Chrysler CHRYSLER 300 1971 Chassis Service Manual Download

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Summary of Contents for CHRYSLER 300 1971

Page 3: ...t can be found at the beginning of the particular section Example M T S C 69 3 may be called out in the beginning of the subject matter This refers to the year zy 1969 and the session issue number 3 The Master Technician Service Conference is a training supplement available wherever Chrysler Corporation automotive services are available It should be clearly understood that the Master Technician s ...

Page 4: ... stamped on the front of the block just below the left cylinder head All 383 426 and 440 cubic inch engines have the serial numbers stamped on the cylinder block pan rail at the left rear corner below the starter opening On all engines information identifying undersized crankshaft oversized tappets low compressibn oversized cylinder bores engine built that day the shift and 10 000 day calendar is ...

Page 5: ... 7 114 7 112 7 314 8 8 8 114 8 112 8 314 9 9 114 9 114 9 112 9 314 10 10 114 10 112 10 112 10 314 11 114 11 314 12 17 17 112 18 18 112 19 19 112 20 20 112 2 1 21 112 22 22 112 23 23 112 24 24 112 25 25 112 26 26 112 27 27 112 28 29 30 14 114 14 112 15 15 112 15 314 16 114 16 314 17 17 112 18 18 114 18 314 19 114 19 112 20 20 112 20 314 21 114 21 314 22 22 112 23 23 114 24 114 25 CAPACITY CONVERSIO...

Page 6: ...INTRODUCTION AND GENERAL INFORMATION 5 z 5 r zyxwvu m zyxwvutsr 2 m c zyxwvuts c I n 3 zyxwvuts u 3 c 0 Y m v 0 m Q 0 c E na m I 0 0 0 0 MyMopar com ...

Page 7: ...rade mark shall be legible in the center of the bolt head and not over 1 3 of the cross flats dimension 1 zyxwvutsrqponml 80 zyxwvutsrqp I 120 zyxwvutsrq Fig 3 Bolt Head Identification GRADE 8 zyxwvu 60 PB283 SIZE GRADE 1 GRADE 5 GRADE 8 6 32 8 32 10 24 10 32 12 24 1 4 20 1 4 28 5116 18 5 16 24 10 12 Below dotted line Ft Lbs 17 20 25 40 130 185 45 130 185 100 200 280 110 Above dotted line In Lbs z...

Page 8: ...easonable types of driving conditions Since these conditions vary with the individual car owner s driving habits the area in which the car is operated and the type of service to which Page LUBRICATION AND MAINTENANCE GUIDE LUBRICATION AND MAINTENANCE 2 SCHEDULES Normal S e r v i c e 3 Trailer Towing and Severe Service 4 MANIFOLD HEAT CONTROL VALVES 19 MATERIALS ADDED TO ENGINE OILS 14 PARKING BRAK...

Page 9: ...e oils contain sufficient chemical additives to provide maximum engine protection Both the SAE grade and the API designation must be found on the container Gear Lubricants The SAE grade number also indicates the viscos ity of Multi Purpose Gear Lubricants defined by MIL L 2105B An example is SAE 75 which is a light viscosity lubricant zyxw Lubricants Greases Semi solid lubricants such as specified...

Page 10: ...ge Replace Fluid and or Lubricate Service 12 X 12 X Miles whichever EngineCrankcaseOil occursfirst Every Engine Manifold Heat Control Valve X 13 19 X Replace lining if necessary Vehicles equipped with Fresh Air Induction System Floor Mounted Gearshift Controls Parking Brake Mechanism Speedometer Cable Pointsthat Should Not Be Lubricated zyxwvut 24 X 11 X 26 X 27 MyMopar com ...

Page 11: ...ine Manual Transmission Valiant All Other 360 Cu In Engine Manual or Automatic Transmission All Air Conditioning or Maximum Cooling All 360 Cu In Engine Police Taxi All 383 2 BBL Cu In Engine Manual or Automatic Transmission All Air Conditioning Barracuda Satellite Maximum Cooling Barracuda Satellite Fury Chrysler Fury Chrysler 383 2or 4BBL Cu In Engine Police Manual Transmission 383 2 BBL Only Au...

Page 12: ...Engines 4 BBL 16 3 pts All 440Cu In Engines 19 pts 426 Hemi 16 8 pts 340 and 360 Cu In Engines 16 3 pts 12qts 13 1 4 qts 12 1 2 qts 12 1 2qts 13 1 4 qts 14 1 4 Qts 13 Qts 12 Qts 15 Qts 14 1 4 Qts 14 1 2 Qts 14 1 4Qts 14 pts 14 pts 14 pts 13 1 4 pts 15 3 4 pts 15 3 4pts 15 3 4 pts 13 1 4 pts 13 1 4 pts 13 1 2 pts NOTE Models equipped with Auxiliary Cooler Add approximately 1 2 pint to above quantit...

Page 13: ...0 6 LUBRICATION AND MAINTENANCE rn I zyxwvutsr 3 zyxw u II Li T z t MyMopar com ...

Page 14: ... parts of the underbody CAUTION zyxwvutsr Do not attempt to raise one entire Fig 4 Upper and lower Ball Joint lubrication Satellite and Barracuda Models NP155 Fig 6 Upper and lower Ball Joint lubrication Imperial Models ride of the vehicle by placing a jack midway between front and rear wheels This practice may result in permanent damage to the body Bumper Jack The bumpers are designed to accept a...

Page 15: ...main for future regularly scheduled lubrication 3 Fill and flush the joint with lubricant If high pressure equipment is used care must be taken to fill and flush the joint slowly to avoid damaging the seals IE ROD END FITTINGS STEERINGGEAR ARM BALL Fig 8 Steering Linkage Lubrication Satellite and Barracuda Models Fig 10 Steering Linkage Lubrication Imperial Models STOP FILLING WHEN GREASE BEGINS T...

