon Chromium Steel 002 to 0035 0010 to 0025 Silicon Chromium Steel 2 4 372 to 373 001 to 003 004 45 None 388 372 to 373 001 to 003 004 45 None 388 Nitrogen Treate...

Page 144: ...061 Indicator Cylinder Bore Compressor Piston Ring Vacuum Gauge Wrench Starting Motor Flange Nut Tester Clutch and Valve Spring Scale and Gauge Piston Fitting Reamer Solid Valve Guide Cleaner Valve Guide Timing Light 6 and 12 Volt Driver Welch Plug Installer Wrench Torque 100 Foot Pounds Sensory Type Reamer Cylinder Bore Ridge Tool Main Bearing Seal Tool Rocker Arm and Spring Compressor Sleeve Gui...

Page 145: ...de 389 to 390 inch SpitFire C 3433 Reamer Valve Guide 379 to 380 inch SpitFire C 3436 Gauge Valve Stem Length SpitFire C 3466 Plate Engine Lifting C 3495 Tool Piston Ring Installer FirePower C 3501 Cylinder Bore Deglazing Hone C 3506 Removing and Installing Tool Chain Case Cover Oil Seal C 3509 Tool Camshaft Holding C 3511 Tool Rear Main Bearing Seal Installing C 3574 Tool Main Bearing Seal DD 883...

Page 146: ... 7 Intake Manifold Bolt 30 Main Bearing Cap Bolt 86 Oil Filter Bolt 25 Oil Level Indicator Tube Bracket Bolt Nut 10 Oil Pan Bolt 15 Oil Pan Drain Plug 35 Oil Pump Cover Bolt 10 Oil Pump Mounting Bolt 35 Spark Plugs 30 Vibration Damper Hub Bolt 135 Vibration Damper Inertia Member Flange Bolt 15 Water Outlet Elbow Bolt 35 Water Pump Housing Bolt 30 Inch Pounds Crankcase Ventilator Outlet Pipe Bolt 1...

Page 147: ...CHRYSLER SERVICE MANUAL ENGINE 9 57x82 A Fig 1 SpitFire V 8 Engine End Sectional View o 57x83A Fig 2 F rrePower V 8 Engine End Sectional View MyMopar com ...

Page 148: ...ons for compres sion pressures Check coil and condenser and inspect primary and secondary wires Service the Air Cleaner DO NOT WASH OR OIL Normal operation Replace filter element every 15 000 miles Service more frequently under severe dusty conditions See Fig 3 Test fuel pump for pressure and vacuum and adjust car buretor Refer to Fuel and Exhaust System Section VII Carburetor Adjustments Check ma...

Page 149: ...il mixture should be left in engine for a minimum of 500 miles It is not necessary however to drain the mixture before normal oil change is required nor is it necessary to use the oil additive at subsequent oil changes 57x219 Fig 4 Cylinder Head SpitFire Engine 57x221 Fig 5 Cylinder Head FirePower Engine Start engine warm up to 160 degrees F check timing and adjust carburetor as neces sary 5 REMOV...

Page 150: ...H RODS Fig 8 Tightening Cylinder Head Bolts SpitFire 7 Insert cylinder head bolts into rocker arm support brackets and place rocker arm assem blies in position on head lining up all push rods to their respective rocker arms Starting at top center tighten all cylinder head bolts to 60 80 foot pounds torque in sequence shown in Figure 8 and 9 Then repeat the procedure tightening all head bolts to 85...

Page 151: ...LVE ROCKERS DOWEL SLOT FOR CYLINDER HEAD BOLT INTAKE VALVE ROCKER EXHAUST VALVE ROCKERS 55x725A BRACKET DOWEL Fig 11 Rocker Shaft Assembly Disassembled View SpitFire arranging spark plug cables Tighten screws securely Install generator Tighten generator bracket bolts to 50 foot pounds torque and generator mounting nut to 20 foot pounds torque NOTE When adjusting fan and accessory belt drives as sh...

Page 152: ...lve stem lock grooves to prevent damage to valve guide when valves are removed 10 VALVE INSPECTION Clean valves thoroughly and discard burned warped or cracked valves Check valve stems for wear Intake valve stems should measure 372 to 373 inch and exhaust valve stems should measure 371 and 372 inch If wear ex ceeds 002 inch replace the valve Remove car bon and varnish deposits from inside of valve...

Page 153: ...OViS MINIMUM MEASUREMENT 55x733 Fig 17 Checking Valve Stem Position SpitFire 380 inch Reamer Tool C 3427 404 to 405 inch Slowly turn reamer by hand and clean guide thoroughly before installing new valve CAUTION Do not attempt to ream valve guides from stand ard directly to 030 inch Use step procedure of 005 015 and 030 inch so the valve guides may he reamed true in relation to valve seat 12 REFACI...

Page 154: ...eds maximum grind to approach but do not go below minimum allow able on gauge 13 TESTING VALVE SPRINGS Whenever valve springs are removed they should be tested with spring tester Tool C 647 Attach torque wrench check tension and mul tiply reading by 2 The valve springs should test 170 to 184 pounds when compressed to 1 6 inch Discard springs that do not meet these specifications Check each spring ...

Page 155: ...hould run at fast idle for sufficient time to allow all of air inside of tappets to be worked out b Tappet Noises To determine source of tappet noise run en gine at idle with cylinder head covers removed Feel each valve spring to detect the noisy tappet NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by ap plying side thru...

Page 156: ...cap Invert tappet body and re move plunger cap plunger flat check valve check valve spring check valve retainer and plunger spring Separate plunger check valve retainer and check valve spring Place all parts 51x481C Fig 24 Tappet Immersed in Clean Kerosene in their respective place in tappet holder Tool C 3068 e Cleaning and Assembly Clean all tappet parts in a solvent that will re move all varnis...

Page 157: ...e has lifted 020 inch SpitFire and 024 inch FirePower The timing on the vibration dam per should now read from 5 degrees BTDC before top dead center to 7 degrees ATDC after top dead center Before making this check it is well to check the accuracy of the TDC top dead center mark on the damper by bring ing Number One piston to TDC by means of an indicator placed in spark plug opening Af ter valve ti...

Page 158: ...move fuel pump eccentric attaching bolt cup washer and eccentric Remove timing chain with crankshaft and camshaft sprockets Remove the camshaft and crankshaft gear keys from their respective slots CRANKSHAFT SPROCKET RETAINER WASHER M flff B 56x556 A Fig 28 Installing Fuel Pump Eccentric 19 INSTALLATION OF TIMING GEARS AND CHAIN a Installation Place both camshaft sprocket and crankshaft sprocket o...

Page 159: ...tisfactory slide crankshaft oil slinger over shaft and up against gear flange away from gear 20 TIMING CHAIN CASE COVER OIL SEAL REPLACEMENT a Removing Oil Seal Position puller screw of Tool C 3506 through PULLER BLOCKS i UP OF SEAL RETAINER PULLER SCREW 56X221 REMOVING AND INSTALLING PLATE SLEEVE 56X222 Fig 31 Removing Oil Seal case cover with inside of case cover up Posi tion puller blocks direc...

Page 160: ... and crankshaft oil slinger c Installing Chain Case Cover Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs Using a new gasket slide chain case cov er over locating dowels and tighten bolts 15 foot pounds torque 21 INSTALLING VIBRATION DAMPER Fig 35 Place damper hub key in slot in crankshaft CHAIN CASE COVER 57x222 Fig 34 Checking to Determine if Seal is ...

Page 161: ...T W JL 56X1 Fig 39 Camshaft Holding Tool C 3509 24 CAMSHAFT INSTALLATION Install Tool C 3509 in place of distributor drive gear and stub shaft Fig 39 Hold tool in position with distributor lock plate screw This tool will restrict the camshaft from being pushed in too far and prevent knocking out the Welch plug and should remain installed until camshaft and crankshaft sprockets and timing chain hav...

Page 162: ...lock must be in exact align ment to insure proper lubrication Fig 40 Camshaft bearing index can be checked after installation by inserting a pencil flashlight in bearing shell The complete circumference of camshaft bearing hole should be visible by look ing through main bearing drilled oil passage Another oil hole in cam bearings should be visible by looking down the left bank oil hole above and b...

Page 163: ...ean c Cylinder Walls Cylinder walls which are badly scored scuffed scratched or worn beyond specified limits should be rebored Whatever type of boring equipment is used boring operation should be closely co ordinated with the fitting of pistons and rings in order that specifications may be maintained SPRING SCALE TOOL INVERTED PISTON 57x225 Fig 42 Checking Ring Gap in Cylinder Bore FirePower Typic...

Page 164: ...18 NOTE Be sure the mark Top on each com pression ring is to the top of piston when ring is installed f Fitting Pins The piston pin should be a tight thumb press fit in connecting rod Fig 44 and in piston Fig 45 at normal room temperature 70 F If proper fit cannot be obtained with standard pins ream piston and connecting rod and in stall oversize piston pin Piston pins are sup plied in standard an...

Page 165: ...cap wipe off oil from the journal and inserts Place the Plastigage on bearing parallel with crankshaft Reinstall cap and tighten attaching nuts alternately to speci fied torque Remove cap and measure the width of the compressed material with the graduated scale to determine bearing clearance Allowable clear ance is from 0005 to 0015 inches If taper of compressed material is evident measure with th...

Page 166: ...se same technique as described in Paragraph 31 CAUTION If bearings are measured with the engine in the chassis the crankshaft must be supported in order to take up clearance between the upper bearing insert and crankshaft journal This can be done by snugging bearing caps of adjacent bearings with 005 to 015 inch cardboard be tween lower bearing shell and journal Be sure to remove cardboard Use ext...

Page 167: ...idler arm support bracket and allow linkage to settle away from bottom of pan Remove bolts that hold pan to cylinder block and remove pan b Installation Clean pan thoroughly and install new seals and gaskets End seals should be bottomed in their PUMP BODY SEAL RING SEAL RING OUTER ROTOR INNER ROTOR AND SHAFT LOCKWASHER 57x123 STRAIGHT EDGE STRAINER AND SUCTION PIPE PLUG PLUNGER SPRING RELIEF VALVE...

Page 168: ... replace oil pump body If clearance between pump rotor and outer rotor Fig 56 is more than 010 inch replace pump rotor and outer rotor Check OUTER ROTOR FEELER STOCK 57x126 Fig 55 Measuring Clearance between Outer Rotor and Oil Pump Body oil pump relief valve plunger for scoring and for free operation in its bore If plunger is scored replace plunger The spring should con form to Specifications on ...

Page 169: ...lter base and new Fig 58 lnstalling Rear Main Bearing Oil Seal filter element Install outer shell and tighten center bolt securely NOTE FirePower Engine Remove air clean er Loosen oil filter Raise car Remove filter from below car 39 REPLACEMENT OF REAR MAIN BEARING OIL SEAL Crankshaft removed Remove old oil seals from cylinder block and bearing cap Install a new rear main bearing oil seal in block...

Page 170: ...tact points h Defective ignition switch i Moisture on ignition wires caps or plugs j Cracked distributor cap k Fouled spark plugs 1 Stuck valves m Improper spark plug gap n Improper timing ignition o Damaged distributor rotor p Dirt or water in gas line or carburetor q Ice in carburetor or fuel line r Carburetor flooded s Fuel level in carburetor bowl not correct DIAGNOSIS t Insufficient supply of...

Page 171: ...el o Weak valve springs p Carburetor in poor condition q Valves sticking when hot r Dirt or water in gas line or carburetor s Ice in gas line or carburetor t Improper carburetor float level u Worn camshaft lobes v Defective fuel pump w Pistons or pins fit tight x Valve timing incorrect y Too rich or lean fuel mixture z Incorrect valve tappet clearance C 300 aa Blown cylinder head gasket bb Low com...

Page 172: ...ted valves 1 Incorrect valve tappet clearance C 300 m Incorrect carburetor idle adjustment n Improper carburetor float level o Low compression 46 ENGINE MISSES AT HIGH SPEED Possible Causes a Dirt or water in gas line or carburetor b Dirty jets in carburetor especially the economizer jet c Weak coil or condenser d Incorrect ignition timing e Distributor points dirty or incorrectly spaced f Trailin...

Page 173: ...n be traced to one or more of the following 1 Normal wear 2 Failure to keep air cleaners carburetor and crankcase filler cap installed and serv iced 3 Failure to service the oil filter 4 Careless filling of the oil pan by allowing dirt or foreign material to fall in 5 Failure to clean cylinder walls properly after reboring or honing 6 Failure to prevent grindings and stone dust from getting on cyl...

Page 174: ...E ON FAST STARTS OR RAPID ACCELERATION Possible Causes a Low oil level in oil pan b Oil pump suction tube not aligned or bent causing the oil strainer to extend above the oil surface in the pan c The foot on the oil strainer should touch the bottom of the oil pan d Oil pump rotor pin sheared e Expansion plug missing in oil pump cover f Oil filter and oil filter by pass plugged g Air leak in oil pu...

Page 175: ...ick These de posits are caused by poor maintenance of the engine oil or filter low engine operating tem peratures due to an inoperative thermostat or short intermittent engine operation The latter condition does not allow the engine to reach operating temperature to evaporate the conden sation in the crankcase Extremely slow driving of the vehicle does not induce sufficient crank case ventilation ...

Page 176: ...ted to pre igni tion or detonation 62 CONDITIONS WHICH CAN CAUSE EXHAUST VALVE FAILURE a Back pressure due to restrictions in the exhaust system which prevent rapid expulsion of the hot gases b Excessively lean fuel air mixtures c Carburetion improper size jets d Air leaking into the intake manifold e Air leak at carburetor mounting or throt tle body gaskets f Air leaks in vacuum line for booster ...

Page 177: ...the fuel air mixture in the com bustion chamber is ignited by spontaneous com bustion before the flame reaches it The mixture is burned much more rapidly than during nor mal combustion Thus detonation produces ex cessive temperatures and pressures Detonation is most easily recognized by a pinging sound during acceleration or continuous wide open throttle operation such as climbing a steep hill A d...

Page 178: ...LUGS 71 HOT STARTING NOISE A form of audible pre ignition sometimes oc curs when a hot engine is started Usually the noise is limited to two or three sharp raps which are heard just as the engine begins to fire This condition does not cause damage to the engine and is common with high compres sion engines It cannot be eliminated by retard ing ignition timing or changing spark plugs Slow cranking s...

Page 179: ...inutes to bleed out When changing an oil filter element there is always a possi bility that air may be trapped in the cover of the filter and not work out through the tappets until some time later after the tappets have originally quieted c Tappet varnish The problem of tappet varnish will not neces sarily hinder the tappets since they are de signed to allow the varnish to build up in areas that d...

Page 180: ...result when the aerated oil enters the tappet i Excessive oil supply When the oil level is too high in the oil pan the crankshaft and connecting rods dip into the oil and churn it causing an aerated condition j Low oil supply This condition permits the reuse of a small quantity of oil which does not have sufficient time to cool and rid itself of the normal air in duced into the oil k Air entering ...

Page 181: ...nd it is only ne cessary to relieve the ends of the hole at the top and bottom g Tight tappet While rare this condition occurs where the tappet or the tappet bore is of incorrect size bell mouthed or out of round causing the tap pet to stick in its bore A condition of this nature is indicated by heavy wear or scuff marks on portions of the side of the tappet body Unless the tappet bores in the cyl...

Page 182: ...rting a shim of sufficient size to take up the dry lash The lift of the valve can then be measured with a dial indicator and compared with other valves shimmed in the same manner The normal valve lift should be approximately 360 inch Since wear of up to 030 inch is permissible the mile age of the engine as well as the comparison check with other cylinders should be taken into consideration before ...

Page 183: ...e and Exhaust Manifolds 27 Manifold Heat Control Valve 31 Service Diagnosis 32 DATA AND SPECIFICATIONS MODEL FUEL PUMP Make Model Type Driven By Pump Pressure pounds CARBURETOR Make Type Model THROTTLE BORE Primary and Secondary LC 1 Carter M 2663S Mechanical Camshaft 5 to 7 Ball and Ball Dual Downdraft BBD 2685S LC 2 Carter M 2663S Mechanical Camshaft 5 to 7 Carter 4 Barrel Downdraft AFB 2650S 1 ...

Page 184: ...012 inch 1350 to 1400 rpm 1375 to 1425 rpm LY 1 1 inch 031 inch One Full Turn Open 500 rpm Middle Hole of Arm 429 or J fc inch inch z inch 34 inch One Notch Rich 012 inch SPECIAL TOOLS CARBURETOR C 3225 Stand Carburetor Repair C 3400 Repair Stand T 109 22 Bending Tool T 109 28 Gauge Unloader inch T 109 29 Closing Shoes Clearance Gauge wire 017 to 022 inch T 109 31 Choke Unloader Gauge J inch T 109...

Page 185: ...engine consumes fuel the float level in the carburetor bowl drops and needle valve opens to admit fuel into float chamber which releases the pump pressure and starts the pumping cycle again Actually change in float level is negligible 1 TESTING FUEL PUMP On Car If fuel pump fails to pump fuel to carburetor following checks should be made to determine cause of failure before removing fuel pump from...

Page 186: ...is will allow the pump to operate at full capacity which it must do to prime a dry carburetor The vacuum reading should be at least 10 hg Vacuum at 500 r p m with the fuel line disconnected at the carburetor 5 VOLUME TEST The fuel pump should supply 1 quart of fuel in 1 minute or less at 500 r p m Fig 2 Pressure Testing Fuel Pump If the pump does not perform to the above test requirements the fuel...

Page 187: ...matic VAPOR BLEED 045 DIAMETER ORIFICE INLET 58x60 PICKUP TUBE Fig 4 Vapor Separator Unit Sectional View this position then install follower spring Be sure follower spring ends are over dimple in housing and tang on damper arm Invert pump and install filter gasket Engage ends of bowl retaining strap in slots of filter housing Tilt retaining strap to the side far enough to install the ceramic filte...