Page 16: ...andard and Sure Grip The lubricant installed in the rear axle at time of assembly is a high quality product and regular Fig 12 Filler Plug Location 8 1 4 Inch Axle NP157A Fig 14 Drain and Filler Plug Location 9 3 4 Inch Axle ly scheduled changes of the lubricant are not re commended in vehicles where operation is classi fied as normal passenger car service The only exceptions however would be wher...

Page 17: ...LI Fig 15 Brake Master Cylinder For vehicles used for police taxi or trailer tow ing service the axle fluid level should be checked every 3 months or 4 000 miles whichever occurs first The lubricant should be drained and axle refilled with the specified lubricant every 36 000 miles If the axle is submerged in water such as on a boat launching ramp where water can enter the axle vent and contaminat...

Page 18: ...Brake Hoses Inspect brake hoses for cracking abrasion cuts or tears in the outer covering Examine all con nections for leakage Correct leakage and re place hose where cover damage exposes the fabric braid PARKING BRAKE MECHANISM Valiant models use a hand operated parking brake lever Fig 16 Imperial Chrysler Fury Satellite and Barracuda Models use a foot operated lever Figs 17 and 18 Pivot points i...

Page 19: ... operation Drain zyxw V 8 engine cooling sys tem by removing drain plugs in sides of cylinder block and opening drain cock in lower radiator tank On 6 cylinder engines remove the single drain plug in right side of engine and open drain cock in lower radiator tank Discard old solutions Flush the system thoroughly with water If there is an indication that the system contains a consid erable amount o...

Page 20: ...nsafe nightime driving conditions If a vehicle is to be loaded abnormally such as for a vacation trip or with a salesman s products the headlight aiming should be checked and ad justed to serve the new conditions Refer to Lighting System Group 8 for adjusting procedures Fig 21 zyxwv Shaded Area Covers Region Where 4 10 degrees F During Some Winter Months Minimum Temperatures M a y Be Consistentfy ...

Page 21: ...aminants reduce the lubricating qualities of the oil causing excessive wear which can material ly affect the operating efficiency of the engine To provide maximum protection to engine parts it is recommended under normal operating conditions that engine oil be drained and replen ished with new oil of the proper viscosity and months or 4 000 _ _ zyxw API classification every three 3 miles whichever...

Page 22: ...uency of Oil and Oil Filter Change 1 Police Taxi and Limousine Operation a Change oil every two months or 2 000 b Change oil filter at each oil change miles whichever occurs first 2 Police Equipped with High Performance Engine NR80 Fig 23 Engine Oil Filter 378 340 and 360 Cu In Engines Except Valiant Models c Fig 25 Engine Oil Filter 383 and 440 Cu In Engines a Change oil every month or 2 000 mile...

Page 23: ...T AIR CLEANER P Y m A Fig 27 Crankcase Ventilation System 318 Cu In Engine VENTILATOR VALVE VACUUM VENT LINE PY774A Fig 2 9 Crankcase Ventilation System 383 Cu In Engine with 2 Barrel Carburetor A closed crankcase inlet air cleaner with a hose connecting it to the carburetor air cleaner housing provides the air inlet for the system The crankcase inlet air cleaner is also provided with inlet fittin...

Page 24: ...uretor passages and crankcase inlet air cleaner VENTILATOR VALVE VENTILATOR VALVE HOSE CRANKCASE INLET AIR CLEANER PY776A Fig 31 Crankcase Ventilation System Three 2 Barrel Carburation 1c I Fig 33 Check Vacuum at Ventilator Valve Every six months the system must be tested for proper operation and cleaned if necessary This includes inspecting the operation of the valve checking the hoses and carbur...

Page 25: ...cked Install a new Chrysler Ven tilator Valve Part Number 3577098 or equivalent LATOR VALVE 4 With a new ventilator valve installed if the pa per is not sucked against the crankcase inlet air cleaner opening in the rocker cover with noticea ble force it will be necessary to clean the ventila tor hose vent tube and passage in the lower part DO NOT ATTEMPT TO CLEAN THE VENTI I P Fig 35 Shake Ventila...

Page 26: ...ctrical for tests and adjustments AIR CLEANER Clean and or replace if necessary See Carburetor Air Cleaners 5 CRANKCASE VENT VALVE Replace Check function of the entire crankcase ventilating system See pagel6 6 IGNITION TIMING Check timing and set as required See decal located in engine compart ment or Ignition System Group 8 Electrical 7 IDLE RPM Check after carburetor or igni zyxwvu I i NU549A Fi...

Page 27: ... Limousine For vehicles or type of service listed above clean and inspect filter element every engine oil change and replace every year IlTER ELEMENT zyxw I i d 1 HOUSING PY783 Fig 41 Carburetor Air Cleaner Dry Type FILTER ELEMENT J PB137 Fig 43 Cleaning Filter Element Disconnect the air cleaner hose at the air cleaner Remove cleaner from carberetor and re move filter element from cleaner Examine ...

Page 28: ...so apply same type of cleaner to fast idle cam and pivot pin to remove dirt oil and any other deposits that may have collected and cause s t i c h g or erratic motion This service will assure freedom of movement of the choke mechanism FUEL FILTERS The fuel filters Figs 45 46 and 47 are of the disposable type 318 Cu In Engines Fuel Filter is on suction side of Fuel Pump Under normal operating condi...

Page 29: ...oint Except Imperial NP332 Manual The lubricant installed in the steering gear at time of assembly is a high quality product and regularly scheduled changes are not required Every six months remove plug in steering gear housing Fig 52 and check lubricant level Lubri cant should cover worm gear If lubricant is below prescribed level replenish with Multi Purpose Gear Oil SAE 90 as defined by MIL L 2...

Page 30: ...ges therefore will not be required If the vehicle is used for police taxicab limousine or other commercial type operation or for towing trailers the transmission fluid should be changed every 36 000 miles Fluid Level Check The fluid level should be checked every six months The correct level is at the bottom of the filler plug hole Fig 55 If lubricant is below this specified level replenish with au...

Page 31: ...ransmission Fluid Part Number 3549660 or there equivalent Fluid Level Check The fluid level should be checked every six months This check should be made when engine temperature gauge indicates a normal warmed up condition and transmission fluid is heated to its normal operating temperature Check level with parking brake applied firmly and the engine idling CAUTION Before removing level indicator w...

Page 32: ...d leakage resulting from hardening or shrinking of the seals in high mile age vehicles Such a product is available under Part Number 2298923 Transmission Sealer or its equivalent TIRES All tires especially wide tread 70 Series and Fi berglass belted tires should be rotated no later than every second oil change Fig 59 and should be in correct balance to obtain the most uniform treadwear If owner in...

Page 33: ...ponents Lubrication foot pounds On all other models tighten nuts to 65 foot pounds 2 Tighten wheel bearing adjusting nut Fig 62 to 70 inch pounds on Valiant models and 90 inch pounds on all other models while rotating wheel 3 Position nut lock on adjusting nut zyx so one pair of cotter pin slots align with hole in spindle 4 Back off adjusting nut and nut lock to the next slot and install cotter pi...

Page 34: ...that should not be lubricated some because they are permanently lubricated some because lubricants will be detri mental to their operating characteristics and some because lubricants will cause component failures In any event rubber bushings should not be lubricated not only because lubricants will cause UPPER 426 HEMI BELLCRANK LOWER PB94 Fig 66 Throttle Linkage lubrication Barracuda and Satellit...

Page 35: ...oon type flexible seals On all models except Imperial the lower ball joints and steering arm assemblies should not be replaced for looseness if the axial end play Page TIGHTENING R E F E R E N C E 22 TORSION BAR 6 TORSION BAR RUBBER ISOLATOR Imperial 6 UPPER BALL JOINTS 18 UPPER CONTROL A R M 16 WHEEL ALIGNMENT zy 3 Camber 3 Caster 3 Steering Axis Inclination 3 Toe In 3 Toe Out 3 Up and Down movem...

Page 36: ...ng h Incorrect front wheel alignment h Measure and adjust front wheel alignment i Shock absorber inoperative i Replace shock absorber a Ball joints require lubrication a Lubricate ball joints b Low or uneven tire pressure b Inflate tires to recommended pressures c Low power steering fluid level c Fill pump reservoir to correct level d Lack of assist of power steering d Inspect test and service the...

Page 37: ...he specifications are recommended by the Chrysler Motors Corporation should always be used There are six basic factors which are the founda tion to front wheel alignment height caster camber toe in steering axis inclination and toe out on turns Fig 1 All are mechanically adjustable except steering axis inclination and toe out on turns The latter two are valuable in determining if parts are bent or...

Page 38: ...Front Suspension Height 7 Check steering gear for roughness binding or sticking condition and adjust as necessary 8 Check rear springs for cracks or broken leaves and U bolts for proper tightness and measure height differential between left and right sides of vehicle Vehicle should be on level floor or on alignment rack with a full tank of fuel and no luggage or passenger load 9 Front suspension h...

Page 39: ...t suspension height 4 Refer to Specifications and adjust if necessary by turning torsion bar adjusting bolt clockwise to increase height and counterclockwise to decrease height 5 After each adjustment jounce vehicle before remeasuring Both sides should be measured even though only one side has been adjusted zyxwvuts 6 Measure other side in same manner The maximum allowable difference in suspension...

Page 40: ...f necessary 2 Inspect torsion bar for scores and nicks Dress down all scratches and nicks to remove sharp edges then paint repaired area with a rust preventative 3 Remove all foreign material from hex open ings in anchors and from hex ends of torsion bars 4 Inspect torsion bar adjusting bolt and swivel and replace if there is any sign of corrosion or other damage Lubricate for easy operation lnsta...

Page 41: ...55 foot pounds Tighten lower bolt nuts as specified and install cotter pin 5 Place a load on torsion bar by turning ad justing bolt clockwise 6 Install tie rod end in steering knuckle arm and install nut tighten 40 foot pounds and install cotter pin 7 Install wheel tire and drum assembly and adjust front wheel bearing Group 22 8 Lower vehicle to floor and install upper con trol arm rebound bumper ...

Page 42: ...eal Damaged seals require removal of the seals and inspection of the tie rod assembly end at the throat opening If the parts have not lost all the lubricant and are not contaminated worn or zyxwv e f KNUCKLE A R M T I E ROD END Fig 8 Steering Linkage Barracuda Satellite NUT COllER PINzyx A TIE ROD I KNUCKLE ARM GEAR ARM CENTER LINK 7 LOCK WASHER N U T NP97 Fig IO Steering Linkage Imperial rusted u...

Page 43: ...dler arm and steering gear arm studs and tighten nuts 40 foot pounds Install cotter pins 3 Connect tie rod ends to steering knuckle zyxwvu RETAINER INSULATOR NN43C INSULATOR RETAINER NUT 4 Fig 12 Sway Bar Assembly Valiant Fig 14 Sway Bar Fury Chrysler arms and center link Tighten nuts 40 foot pounds and install cotter pins 4 Measure and adjust front wheel toe SWAY BAR Figs 12 13 14 and 15 Removal ...

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Page 45: ...mperial lnstallation Imperial 1 Position link with retainer and rubber insula tor in lower control arm bracket followed by rub ber insulator and retainer concave side toward rubber insulator and nut Tighten nut to 100 inch pounds 2 Position sway bar assembly in vehicle and install attaching screw and washer assemblies and tighten finger tight only 3 Install retainer on link followed by rubber insu...