Page 188: ...t through opening to clear If necessary use air pressure to clear return line after removing tank filler cap SERVICE DIAGNOSIS 10 FUEL PUMP LEAKS FUEL a Tighten loose housing screws b Install new diaphragm c Tighten loose inlet or outlet or outlet fuel fittings 11 FUEL PUMP LEAKS OIL a Install new diaphragm b Tighten fuel pump mounting bolts c Install new pump to block gasket d Install new pull ro...

Page 189: ...n repair stand Tool C 3225 if available This Tool is used to protect throttle valves from damage and provide a suitable base for working Remove hair pin clips that retain fast idle and pump connector rods disengage from choke and throttle levers as shown in Figure 7 Remove air horn and integral automatic choke as shown in Figure 8 discard gasket Remove fuel inlet needle valve seat gasket and float...

Page 190: ...S AND SPRINGS SCREW SCREW AIR HORN LOOSE LEVER CHOKE LEVER WASHER SCREW FAST IDLE ROD STEP UP RODS STEP UP PISTON SPRING GASKET SCREWS GASKET GASKET DISCHARGE CHECK BALL MAIN BODY FAST IDLE CAM SCREW HAIRPIN CLIP THROTTLE VALVES IDLE SPEED SCREW FAST IDLE SCREW WASHER LOOSE LEVER THROTTLE SHAFT HAIRPIN CLIP PUMP ROD 56x192C Fig 6 Carburetor Assembly BBD 2685S Disassembled View MyMopar com ...

Page 191: ...to main body Separate bodies and discard gasket Disengage accelerator pump plunger from rocker arm by pushing up on bottom of plung er and sliding slotted end off rocker arm hook as shown in Figure 13 If pump plunger leather is worn hard or cracked a new pump plunger should be installed at reassembly Place plung ACCELERATOR PUMP PLUNGER FLOAT FULCRUM PIN RETAINER AIR HORN GASKET FUEL INLET NEEDLE ...

Page 192: ...am choke piston in its well Slide choke lever loose lever and washer off end of choke shaft as shown in Figure 16 Turn choke shaft ACCELERATOR PUMP ROCKER ARM PUMP PLUNGER 56x264 GASKET BAFFLE PLATE THERMOSTATIC COIL PLATE STRAP RING CHOKE HOUSING GASKET HEAT TUBE CAP RETAINER SCREW 57x322 Fig 14 Removing or Installing Choke Baffle Plate and Gasket clockwise until choke piston clears the top of it...

Page 193: ...d body During manufacture location of idle trans fer port and spark advance control ports to valves is carefully established for one particular assembly See Fig 18 If a new shaft should be installed in an old worn throttle body it would be very unlikely that original relation ship of ports to valves would be obtained Changing port relationship would adversely af fect normal car operation between s...

Page 194: ...ING NOTCH AND MATING LUG HOUSING 57x324 THERMOSTATIC COIL AND HEAT RETAINING PLATE Fig 20 lnstalling Heat Retainer Plate 57x323A Fig 21 Alignment of Index Marks of Choke hand coil side down Clean dirt dust or other foreign material that may be present from re tainer plate and out of choke housing When reassembling match lug in the housing with notch on plate as shown in Figure 20 Install plate and...

Page 195: ... plunger and pour out gasoline after test Reinstall the venturi cluster gaskets and idle bleed screws Tighten screws securely Refer to Fig 12 Install main metering jets and gaskets step up piston gasket spring piston and rods Refer to Fig 11 Before in stalling the step up piston be sure the step up rods are able to move freely each side of ver tical position as shown in Figure 23 Be sure step up p...

Page 196: ...n be inserted between the throttle valve and the bore side opposite port as shown in Figure 25 The index mark on the fast idle cam should be in direct line with the fast idle screw shank b Choke Shaft Lever Adjustment Invert the carburetor and open the throttle THROTTLE VALVES HELD CLOSED WIRE GAUGE 015 INCH CHOKE VALVE HELD CLOSED HIGH STEP OF FAST IDLE CAM IDLE SPEED SCREW BACKED OFF 56x276 A FA...

Page 197: ...ith throttle valves seated THROTTLE LEVER ARM BENDING TOOL 0 56x279 TOP OF PLUNGER SHAFT IDLE SPEED SCREW BACKED OUT TOP OF AIR HORN CENTER HOLE THROTTLE VALVES FULLY CLOSED 56x280B Fig 30 Checking Accelerator Pump Travel distance from top of plunger shaft to top of air horn bowl cover should be 1 2 inch db or minus 4 inch when measured with a steel scale as shown in Figure 30 To adjust pump setti...

Page 198: ...M INNER PRIMARY THROTTLE SHAFT DOG PRIMARY THROTTLE SHAFT ARM OUTER THROTTLE OPERATING ROD SECONDARY THROTTLE OPERATING LEVER CHOKE VALVE CHOKE CONNECTOR ROD FUEL INLET FITTING AND SCREEN INDEX MARK RETAINER THERMOSTATIC COIL HOUSING MAIN AND THROTTLE BODY CASTING IDLE MIXTURE ADJUSTING SCREWS AIR HORNk STEP UP PISTON AND ROD COVER PLATE 2 PUMP CONNECTOR LINK FAST IDLE CONNECTOR ROD PUMP ARM FAST ...

Page 199: ... exhaust the leaner adjustment is in right direction Try turning needles clockwise another Vi turn or a total of 1 4 turn from initial setting This may further improve idle or make it worse If with this setting the idle was improved reset idle speed to 500 r p m and then try individual ad justments of each needle turn clockwise leaner and counter clockwise richer to find best adjustment for each n...

Page 200: ...e from carbure tor Remove the hairpin clips that attach the choke connector rod to the choke shaft lever and the lever at the choke piston housing Dis engage rod and remove from carburetor Remove the screws attaching the step up pis ton and rod cover plates Hold cover down with a finger to prevent the piston and rods from flying out Lift off the plates and slide the step up pistons and rods out of...

Page 201: ...interchange PUMP DISCHARGE PASSAGE PRIMARY J T A R Y J Fig 34 Removing or Installing Metering Jets Secondary PRIMARY VENTURI CHOKE SIDE 57x796 Fig 35 Removing or Installing Primary Venturi Choke Side and Pump Side able side for side and must be re installed in their original location at reassembly Remove the screws that attach the secondary venturi choke and pump side to the main body Lift the sec...

Page 202: ...d worn body it would be very unlikely that the original relationship of these ports to the valves would be obtained A very slight change in the port relationship to the valves would adversely affect normal carburetor op eration between the speeds of 15 and 30 miles per hour It is recommended that if the throttle shafts are excessively worn that a new carburetor be installed However if the throttle...

Page 203: ...ar of notch The thermostatic coil spring heat retainer plate and coil housing are serviced as an as sembly only If the housing is cracked or brok en install a complete new assembly The index mark out in the rim of the housing is correct for the one coil originally installed Do not attempt to separate the thermostatic coil from the heat retainer plate 24 CARBURETOR ASSEMBLY a Main and Throttle Body...

Page 204: ...e fix attempt to reseat as follows c Intake Check Ball Remove the screw plug gasket ball seat and ball from the bottom of the throttle body flange Install a new ball and ball seat Install screw plug and new gasket then retest as described previously d Discharge Check Needle With the discharge check needle installed in sert a piece of drill rod down on the needle Lightly tap the drill rod with a ha...

Page 205: ...ght with Gauge Check the outer float in the same manner If an adjustment is necessary bend the float arm using Tool T109 22 until correct clearance has been obtained After bending arm recheck the float alignment h Float Drop Setting Holding the air horn in an upright position measure the distance from the top of the floats outer end to the air horn gasket as shown in Figure 43 This measurement sho...

Page 206: ... ease of work ing and should be made in the following order a Fast Idle Adjustment With the choke valve held tightly closed tight en the fast idle adjusting screw on the high CHOKE VALVE CLOSED 012 INCH GAUGE sf FAST IDLE ADJUSTING SCREW HIGH STEP OF FAST IDLE CAM CHOKE VALVE TIGHTLY CLOSED FAST IDLE CAM INDEX MARK FAST IDLE 57 x 809 U J ADJUSTING SCREW Fig 45 Checking Fast Idle Indexing step of t...

Page 207: ... gauge between the upper edge of the choke valve and the inner wall of the air horn as shown in Figure 47 If an adjustment is necessary bend the un loader lip on the throttle shaft lever using Tool T109 41 until correct opening has been obtained T SCALE THROTTLE VALVES CLOSED IDLE SPEED SCREW x BACKED OUT THROTTLE CONNECTOR ROD BEND AT THIS 5 7 x 8 0 7 r ANGLE Fig 48 Checking Accelerator Pump Trav...

Page 208: ...i l l 0 1 7 T O 022 INCH GAUGE Fig 50 Checking Clearance between Closing Shoes and close the choke valve The tang on the sec ondary throttle lever should freely engage in the notch of the lock out dog If an adjustment is necessary bend the tang on the secondary throttle lever until engage ment has been made Use Tool T109 22 for this operation After adjustments have been made reinstall carburetor o...

Page 209: ... double rocker shaft engine ex haust system is dual exhaust system which con sists of exhaust and intake manifolds heat con trol valve two exhaust pipes two exhaust muf flers and two tail pipes as shown in Figure 52 The exhaust system of the Imperial Models is a dual system with four mufflers as shown in Figure 53 The Manifold Heat Control Valve Housing is now cast integral with the Right Exhaust ...

Page 210: ...X N U T EXHAUST PIPE 57x391 Fig 52 Dual Exhaust System Models LC2 LC3 BRACKET AND SUPPORT REAR MUFFLER EXTENSION BRACKETS AND SUPPORTS TAIL PIPE FRONT MUFFLER C L A M P CLAMP EXTENSION CLAMP EXHAUST PIPE GASKETS PIPE BRACKET AND SUPPORT REAR MUFFLER EXTENSION CLAMP FRONT MUFFLER CLAMP EXTENSION CLAMP EXHAUST PIPE Fig 53 Dual Exhaust System Model LY1 57x392 MyMopar com ...

Page 211: ...d off studs out and away from cylinder head Use care when removing manifold attaching nuts and bolts because constant heating and cooling of manifolds may have caused them to freeze Lubricate with a good grade of penetrat ing oil and allow to stand for several minutes before attempting removal c Removal of Right Side Exhaust Manifold Remove automatic integral choke heat tube from exhaust manifold ...

Page 212: ... connection Remove bolts from left hand exhaust manifold flange Dis card gasket Remove cross over pipe b Y Exhaust Pipe Remove clamp bolt from clamp connecting Y pipe and exhaust pipe Remove bolts from right hand exhaust manifold flanges discard gasket On all cars be sure the exhaust system is suffi ciently supported Remove Y pipe c Muffler Loosen or remove clamp bolts at exhaust pipe to exhaust e...

Page 213: ...nd release quickly The counterweight should respond by moving clockwise approximately y inch and returning to its normal position If no move ment is observed the valve shaft may be fro zen or the coil is weak or broken In either case heat control valve should be disassembled and replaced with new parts LOCKWASHER WIDE OPEN STOP ANTI RATTLE SPRING CLOSED STOP COUNTERWEIGHT THERMOSTATIC COIL SPRING ...

Page 214: ... manifold for distortion Be sure manifold registers evenly with cylinder head Tighten nuts to 25 foot pounds torque e Install new gasket after checking flange for cracks or foreign material that will not allow gasket to seat properly Tighten bolts evenly f Remove exhaust manifold and check mat ing surfaces Place manifold on smooth surface and check mating flanges for alignment If man ifold shows s...

Page 215: ...EAT CONTROL b Check for weak or broken anti rattle VALVE RATTLE spring and make necessary repairs or replace ment a Check for broken thermostatic spring and c Check shaft for looseness in body and cor make necessary correction rect condition as necessary MyMopar com ...

Page 216: ...orbers 9 Servicing the Oriflow Shock Absorbers 10 DATA AND SPECIFICATIONS Models TYPE DIMENSIONS TYPE NO OF LEAVES SEDANS TOWN COUNTRY WAGON WIDTH LENGTH SHACKLE HANGER FRAME LC 1 LC 2 LC 3 LY 1 Welded Double Channel Box Section Side Rails See Figures 1 2 3 4 and 5 REAR SPRINGS Semi Elliptic 5 6 7 7 6 7 2 5 2 5 2 5 2 5 57 in 60 in 60 in 60 in Silent Block Rubber Bushings Side Strapped with Rubber ...

Page 217: ...S REAR SPRING SILENT BLOCK NUT SHOCK ABSORBER STUD NUT REAR SPRING U CLIP BOLT NUTS REAR SPRING SHACKLE NUTS SHOCK ABSORBER MOUNT NUT REAR ESSENTIAL TOOLS y2 UPPER LOWER Foot Pounds 100 60 70 70 50 60 C 3413 Remover and Installer Shock Absorber Lower Mounting Assembly 483 8 5V8 GAUGE HOLE IN EACH SIDE OF FRAME Fig 1 Frame Dimensions Windsor 57x103A MyMopar com ...

Page 218: ...nued for the Im perial Models See Paragraph 8 Universal Joint Section XII for adjustment proce dures 1 CHECKING FRAME DIMENSIONS In case of collision frame members can often be satisfactorily straightened to the required dimensional limits In case of serious damage or fracture to front crossmembers upper and lower control arms and steering knuckle the component parts ball joints and steering arms ...

Page 219: ...ORBERS CHRYSLER SERVICE MANUAL GAUGE HOLE IN EACH SIDE OF FRAME 57x231 Fig 3 Frame Dimensions Convertible New Yorker 69 i6 GAUGE HOLE IN EACH SIDE OF FRAME 13V TT TOP OF FRAME LINE 57x140A Fig 4 Frame Dimensions Imperial MyMopar com ...

Page 220: ...hen welding frame members care must be taken to localize the heat so that the steel hardness of frame will be retained Reinforcement welds should run lengthwise along side of reinforcement Figures 1 2 3 4 and 5 show various di mensions to be used as a guide for checking frame alignment These dimensions are the true distance between two points as measured with a steel tape Figure 5 shows a few of v...

Page 221: ...ion of frame rivets cannot be used to attach a new body bracket to frame Cut damaged bracket off frame file surface smooth Clamp new bracket in correct posi tion and weld securely to frame member The shielded arc weld method is recommended for frame welding or replacement of body frame support brackets The heat generated from welding operation is localized and burning of material is held to a mini...

Page 222: ...asionally to make sure they are tight but not binding Tighten to 50 foot pounds torque No lubrica tion of any kind should be used on rubber bush ings The height of the car may be affected if rear spring height varies more than inch on one side as compared with other side To check this measure vertical distance from top of rear spring main leaf to underside of frame side rail on both sides of car I...

Page 223: ... Keep tapered bar in place Clean the lower grooved surface of the longer spring leaf as far as interliner makes Fig 13 Prying Interliner Fastner Through Leaf contact Use sandpaper wrapped around a flat file and scrub vigorously to remove any dirt or rust spots to obtain smooth metallic surfaces to left and right of groove Wipe off excess par ticles including dirt in groove itself with a clean clot...

Page 224: ...ity through the orifices In turn slow movement of piston causes fluid velocity to decrease and offer minimum resist ance at termination of stroke To improve the riding qualities of the 1958 cars the valving of the front shock absorber has been revised to afford more control to spring action under varying road conditions 6 TESTING ORIFLOW SHOCK ABSORBERS Oriflow shock absorbers are designed to oper...

Page 225: ... shock absorber b Installation Place upper mounting retainer washer cupped TOOL SHOCK ABSORBER ASSEMBLY 57x71 Fig 16 Installing Shock Absorber Eye Bushing Fig 17 Rear Shock Absorber Installed side up on shock absorber piston rod Compress shock absorber piston rod into shock absorber Insert assembly up through opening in frame to allow piston rod to enter upper housing bush ing While holding in pos...

Page 226: ...NSTALLATION OF REAR SHOCK ABSORBERS Fig 17 To remove rear shock absorber remove nuts from shock absorber mounting stud pins which pass through eyes at top and bottom of shock absorber and remove shock absorber When installing a shock absorber install bushings in the shock absorber s eye Install inner bushing retainers shock absorber and bushing assembly and outer retainers and nut The concave face...

Page 227: ...embly 17 Final Test Adjustments and Specifications 21 Removal and Installation Power Steering Pump Sleeve Type 22 Removal and Installation Power Steering Pump Slipper Type 28 Service Diagnosis 31 DATA AND SPECIFICATIONS MODELS LC 1 LG 2 LC 3 LY 1 Steering Type Manual Worm and Three Tooth Roller None None None Power Ratio Manual Power Turning Radius Curb to Curb Number Wheel Turns Manual Power Trea...

Page 228: ...ith Power Steering Y in Vs in Preferred 21 degrees 45 minutes 1 degree inner wheel when outer wheel is 20 degrees 5 to 7 degrees at 0 degree Ball and Socket Tapered Roller Bearing 1 25 1 25 1 25 1 375 75 75 75 844 Ji 16 NF Symmetric Idler Arm Equal Length Tie Rods possible on Left and Right wheel POWER STEERING PUMP SPECIFICATIONS MODELS Fluid Capacity of Hydraulic System Type of Fluid Maximum Pum...

Page 229: ...Adjusting Screw Snap Ring C 3309B Gauge Pressure Check C 3318 Hose Low Pressure C 3332 Remover Gear Shaft Bearing C 3333 Driver Gear Shaft Bearing C 3350 Remover and Installer Gear Shaft Seal C 3388 Hose Coupling C 3532 Adapters C 3602 Fixture Pump Assembly C 3615 Puller Steering Pump Pulley C 3633 Nut Wrench Gear Cross Shaft Retainer C 3634 Adjusting Wrench Gear Support Nut C 3638 Seal Remover Ge...