Page 46: ...on of control arm assembly 2 Remove strut from control arm 3 Remove torsion bar adjusting bolt and swivel 4 Place lower control arm assembly in an ar bor press with torsion bar hex opening up and with a support under outer edge of control arm 5 Place a brass drift into hex opening and press shaft out of lower control arm The bushing inner shell will remain on shaft Fig 23 6 Cut and remove rubber p...

Page 47: ...ded portion of tool locking it securely against lower stud Tighten tool enough to place lower ball joint stud under pressure then strike steering knuckle sharply with a hammer to loosen stud Do not attempt to force stud out of knuckle with tool alone 8 Remove tool and disengage ball joint from knuckle 9 Remove nut and washer attaching lower con trol arm pivot shaft to frame 10 Using a brass drift ...

Page 48: ...ten shock absorber nut 50 foot pounds 9 Adjust front wheel alignment as necessary Rem0vat Imperial 1 Raise vehicle on hoist so front suspension is in full rebound under no load 2 Loosen and remove lower control arm strut spring pin nut and retainer 3 Loosen and remove attaching bolts to lower control arm bumper and plate assembly and re move bumper assembly 4 Slide strut and bushing retainer from ...

Page 49: ... arm using Tool C 3894 Use care not to damage seal 6 Using Tool C 3964 remove ball joint stud from lower control arm Fig 20 and remove steering arm and ball joint assembly N Ozy d 1 5 8D Fig 25 Removing Upper Ball Joint Stud Valiant Installation 1 Place a new seal over ball joint if necessary and using a 1 7 8 inch socket press retainer por tion of seal down on ball joint housing until it is secur...

Page 50: ...ntrol arm as 10 INCH BRAK __ Fig 27 Upper Control Arm Valiant Fig 29 Upper Control Arm Fury Chrysler close to wheel as possible and raise vehicle until wheel clears floor 2 Remove wheel and tire as an assembly 3 On Valiant Barracuda and Satellite models remove upper and lower ball joint stud nuts using Tool C 3711 On Valiant models it may be neces sary to add approximately 7 16 inch of flat wash e...

Page 51: ...to support brackets Lift control arm up and away from support C 3964 Disassembly 7 Remove ball joint Fig 31 using Tool C 3560 Tool C 3714 Valiant The seal will come off as ball joint is removed Assembly When installing new bushings be sure control arm is supported squarely at the point where bushing is being pressed in Do not use oil or grease to aid in installation 1 Position flange end of new bu...

Page 52: ...llation of upper ball joint 2 Thread ball joint into upper control arm us ing Tool 2 3561 Make sure threads properly en gage those in control arm 3 Tighten to a minimum of 150 foot pounds until seated The ball joint will cut threads into a new arm during tightening operation 4 Install upper ball joint balloon seal using Tool C 4034 To facilitate installation of seal the ball joint stud should be p...

Page 53: ...EVE ASSEMBLY STUB FRAME ASSEMBLY 4 Position ball joint stud in steering knuckle and install a retaining nut 5 Tighten nut as specified Install cotter pin lubricate ball joint 6 Install lower ball joint stud nut and tighten 85 foot pounds Fury and Chrysler 115 foot pounds zyxwv 7 Install wheel tire and drum assembly and adjust front wheel bearings Group 22 8 Lower vehicle and adjust front suspensio...

Page 54: ...ing type rubber isolators Fig 34 The bracket and sleeve assembly with rubber isolator will be serviced as an assembly only Removal 1 Raise vehicle so front suspension is in full rebound under no load 2 Position a jackstand under front crossmember which will support crossmember when bracket and sleeve assembly is loosened and removed 3 Loosen and remove bracket and sleeve assem bly attaching bolts ...

Page 55: ...nsion Station Wagon 360 C I Engine 17 5 17 5 17 8 41 86 86 88 88 90 88 88 88 92 92 90 86 59 6 60 1 61 6 62 0 63 4 115 0 117 5 117 5 18 8 18 8 47 17 9 50 38 5 41 44 83 86 85 86 85 86 87 86 87 90 88 90 90 94 94 94 96 94 96 96 98 94 98 1 oo 92 98 92 98 98 94 94 98 98 98 96 1 00 1 06 Tread Inches Front with9 inch brakes Front with 10 inch brakes Front with 11 inch brakes Front with Disc brakes Tread I...

Page 56: ...r Assembly Nut Front Sway Bar Link Nut Sway Bar to Frame Sway Bar to Strut Sway Bar Plat to Cross Member Idler Arm Tie Rod End All Tie Rod Sleeve Clamps Shock Absorber Upper Shock Absorber Lower Foot Pounds except where indicated Inch Pounds Valiant 125 55 85 200 65 145 55 100 105 45 100 200 65 40 115 25 50 Barracuda 125 100 85 200 65 145 55 120 105 52 100 200 30 65 40 115 25 50 Satellite 125 100 ...

Page 57: ...arks on the pressure face of gear teeth or in the bore are caused by instantaneous fusing of the mating surfaces Scored gears should be replaced Fill rear axle to required capacity with proper lubricant See Specification Section b Improper grade of lubricant b Replace scored gears Inspect all gears and bearings for possible damage Clean out and refill axle to required capacity with proper lubrican...

Page 58: ...ed ring gear and pinion Replace with a new matched gear and pinion set d Check teeth on ring gear and pinion for contact If necessary replace with new matched set e Adjust drive pinion bearing preload f Adjust differential bearing preload 9 Correct drive gearlash h Drain and flush lubricant See procedure in Sure Grip section of Group zyx 3 a Drain excess lubricant by removing filler plug and allow...

Page 59: ...n in a saw tooth fashion are usually noisy and often produce noises that seem to originate in the rear axle Tire noise changes with different road surfaces but rear axle noise does not Inflate all tires to approximately 50 pounds pressure for test purpos es only This will materially alter noise caused by tires but will not affect noise caused by rear axle Rear axle noise usually ceases when coasti...

Page 60: ...by road testing the vehicle in ques tion on a smooth road black top However ex treme caution should be taken not to confuse tire noise with bearing or gear noise If doubt should exist tire treads should be examined for irregulari ties that will often produce such noise Differential bearing noise will usually produce a constant rough tone which is much slower than the noise caused by the pinion bea...

Page 61: ...ks pointing to front of vehicle measure the distance between the outside edges of the two pieces of tape Record this measurement as the front of tire reading zy 4 Rotate the rear wheels so that the reference marks of each rear wheel now point to the rear of vehicle Measure the distance between the out side edges of the two pieces of tape and record this measurement as the rear of tire reading zy 5...

Page 62: ...ND PINION CONE AND ROLLERS NY1606D z Fig zyxwvutsrq I 7 1 4 in Rear Axle Assembly SERVICE PROCEDURES AXLE SHAFTS AND BEARINGS CAUTION It is absolutely necessary that any time an axle assembly is serviced and the axle shaft is loosened and removed both brake sup port plate gaskets and the inner axle shaft oil sealmust be replaced Ond Disassembty 1 With wheels removed remove clips holding brake drum...

Page 63: ...y tightening bolts in tool alternately Fig 5 Some models equipped with 7 1 4 inch axle install bearings and retainer collars using Tool C 3971 and adapter SP 5126 1 I I C 3926 NK391A Fig 4 Removing Axle Shaft Bearing zy NY 1023 TOOL Fig 6 Installing Axle Shaft Oil Seal 2 Install new axle shaft oil seals in axle housing using tool C 3734 Fig 6 3 Apply a light film of Multi purpose Lubri cant NLGI g...

Page 64: ...panion Flange Fig 10 Bearing Cap ldenfificafion drain lubricant from housing 2 Remove cover and with a suitable cleaning solvent clean inside the axle housing and differen tial case and drive gear assembly 3 Measure for differential side play Position a screwdriver or pinch bar between left side of axle housing and differential case flange then using a prying motion determine if side play is prese...

Page 65: ...sembly from the housing Fig 12 Differential bearing cups and preload adjusting spacers must be kept with respective bearing cones Do not remove spreader tool 13 Remove drive pinion and rear bearing as sembly from axle housing 14 Using a flat end brass drift remove front and rear bearing cups from housing 15 Mount differential case and ring gear assem bly in a vise equipped with soft jaws brass 16 ...

Page 66: ...arings and front and rear pin ion bearing cone and cup assemblies should have a smooth appearance with no broken or dented Fig 15 Installing Differential Bearing Cone surfaces on rollers or roller contact surfaces The bearing roller retainer cages must not be distorted or cracked 7 Differential side gears and pinions should have smooth teeth with a uniform contact pattern without excessive wear or...

Page 67: ...s well as to determine pinion depth of mesh Fig 16 1 Start both drive pinion bearing cups into axle housing 2 Place rear spacer SP 3244 on main tool Seat rear pinion bearing cone on spacer and hold tool in housing 3 Place centralizing sleeve SP 3245 on tool and place front pinion bearing cone on centralizing sleeve followed by tool sleeve centralizing washer Using Tool C 3715 1 With main tool left...

Page 68: ...which varies during rotation indicates a binding condition which should be corrected Use thinner shim to increase preload and thicker shim to de crease preload Always perform steps 3 and 4 in exactly the same manner each time to obtain ac curate readings Preload shims are available in one thousandths of an inch increments from 074 to lo6 inch TOOL NY1024 Fig 20 Installing Companion Flange 254 SPAC...

Page 69: ...per spacers to provide 004 in to 007 in backlash 7 Remove differential case and ring gear assem bly from axle housing 8 With proper spacers selected for left and right sides of assembly as specified by Differential Preload Spacer Chart attach spread er Tool C 3721 with tool dowel pins seated in lo cating holes of axle housing Tighten tool screw DIFFERENTIAL PRELOAD SPACER SELECTION CHART Backlash ...

Page 70: ...hould be taken on teeth approximately 90 degrees apart to find the point of least backlash and mark the tooth HEEL E N D O A S T SIDE CONCAVE NR199 Fig 15 Incorrect Tooth Contact Pattern Increase Spacer Thickness THINNER SPACER NEEDED f 3 HEEL END DRIVE SIDE CONVEX HEELEND COAST SIDE CONCAVE NR201 Fig 27 Incorrect Tooth Contact Pattern Decrease Spacer Thickness 16 At point of minimum backlash dial...

Page 71: ...mp screws to 15 foot pounds zyx 5 Connect brake lines to rear wheel cylinders and connect hydraulic flexible line and bleed wheel cylinder 6 Install brake drums and rear wheels and tighten to 55 foot pounds and adjust brakes LUBRICATION Multipurpose Gear Lubricant as defined by MILL 2105B API GL 5 should be used in all rear axles with conventional differentials Chrysler Hypoid Lubricant part numbe...

Page 72: ...es in the case The differ ential pinion gears have a smooth surface and are held in position by a solid pinion shaft mounted and locked in the case by means of a lock screw All four of the gears are in mesh with each other and because the differential pinions turn freely on the pinion shaft they act as idler gears when the rear wheels are turning a different speed The differential case is supporte...

Page 73: ...justment of the interre lated components replacing worn or damaged components the following suitable factory zy ap proved tools Fig 2 are considered essential in order to properly service the 8 1 4 in rear axle in the circular grooves When the axle shafts and assembly C washers are properly installed the outer por For additional tips on 1 4 axles see Master tion of the C washer will be positioned ...