Page 230: ...dler Arm Bolt Bushing Nut 60 Tie Rod Clamp Bolt and Nut 150 In Pounds CONSTANT CONTROL FULL TIME POWER STEERING Foot Pounds Torque Steering Wheel Nut 40 Steering Arm Nut 120 Steering Gear Housing to Frame Bolt 50 Steering Valve End Plug 50 Steering Valve Body Attaching Bolts 15 Steering Column Support Nut 150 Steering Gear Shaft Cover Nut 100 Steering Gear Shaft Adjusting Screw Lock Nut 50 Pressur...

Page 231: ...y Foot Pounds 15 Thread Size Foot Pounds 10 20 25 PUMP MODELS Slipper Type Sleeve Type Pump Assembly Bolt Hose Connector Outlet Flow Divider Valve Plug Thread Size 56x18 5 x18 14 xU Foot Pounds 15 30 20 PLATE SHIMS BUSHINGv S E A L CAGE AND ROLLERS i HOCKWASHER CUP WORM CAGE AND ROLLERS PLUG 57x366 Fig 1 Steering Gear Assembly Disassembled View MyMopar com ...

Page 232: ...shaft Correct backlash can be obtained by turning adjusting screw in or out as required The steering wheel and arm are splined to the steering tube and steering gear shaft re spectively Both steering wheel and steering gear arm have master serrations to insure correct installation The high point is the point of least clearance between the worm and roller and is at mid point of worm and roller trav...

Page 233: ...ists Final tightening of cover screws cause end play to disappear with torque of to pound required to rotate the tube when measured with the pull applied at rim of steering wheel Add or remove shims in event a bind or excessive end play occurs Shims are available in 003 006 011 and 025 inch Install gear shaft Before installing cover turn adjusting screw all the way out Place steering wheel on tube...

Page 234: ... thickness to eliminate a binding condition If any tightness exists too many shims have been removed or the steering as sembly is out of alignment See Steering Gear Alignment Paragraph 4 b Adjustments of Roller Tooth and Worm In Car Disconnect steering gear ar mat link Rotate steering wheel to mid position and check for backlash by attempting to move steering gear arm back and forth If backlash ex...

Page 235: ...pin to secure the nut lock NOTE This procedure should result in from 000 inch no preload to 003 inch bearing free play measured axially It is important to remove any burrs or nicks on the spindle thread to insure accurate readings NOTE Check to make certain that cancelling dogs on steering wheel actuate the direction switch CONSTANT CONTROL FULL TIME POWER STEERING The Constant Control Full Time P...

Page 236: ...ON 58x198 Fig 7 Steering Gear Housing Sectional View scribed as flowing to left or flowing to right as shown in the following illustrations When the car is in the straight ahead direc tion the steering valve is in the neutral cen ter position and oil flow through both of the grooves in the steering valve body is equal since in the neutral position Fig 8 the two lands of the steering valve are cent...

Page 237: ... the turn As the wormshaft rotates inside the power piston the piston is prevented from in stantly climbing down the wormshaft by the resisting forces which the steering linkage and wheels transmit to the steering gear cross shaft Instead the wormshaft is drawn out of the piston a very small amount a few thousands of an inch The center thrust bear ing race which is in effect clamped axially to the...

Page 238: ... power assist is provided The force of this reaction spring also con tributes to increased on center feel The feel is further provided by operating oil pressure which tends to return the center thrust bearing race to its neutral position The driver feels this force on the reaction rings shown in Figure 6 as a force proportional to operating oil pressure It causes the driver to exert a steering eff...

Page 239: ...osition over the steering gear housing and tighten clamp bolts Install jacket tube clamp at instrument STEERING GEAR TOOL 58x231 Fig 12 Removing Steering Gear Arm with Puller C 3646 58x64 Fig 13 Removing Coupling Pin panel Do not tighten Connect direction sig nal wires at connectors Install steering wheel and steering wheel nut Tighten nut to 40 foot pounds torque Install horn wire stationary plat...

Page 240: ...ons by turning the steering tube coupling from one extreme of travel to the other Remove coupling pin Fig 13 and remove coupling NOTE Support the coupling when driving the pin out to avoid damaging the bearings Remove the valve body housing attaching screws and remove valve body and the three 0 rings Fig 14 Remove valve lever by prying under the spherical head Fig 15 DO NOT USE PLIERS CAUTION Use ...

Page 241: ... damaging the piston assembly TOOL i POWER TRAIN a JACKET TUBE SUPPORT H 5 8 x 3 9 1 Fig 19 Removing or Installing Power Train TOOL JACKET TUBE SUPPORT SEAL 58x40 Fig 20 Removing Worm Shaft U p p e r O i l Seal with Tool C 3638 CAUTION Do not turn worm shaft more than one half turn during disassembly Remove column jacket support assembly reaction spring reaction ring and spacer fer rule 0 ring cen...

Page 242: ...air pressure into the ferrule chamber Fig 21 Inspect grooves for burrs Make sure passage from JACKET TUBE SUPPORT REACTION RING 58x45 Fig 23 Installing Reaction Seal into Jack Support CYLINDER HEAD OIL SEAL O RING FERRULE 58x46 Fig 24 Removing Reaction Ring from Cylinder Head ferrule chamber to upper reaction chamber is unobstructed b Reassembly Install worm shaft upper oil seal with sealing lip t...

Page 243: ...d from valve hous ing install the valve in the valve housing so that the valve lever hole is aligned with the steering gear valve lever opening in the bottom of the valve housing Valve must fit smoothly in housing without sticking or binding If valve end plug had been removed install new seal and tighten plug to 50 foot pounds torque Lubricate pressure control valve piston and slide it into the pr...

Page 244: ...Tool C 3350 Fig 28 Place adapter against seal and the tool nut on the threaded end of gear shaft Tighten tool nut until adapter shoulder contacts housing Fig 29 Install oil seal back up washer and snap ring CAUTION Make sure snap ring is properly seated in groove 17 ASSEMBLY OF POWER TRAIN Refer to Figure 30 and proceed as follows Place piston assembly on work bench in a vertical position worm sha...

Page 245: ...ING WORM SHAFT SEAL RETAINER SLEEVE OM RINGS SEAL CYLINDER HEAD AND FERRULE O RING REACTION O RING R A C E 58x54 SPRING REACTION RING CENTER RACE BEARING RACE SPACER ASSEMBLY REACTION RING SPRING REACTION RING NUT SEAL O RING SUPPORT BEARING SEAL NUT PIN ADAPTER Fig 30 Steering Gear Disassembled View f CO MyMopar com ...

Page 246: ... If adjusting nut is tightened properly read ing on scale should be 8 to 16 ounces Depress flange of adjusting nut into the depression in worm shaft to lock securely Fig 32 CAUTION Use a chisel with a large radius on the ends to avoid completely shearing the metal IMPORTANT The torque of 8 16 inch ounces must remain after the adjusting nut is securely locked Install center bearing spacer over cent...

Page 247: ...Aligning Tool C 3649 Install cover spanner nut and tighten to 100 foot pounds torque with Tool C 3633 Fig 16 Install valve lever double bearing end first into center bearing spacer through hole in steering housing so that slots in the valve lever are parallel to worm shaft in order to engage the anti rotation pin in center bearing race Fig 35 Install valve body on housing making sure that the valv...

Page 248: ...ture between 150 F and 170 F checked with thermometer in the re servoir the oil pressure should be 850 to 950 psi for satisfactory power steering operation d With gear shaft on center plus or minus 2 degrees readjust the gear shaft backlash This will require loosening the adjusting screw until backlash is evident Then retighten ad justing screw until backlash just disappears Continue to tighten fo...

Page 249: ...allowed to fall below the baffle of the reservoir Remove hose clamp and hose from discharge outlets Fig 38 Loosen bracket fan belt ad justing screw and remove fan belts Remove pump b Disassembly Do not disassemble the hydraulic pump in dirty surroundings or on a dirty work bench Use clean paper on bench After the pump has been disassembled place the parts in a suitable cleaning solvent clean and p...

Page 250: ... Use care when removing cap and retainer to prevent spring and fitting from escaping due to spring force Remove flow valve and spring Remove and disassemble both end caps from inlet cap body and pump housing Figs 40 and 41 Plunger spring will tend to push the cylinder blocks out of body Use care when dis assembling Fig 42 Removing or Installing Housing from Pump Body TOOL Fig 43 Removing or Instal...

Page 251: ...cks showing such scoring should be re placed Hairline marking seen on sleeves are normal Sleeves bearing such marks need not be replaced Examine flow valve spool and valve liner Slight hair line scratches are permissible Burrs from heavy gouges or scratches which may cause the flow spool to stick must be removed This may be done by polishing with a smooth stone CAUTION Do not break the sharp edges...

Page 252: ...ble pump in a clean work place Press drive shaft and bearing sub assembly into bearing cap Check rotation of shaft to make certain shaft turns freely Use a sleeve which bears on outer race of ball bearing and press the sub assembly in place CAUTION Make certain that the shaft bearing and sub assembly are properly aligned otherwise the shaft may push sleeve bearing out of bearing cap or may scratch...

Page 253: ...ss flow spring with fitting and screw fitting into place Tight en to 20 foot pounds torque Install and align a new reservoir O ring on bearing cap Lubricate 0 ring for ease in assembling reservoir Align reservoir so that the indentation on back will mate with angu lar boss on suction end cap NOTE Reservoir alignment may be achieved by sighting thru the 9 32 inch hole in the back of the reservoir P...

Page 254: ...he pressure relief valve When pressure in the unit reaches this amount it overcomes the force of the spring on the relief valve forcing the valve plunger off its seat and allowing the oil to flow through the opening around the plunger Openings in the pressure relief valve body return the oil to the reservoir a Removed Relieve tension and remove fan belt Place a suitable container under the pump Di...

Page 255: ...t Fig 52 NOTE Relief valve is serviced only as an as sembly TOOL 58x281 Fig 55 Removing Pump Oil Seal If there was evidence of a malfunction in the flow control valve remove the flow control valve plug snap ring with snap ring pliers C 3229 Fig 53 Remove the flow control valve plug by threading a tap Tool C 3655 into the plug as shown in Figure 54 With the tap se curely threaded in plug install to...

Page 256: ... to install snap ring then drive snap ring and plug with Tool C 3233 until snap ring seats PRESS PUMP SHAFT PULLEY PUMP 58x229 Fig 58 Installing Pump Pulley in its groove in housing bore Install relief valve and gasket assembly Install oil seal with Tool C 3640 Lip of seal must face toward pump body and top of seal must be flush with front insert Fig 57 Support pump body in holding fixture Tool C ...

Page 257: ...pump output low g Steering gear malfunction 1 Cross shaft adjustment too tight 2 Pressure control valve stuck in closed position 3 External oil leakage at the following points Lower sector shaft oil seal Sector shaft adjusting screw seal Sector shaft cover 0 ring seal Valve hous ing to gear housing O rings 4 Defective or damaged valve lever If pressure gauge will build up to 850 to 950 psi check t...

Page 258: ...right Move steering valve housing up on steering housing e Valve lever damaged f Column support spanner nut loose 32 TEMPORARY INCREASE IN EFFORT WHEN TURNING STEERING WHEEL TO RIGHT OR LEFT a Low oil level b Loose pump belt c Oil on pump belts d Binding steering linkage e Engine idle to slow f Defective power steering pump g Air in system Work steering wheel from right to left until air is expell...

Page 259: ...n pump is at 175 F b Air in steering system check all connec tions to make certain that they are tight c Discharge and return line hoses the hoses must not touch any part of the body or frame except where they are attached to the pump or steering column d Loose pulley e Water in oil 40 HARD OR JERKY STEERING TOWARD END OF FULL LEFT OR RIGHT TURN Loose drive belt tighten drive belts to speci fied t...

Page 260: ...roper oil level b Reservoir air vent plugged c Air in system d Dirt in pump e Pump bushings shaft slippers rotor worn or damaged 45 LOW OIL PUMP PRESSURE a Pump drive belt or pulley loose b Low oil level in reservoir c Pressure relief valve spring weak or valve stuck in open position d Flow control valve stuck or a broken flow control valve spring e Worn pump rotor slippers or broken and distorted...

Page 261: ...age Adjustments 34 Hydraulic Control Pressure Checks and Adjustments 35 Governor Pressure Chart 36 Servicing the Gearshaft Control Unit 36 Replacing Illuminating Bulb 37 Replacing Back Up Light Switch 38 Removal and Installation of Control Cable 38 Servicing Component Parts with Transmission in Vehicle 39 Transmission Regulator Valve Assembly 39 Torque Converter Control Valve Assembly 39 Valve Bod...

Page 262: ...ATIOS 1 Low 2 45 to 1 2 Second 1 45 to 1 D Drive 1 00 to 1 R Reverse 2 20 to 1 N Neutral FRONT REAR PUMPS Type Gear Rotary End Clearance Front Pump 001 to 0025 inch End Clearance Rear Pump 001 to 0025 inch THRUST WASHERS Input Shaft 115 to 117 inch Natural 097 to 099 inch Black 078 to 080 inch Red 059 to 061 inch Orange Front Clutch and Sun Gear 062 to 064 inch Output Shaft 062 to 064 inch SNAP RI...

Page 263: ...ne Rear Support Insulator Nuts 30 35 Extension to Transmission Case Screws 25 30 Filler Tube Nut 35 40 Front Oil Pump Housing to Transmission Case Screws 14 16 Oil Strainer Elbow Screws 14 16 Front Universal Joint Nut 33 37 Governor Body to Governor Support Screws 6 8 Governor Locating Screw 5 7 Governor Oil Pressure Take Off Plug 10 12 Intermediate Support Locating Screws 25 30 Kickdown Band Adiu...

Page 264: ...e Converter Housing Screws 45 50 Transmission Regulator Valve Retainer 45 50 Valve Bodies to Transfer Valve Retainer 50 60 Inch Pounds TORQUE CONVERTER TIGHTENING REFERENCE Thread Size Item Inches Block to Threaded Aluminum Plate Bolt 16 Block to Threaded Aluminum Plate Bolt 14 Converter Housing and Plate to Threaded Block Bolt 16 Converter Housing and Plate to Threaded Block Bolt 14 Converter Hou...

Page 265: ...xture C 3487 Support C 3527 Gauge Overrunning Clutch Assembly C 3528 Stand pair Valve Body Holding C 3529 Fixture Compressing Servo Reverse and Kickdown Spring supersedes C 3289 which can be converted to C 3529 C 3531 Tool Remover and Installer Reaction Shaft supersedes C 3297 If C 3297 is available use C 3535 Adapters to convert to C 3531 C 3533 Compressor DD 1150 Tachometer SPECIAL TOOLS TORQUE ...

Page 266: ...AR OUTPUT SHAFT SUPPORT REAR OIL PUMP EXTENSION GOVERNOR ASSEMBLY SPEEDOMETER PINION OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT DRIVE HOUSING REAR CLUTCH PISTON REAR CLUTCH ASSEMBLY FRONT CLUTCH PRESSURE PLATE TORQUE CONVERTER REACTION SHAFT FRONT OIL PUMP TORQUE CONVERTER STATOR TORQUE CONVERTER TURBINE KICKDOWN PLANET PINION CARRIER ASSEMBLY OIL STRAINER REVERSE SUN GEAR LOW REVERSE PLANET PINION CARRIE...

Page 267: ...s obtained by application of the rear clutch and rear band In the drive range the transmission shifts through all three gear ratios automatically Shift points are de termined by throttle opening and car speed If additional acceleration is desired while in drive range the transmission will downshift de pending on vehicle speed to second gear or breakaway automatically when the accelerator pedal is ...

Page 268: ...utton slide engages the actuator shaft This action allows the lock spring to hold the button in the engaged posi tion Refer to Fig 3 When the operator pushes another button to select a different range the top or bottom por tion depending on which button was pushed of the slide contacts the actuator thereby re leasing the first button from the restraint of the lock spring The first button is then f...

Page 269: ...lmost all driving is done in the D drive position The transmission in this push button position selects the proper ratio automatically for road speed and driving conditions A downshift to the breakaway position al ways occurs below 8 M P H at closed throttle If road conditions warrant such as pulling on a steep hill under heavy load the 3 2 downshift may occur under part throttle otherwise the tra...

Page 270: ...e open throttle 2 3 upshift are reached If the vehicle is accel erated with the 2 second button engaged to wide open throttle upshift speed an upshift to direct will occur thus eliminating over speeding the engine in second gear 6 R reverse Stop the vehicle and with foot brake lightly applied push the R reverse button in d Mountain Driving When driving in the mountains with either heavy loads or w...

Page 271: ...planet pinion carrier is attached to and prevented from turning backward by an overrunning clutch and becomes stationary in forward drive overruns on coast There fore the reverse planet carrier pinions are forced to rotate in a forward direction and force the reverse annulus to rotate in the same direction transmitting the power flow to the output shaft with the resulting ratio of the kickdown and...

Page 272: ...P H This will force the transmission to downshift and the power flow will be the same as D drive posi tion breakaway Kickdown Forced Downshift in D Drive Position at approx 30 to 70 M P H This will force the transmission to downshift and the power flow will be the same as D drive posi tion 2nd speed d 1 Low Position Low Speed See Fig 7 In 1 low position the power flow is the same as D drive positi...

Page 273: ...eleased Hence there is no drive connection between the engine and the rear wheels g Power Flow Summary The chart summarizes power flow conditions in the various ranges as regards to gear train ele ments involved and the ratios obtained BAND CLUTCH APPLICATION CHART Range Ratio Drive position breakaway 2 45 Drive position second speed 2 Second position second speed 1 45 Drive position direct 1 00 R...

Page 274: ...14 TORQUE FLITE TRANSMISSION CHRYSLER SERVICE MANUAL z I o MyMopar com ...

Page 275: ... GOVERNOR CONTROL SYSTEM IN DRIVE BREAKAWAY HALF THROTTLE LEGEND BLUE LINE 90 P S I BLUE DOT PUMP SUCTIONJ 0 5 P S i YELLOW CONVERTERJ 30 P S I YELLOW DOT LUBE 50 3O P S I GREEN THROTTLE 0 90 P SJ BROWN GOVERNORI O 90 P S I Fig 10 Hydraulic Circuit D Drive Breakaway 56X70 IB MyMopar com ...