Page 74: ...small bore models use Tool C 4105 Fig 5 Tool C 4105 damages bearing separator and bearing must be discarded and a new bear ing used To remove bearing on large bore mod els use Tool C 4131 Attach Tool C 637 to end of selected remover using a slide hammer motion remove axle shaft bearing and inspect and discard if axle shaft or bearing shows any of the condi tions in step 7 If large bore axle shaft ...

Page 75: ...e Gear Runout 6 Disconnect propeller shaft at differential pin ion flange and secure in an upright position to prevent damage to front universal joint zy 7 Remove shock absorbers from spring plate studs and loosen rear spring U bolts nuts and remove U bolts 8 Remove axle assembly from vehicle 9 Using a suitable cleaning solvent wash and clean the outer surface of axle assembly and blow dry with co...

Page 76: ...tion during reassembly Fig 11 11 Loosen and remove differential bearing cap bolts and remove bearings caps and threaded adjusters 12 Remove differential case and ring gear as sembly from rear axle assembly A possible light prying action might be necessary to unseat the differential Differential bearings cups and threaded adjuster must be kept with respective bearing cones 13 To remove drive pinion...

Page 77: ...ential bearing caps should be smooth and free of any raised edges Front and rear pinion bearing cup bore machine surfaces TOOLzyxw A Fig 14 Removing Differentiol Bearing Cone should be smooth Raised metal on shoulders of bores incurred in removal of cups should be flat tened by use of a flat nosed punch 3 Axle shaft oil seal bores at both ends of housing should be smooth and free of rust and corro...

Page 78: ...t washers on differential side gears and position gears in counterbores of differ ential case 2 Position thrust washers on both differential pinion gears and mesh the pinion gears with the side gears having pinion gears exactly 180 degrees apart 3 Rotate side gears to align pinion gears and washers with differential pinion shaft holes in case 4 Install differential pinion shaft with care not to da...

Page 79: ...f tool followed by compression sleeve SP 535 Centralizing washer SP 534 and main screw nut SP 3193 Hold compression sleeve with companion flange holding Tool C 3281 and tighten nut Fig 18 allowing tool to rotate as nut is being tightened in order not to brinnel bearing or cups Do not remove tool after install ing cups Pinion depth of mesh will be determined next DRIVE PINION DEPTH OF MESH Using To...

Page 80: ...s properly seated remove tool and pinion bearing cones 9 Lubricate rear drive pinion bearing cone and install bearing cone on pinion stem using Tool 2 4040 or DD 955 An arbor press may be used in conjunction with Tool Fig 20 10 Insert drive pinion with rear bearing and NU987 Fig 21 Installing Drive Pinion Oil Seal TOOL NU988 Fig 22 Installing Drive Pinion Companion Flange new collapsible spacer th...

Page 81: ...is unac ceptable if final pinion nut torque is below 170 foot pounds or pinion bearing preload is not with in specifications NOTE UNDER NO CIRCUMSTANCES SHOULD THE PINION NUT BE BACKED OFF TO LESSEN PINION BEARINGS PRELOAD IF THE DESIRED PRELOAD zyxwvutsr I S EXCEEDED A NEW COLLAPSIBLE TIGHTENED UNTIL PROPER PRELOAD IS OBTAINED SPACER MUST BE INSTALLED AND NUT RE NU990 Fig 24 Measuring Drive Pinio...

Page 82: ...l bearing preload It is important to rotate the gears several revolu tions prior to each reading to insure that the bearings have seated Make sure that the lash reading is taken each time on the same gear tooth PATTERN CLOSE TO CENTER i HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE NR198 Fig 27 Desired Tooth Contact Under light load PATTERN MOVES TOWARD CENTER AND DOWN t 9 HEEL END DRIVE ...

Page 83: ...r observing the contact pattern you find it resembles that in Fig 28 the drive pinion is too far away from centerline of the ring gear the contact pattern will appear high on the heel on drive side and high on toe on coast side TO correct this type tooth contact pattern increase the thickness of shim pack located behind the rear pinion bearing cup Fig 29 which will cause the high heel contact on d...

Page 84: ...able if final pinion nut torque is below 170 foot pounds or pinion bearing preload is not with in the correct specifications CAUTION UNDER NO CIRCUMSTANCES SHOULD THE PINION NUT BE BACKED OFF TO LESSEN PINION BEARING PRELOAD IF THE DESIRED PRELOAD IS EXCEEDED A NEW COLLAPSIBLE TIGHTENED UNTIL PROPER PRELOAD IS OBTAINED IN ADDITION THE UNIVERSAL JOINT FLANGE MUST NEVER BE HAMMERED ON OR POWER TOOLS...

Page 85: ...r axle housing to carrier bolt Some 8 3 4 in large stem differential and carrier assemblies have incorporated a collapsible spacer which bears against the inner races of the front and rear bearings This collapsible spacer is used to establish preload on the pinion bearings Adjustment of pinion depth of mesh is obtained by placing a machined shim between the pinion head and the rear pinion bearing ...

Page 86: ...ugh 7 for axle shaft installation AXLE SHAFTS AND BEARINGS CAUTION It is absolutely necessary that any time an axle assembly is serviced and the axle shafts are loosened and removed the axle shaft gaskets and inner axle shaft oil seals must be replaced Removal 1 With wheels removed remove clips holding zyxwvu BLOCKS BEARING ADAPTER REMOVING SP SP 320 ___ SLEEVE SP 5041 NK360A RING BLOCK HOLDING SP...

Page 87: ...rch The use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because heat is fed into the axle shaft Fig 9 Removing Bearing Rollers 002 zyxw SHIM STOCK Fig 11 Seal Journal Protection bearing journal and thereby weakens this area 1 zyxwvut Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut deep grooves into retaining col...