Page 276: ...RIVE SECOND HALF THROTTLE LEGEND BLUE LINEJ 9Q P S I BLUE DOT PUMP SUCTION 0 5 P S I YELLOW CONVERT ER 30 P S I YELLOW DOT LUBE 1Q 3O P S I GREEN THROTTLE 0 90 P S I GREEN DOT THROTTLE COMP ENSATOR 30 90 P S I BROWN GOVERNOR 0 90 P S I Fig 1 1 Hydraulic Circuit D Drive Second 56X702B MyMopar com ...

Page 277: ...CHRYSLER SERVICE MANUAL TORQUE FLITE TRANSMISSION 17 MyMopar com ...

Page 278: ...TORQUE FLITE TRANSMISSION CHRYSLER SERVICE MANUAL E I MyMopar com ...

Page 279: ...HRYSLER SERVICE MANUAL TOROUE FLITE TRANSMISSION 19 p r U I f REVEF cfl o H z Di o S z C 1 LEGE P S I ip sue ERTER o to UBE h O 3 o o rLEl 0 1 ROTTL 1 2 O is o o A N0R i ir ui O z CO u u D D MyMopar com ...

Page 280: ...ETERING HOLES GOVERNOR CONTROL SYSTEM IN REVERSE LEGEND BLUE DOT PUMP SUCTlON 0 5 P S I YELLOW CONVERTER 30 P S I YELLOW DOT LUBE 10 30 P S I RED LINEJ 225 P S I 3 O SO O tn so co CO CO I I O o IS M o 56X706B Fig 15 Hydraulic Circuit R Reverse MyMopar com ...

Page 281: ... of the control pressure is discontinued In order to develop the required capacity a system of levers is used to actuate the clutch apply plate Although no pressure is applied to the front clutch piston in reverse or neutral oil is present in the clutch piston chamber With high rota tive speeds of the clutch retainer in reverse or neutral it is possible to build up sufficient cen trifugal oil pres...

Page 282: ...y to second the accumu lator piston is again moved by line pressure kickdown servo apply acting on the large end of the piston The force of line pressure as sisted by the accumulator spring is sufficient to overcome the force of line pressure front clutch which is acting on the small area of the accumulator piston This action cushions the application of the kickdown band 7 PRESSURE REGULATING VALV...

Page 283: ...he valve to move out slightly venting excess oil and bringing the governor once more in balance at a lower pressure The governor weight assembly is constructed so that for vehicle speeds under approximately 25 mph both weights act as a unit with the result that small changes in vehicle speed result in comparatively large changes in centrifugal force and governor pressure Above approxi mately 25 mp...

Page 284: ...mission The front and rear pump check valves are combined as a leaf spring unit and mounted in the regulator valve body behind the front pump b Manual Valve The manual valve obtains the different trans mission drive ranges as selected by the vehicle operator The manual valve is moved by a cable which is connected to the push button control unit on the instrument panel It is held in these positions...

Page 285: ...he 1 2 shift the servo apply pressure rises further to the value of line pressure providing a safety margin of band load At light throttle low throttle pressure the shift valve is made to upshift at approximately 10 mph and balance pressure is at a low value corresponding to the small force of throt tle compensator pressure on the kickdown pis ton The resulting band application load is therefore i...

Page 286: ...mooth 3 1 downshift g Kickdown Valve The kickdown valve makes possible a forced downshift from direct to second second to breakaway and direct to breakaway by depress ing the accelerator pedal past the detent feel near wide open throttle It is desirable to limit the maximum vehicle speed at which kickdown may be made ap proximately 70 mph from drive to second and approximately 30 mph from drive or...

Page 287: ...r pressure attains a sufficient value to move the shuttle valve toward the shuttle valve plug cutting off the feed of line pressure to the shut tle valve Oil must then flow to the apply pres sure area of the kickdown servo only through the hole in the servo pressure bleed valve Kick down piston application is therefore retarded 9 OPERATIONAL SUMMARY With the D drive button pushed in the manual val...

Page 288: ...ry reaction area of the regulator valve MAINTENANCE ADJUSTMENTS AND TESTS CAUTION While in the process of making adjustments and tests do not stall test the torque converter For safety reasons and because damage to the trans mission may result wide open throttle stall op eration should not be attempted 10 ROAD TESTING THE TRANSMISSION First check the transmission fluid level and set engine idle Go...

Page 289: ...e Idle H Starting Switches I Handbrake Adj OPERATING DIFFICULTY Shift Abnormalities Harsh N to D or N to R Delayed N t o D Runaway on UpsMft and 3 2 K D Harsh Upshift and 3 2 K D No Upshift No K D or Normal Downshift Shifts Erratically J Regulator Valve Spring K Converter Control Valve L Breather M Output Shaft Rear Bearing S R N T C Cooling 0 K D Servo Band Linkage P L R Servo Band Linkage Q Oil ...

Page 290: ...t side of the trans mission case Fig 22 Check for a stuck or scratched valve and or buckled spring L Breather Check to determine whether breather is free of dirt and undercoating M Output shaft rear bearing snap ring Check for rough bearing and or unseated snap ring and correct thickness snap ring N Torque converter Check oil cooler lines for being bent kinked or having loose connec tions O Kickdo...

Page 291: ... reverse servo lever and band when air pressure is applied If the clutches and servos operate properly no drive conditions as well as erratic or no upshift conditions indicate that the malfunc tioning exists in the control valve body assem bly Disassemble clean inspect and service the valve body assembly as described under Re conditioning of Valve Body and Transfer Plate Assemblies Upon completion...

Page 292: ...ring and housing gasket Governor line lubrication rear clutch apply and throttle compensated pressure check plugs in transmission case or support pressure test holes Neutral starting switch If oil is found inside torque converter hous ing determine whether it is Automatic Trans mission Fluid or engine oil Check torque con verter drain plug for tightness Leaks at these locations should be corrected...

Page 293: ...il leakage If it is not add a thin washer and retighten Refill transmission to proper level as out lined in Lubrication Section Check starter op eration by pushing the various push buttons and returning to neutral CAUTION Neutral starting switch failure may occur due to very high amperage current flowing through the switch This results when a juniper wire or re mote control starting switch is impr...

Page 294: ...E This will be a true torque of 70 75 inch pounds which reading should be used if torque wrench C 3380 is used without the adapter C 3580 as may be done if adjustment is made with transmission removed from vehicle Back off adjusting screw 2 turns LUBRICATION PRESSURE REAR CLUTCH APPLY PRESSURE TEST PLUG INTERMEDIATE SUPPORT LOCATING SCREW CARBURETOR TO BELL CRANK ROD DASH PANEL BELL CRANK TO ACCEL...

Page 295: ...RETOR All operations are the same as the four bar Fig 24 Checking Governor Pressure rel except that since there is no intermediate throttle control assembly adjustment is made on the bellcrank to carburetor rod 17 HYDRAULIC CONTROL PRESSURE CHECKS AND ADJUSTMENTS a Line Pressure NOTE Line pressure adjustment must be made in D drive position with engine at 1200 R P M and wheels free to turn Oil mus...

Page 296: ...ain an upshift into direct ratio After the shift takes place compensated throt tle pressure should read 26 to 32 psi As throt tle lever at transmission is advanced toward full throttle compensated throttle pressure should begin to rise after 0 to 5 movement If compensated throttle pressure rises imme diately when the lever is moved or if the pres sure is incorrect or fails to rise after approxi ma...

Page 297: ...oving screws at bottom of plate On Imperial models remove faceplate to ex pose the two gearshift housing to support re taining nuts Remove nuts and pull gearshift housing rearward and down from back of in strument panel Disconnect back up light switch and starting motor switch leads NOTE Illuminating lamp bulb and light con ductor Fig 26 are fastened to the gearshift housing support bracket and ne...

Page 298: ...he four tabs Replace housing as outlined in Paragraph 18 To replace the starter switch first remove housing as outlined in Paragraph 18 Drill out the two rivets holding the switch to the flange The switch replacement kit consists of the switch and two soft tubular rivets Install switch on flange and check clearance between end of N neutral push button slide and end of switch plunger Bend the flang...

Page 299: ...ssistance of the retrieving tool place valve in position and seat properly in regulator valve body Install regulator valve spring sleeve cup gasket adjusting screw and lock nut and tighten to specifications Check line pressure and adjust if necessary 25 TORQUE CONVERTER CONTROL VALVE ASSEMBLY a Removal Remove the torque converter control valve spring retainer Fig 22 gasket and spring Using a mecha...

Page 300: ...crews with washers VALVE BODIES AND TRANSFER PLATE ASSEMBLIES x660A CONTROL CABLE ADAPTER Q 4M p SPRING LOCK L MANUAL VALVE Fig 29 Removal and Installation of Valve Bodies and Transfer Plate Assembly 56x658 Fig 30 Setting Manual Valve Control Lever Clearance Remove cover and spring from transfer plate Remove the three transfer plate screws and washers and remove valve bodies and transfer plate ass...

Page 301: ...re on the kickdown piston rod guide and remove the snap ring Loosen compression portion of tool and remove piston rod guide piston spring and piston rod Using C 484 pliers remove the kickdown piston from transmission case Fig 31 Refer to Kickdown Piston Inspection Paragraph 92 b Instcdlcrtion Lubricate piston rings and place kickdown pis ton assembly into position compress outer ring and start ass...

Page 302: ...e sure spring is properly seated in groove Install propeller shaft flange and drum assem bly Install propeller shaft flange washer con vex side towards nut and nut Apply hand brake or use wrench Tool C 3281 and tighten propeller shaft flange nut to specifications Connect front universal joint and tighten nuts to specifications Refill transmission if necessary with Auto matic Transmission Fluid Typ...

Page 303: ...ever and tighten cable clamp bolt Install propeller shaft flange and drum as sembly washer and nut Apply hand brake or using Tool C 3281 to hold flange tighten nut to Data and Specifications Install adjust ing screw cover plate on hand brake support Connect front universal joint and tighten to specifications Install speedometer pinion and sleeve assembly Tighten to specifications and connect speed...

Page 304: ...Tool C 3229 remove governor weight assembly snap ring large one and remove governor weight assembly from governor body Remove governor locating screw from gover nor support Remove the five rear oil pump housing to output shaft support screws and washers and install guide studs Tool C 3288 Remove pump housing gear and governor as sembly from output shaft Use dye and mark pump gears in relation to p...

Page 305: ...Tool C 3487 do not lower engine more than three inches from floor pan to avoid disrupting the set position of water hose and other engine attachments Remove the two transmission case to torque converter housing screws and lockwashers from right side of transmission and install guide studs Tool C 3276 With transmission sup ported by a suitable jack remove the two trans mission case to torque conver...

Page 306: ...ld be observed during disassembly of transmission Cleanli ness through the entire disassembly and as sembly cannot be over emphasized Unit should be thoroughly cleaned when removed from ve hicle preferably by steam When disassem bling each part should be placed in a suitable solvent washed then dried by compressed air Do not wipe parts with shop towels All of the mating surfaces in the transmissio...

Page 307: ...ove three transfer plate bolts and washers Remove valve bodies and transfer plate assem bly from transmission case as shown in Fig ure 40 Mating surfaces are machined use ex treme care so as not to damage these surfaces Place valve body in stand Tool C 3528 Remove the neutral starting switch with cupped wash OIL STRAINER Fig 39 Removal and Installation of Accumulator Cover er and 0 ring located in...

Page 308: ...ing has two purposes it acts as a guide for the brake shoes and re tains the brake support grease shield to the transmission extension Remove the brake sup port grease shield from extension If a screw driver or sharp instrument is used in removing this shield care must be exercised not to dam TOOL 57x98 53x60 Fig 43 Removal and Installation of Speedometer Drive Pinion Assembly age the neoprene sea...

Page 309: ...against support screw as shown in Figure 44 Remove extension gasket 41 GOVERNOR AND REAR OIL PUMP HOUSING REMOVAL Using a small screw driver remove the governor valve shaft snap ring from the weight assembly end as shown in Figure 45 Remove governor valve shaft and valve from GOVERNOR VALVE 56x608 Fig 46 Removal and Installation of Governor Valve and Shaft GOVERNOR LOCATING SCREW 56x609 Fig 47 Rem...

Page 310: ...pinion from output shaft as 56x613 Fig 52 Removal and Installation of Unit No 1 shown in Figure 50 Mark in the same manner as previously described 42 OUTPUT SHAFT SUPPORT REMOVAL Remove output shaft support to transmission case screw and washer Fig 49 Slide the output shaft rear support assembly and gasket from transmission case as shown in Figure 51 If rear support is stuck to transmission case i...

Page 311: ...tion in front of unit 45 REMOVING UNIT NO 3 FRONT CLUTCH PISTON RETAINER AND INPUT SHAFT ASSEMBLIES J P 56x6 7 Fig 56 Removal and Installation of Low Reverse Band Keep unit centered as much as possible and remove from transmission case as shown in Figure 55 Use extreme care when removing to prevent damage to seal rings on input shaft and sealing surfaces in reaction shaft alumi num 46 LOW REVERSE ...

Page 312: ...rse lever shaft stop plug at rear of transmission case Using pliers KICKDOWN BAND LEVER LOW AND REVERSE BAND LEVER IKICKDOWN AND REVERSE LEVER SHAFT Fig 59 Removal and Installation of Kickdown and Reverse Lever Shaft 56x621 Fig 60 Modification of Tool C 3289 remove kickdown and low reverse shaft lever spacer flat Thread a guide stud Tool C 3288 into shaft and remove shaft from case as shown in Fig...

Page 313: ...UMP REMOVAL Remove front oil pump drive sleeve if in stalled Remove the transmission regulator ACCUMULATOR PISTON Fig 63 Removal and Installation of Accumulator Piston GASKET CUP SPRING Fig 64 Removal and Installation of Regulator Valve Retainer valve spring adjusting screw locknut gasket cup spring sleeve and valve Figs 64 65 and 66 Remove the torque converter valve retain er gasket spring and va...

Page 314: ...threaded holes provided in the regulator valve body install guide studs Tool C 3283 as shown in Figure 68 Pull regulator valve body 56x651 m Z Z REGULATOR VALVE Fig 69 Regulator Valve Body and Valves off of torque converter reaction shaft and re move gasket Regulator valve body Fig 69 is made of aluminum and requires care in han dling to avoid damage 53 TORQUE CONVERTER REACTION SHAFT REMOVAL Refe...

Page 315: ... inspect valve body mating surface on transmission case for any burrs or irregularity in surface Sur faces should be smooth and flat Inspect servo and accumulator bores for any scores or scratches Light scratches may be removed with crocus cloth Check regulator valve body mating surface in front of case for any irregularities Disregard any scratches which may have been caused by torque con verter ...

Page 316: ...is seated properly Slide governor body and support from rear oil pump housing Remove the two governor sup port seal rings and inspect Remove the four governor body to support bolts and lockwash ers Separate body from support Washers are part of bolt and serviced as an assembly Mat ing surfaces are machined and can be easily damaged Inspect oil passages and make sure they are free from dirt or fore...

Page 317: ...it can be placed in the propeller flange and brake drum assembly to aid in disassembly as shown in Figure 75 Using a screw driver re move output shaft drive housing snap ring as shown in Figure 76 Refer to Figure 77 and complete disassembly of unit as follows Re move reverse annulus gear B from output shaft assembly K Remove thrust plate C from kickdown planet pinion carrier Remove intermediate sh...

Page 318: ...two small N interlocking seal rings for excessive wear broken ends and make sure they rotate freely in the grooves Intermediate shaft and clutch feed tubes are serviced as an assembly 67 KICKDOWN PLANET PINION CARRIER ASSEMBLY INSPECTION Inspect planet pinion carrier for cracks and pinions for broken or worn gear teeth Using a feeler gauge check end clearance on individ ual planet pinion gears cle...

Page 319: ... roller type thrust washer H over intermediate shaft and into position in carrier assembly 70 UNIT NO 2 SUN GEAR REVERSE PLANET PINION CARRIER OVERRUNNING CLUTCH AND REAR CLUTCH PISTON RETAINER ASSEMBLIES DISASSEMBLY The letters referred to in the Disassembly In spection and Assembly of this unit pertain to Figure 79 With unit setting in upright position remove sun gear and front clutch thrust was...

Page 320: ...n gear from overrunning clutch and reverse planet pinion carrier assem blies as shown in Figure 81 Install gauge Tool C 3527 in intermediate support and cam assembly as shown in Figure 82 Remove intermediate support and cam as sembly from overrunning clutch hub Fig 83 Using a screw driver remove snap ring D from low and reverse band drum assembly G Remove the low and reverse planet pinion carrier ...

Page 321: ...ing discs for evidence of wear burning glazing and flaking off of facing ma terial If grooves in facing are worn off or if facing is burned or flaking off replace all of driving discs Replace driving discs if splines have become damaged Inspect the steel clutch plates and pressure plate surfaces for evidence of burning scoring and damaged driving lugs replace if necessary 73 PISTON AND SEAL RINGS ...

Page 322: ...ar for nicks or burrs Inspect inner ring sealing area in bore of sun gear for grooves or scratches Inspect thrust area of sun gear for nicks scratches or burrs Inspect seal rings neo prene for deterioration wear nicks or hard ness Install new seal rings if necessary In spect front clutch and sun gear thrust washer for scratches or excessive wear 77 INTERMEDIATE SUPPORT AND CAM ASSEMBLY INSPECTION ...

Page 323: ...against cam otherwise damage to springs will result when overrunning clutch hub is installed With intermediate sup port and cam assembly resting on bench lubri cate bushing and install low and reverse band drum assembly over hub While holding the two assemblies together remove gauge Tool C 3527 Lubricate bearing surface on reverse sun gear and install intermediate support and planet pin ion carrie...

Page 324: ... freely in the grooves Do not remove rings unless condition warrants When replacing rings use extreme care not to damage interlock portion of ring Make sure all oil passages are open by blowing out with compressed air Check splines and lugs for nicks or burrs Inspect bearing and thrust surfaces for nicks or scratches Inspect steel back bronze type bushing for scratches or scoring or excessive wear...

Page 325: ...G FOR PROPER TRAVEL OF CLUTCH PRESSURE PLATE It is very important that the front clutch pres sure plate has the proper amount of travel Insufficient travel may cause the clutch plates to drag Excessive travel may cause delayed engagement or may allow slippage of the clutch To check for proper travel of the clutch pressure plate proceed as follows Check clear ance by temporarily installing pressure...

Page 326: ...nstalled Inspect lever shaft I for excessive wear LOW AND REVERSE BAND REVERSE BAND STRUT ANCHOR KICKDOWN BAND KICKDOWN BAND STRUT ANCHOR LEVER SHAFT PLUG LEVER SHAFT SPACER LEVER SHAFT LOW AND REVERSE BAND LEVER KICKDOWN BAND LEVER LOW AND REVERSE SERVO PISTON PLUG PISTON ROD GUIDE SNAP RING LOW AND REVERSE SERVO PISTON SPRING RETAINER L O W AND REVERSE SERVO PISTON SPRING L O W AND REVERSE SERVO...

Page 327: ...SLEEVE Inspect the front seal ring neoprene for nicks deterioration and hardness Inspect the interlocking seal ring for wear or broken locks and make sure it turns freely in the groove It is not necessary to remove rings unless con dition warrants Inspect driving lugs for ex cessive wear and bearing surface on outer di ameter for nicks burrs or scratches FRONT OIL PUMP HOUSING 53x28 Fig 91 Install...

Page 328: ...ed by using a surface plate and crocus cloth Inspect front and rear pump check valve for proper seating on both surfaces If necessary to remove valve use a pair of long nose pliers When installing check valve make definitely sure rear pump check valve with metering hole is positioned toward outside of regulator valve body Check regulator valve spring seat snap ring After the valves and regulator v...

Page 329: ... install the two remaining bolts and washers then tighten to specifications Improper tightening of these bolts may cause pump gears to bind Lubricate and install front pump drive sleeve bearing into surface first as shown in Figure 94 then engage the driving lugs of the oil pump inner rotor to determine if oil pump rotors turn free ly Main body of driving sleeve should be flush with oil pump housi...

Page 330: ...uide seal ring slightly binds on case Then work seal ring into position by gradually com pressing spring Install snap ring Fig 62 and make sure it is properly seated Loosen compressing portion of tool and remove 101 REVERSE SERVO PISTON INSTALLATION Lubricate the low reverse servo piston seal ring and install on piston lip of seal facing top end of piston Install cushion spring and plug into servo...

Page 331: ...t through rear of transmission case Align identified locating hole in intermediate support with threaded locating hole inside of transmission case as shown in Figure 99 By supporting and keeping unit centered as much as possible guide it through bands until it con tacts the hub on the front clutch While push ing in on assembly rock sun gear to engage clutch plates of rear clutch on hub of front cl...

Page 332: ...oil pump housing to output shaft support bolts and washers Dished type washers are used to prevent cut ting or chipping of soft metals and should be in stalled on bolts with dished portion facing away from bolt head Draw down evenly tighten to specifications After bolts have been properly tightened turn output shaft to make sure pump gears are free to rotate If not disassemble pump to determine ca...

Page 333: ...KE SHOE ADJUSTING BRAKE SHOE ADJUSTING NUT BRAKE SHOE ADJUSTING SCREW 53x38 113 RECHECKING FRONT CLUTCH END CLEARANCE Prior to installing the valve bodies and transfer plate assembly recheck front clutch end clear ance using dial indicator Tool C 3339 as shown in Figure 41 To make this check pull front clutch forward by pulling on the input shaft or by carefully inserting screw driver between the ...

Page 334: ...fications Dished type washers are used to prevent cutting or chipping of soft metals and should be installed on bolts with dished portion facing away from head Install accumulator spring through transfer plate and position in piston Install accumulator cover as shown in Figure 39 three bolts with washers and draw down evenly Place oil strainer assembly in position on transfer plate assembly Instal...

Page 335: ...ool C 3528 119 FRONT VALVE BODY REMOVAL Remove the two front valve body to transfer plate bolts and lockwashers and separate front valve body from transfer plate assembly as shown in Figure 106 Remove upper valve body plate from transfer plate 120 CLEANING AND INSPECTION Place all parts in clean solvent wash thorough ly and dry with compressed air Make definitely sure all passages are free from ob...

Page 336: ...ities Inspect all springs for distortion and collapsed coils Inspect all valves and plugs for burrs nicks and scores Small ones may be removed with crocns cloth providing extreme care is used not to round off the sharp edge portion of valve The sharp edge portion is vitally important to this type valve The sharp edge helps to prevent dirt and foreign matter from getting between valves and body thu...

Page 337: ...d edge towards ball Place throttle compensator valve cover G in position over spring and body and install the three screws and lockwashers Draw down evenly and tighten Place the two check valve balls D and seats C in position in valve body and in stall cover B screws and lockwashers A Draw down evenly and tighten 125 REAR VALVE BODY DISASSEMBLY Fig 108 Keeping thumb pressure against the kickdown p...

Page 338: ...valve F large end first into valve body and place spring E on pilot Place the 1 2 shift valve kickdown plug C over the 1 2 shift valve spring G Place kickdown plug cover over 3 1 relay valve spring and 1 2 kick down plug Compress springs and guide the 1 2 kickdown plug into valve body Install the three cover screws and lockwashers and draw down evenly and tighten Remove piece of metal or 6 scale I...

Page 339: ...CKER VALVE PIN 56x668 Fig Ill Removal and Installation of Shuttle Valve Plug Spring and Valve Fig 112 Removal and Installation of Throttle Valve Spring Kickdown Valve and Detent Plug assembly R or manual valve U If con dition warrants however such as damage proceed as follows Remove the throttle valve lever shaft snap ring V Fig 110 Remove any burrs from throttle valve and manual valve lever shaft...

Page 340: ...fixture Tool C 3528 Place steel plate upper over pilots on Tool C 3528 and into position on transfer plate 132 FRONT VALVE BODY INSTALLATION Position front valve body on steel plate up per as shown in Figure 106 and install two bolts and lockwashers in outer end of valve and draw down finger tight VALVE BODY RETAINER PLATE TOOL 56x672 Fig 114 Tightening Valve Body Screws 130 REAR VALVE BODY INSTAL...

Page 341: ...ve all obstructions dirt etc from vent hole screens when so equipped Remove the bolts holding metal dust shield to converter housing adapter plate Using wrench Tool C 589 remove stud nuts and lock washers which hold converter unit to the crankshaft The torque converter assembly is a welded unit and cannot be serviced except as an assembly If torque converter is being re moved for replacement of st...

Page 342: ...tes after water has come to a boil Steam Place ring gear on a flat surface and direct the steam flow around the gear for approximately two minutes Flame Place ring gear squarely on a flat surface Using a medium size tip direct a slow flame around the inner rim of the gear being careful not to direct the flame onto the teeth of the ring gear Place a few drops of water on the face of the gear at int...

Page 343: ...opposite the hub low spot previously marked on the impel ler shell The subsequent heating operation can now be done through the opening in the adapter plate as shown in Figure 118 The size of the spot to be heated is governed by the magnitude of hub runout and is usually about y2 inch diameter for 008 inch total in dicator reading Using an acetylene torch con taining a No 3 tip and set to maximum ...

Page 344: ...rter with ears of the washer behind the converter pump drive lugs The square end of the bolt can be held with a wrench as the nut is tightened Dial indicator set Tool C 3339 can now be attached as shown in Fig ure 120 Locate the indicator so that it is bearing on the transmission pilot bore of the converter housing and rotate the converter as outlined in Paragraph 134 a 3 Fig 121 Eccentric Dowel O...

Page 345: ...Majority of correc tions will be for one direction only but it is possible that the housing bore may be out in two directions In the latter case it may be necessary to use the next higher step dowels adjusting these dowels with the housing in stalled to bring within tolerance Care should be taken to back up adapter plate when insert ing lower dowel to avoid distortion or breakage of adapter plate ...

Page 346: ...e converter with the drain plug removed This will remove any residual solvent and trapped dirt Reinstall the drain plug or plugs Install transmission as outlined in transmission section SHIM THICKNESS TABLE Location of Housing Face Low Point Near one of the lower trans to housing bolt holes Near one of the upper trans to housing bolt holes Between the two lower trans to housing bolt holes Between ...

Page 347: ...d 17 Red 17 Red 17 Red 3 15 1 AND 3 18 1 19 L Purple 19 L Purple 18 Black 18 Black 18 Black 3 31 1 AND 3 36 1 20 L Blue 20 L Blue 19 L Purple 19 L Purple 19 L Purple 3 54 1 21 Yellow 21 Yellow 20 L Blue 20 L Blue 20 L Blue 18 Black 3 73 1 21 Yellow 21 Yellow 21 Yellow 21 Yellow 21 Yellow 3 90 1 21 Yellow 21 Yellow 21 Yellow 21 Yellow 3 91 1 21 Yellow 21 Yellow 21 Yellow 21 Yellow 4 1 1 21 Yellow 4...

Page 348: ...Bearing 7 Rear Axle Control Strut 7 Checking Propeller Shaft Angles 11 Service Diagnosis 11 DATA AND SPECIFICATIONS Models Propeller Shaft Number Used Diameter With TorqueFlite Transmission Diameter with Air Conditioning And TorqueFlite Transmission Length Centerline to Centerline of U Joints With TorqueFlite Transmission LC 1 2 1 3 0 in 3 25 in 58 96 LC 3 1 3 0 in 3 25 in 58 96 Town 8s Country LC...

Page 349: ...HING RETAINER ROLLER AND BUSHING ASSEMBLY BOLT ROLLER AND BUSHING ASSEMBLY ROLLER DUST SEAL DUST SEAL RETAINER 55x767 A Fig 1 Rear Universal Joint Cross Type Disassembled View CENTERING BUTTON BUTTON SPRING BALL AND ROLLERS GREASE COVER v GASKET PIN NUT LOCKWASHER SHAFT BOLT THRUST WASHER BODY BALL AND ROLLERS BUTTON SPRING CENTERING BUTTON PROPELLER SHAFT 54x49 Fig 2 Front Universal Joint Ball an...

Page 350: ...ls needle bearings thrust wash ers centering button and button spring at each end extends through the propeller shaft ball head and rides in ball channels in the body of the joint assembly This balanced installation is designed to absorb thrust and torque of the drive line This type of joint is used in Chrysler Models LC 1 2 and 3 at front universal joint The Cross Type universal joint is used at ...

Page 351: ...unnion type universal joints will only be necessary when excessive backlash exists between balls and trunnion In some instances it will be found that universal joint body has worn and it will be necessary to replace all parts including body pin thrust washers and centering buttons Worn rollers should also be replaced 3 UNIVERSAL JOINT MAINTENANCE BALL AND TRUNNION The universal joints propeller sh...

Page 352: ...ust cover protruding through back end of body With other hand pump body back and forth as shown in Figure 6 until entire dust cover has passed through body During operation cone may have reversed itself inside dust cover Pull it out to its normal position Insert 2y2 ounces of heavy fiber universal joint grease in joint of LC 3 2 ounces in the UNIVERSAL JOINT CENTERING PIN PROPELLER SHAFT UNIVERSAL...

Page 353: ...arts are not serviced separately After disassembly clean and inspect parts and replace those worn or damaged as necessary c Assembly Lubricate all parts before assembling If splined joint at rear of front propeller shaft has been disassembled fill cavity with one ounce by weight of MS 1124 The center bearing is a sealed bearing and does not require lubrica tion Install dust shields and retainers o...

Page 354: ...peeds of 15 to 20 miles per hour In order to control this shudder or vibration a rear axle control strut as shown in Figure 9 has been incorporated in rear axle design for purpose of controlling rise of nose of rear axle carrier under varying load conditions Corrections of propeller shaft shudder should be made as follows Before diagnosing a shud der condition make sure engine has been tuned and i...

Page 355: ...aft with level readable from the left side of shaft Fig 12 note the location of the leading edge of bubble in level gauge if bubble is still at zero or level position or within three gradua tion marks fore or aft rear axle joint angle is within specifications and should be consid ered standard adjustment If leading edge of bubble is forward of the third graduation the propeller shaft angle should ...

Page 356: ...ket NOTE Always recheck center joint working angle after shimming center joint working angle To check propeller shaft alignment with protractor proceed as follows Measure rear universal joint working angle This angle should be 1 to 3 degrees at zero ADD SHIMS 58x705 Fig 16 Bubble Location Forward of Center passenger load Reasonable care must be ex ercised to obtain accuracy of this measurement NOT...

Page 357: ...ctions up or down when viewed in same direction from front to rear of car the working angles are obtained by adding the angles below horizontal Therefore the mid dle joint working angle as shown in Figure 18 is 2 and the rear joint working angle is 3 If the adjacent shafts were pointing in the same direction then the angles below horizontal Fig 20 Checking Rear Propeller Shaft Angles would be subt...

Page 358: ...ft and remove undercoating material if present with solvent b Check transmission flange nuts and rear axle differential flange nuts for looseness Tighten to Data and Specifications c Check alignment of balance arrows on both shaft and front universal joint These ar rows must be exactly in line If not reposition splines so that arrows are properly aligned 9 UNIVERSAL IOINTS NOISY a Check universal ...

Page 359: ... 3 Tubeless Tires 4 Testing Tire and Wheel Assemblies for Leakage 5 Repairing Punctures 5 Recommended Tire Pressures 6 Captive Air Safety Tire 7 Service Diagnosis 11 DATA AND SPECIFICATIONS MODELS WHEELS Type Rim Size Flange Type No of Nuts to Attach Wheel Stud Hole Circle diameter Stud Size LC 1 LC 2 LC 3 LY 1 Steel Disc Drop Center Safety Wheel MyMopar com ...

Page 360: ...hree Seater Two Seater Three Seater LC 1 LC 1 LG 3 LG 3 WHEELS Type Rim Size Flange Type No of Nuts to Attach Wheel Stud Hole Circle diameter Stud Size 14x6 K 5 Steel Disc Drop Center Safety Wheel 1 4 x 6 K K 5 H 20 14x6 K 5 J4 20 TIRES Type Cord Material Size Super Soft Cushion Tubeless Rayon 8 50 x 14 Captive Air Nylon 8 50 x 14 Super Soft Cushion Tubeless Rayon 9 00 x 14 Captive Air Nylon 9 00 ...

Page 361: ...ction With the anvil of indicator bearing on the inner tire bead sur face of wheel as shown in Figure 2 slowly rotate wheel and note the total runout Mark high and low spots and the amount on wheel If radial runout of wheel exceeds 045 inch replace the wheel NOTE Do not check runout on outside of wheel rim since this method can easily give a false reading 4 CHECKING WHEEL FOR WOBBLE LATERAL RUNOUT...

Page 362: ...er rim of wheel To check balance of rear wheels place jack under frame side rail about 12 inches forward of rear spring front hanger Raise one wheel off the floor at a time Block the other wheel Place a crumpled cloth or towel on fender above wheel With the engine running and transmis sion in direct drive spin the wheels through speed ranges of 20 30 and 40 miles per hour Do not exceed 40 miles pe...

Page 363: ...arefully for punc turing object If tire is flat inflate and listen for first air leak If air leakage is slow and cannot be heard remove tire from car and submerge in water test tank Apply a soap solution if test tank is not available covering surface of tire the valve stem and the juncture of tire and rim flange A slow leak will be indicated by an accumula tion of soap bubbles 10 REPAIRING PUNCTUR...

Page 364: ...ement to obtain a good adhesion Two types of equipment are available for curing inside patches the Electric and the Match Patch The Electric type has a fuse plug that automatically cuts off the power when the curing is completed The Match Patch or powder burning type depends upon the heat resulting from a slow fire C clamps are used with both types of equipment to apply pressure during the curing ...

Page 365: ...ANT When outer chamber of tire is deflated it is recommended that continued driv LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR 57X23 ing speed should not exceed 40 M P H until tire has been repaired 15 RIM PREPARATION Scrape off all rust flakes and clean rim flanges and bead seats with a wire brush or steel wool To prevent leakage badly rusted pitted rims should be heavily coated with vulcanizing ce...

Page 366: ...dewall valve in this tilted position Should additional pressure be required to seat tire beads firmly against rim flanges ap ply it to the outer compartment and then re lease to the desired operating pressure through the needle valve in the tire sidewall Under this procedure pressure in the inner compartment will be 2 or 3 pounds above ori ginal inflation which provides a reserve that will filter ...

Page 367: ...he padding inside the case in which the valve is supplied If inflation valve does not insert easily into tire sidewall because of con tact with inflated inner chamber tilt inflating valve slightly toward rim 23 DISMOUNTING Remove valve core from rim valve to permit escape of all air from safety shield Deflation of the outer compartment will not be required for dismounting after the safety shield h...

Page 368: ...WHEELS AND TIRES CHRYSLER SERVICE MANUAL Fig 16 Toe Out Wear Fig 13 Under lnflation Wear 57x31 Fig 14 Spotty Wear 57x33 Fig 17 Camber Wear 57x32 157x36 Fig 15 Toe In Wear Fig 18 Over Inflation MyMopar com ...

Page 369: ... shield should be removed from service and replaced with a new one When captive air safety shields are removed to replace tire or for tire inspection etc in spect the outside surface of the bead channels and safety shield surface for chafing or exces sive wear If no fabric chafing is apparent safety shields may be reapplied for further use SERVICE DIAGNOSIS 26 LEAKAGE CAUSES AND CORRECTIVE METHODS...

Page 370: ...he deflated tire is at fault Repeat test until all tires in cluding spare have been checked Only one tire at a time should be deflated to 25 pounds pres sure for testing Reinflate the tire already tested before proceeding to the next tire NOTE Sometimes a thumping tire will operate satis factorily when changed from one side of the car to the other This changes the direction of the tire s rotation ...