Page 88: ...icate wheel bearings with Multi Purpose Grease NLGI Grade 2 EP 3 Install a new axle shaft bearing cup cone and collar on shaft using Tool C 3971 A Fig 13 and tighten bolts of tool alternately until bearing and collar are seated properly and polish with No 600 crocus cloth if necessary lnstallation 1 Clean axle housing flange face and brake support plate thoroughly Install a new rubber coated steel...

Page 89: ...prevent dam age to front universal joint zyxw 7 Remove shock absorber from spring plate studs and loosen rear spring U bolt nuts and remove U bolts 8 Remove the assembly from vehicle Installation 1 With body of vehicle supported at front of rear springs position the rear axle assembly spring seats over the spring center bolts 2 Install spring U bolts and tighten nuts to 45 foot pounds and install ...

Page 90: ...r in stand The front pinion bearing cone shim pack and bearing spacer Fig 1 7 Marking Bearing Caps and Adjusters where used will drop from carrier 7 Apply identifying punch marks on differential bearing pedestals of carrier differential bearing caps and bearing adjusters for reassembly purposes Fig 17 8 Remove both differential bearing adjuster lock screws and locks 9 With a 3 4 inch socket loosen...

Page 91: ...nge The hole is reamed only part way through making it necessary to remove lock pin from one direction 9 With a brass drift and hammer remove dif ferential pinion shaft and axle drive shaft thrust block 10 Rotate differential side gears until each dif ferential pinion appears at large opening of case Remove each pinion and thrust washer at that time 11 Remove both differential side gears and thrus...

Page 92: ...he blocks must be smooth 7 Inspect differential pinion shaft lock pin for damage or looseness in case Replace pin or case as necessary 8 Inspect drive gear and pinion for worn or chipped teeth or damaged attaching bolt threads If replacement is necessary replace both the drive gear and drive pinion as they are available in matched sets only 9 Inspect drive pinion bearing cones cups and rollers for...

Page 93: ...ons and thrust washers with differential pinion shaft holes in case 4 From pinion shaft lock pin hole side of case insert slotted end of pinion shaft through case and the conical thrust washer and just through one of the pinion gears 5 Install thrust block through side gear hub so that slot is centered between the side gears 6 While keeping all of these parts in proper alignment push pinion shaft ...

Page 94: ... of the pinion in back of the rear bearing The thickness of the rear pin ion bearing mounting shim suitable for the carrier can be determined by using Tool C 758 D4 zyxwvut f r zyxwvuts 11 PINION LOCATING WASHER O R SHIM I sp 3250rQ ASSEMBLY OF SP 526 CARRIER ASSEMBLY I z 3 z h SP 1730 KP152A s d Fig 26 Pinion Preload with Spacer 8 3 4 in Ring Gear PINION BEARING PRELOAD WITH BEARING SPACER Small ...

Page 95: ...e snug but not too tight similar to the pull of a feeler gauge Fig 29 This shim is then used in determining the correct thickness shim for installation 4 To select a shim for installation read the marking on end of pinion head zyxwvut 4 1 2 1 2 etc When marking is minus add that amount to the thickness of shim selected in step 3 When the marking is plus subtract that amount Example With a shim 086...

Page 96: ...sure bear ing cones are lubricated with hypoid gear lubricant zyxwvutsr 4 Turn tool several complete revolutions in both directions to permit bearing rollers to seat After bearing rollers are properly seated check bearing preload by rotating tool with an inch pound torque wrench The correct bearing preload should be from 20 30 inch pounds for new bear ings and 0 15 inch pounds for the original bea...

Page 97: ...that varies during rotation indicates a binding condition which has to be corrected The assembly is unacceptable if final pinion nut torque is below 170 foot pounds or pinion bearing pre load is not within the correct specifications CAUTION UNDER NO CIRCUMSTANCES SHOULD THE PINION NUT BE BACKED OFF TO LESSEN PRELOAD IF THIS IS DONE A NEW COLLAPSI BLE SPACER MUST BE INSTALLED AND NUT RE TIGHTENED U...

Page 98: ...cups are properly square with bearings and end play is eliminated with some backlash existing between the drive gear and pin ion Fig 30 5 Tighten one differential bearing cap bolt on each side to 85 90 foot pounds zyxwvut KP21 Fig 31 Measuring Backlash Between Drive Gear and Pinion DRIVE GEAR AND PINION BACKLASH Correct drive gear and pinion backlash when properly set is 006 to zyxw 008 inch at po...

Page 99: ...le load is being applied with a round bar or screwdriver between the carrier casting and differential case flange This action will leave a distinct contact pattern on both the drive and coast side of the drive gear teeth 2 Observe the contact pattern on the drive gear teeth and compare with those in figures 32 33 Fig 35 lircorred Tooth Contact Pattern Decrease Spacer Thickness and 35 to determine ...

Page 100: ...inion bearing preload the fol lowing procedure for the removal and replacement of the drive pinion flange and pinion oil seal must be followed to assure that the proper bearing pre load is maintained in the axle assembly If this procedure is not followed it could result in a pre mature failure of the axle 1 Raise vehicle on hoist and make scribe marks on propeller shaft shaft universal joint drive...

Page 101: ...e increased torque output of the 440 cu bic inch engine with Power Pak or the 426 cubic inch Hemi engine in vehicles equipped with 4 speed manual transmission the 9 3 4 in rear axle assembly will appear on those models that are so equipped Fig 1 The standard differential used in both instances will be a SURE GRIP differential with a plate type clutch The new differential in this year s 9 3 4 rear ...

Page 102: ... light press fit to a close sliding onto the shoulder of the shaft and held in place fit on the pinion stem The front and rear bearing by a collar that has a very tight interference fit cups are a press fit against a shoulder recessed in The bearings are lubricated with Multi Purpose the carrier The drive pinion depth of mesh ad Grease NLGI grade 2 E P or equivalent Oil justment is controlled by l...