Page 371: ... Fenders All Models 31 Removal and Installation of Radiator Grille and Bumper Assembly All Models 34 Maintenance 34 Cleaning of Interior Upholstery 37 Paint Finish Conditions 38 Body Sealing 39 Cowl Sealing 41 Windshield Sealing 43 Roof Sealing 45 Door Openings 47 Front Door Vent Window 53 Rear Quarter Vent 57 Rear Window 60 Rear Quarter Panel 61 Luggage Compartment 61 Floor Panel 64 Town and Coun...

Page 372: ... HEATER OPENING COWL BRACES B POST A B r t C T FRONT FLOOR PAN COWL PANEL A P O 5 T Fig 1 Basic Body Construction LC 1 LC 2 LC 3 Models 57x572 ROOF PANEL WELDED JOINT SILL REAR DECK COWL VENT REAR QUARTER PANEL HEATER OPENING COWL BRACES FRONT FLOOR PAN A POST COWL PANEL Fig 2 Basic Body Construction LY 1 Imperial 57x573 MyMopar com ...

Page 373: ... comfort WINDSHIELD WASHER JET SEAL and serviceability See Figures 1 and 2 for basic body construction of these bodies Body bolt inspection and tightening should be performed regularly All models of the Chrysler and Imperial have 12 body bolts except the con vertible which has 14 If tightening bolts and screws located on such assemblies as deck lid doors hood rad iator support and front end does n...

Page 374: ...s With helper remove other two attaching nuts and washers and lift hood from car b Installation When installing use helper to assist in mount ing hood to hinges Install attaching washers and nuts align hinges with aligning marks Tighten nuts a little more than finger tight Close hood align and adjust Seal top of hood hinge bracket to dash panel with sealing putty c Adjustment Hood Fits Cowl Loosel...

Page 375: ...ollow Contour of Fender Insert small block of wood about one inch square between fender flange and hood opposite low spot on hood Close hood slowly With hand placed ahead of wood block apply pressure gently to hood Repeat operation about every six inches until correct hood fit is obtained Hood Projects Beyond Front of Fender This condition can be corrected by shifting fender forward with standard ...

Page 376: ...ont pillar Also check to see if front of fender is flush with front of hood When correct fitting has been obtained tighten bolts previously loosened and remove tool 56x329 Fig 10 Pulling Front Fender in Position Typical 57x765 Fig 11 Hood Striker Plate Adjustment Adjustment of Hood Striker and Lock As sembly Fig 11 The hood striker is mounted on a plate which is attached to the underside of hood T...

Page 377: ... lower door place jack under door as near hinge as possible This will hold weight of door as hinge bolts are loosened The amount of vertical movement is limited however the amount of movement can be de termined by scribed line previously made Loos en the mounting bolts on both hinges 4 to y turn Raise or lower jack until desired clearance is obtained Tighten hinge bolts securely Check scribe lines...

Page 378: ... original posi tion After using Bar Units check door for proper fit and ease of window operation d Striker Plate Adjustment Fig 12 NOTE Front and rear door glass wiadow frames are removable and should not be ad justed or aligned to roof line until doors and striker plates are properly adjusted After door has been centered in its opening and all hinge bolts have been tightened 18 to 20 foot pounds ...

Page 379: ... hinge bolts at the pillar Open the door a few inches Lift the rear door edge or pull down on the rear edge depending on adjustment needed Retighten the bolts To move the lower part of the door fore or aft loosen only the lower hinge bolts at the pillar Open the door a few inches and pull down Fig 19 Weatherstrip and Sealing Lip at the rear edge or lift up as needed Retighten the bolts Loosen the ...

Page 380: ...glass stops Loosen the small bolt that holds the division bar bracket as shown in Figure 22 58x21 Fig 23 Leveling the Glass and Rear Channel Raise the glass all the way and shift it by hand so the top edge is level Hold it in that position and retighten the bolt the pivot shaft nut and the upper glass stops Check glass op eration again If it runs too tightly or too loosely in the channels adjust t...

Page 381: ...ttaching bolt Ad just the rear channel fore or aft until you get a good seal at the rear edge of the front door Tighten the upper rear channel nut to hold this adjustment Lower the glass and tighten the rear channel lower attaching bolt as shown in Figure 27 Always check glass operation Lower and raise the glass If there is any bind loosen the front channel lower attaching bolt Lower the glass so ...

Page 382: ...o adjust the rear channel To tip the rear leg of the frame in or out loosen the three frame mount ing bolts at the rear face of the door adjust and retighten At vent wing a curved division bar acts as the front run channel Move the lower end of the division bar in or out by loosening the lock 58x28 Fig 29 Front Door Glass Adjustment Imperial nut on a special adjusting screw Turn the screw to pull ...

Page 383: ...er unit assembly screws as shown in Fig ure 31 Shift the regulator as needed to level the glass and smooth out operation Finally loosen and adjust the two upper stops for proper glass travel NOTE Front and rear door glass window frames are removable and should not be ad justed or aligned to roof line until doors and striker plates are properly adjusted After door has been centered in its opening a...

Page 384: ... deck lid made possible by a new torsion bar hinge mech anism Lifting deck lid is accomplished with a finger tip the weight of heavy lid is counr terbalanced in all positions by spring tension of two torsion bars See Fig 32 The torsion bars are long small diameter steel bars that are free at one end and anchored to support bracket at other See Fig 33 A roller sleeve on free end operates against a ...

Page 385: ...f two bolts in each hinge that attach lid to hinge arm Leave remaining two bolts finger loose Brace deck lid in such a manner so as to hold lid in position while removing last two bolts This will keep lid from sliding down and damaging rear deck Remove last two bolts and lift deck lid up and away from rear of car When installing deck lid observe same pre caution Lift lid and slide down into positi...

Page 386: ...ed For instance if contour were increased lid would become shorter whereas if contour were decreased lid would become longer Each time lid contour is changed in all probability lid would have to be relocated on hinges f To Increase the Deck Lid Contour Insert plastic mallet between lid and quarter panel as shown in Figure 37 then apply pres Fig 38 Increasing Rear Deck Lid Contour sure on lower cor...

Page 387: ... of lid as they are pulled out a good seal is evident If paper fits loosely on one side and tight on other deck lid should be aligned 11 BODY ALIGNMENT When checking alignment of body that is badly damaged frame should be inspected and nec essary repairs if any made to frame before taking measurements for squaring up of body The door and other glass should be removed to prevent breakage Reinforcem...

Page 388: ...torque In some instances shims may be re moved to correct door misalignment If front door is high at rear edge remove shims from the Number Two body bolts Excessive shims on the Number Four body bolt will be indicated at rear door binding at bottom a Body Mounting Bolts The body mounting bolts except four at rear are accessible from under car The four at rear IING NOT SQUARE REMOVE SHIMS SHIM BODY...

Page 389: ...point such as moulding bead corner or A post Make corresponding measure ments on repair panel for accuracy make sure measurements are taken from same points on each panel Scribe line around area to be cut from re pair panel and drill 4 inch hole at corner of scribed line as starting point for cutting and cut out new piece along scribed line Straighten out and finish edge of piece that was cut from...

Page 390: ...STALLATION OF DOOR TRIM PANEL Cars without Electric Window Lift Remove door and window regulator handles garnish moulding if so equipped Starting at lower corner of panel Fig 47 work panel out frdm door Screwdriver can be used in operation if necessary When installing panel make sure all clips are secured in place and install panel in posi tion on door Force each clip into position with WITCH RETA...

Page 391: ...e Control Handle Shaft P Ventilator Bracket Screw Q Lock Rotor Release Link Screw R Ventilator to Window Frame Screws S Window Frame Bolt Covers the attaching screws Install the glass run chan nel and re cement the lower ends Check operation of glass and regulator Re pair any damage to water curtain Install the trim panel and garnish moulding c Adjustments To adjust the frame IN or OUT loosen the ...

Page 392: ...ow frame alignment with the door opening 57x768 Fig 54 Installing Glass Run Channel Install the frame bolt moulding S and re cement the upper weatherstrip to the door In stall the water curtain and repair any damage Install the trim panel and garnish moulding c Adjustments Refer to Figure 51 57x656 and proceed as follows Loosen frame mounting bolts A B C D and F Loosen the division bar mounting bo...

Page 393: ...door attaching screws and frame and glass assembly C UPPER PIVOT TO GLASS SCREW B VENTILATOR TO DOOR MOUNTING BOLT D LOWER PIVOT AND SPRING Fig 56 Removing Ventilator Fig 57 Removing or Installing Glass Frame and Door Ventilator 20 REMOVAL AND INSTALLATION OF DOOR VENTILATOR ASSEMBLY Cars with Removable Glass Frame Assembly Remove garnish moulding remote control han dles arm rest if so equipped an...

Page 394: ... through opening in door When installing remote control assembly coat all parts liberally with lubriplate Install assembly through opening in door and secure with attaching screws Bend bottom catch of window felt run channel inward and install cap screws holding remote control base to door panel Check the assembly for proper opera tion Install trim panel garnish moulding and door handles 23 REMOVA...

Page 395: ...S R U N X I ATTACHING SCREWS 4 FRONT GLASS RUN ATTACHING SCREWS UPPER STOP SCREWS REGULATOR ATTACHING SCREWS LOWER PANEL RETAINING BRACKETS 57x672 Fig 59 Rear Quarter Window Adjustment Club and Convertible Coupe BUMPER 57x669 Fig 60 Removing or Installing Door Handle adjustable stop located at the rear of window Downward travel is controlled by a non ad justable stop in reinforcement of pillar pos...

Page 396: ...DING RIGHT WEATHERSTRIP WINDSHIELD GLASS LOWER MOULDING CENTER LOWER MOULDING LEFT 57x772 WEATHERSTRIP MOULDING UPPER RIGHT MOULDING RIGHT PILLAR MOULDING CAP UPPER MOULDING UPPER LEFT MOULDING LEFT PILLAR MOULDING CAP LOWER MOULDING LOWER RIGHT MOULDING LOWER LEFT WINDSHIELD GLASS 57x762 Fig 63 Windshield and Moulding Assembly Imperial Models NOTE Whenever the door handle or lock and barrel assem...

Page 397: ...t side mouldings and upper and lower moulding re taining clips as shown in Figure 67 and re move horizontal mouldings Remove moulding retaining screws as shown in Figure 68 Re move head lining and remove upper moulding attaching screws and moulding Fig 69 Fig 67 Removing or Installing Upper and Lower Moulding Clips Imperial Models 57x720 Fig 68 Removing or Installing Moulding Retaining Screws Impe...

Page 398: ...own in Figure 74 Do not use a strong solution Coat weather strip with Sealer and center and insert upper end of glass in weatherstrip as shown in Fig ure 75 Hold glass in position and insert wedge in weatherstrip groove as shown in Figure 76 WEATHERSTRIP BODY FENCE SCREW OUTSIDE MOULDING UPPER MOULDING LOCATING HOLES Fig 72 Windshield Weatherstrip and Moulding Sides OUTSIDE MOULDING BODY FENCE WEA...

Page 399: ...rome Mouldings Fig 78 Removing Rear Window Belt Mouldings 157x770 i Fig 79 Removing Lower Corner Moulding ing on Imperial Models if removed Reinstall windshield wiper blades and check for water leaks as indicated in Paragraph 38 27 REMOVAL AND INSTALLATION OF REAR WINDOW ALL MODELS EXCEPT CON VERTIBLE COUPE AND TOWN AND COUNTRY WAGON Cover rear deck fenders and other components to protect finish P...

Page 400: ... ure 79 Remove upper and lower mouldings clips from weatherstrip Remove upper and lower horizontal moulding Fig 80 Insert wedge tool in weatherstrip locking strip and twist it slightly while sliding it around weath erstrip to unlock it from glass opening and remove glass Fig 81 NOTE When installing rear glass weatherstrip on Imperial Models space moulding retaining clips equally apart on body fenc...

Page 401: ...ve electrical wire leads motor to bracket attach ing screws and remove electric motor WEATHERSTRIP OUTSIDE MOULDING CLIP BODY FENCE NUT AND WASHER 57x755 INSIDE MOULDING SCREW BODY FENCE WEATHERSTRIP OUTSIDE MOULDING SCREW 57x756 Fig 87 Lower Rear Window Weatherstrip and Moulding CAUTION When installing window lift motor make sure the motor shaft to gear box coupling is properly aligned before tig...

Page 402: ...Y AND SHEET METAL CHRYSLER SERVICE MANUAL NUT FENDER 57x745A Fig 89 Front Fender Assembly Chrysler Models NUT SHIELD FENDER STRAP TRAY BRACKET 57x746A Fig 90 Front Fender Assembly Imperial Models MyMopar com ...

Page 403: ...RADIATOR GRILLE ORNAMENT RADIATOR GRILLE GRILLE BAR OUTER LEFT WASHER LOCK WASHER GRILLE BAR EXTENSION x BUMPER BUMPER GUARD 58x707 LICENSE PLATE BRACKET Fig 91 Bumper and Grille Assembly Saratoga and New Yorker Models RADIATOR GRILLE BAR N O 6 BAR N O 5 BAR N O 3 BAR N O 2 BAR N O 1 SUPPORT SUPPORT OUTER BAR EXTENSION 58x708 BRACKET CLOSURE GRILLE BAR BUMPER PARKING LIGHT GUARD IMPACT BAR PARKING...

Page 404: ...ion Install attaching bolts and screws but do not tighten Check hood to fender alignment and tighten all attaching bolts nuts and screws securely Install and connect the battery clip wire harness to shield and install lead wires to starting motor solenoid if left hand splash shield was removed 31 REMOVAL AND INSTALLATION OF RADIATOR GRILLE AND BUMPER ASSEMBLY ALL MODELS Refer to Figures 91 and 92 ...

Page 405: ... silencer and cement silencer in place if necessary On Special Club Coupe Fig 95 Marking Holes Models remove the body front pillar and roof side rail weatherstrip and the drive nails at ends of headlining seams Use a dull putty knife to separate the headlining from the roof rail Carefully remove the material from the ce mented surfaces on Special Club Coupe If new headlining is to be installed rem...

Page 406: ...ig 99 Cementing Upper Rear Glass Quarter and Header Bar Fig 99 Cement to quarter panel and tack list ings and seams to quarter panel opening When cement is tacky stretch headlining forward and over the cemented area end onto the barbs on windshield header Make sure the first seam of headlining is straight In most cases the listing is longer than necessary Cut the material at ends to prevent wrinkl...

Page 407: ...er press headlining onto ce mented surface Install the material across top and to a point about six inches from lower corners of window Press material in place at quarter panel Install remaining portion of headlining at rear window and work out wrinkles Tuck in remaining portion at forward edge of quarter panel Locate center of dome light bracket Cut a small hole in headlining at this point and pu...

Page 408: ...shion or seat back Wipe dry as possible with a turkish towel Allow to dry over night before sitting on cush ion or seat back Wet a piece of clean white cheese cloth with a little solvent cleaning fluid and wring out excess Rub out the spot Use a brush on stubborn spots Go over cleaned area with cheesecloth wetted with solution of household detergent and water Wipe dry with clean piece of cheeseclo...

Page 409: ...an and hardtop bod ies except in those specific cases where the particular model or body type is specified Always make the necessary adjustments to the doors extruded aluminum door upper frames window frames vent windows and luggage compartment lid before attempting to seal any part of the body where such adjust ments may be required If the sealing operation is performed first changing of the adju...

Page 410: ...accomplished under these circumstances Dry the car with compressed air if necessary after the water test before proceeding with the sealing opera tion The weatherstrip must be absolutely dry Use a heat lamp or compressed air to dry the weatherstrip The door weatherstrips luggage compart ment lid weatherstrips and most other seals are made of porous sponge rubber which will absorb water All adhesio...

Page 411: ... Hood Fig 107 Dash Panel Outer Locate the hood to cowl seal weatherstrip lac ing on the hood properly and lock in place Fig 108 Inspect the hood hinge mounting since water can enter through the mounting stud openings Seal around the hinge mounting plate with a sufficient amount of black mastic sealer It is also advisable to seal around both the fender to cowl upper attaching bolt and bracket 37 CO...

Page 412: ...ES SEAL SEAM AND BOLTS SEAL HOLE SEALER SEAL SIDES AND TOP DO NOT REMOVE HEATER BLOWER HOUSING PACK SEALER BLOWER DOOR OPENING FIREWALL WATER DEFLECTOR 1 4 INCH SHIM FRESH AIR DOOR HINGE SEAL AROUND NUTS FRESH AIR DOOR PACK SEALER BRAKE OPENING 58x84 Fig 109 Cowl Upper Panel Air Intake MyMopar com ...

Page 413: ...by one of three causes Leaks between the glass and weatherstrip are caused by the weather strip not fitting the contour of the glass tightly often caused by overlapping of the weather strip lock Leaks between the weatherstrip and the windshield opening flange or fence usually WINDSHIELD OPENING FRAME LOWER REINFORCEMENT SEALER WINDSHIELD HEADER WINDSHIELD HEADER REINFORCEMENT WINDSHIELD OPENING FR...

Page 414: ...remaining excess off with a cloth moistened with solvent The use of the weatherseal ce ment between the glass and weatherstrip will also correct crunching noises at the windshield To correct a gap between the windshield glass and weatherstrip it is necessary to remove the glass from the weatherstrip Insert a piece of c incft round plastic welt or insulated wire in the lower glass channel of the we...

Page 415: ...lking putty 39 ROOF Before proceeding with the roof water leak cor rection the roof should be carefully water tested to locate exactly where the water is coming in A leak at the flange joint of the roof to the windshield frame or the joint of the roof to the drip rail at the forward end will often appear as a leak in the joint seam at the knee of the front door hinge pillar A pillar Fig 112 Inspec...

Page 416: ...14 it is necessary to remove that portion of the head lining to expose the attaching nuts After re moving the headlining remove the trim mould ings and seal around each retaining stud and clip with body caulking putty On Imperial Southampton models inspect the joint seam where the front and rear sections of the roof are joined together Fig 115 Seal this joint with liquid body sealer Form a ball of...

Page 417: ...If the seams are rough large or deep smooth by metal finishing Then apply cold sol der with a spatula or putty knife smoothing it down as much as possible and let it completely set up Finish off with a sander and paint Note particularly the metal seam joints and the coach joints at the junction of the floor side sill to floor pan and the A B and C pil lars Fig 118 Water and dust can get through th...

Page 418: ...UAL ROOF RAIL OUTER ROOF RAIL INNER CENTER PILLAR 58x92 ROOF RAIL COLD SOLDER WINDSHIELD PILLAR 4 DR SED CLUB SED AND SURBURBAN ONLY WINDSHIELD PILLAR ROOF RAIL WINDSHIELD PILLAR SP 4 DR AND SP CL CPE ONLY 58x93 Fig 117 Door Openings MyMopar com ...

Page 419: ...ODY AND SHEET METAL 49 SEALER BEAD OF SEALER LENGTH OF GROVE IN DOOR WEATHERSTRIP SEALER PRESS SEALER INTO CORNER JOINT OF WEATHERSTRIP 58x94 Fig 118 Door Pillars Chrysler Models 58x95 Fig 119 Doors Imperial Models MyMopar com ...

Page 420: ...Y AND SHEET METAL CHRYSLER SERVICE MANUAL NORMAL WEATHERSTRIP PULLED TOO TIGHT AT CORNER DRAIN HOLE WINDCORD SHIM HERE TO RAISE WEATHERSTRIP GLASS DOOR WINDOW FRAME 58x96 Fig 120 Door Weatherstrip MyMopar com ...

Page 421: ...e door inner panel and flange and the window frame areas which are to be bonded to the weatherstrip Allow the cement to set until tacky and then carefully and firmly press the weatherstrip into place Build up the low areas of the weatherstrip to obtain a greater overlap of the weatherstrip against the door opening install the closed cell rubber shim stock under the weatherstrip To obtain greater c...

Page 422: ...nstall the front door hinge pillar weather strip locating the upper tab of the weatherstrip i s inch above the top of the vent window frame Fig 121 On convertible models the hinge pillar weatherstrip must be flush with the top of the vent window frame On the front door of 4 door hardtop models locate the inner tab of the lock pillar weather strip inside the rear flange of the inner door panel and ...

Page 423: ...shield in place using weatherstrip cement Be sure to tuck in the bottom edge of the shield through the long slot at the lower edge of the door inner panel Seal at corners with waterproof tape Seal around all the bolts screws and washers Seal around all the trim panel retaining clips using body caulking putty or white mastic 42 FRONT DOOR VENT WINDOW Leaks through the vent windows can be located by...

Page 424: ... face using a 32 drill Drive a piece of i g inch bronze or brass rod into this hole Cut off the brass rod so that i 6 inch protrudes from the latch face File off the protruding brass rod creating a chamfer or radius so the rod will not interfere when locking the vent window Adjust the vent window in the open ing Application of black mastic or body sealer to the corners of the vent weatherstrip Fig...

Page 425: ...SEALER 58x102 Fig 126 Vent Wing Assembly ROOF RAIL EXTENSION WEATHERSTRIP RETAINER WEATHERSTRIP ROOF RAIL EXTENSION WEATHERSTRIP WEATHERSTRIP RETAINER BEAD OF SEALER ROOF RAIL WEATHERSTRIP VIEW IN DIRECTION OF ARROW 58x103 Fig 127 Window Frame Weatherstrip MyMopar com ...

Page 426: ...g putty will aid greatly in obtain ing a good seal at the weatherstrip Weather strip that is curled distorted torn or tattered should be replaced by new weatherstrip 43 REAR QUARTER VENT OR WINDOW SEDANS Leaks at the rear quarter vent or window Fig 128 are sometimes difficult to locate since the water that leaks in often appears in other areas Leaks at the forward upper and lower corners may cause...

Page 427: ... Windsor sedan Seal between the extruded aluminum moulding and the roof rail and the junction of the end of the moulding to the rear quarter panel Fig 128 Seal be tween the extruded aluminum moulding and the front edge of the quarter window frame upper portion of C pillar Install the ex truded aluminum mouldings Pack all three MOULDING WEATHERSTRIP 58x105 VIEW IN DIRECTION OF ARROW A FROM INSIDE O...

Page 428: ...ck the rear corner junction of the roof rail and quarter panel to plug all holes and openings Lay a bead of body caulking putty all around the inside of the rear quarter window opening SECTION IN DIRECTION OF ARROW QUARTER PANEL SEALER SEALER SEALER ALUMINUM EXTRUSION MOULDING 58x107 Fig 130 Rear Quarter Window Weatherstrip MyMopar com ...

Page 429: ...sure of the weatherstrip against the window opening to squeeze out some of the body caulking putty Clean off the excess body caulking putty On two door hardtop models it is essential to have a waterproof shield between the rear quarter window space in the rear quarter panel and the luggage compartment Otherwise water that would enter the rear quarter past the rear quarter window could blow into th...

Page 430: ...caulking putty Apply liquid body sealer along the outer edge of the upper portion and sides of the rear window weatherstrip Fig 133 Be sure to seal around each clip and under the lip of the weatherstrip Water leaking around these clips may appear on the rear window shelf panel or inside the luggage compartment On Imperial bodies a leak at the rear window corner moulding joint cover retaining bolt ...

Page 431: ... of the leaks has been traced to the lug gage compartment itself correct as follows Be sure to obtain proper fit and alignment of the luggage conipartment lid before trying to correct the leak at the lid weatherstrip In spect the luggage compartment lid drain trough and weatherstrip retainer joints for rough and porous welds Seal with body caulking putty or body sealer as required Fig 136 Brush a ...

Page 432: ...AN EXTENSION DECK OPENING LOWER PANEL VIEW IN DIRECTION OF ARROW REINFORCEMENT TAIL LAMP OPENING LOWER 58x111 Fig 134 Tail Lamp Opening VIEW IN DIRECTION OF ARROW A SEALER _ FLOOR PAN RUBBER CORD QUARTER PANEL WHEELHOUSE OUTER VIEW IN DIRECTION OF ARROW B 58x112 Fig 135 Rear Floor Pan Extension MyMopar com ...

Page 433: ...ulking putty If the seam joint between the outer periphery of the cover and the deck lid is leaking seal with liquid body sealer from the inside In some instances it may be necessary to remove the moulding and seal this seam joint from the outside Seal around the periphery of the hub cap Fig 138 with clear liquid sealer Seal all openings and joint seams on the in side of the luggage compartment lo...

Page 434: ...termine the exact source of the leak Be sure all under body plugs are in the floor panel Be sure all door sill drain openings are open Often undercoating closes off these openings Using liquid body sealer reseal all joint seams of the floor the luggage compartment floor the quarter extension panels and all excess opening covers Fig 141 Seal the floor panel to cowl panel joint seams floor panel to ...

Page 435: ... FLOOR PAN QUARTER PANEL 58x116 DECK OPENING LOWER PANEL DECK OPENING LOWER PANEL SIDE EXTENSION DECK OPENING LOWER PANEL EXTENSION Fig 139 Luggage Compartment Lower Panel REINFORCEMENT QUARTER PANEL SEALER 58x117 VIEW IN DIRECTION OF ARROW Fig 140 Fuel Filler Housing MyMopar com ...

Page 436: ... through the access hole at the rear seat back filler as shown in Figure 143 in order to seal 2 51 REAR PILLARS Water may leak into improperly sealed seams in the rear body upper pillar and work down the pillar into the interior of the body also check for skips in the sealer around the quar ter window opening mouldings Press body sealer into the seam around the upper finish moulding cap as indicat...

Page 437: ...DY AND SHEET METAL 67 REINFORCEMENT REAR FLOOR PAN 58x119 Fig 142 Town and Country Sedan Floor Pan Rear Corner REAR FLOOR PAN WHEELHOUSE FRONT FLOOR PAN 58x120 Fig 143 Town and Country Floor Pan Front of Wheel House MyMopar com ...

Page 438: ...o the glass run channel Press a bead of rope type seal into moulding seams and clean off surplus While rear pillar garnish moulding is removed inspect the outer D shaped open ing as shown in Figure 145 2 This opening should be filled with caulking putty 53 TAIL GATE WEATHERSTRIP The tail gate weatherstrip is designed to fit under a lip and into a channel at the sides of the tail gate opening At it...

Page 439: ...CHRYSLER SERVICE MANUAL BODY AND SHEET METAL 69 SEALER 58x122 Fig 145 Tail Gate Glass Runs and Mouldings TOPSIDE QUARTER COVER 58x123 Fig 146 Convertible Top Seams MyMopar com ...

Page 440: ...nches long above the deflector through the lower run channel and its retainer Build a dam of body sealer at the rear end of lower run channel seal and garnish moulding screw slots Reinstall trim sliding glass upper run channel and garnish moulding On Convertible top seams water seepage may occur along the seams of the top and may be corrected by applying convertible top seam seal er into the seams...

Page 441: ... should be taken to adjust both sides equally to maintain parallelism between header panel and windshield frame Before making this adjustment loosen top header at windshield to remove tension from linkage d Top Header Panel Adjustment If the header does not close easily on dowels loosen the header panel to side rail screws and shift header panel forward or backward as re quired If this is not poss...

Page 442: ...atherstrip is made at the power guide link adjusting plate Fig 148 with top in partially raised position Refer to Figures 147 and 148 for door glass to roof rail weather strip clearance NOTE On Imperial Models there is no power guide link Adjust the lower outside power link for fore and aft and up and down movement To de crease or increase clearance between quarter window glass and roof rail weath...

Page 443: ... The top if raised should start to lower Repeat this test with green wire The top in lowered position shoud start to rise If top operates during these tests but fails to operate when control switch lever is moved to right or left the switch is at fault and should be replaced If top fails to operate during these tests follow procedure outlined in Paragraph 57 59 and 62 62 TESTING WIRES BETWEEN CONT...

Page 444: ...6 DARK GREEN WHITE STRIPE TOP LIFT MOTOR CONVERTIBLE ONLY 16 BLACK WHITE STRIPE REAR WINDOW DEFROSTER MOTOR 16 BROWN WHITE STRIPE REAR WINDOW DEFROSTER SWITCH VARIABLE SPEED WINDSHIELD 1 6 WIPER SWITCH BLACK i 16 BLUE VARIABLE SPEED I 4r YELLOW WINDSHIELD WIPER SJi MOTOR 1 R E D WHITE STRIPE 12 RED WHITE STRIPE TO BATTERY STARTER RELAY TOP LIFT SWITCH AND 25 AMPERE CIRCUIT BREAKER CONVERTIBLE ONLY...

Page 445: ...he Section covering these items in this Manual To service the tail gate and rear quarter window refer to Figure 151 and proceed as follows SERVICE PROCEDURES 65 TAIL GATE a Removal To remove the tail gate proceed as follows NOTE On electric operated models disconnect battery ground cable and wiring at tail gate Lower tail gate glass open tail gate so that tail gate is in straight up position WEATH...

Page 446: ...rms into glass channel slots and install the retain ing washers Lower the tail gate glass to fully lowered position Close tail gate Check opera tion of rear window regulator and fit of rear window glass in upper glass run channel by raising and lowering the rear window glass NOTE The rear window may be repositioned by loosening 4 adjusting screws and by adjust ing the regulator If glass binds in c...

Page 447: ...the rear quarter window glass remove old sealer from weatherstrip and window frame Apply a bead of new sealer all around window opening Install glass in the weatherstrip and insert pull cord in sealing lip slot as shown in Figure 154 The pull cord should be installed so ends of cord are on bot tom and outside of vehicle Slide window glass and weatherstrip into position in window opening Press glas...

Page 448: ...DJUSTMENT WIRING SIGNAL LIGHT 18 WINDOW LIFT CIRCUIT BREAKER 20 AMPERE CIRCUIT BREAKER 15 AMPERE CIGAR LIGHTER SEAT ADJUSTMENT CIRCUIT BREAKER 20 AMPERE 57x598 LEFT TAIL UGHT 18 BLACK Fig 156 Imperial Basic Body Wiring RIGHT REAR DOOR WINDOW LIFT SWITCH RIGHT REAR DOOR AUTOMATIC SWITCH RIGHT FRONT DOOR WINDOW LIFT MOTOR RIGHT FRONT DOOR WINDOW LIFT SWITCH HEATER SWITCH FREEZE UP VALVE HEATER MOTOR...

Page 449: ...to the requirements of API classification For Service MS b An oil of proper SAE number in accord ance with the recommendations for the antici pated temperature as shown in Paragraph 1 The factory does not recommend the use of any lubricant which does not have both an SAE designation and an MS service classification on the container 3 MULTI VISCOSITY OILS When using multi viscosity oils be sure tha...

Page 450: ...0 SAE 20W SAE 10W SAE5W Retain original factory oil in crankcase duringfirst1 000 miles of operation If necessary to add oil during initial period use recommended viscosity oil shown above for lowest anticipated temperature KEY TO LUBRICANTS CL Chassis Lubricant EO Engine Oil MP Gear Lubricant Multi Purpose UJG Universal Joint Grease HGL Hypoid Gear Lubricant WBG Wheel Bearing Grease SPECIAL ATTEN...

Page 451: ...ow oil filter with replaceable element SHROUD FUU MARK WING NUT I WASHER v WING SCREW FILTER ELEMENT ENT I BOLT T SILENCER BODY BRACKET 58x182 52 x 587 Fig 3 Carburetor Air Cleaner is used on ALL Chrysler and Imperial models The oil filter element should be changed every 5 000 miles to coincide with an engine oil change after the initial engine oil change During cold weather operation or when the ...

Page 452: ...fle on the reservoir Whenever the pump is drained or removed for servicing the pump must be filled up to the full mark indicated on the filler neck of reservoir before and after the engine is started Use Automatic Transmission Fluid Type A NOTE Maintain fluid level in pump as rec ommended and replenish as necessary with specified lubricant When reservoir cover is re moved do not permit dirt to fal...

Page 453: ...Saturate wick as shown in Figure 4 with oil and replace 52x590A TORQUE CONVERTER DRAIN Fig 4 Speedometer and Cable Lubrication Points Unit positioned to show Lubrication Points Fig 5 TorqueFlite Transmission and Torque Converter Drain Points c Speedometer Cable Use MOPAR All Weather Speedometer Cable Lubricant Disconnect cable at speedometer housing as shown in Figure 4 and remove shaft Coat shaft...

Page 454: ...er hole with Multi Purpose Gear Lubricant SAE 90 for tem peratures above 10 F SAE 80 for tempera tures below 10 F and SAE 75 for tempera tures below 30 F Do not overfill 17 PARTS REQUIRING NO LUBRICATION Refer to Lubrication Cha rt as shown in Fig ure 1 and to the following information a Rubber Bushings Do not lubricate these bushings They are de signed to grip the contracting metal parts firmly a...

Page 455: ...ng The Music Master Model 851 Fig 3 has five tubes and one transistor It includes a variable tone control with manual tuning and push button tuning CIVIL DEFENSE SYMBOLS 640 KC 1240 KC ON OFF VOLUME CONTROL l MANUAL TUNING TONE CONTROL LOCAL SEARCH TUNING SPEAKER CONTROL DISTANCE SEARCH 57x431 A TUNING Fig 1 Operating Controls 922 ON OFF VOLUME CONTROL CIVIL DEFENSE SYMBOLS 640 KCQ1240 KC MANUAL T...

Page 456: ...RT OF VEHICLE MOUNTING SCREWS BEZEL TO PANEL 2 REQ D 57x434 A Fig 4 Radio Model 851 SPEAKER GRILL SPEAKER MOUNTING SCREW 4 REQ D CONTROL KNOB CONTROL KNOB SPEAKER TERMINALS AND TERMINAL BOARD SPEAKER LEAD A LEAD MOUNTING SCREWS BEZEL TO PANEL 2 REQ D DIAL LIGHT C O N N E C T TO ORANGE LEAD IN HARNESS TO ACCESSORY TERMINAL ON TEMP GAUGE NOT SUPPLIED IN KIT PART OF VEHICLE MOUNTING SCREWS 4 REQ D Fi...

Page 457: ...ge Connect rear speaker wire plug Connect pilot lamp lead to orange wire from harness Plug in antenna lead as shown in Figure 9 Install speaker to grill panel and connect speaker wires Then fasten grill panel to dash Turn on radio to warm up Adjust antenna compensator CAUTION Antenna compensator must be properly adjusted for satisfactory operation of radio MOUNT UNDER GENERATOR GROUND DO NOT CONNE...

Page 458: ...n Adjustment fifteen minutes Unlock push buttons by pulling them out Manually tune in desired station and relock push buttons Repeat operation on other push buttons 8 LOCAL AND DISTANT PUSH BUTTONS Local push button fill tune only strong stations Distant push button will tune all stations with in range of radio NOTE Do not set end push buttons In order to obtain the best performance from search tu...

Page 459: ... FROM 540KC TO I600KC I F FREQUENCY 262 5KC VOLTAGE MEASUREMENTS 1 VOLTAGES IN PARENTHESIS ARE MEASURED WITH VTVM 2 ALL OTHER DC VOLTAGES MEASURED WITH A 20 000 OHMS VOLT METER 3 ALL AC VOLTAGES MEASURED WITH 1000 OHMS VOLT METER 4 ALL VOLTAGES MEASURED WITH RESPECT TO CHASSIS 5 ALL VOLTAGES MEASURED WITH 13 2 VOLTS INPUT WITH NEGATIVE GROUND DUMMY ANTENNA 40UUF SERIES AND 40UUF SHUNT AT ANTENNA S...

Page 460: ...OHMS VOLT METER 8 VOLTAGE SHOWN IN PARENTHESIS ARE MEASURED AS IN A ABOVE EXCEPT THAT RELAY IS IN THE S SEEK POSITION C VOLTAGES SHOULD BE WITHIN 2 0 OF VALUES SHOWN 0 SENSITIVITIES ARE MEASURED AS FOLLOWS I USING A 40UUF SERIES AND 40UUF SHUNT DUMMY ANTENNA FOR MEASURING ANTENNA SENSITIVITY FOR ALL OTHER MEASUREMENTS FEED THE SIGNAL GENERATOR OUTPUT THROUGH A 0 IUF CAPACITOR 2 WITH 400CPS 30 MODU...

Page 461: ...eption is limited to a few strong local stations adjust the antenna trimmer to align the receiver to the antenna with antenna fully extended If the reception is not improved pro ceed with the following steps Substitute a test antenna remove the receiver and substitute test tubes as outlined in Paragraph 10 b 12 RADIO RECEPTION IS NOISY OR ERRATIC The cause of noisy or erratic reception can be isol...

Page 462: ...57x521 RAIN TRAP PLENUM CHAMBER FRESH AIR DOOR FRAME DEFLECTOR OUTLET DUCT LEFT OUTLET fr f HEATER DEFLECTOR OUTLET BEZEL AND RETAINER WATER CONTROL VALVE DUCT DOOR INSIDE DUCT FRESH AIR DOOR DEFLECTOR OUTLET DUCT RIGHT HEATER CONTROL KICKPAD OUTLET OPTIONAL FRESH AIR DOOR FOOT PEDAL DUCT DOOR AND WATER CONTROL VALVE CONTROL CABLES DIST DUCT DAMPER CONTROL CABLE DEFLECTOR CONTROL BLOWER SWITCH 57x...

Page 463: ...nual portion of the receiver will tune in distant stations that the antenna is fully extended and that the an tenna trimmer is adjusted It may also be nec essary to move the vehicle to a location where normal station signal strength is available out of and away from steel reinforced buildings If the touch tuner mechanism starts and runs continuously without the LOC and DIST buttons having been ope...

Page 464: ...th the heater in the car with the rear window defroster so that when air is drawn through the blower from inside the car it is recirculated on the rear window glass INSTANT HEAT CONDITIONAIRE MODEL 803 HEATER The heater assembly consists of a cylindrical stainless steel heat exchanger with a burner assembly mounted at one end The burner is equipped with a nozzle to atomize the fuel a mixer can to ...

Page 465: ... blow er fan and turning the cam clockwise this is a left hand thread Always install a new cam with new breaker points After installing the new cam align the three studs on the back of the breaker points casting with the three eyelets in the end of the motor housing and fit the new breaker points over the motor studs Replace the two ground wires on the stud and tighten the mounting nuts secure ly ...

Page 466: ...e terminals of the solenoid fuel valve and pull the ignition cable off the spark plug Disconnect the fuel line from the fitting on the burner cast ing The fuel line should not be removed from the grommet in the cover unless it requires re placement Remove the burner blower hose Loosen the clamp attaching the burner as sembly to the heat exchanger and break the seal formed by the gasket The burner ...

Page 467: ...he electrodes are burned this indicates an im properly directed spray and nozzle or nozzle seat is at fault c Disassembly of Burner Assembly Fig 18 Remove the two screws from the plug re tainer cap and remove the spark plug and gas kets Unscrew the fuel inlet fitting and remove the screen from the casting Remove the cover of the solenoid and lift out the solenoid coil and sponge rubber gasket Fig ...

Page 468: ...s in line with the guide on the casting Tighten spark plug cap attach ing screws evenly and securely Using an 085 feeler gauge adjust the spark plug gap by bending the ground electrode Do not bend SCREW TUBE BURNER COVER If 57x488 Fig 19 Removing or Installing Coil and Gasket SCREWS GASKET 57x489 Fig 20 Removing or Installing Plunger spark plug electrode Fit the rubber vent tube into the opening i...

Page 469: ... cam on the base end of the control shaft making sure the shaft is completely free to revolve and take its normal position at room temperature about 75 to 85 F With the plastic cam free on the shaft and the microswitch down move the control cable linkage as far as it will go to the left and hold in this position While holding the linkage turn the plastic cam in a counter clockwise direction until ...

Page 470: ...reaker points are bad If there is no spark at the test plug it can be assumed that the nozzle is clogged or the spark plug shorted out and the burner assembly must be removed from the heater CAUTION Be sure the burner is properly grounded and avoid touching any part of the assembly during the following tests Remove the burner assembly from the heat exchanger Pull the fuel line out of the heater ca...

Page 471: ... MUCH SMOKE FROM HEATER Excessive smoking and carbon are caused by a slow combustion air motor or a defective nozzle This condition could also be caused by delayed ignition resulting from spark plug elec trodes which are badly burned out of adjust ment or shorted with carbon The plug gap should be 085 inches and the electrode should be clean and approximately centered in the in sulator of the spar...

Page 472: ...mostat out of adjustment b Fuel line pinched or clogged 36 HEATER BURNS INTERMITTENTLY HEAT OUTPUT IS TOO GREAT a Thermostat out of adjustment or shorted out 37 HEATER BURNS CONTINUOUSLY HEAT OUTPUT IS TOO LOW a Clogged fuel nozzle b Low fuel pressure 38 ODOR OF BURNED GASOLINE IN CAR a Leaking connection in exhaust tube b Broken or loose burner clamp 39 EXCESSIVE AMOUNT OF SMOKE FROM HEATER EXHAU...

Page 473: ...er Heat 16 Pressure Relation Chart 17 Testing Electrical Switches and Control Circuits 18 Removal and Installation of Air Conditioning Unit 20 Removal and Installation of Expansion Valve 21 Removal and Installation of Compressor 22 Testing Procedures 26 Thermal Switch Operation Test 28 Overall Performance Test 29 Air Leaks 30 Service Diagnosis 32 DATA AND SPECIFICATIONS COMPRESSER Location Right C...

Page 474: ...or M W and Tubes C 3363 WRENCH SET Flare Nut Open End Box and 1 Openings two per set C 3420 ADAPTOR Refrigerant Cylinder Valve to Test Hose C 3421 CLIP Set of two Attaching Thermometer to Tube C 3429 SCALE Refrigerant Weighing C 3473 SEAT PULLER and Installing Tool C 3478 CUTTER Tube C 3616 PALM GRIP RATCHET C 3620 SCREW DRIVER BIT C 3621 SCREW DRIVER BIT C 3622 FLEXIBLE DRIVE C 3623 THERMOMETER S...

Page 475: ... air door air is drawn through both the cooling and heating coils by the Centrifugal Blower Fig 3 The air heated by the heating coil is then forced into the distribution duct for temperature dis tribution OUTSIDE AIR COWL VENT INTAKE HEATING CORE TO DISTRIBUTION DUCTS WATER FLOW CONTROL VALVE EVAPORATOR COIL ONE PIECE MOLDED PLASTIC HOUSING BLOWER EXPANSION VALVE COMPRESSOR LINES 57X587A Fig 1 Hea...

Page 476: ...L CIRCUIT WHEN PRESSURE IS NOT REQUIRED RECIRCULATING DOOR CLOSED 57X499 Fig 7 Hydraulic Circuit for Power Piston 1 OPERATING CONTROLS The controls for the heater air conditioner are partially power actuated The main control lever operating through a cable operates the water temperature valve and also the fresh air and recirculating door through two electric switches the solenoid valve and power p...

Page 477: ...ER STRAINER DRIER LINE VALVE 57x593 Fig 9 Heater Air Conditioning Schematic of Components 2 POSITIONING CONTROL LEVER a Moving the main control lever from Off to Cold No 2 position with the toggle switch in Cooling position the following se quence of operation will result 1 Compressor clutch and water valve heating element will be energized Figs 9 and 10 2 Hot water shut off to heater core 3 Fresh...

Page 478: ...CLOSED NO 2 SWITCH CLOSED HEAT CLUTCH CIRCUIT OPEN FOOLER CIRCUIT OPEN FRESH AIR DOOR CLOSED RECIRCULATING DOOR OPEN NO 1 SWITCH OPEN NO 2 SWITCH CLOSED COMPRSSOR CLUTCH 18 BLUE THERMAL SWITCH FOOLER ELEMENT WATER VALVE 1 SWITCH NO 2 RHEOSTAT RESISTANCE DECREASES AS J VyVi WATER VALVE IS OPENED 18 WHITE 18 WHITE NORMALLY CLOSED NORMALLY CLOSED FRESH AIR AND RECIRCULATING DOOR SOLENOID ENERGIZING O...

Page 479: ...40 Fig 12 Lower Distribution Duct and Nozzle ment panel can be rotated through a full circle The grilles also have hinged deflectors which can be used to direct air up along the roof or at the occupants of the front seat 4 TEMPERATURE CONTROL For summer operation the air will be dehu midified and cooled as it passes through the evaporator coil and then reheated by the heater core to a temperature ...

Page 480: ...ut from side opposite en trance with compressed air b Radiator Check radiator pressure cap A 14 pound pres sure cap and a 180 F thermostat is used in all models Check cooling system and add water or anti freeze to maintain proper level The cooling system should be protected to a tem perature of 16 above zero for summer lower for winter c Compresosr Belt Check compressor belt tension Refer to Secti...

Page 481: ...ol SP 2922 to center connection of gauge set manifold Dis connect manifold hose from suction service valve leaving service port open CAUTION Test cap must be absolutely clean before in stallation on gauge set connection Wash with solvent and blow dry Test cap is meter drilled and wire or similar instrument should never be used to open the vented orifice If this is done a doubtful gauge reading may...

Page 482: ...ockwise to be in operating test position After completion of test turn both suction and discharge service valves counter clock wise until they are fully back seated Open both hand shut off valves on manifold to re lease pressure on manifold gauge hoses Dis connect and remove hoses from both service valves Replace valve stem and service port caps and both service valves Adjust fan belt Check both c...

Page 483: ...s necessary only where supply in system is very low or when system has been evacuated The Tool C 3569 Test Torch uses petro leum gas and does not require generating to light Just turn valve on light it and adjust to small flame Move leak detector sniffer tube over all connections When leak is found flame in burner will turn bright green Move detector tube around connection to determine magnitude o...

Page 484: ...dropped to zero before attaching hose to vacuum pump Connect eight foot test hose to center fitting of gauge set manifold and to connection on vacuum pump Tool C 3652 Open both dis charge and suction service valves about one turn rotating both valve stems clockwise Open both gauge set manifold hand valves turn counter clockwise Start vacuum pump and observe compound gauge Operate pump until gauge ...

Page 485: ...gerant gas above the liquid in a tank can hold as much as seven times amount of moisture as it does in liquid phase This means starting with a full tank of Re frigerant 12 containing 6 to 10 PPM mois ture in the liquid phase the vapor above the liquid can contain 42 to 70 PPM As this vapor leaves the tank and is charged into the Air Conditioning System the moisture enters the system with the vapor...

Page 486: ...gine operation with liquid flowing through the moisture detecting eye and if the dot of eye shows pink excessive moisture is present in system If system is dry or contains a minimum of moisture the dot of eye will slowly change to light blue indicating the system contains 10 to 20 PPM of moisture When dry eye shows a dark blue the same color as corresponds to the dot on eye it is indicative that s...

Page 487: ...N COMPRESSOR MOISTURE DETECTING EYE WITH DRIER CARTRIDGE DISCHARGE SERVICE VALVE AT CONDENSER 57 X 503 Fig 18 Moisture Detecting Eye and Drier Cartridge Installation Schematic Drawing 57x629 Fig 19 Charging the System Typical follows Assemble moisture detecting eye and drier cartridge to refrigerant tank Make sure the arrow located on Dry Eye unit points in direction of flow from tank Close refrig...

Page 488: ...lower is on low position Observe suction gauge pressure As evapo rator temperature lowers suction pressure will gradually lower and fluctuate down to between 20 to 10 psi The thermal switch contacts should be open and de energize the clutch When this happens there will be a slight increase in the engine speed which can be noted by the ear or observed on the tachometer Also when the clutch de energ...

Page 489: ...5 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 Press of Refrig 39 7 40 7 41 7 42 6 43 6 44 6 45 6 46 6 47 8 48 7 49 8 50 9 52 0 53 1 55 4 56 6 57 1 57 7 58 9 60 0 61 3 62 5 63 7 64 9 66 2 67 5 68 8 70 1 71 4 72 8 74 2 75 5 76 9 Temp F 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 Press of Ref...

Page 490: ...re than 15 degrees super heat NOTE Subtracting super heat at E B from D will equal 19 TESTING ELECTRICAL SWITCHES AND CONTROL CIRCUITS Refer to Figure 20 and Chart III and proceed as follows With test light Tool C 744 located on windshield attach one end of lead to sole noid valve terminal and the other to ground Start engine and adjust engine speed to 1200 r p m Turn toggle switch to Cool positio...

Page 491: ...Tubing Copper tubing must be attached to car struc ture A flexible connector vibration elimina tor has been placed on the condenser side of compressor to guard against breakage at that point d Brazing the Joints Discharge system before using a torch to braze leaking joints Avoid excessive heat when using an acetylene flame to solder or braze a joint The usual precautions should be followed be fore...

Page 492: ...ins Discharge the System as outlined in Paragraph 11 Disconnect suction and liquid line Remove remaining evaporator housing flange to dash screws and remove evaporator by depressing fresh air door with screw driver as evaporator is rolled out of dash pocket NOTE Whenever the air conditioning unit is removed from car cooling coil fins should be cleaned and the water outlet drains should be checked ...

Page 493: ... to prevent moisture from entering system b Testing Expansion Valve Equipment Required Fig 21 Source of dry air 90 to 250 psi Moisture detecting eye with drier cartridge Air Conditioning gauge set manifold Transmission throttle pressure gauge Compressor capacity test cap with 020 inch bleed hole Container with ice and water to hold tem perature at 32 degrees F 4 inch copper tub ing and fittings as...

Page 494: ...Reinstall expansion valve control bulb and equalizer lines in the reverse order of removal Tighten all connections securely and sweep and charge system as indicated in Paragraphs 13 and 17 NOTE The expansion valve thermal bulb must be firmly held in the well otherwise the sys tem will become flooded Make sure the thermal tube is insulated correctly 27 REMOVAL AND INSTALLATION OF COMPRESSOR Fig 22 ...

Page 495: ... drift or plastic hammer VALVE PLATE AND HEAD REMOVING UP CYLINDER HEAD CYLINDER HEAD PILOT STU TOOL VALVE PLATE ASSEMBLY VALVE PLATE ASSEMBLY 57x683 Fig 24 Replacing Head Gasket 57x682 Fig 23 Removing Compressor Head NOTE Use tab Fig 23 located at side of cylinder head to tap off head If when lifting the cylinder head the valve plate does not separate from head separate head from plate by using a...

Page 496: ...emoving Clutch Assembly from Compressor Loosen and remove the belts Remove the upper right shroud section Remove special locking bolt and washer from compressor crankshaft at front center of clutch Do NOT damage brushes when removing or installing clutch While supporting clutch assembly with one hand remove the pulley with inch cap screw screwed into end of clutch shaft c Removing and Installing D...

Page 497: ...CHRYSLER SERVICE MANUAL AIR CONDITIONING 25 MyMopar com ...

Page 498: ... opened two turns and no pres sure is indicated on gauges the system is empty and has a leak Evacuate charge with sweep test charge locate and correct leak Evacuate and charge with 3 pounds refrigerant 12 HOT CIRCUITS ENGINE RUNNING TEMPERATURE CONTROL OFF SWITCH NO I OPEN SWITCH NO 2 CLOSED 58x735 FRESH AIR DOOR CLOSED RECIRCULATING DOOR OPEN CLUTCH CIRCUIT OPEN FOOLER CIRCUIT OPEN SOLENOID VALVE...

Page 499: ...D SOLENOID VALVE CIRCUIT CLOSED TO THERMAL SWITCH AND CLUTCH TEMFHATUM CONTtOl 58x738 Fig 30 Checking the Clutch Circuit 58x737 Fig 29 Checking the Water Valve Lever CAUTION Do not allow clutch hot wire to ground even momentarily will cause a burn out of No 1 micro switch if circuit is energized Check clutch circuit at clutch white wire connector Fig 30 If hot open circuit in thermal switch circui...

Page 500: ... indicated If cold reach No 1 micro switch by hand switch nearest Off position With the control lever in the Cold position move with fingers the micro switch actuating bar towards switch and release sev eral times A clicking sound should be heard as switch opens and closes contact If no click ing sound takes place it indicates switch is burned out and must be replaced If clicking sound takes place...

Page 501: ...to rheostat connections on control Check ground connec tion see wiring diagram Check recirculating door to be sure it is closed and fresh air door is open If recircula tion door does not go completely closed adjust bellcrank to door linkage All doors and windows must be closed to assimilate the operation of the air conditioning system with 100 fresh air on the street at 25 miles per hour Place one...

Page 502: ...er gized Check the water valve fooler circuit It should be de energized and the light will be out Check the outlet temperature It should have increased still higher Move the control lever to the Off position Check the recircu lation door It should be open and fresh air door should be closed If recirculation door re mains closed attach the yellow wire to the se lector switch see wiring diagram Fig ...

Page 503: ...69 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 53 54 54 54 54 55 55 55 56 56 56 57 57 57 57 57 70 X 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 54 55 55 55 55 55 55 56 56 56 57 57 57 57 57 58 WET BULE 71 X 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 55 56 56 56 56 56 56 56 56 57 57 57 57 57 58 58 72 X 55 55 55 55 5...

Page 504: ...ansion valve equalizer tube plugged c Test compressor capacity c Expansion valve thermal bulb loose in coil d Test for restriction in strainer drier as outlined in Paragraph 24 Inspect lines for d N o t enough oil kinks e Bad compressor reed valves e Test expansion valves as outlined in curTTON PRESSURE Paragraph 26 Clean or replace valve 4 L L O W SUCTION PRESSURE a Not enough refrigerant 37 BLOW...

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