Page 103: ...t Reinstall fill plug and tighten 7 Lower car on hoist and return to customer to drive and evaluate for approximately 100 miles to determine if lubricant corrects the noise condition If after driving vehicle approximately 100 miles and the differential noise is still evident remove the axle assembly and service the differential with the necessary parts AXLE SHAFTS AND BEARINGS CAUTION It is absolu...

Page 104: ... surface slide protective sleeve SP 5041 over the seal surface next to bearing collar 1 Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut deep grooves into retaining collar at 90 degree intervals Fig 5 This will enlarge bore of collar and per mit it to be driven off of axle shaft 2 Remove bearing roller retainer flange by cut ting off lower edge with a ch...

Page 105: ...flange face and brake support plate thoroughly Install a new rubber REAR AXLE 3 49 I2 SHIM STOCK Fig 10 Seal Journal Protection Fig 1 2 Installing New Bearing And Collar asbestos gasket on axle housing studs followed by brake support plate assembly on left side of axle housing 2 Apply a thin coating of Multi Purpose Grease NLGI grade 2 E P or equivalent to the outside diameter of the bearing cup p...

Page 106: ...nnect parking brake cables To maintain proper drive line balance when reassembling make scribe marks on the propel ler shaft universal joint and the pinion flange before removal 6 Disconnect propeller shaft at differential pin ion flange and secure in an upright position to prevent damage to front universal joint 7 Remove shock absorbers from spring plate studs and loosen rear spring U bolts nuts ...

Page 107: ... stem slightly against opposite side of axle housing Fig 16 10 Tighten spreader tool nut sufficiently to ob tain 015 inch movement of dial indicator to per mit removal of differential case and ring gear assembly DO NOT SPREAD OVER 020 INCH AS IT WILL RESULT IN PERMANENT DAMAGE TO CARRIER CASTING 1 1 Remove dial indicator and remove differen tial case and ring gear assembly from axle housing A ligh...

Page 108: ...4C or Tool C 293 and adapters No 62 Fig 18 Care must be taken to insure that bearing remover adapters are located so as not to pull on bearing cage 20 Remove the shims located behind each bear ing and record thickness to aid in reassembly DIFFERENTIAL CASE are serviced as an assembly only DIFFERENTIAL INSTALLATION The Sure Grip Differential and its internal parts The contacting surfaces of the dri...

Page 109: ...nion and observe Fig 21 One figure is found on both the drive pinion and ring gear and indi cates a matched gear set Directly opposite this figure will be one with a or before it or if not a o r the figure will be 0 This number must be positively identified before continuing with the assembly procedure Midway between the two sets of figures described above are numbers and letters These numbers and...

Page 110: ...sition in carrier housing Install bearing caps and tighten cap bolts up snug 8 Install the step plate clamp assembly on the carrier housing Position step plate over pinion and tighten step plate screw against step plate Make sure the four step plate feet are squarely positioned on the pinion 9 Adjust the micrometer so it is directly over and at a 90 degree angle to the step plate Screw the microme...

Page 111: ...r so that an approximate equal distance zyxwvu is zyxwvu NN1030 Fig 28 Checking Pinion Bearing Preload maintained at both ends Correctly position differ ential bearing caps and insert bolts and tighten to 10 foot pounds 9 Using a feeler gauge select the proper thick ness of shims that will snugly fit between arbor and gauge block This fit must be snug but not too tight similar to the pull of a fee...

Page 112: ... bolts finger tight Refer to the measurement taken previously in step 7 of Differential Installation This reading taken before the drive pinion was installed represents the total clearance between the differential bearing cups and the carrier casting Perform the following steps to determine the thicknesses of shims required behind each bearing cone to take up the clearance and establish the correc...

Page 113: ...is action will leave a distinct contact pattern on both the HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE NR200 Fig 32 Effect On Tooth Contact Pattern As Shim Pack Thickness Is Increased drive and coast side of the drive gear teeth zy 2 Observe the contact pattern on the drive gear teeth and compare with those in figures 30 31 and 33 to determine if pattern is properly located With pinion...

Page 114: ...ables 6 Connect hydraulic brake lines at wheel cylin ders and bleed brakes install brake drums and adjust brakes 7 Install rear universal joint of propeller shaft PATTERN MOVES INWARDAND zyx UP HEEL END DRIVE SIDE CONVEX HEELEND COAST SIDE CONCAVE NR202 Fig 34 Effect On 100th Contact Pattern As Shim Pack lhickness Is Decreased in same position as removed match scribe marks on propeller shaft unive...

Page 115: ...nd turning so that the driving wheels can turn at different speeds Extreme differences in traction conditions at the driving wheels may permit one wheel to spin Sure Grip has been engineered to perform its specialized functions with minimum effect on nor mal vehicle operations The cone clutch Sure Grip differentials are simi lar to corresponding 8 3 4 conventional differen tials except for the inc...

Page 116: ...temperature raise car on hoist so rear wheels are free to turn 2 Loosen and remove fill plug and using a suc tion gun remove as much of the old lubricant as possible 3 Fill axle to proper level with Chrysler Hy poid Lubricant Part Number 2933565 or equivalent Reinstall fill plug and tighten 4 Start engine of vehicle and engage in gear and run on hoist with rear wheels free to turn to approximately...

Page 117: ... and adap ter plates No 43 3 Visually inspect differential case for cracks or other visible damage which might render it unfit for further service Assembly If during cleaning and inspection the differential bearings were found to be unfit for further use and were removed follow this procedure for instal lation of new bearings 1 Position each differential bearing cone on hub of differential case ta...

Page 118: ...ECOME SUBMERGED IN WATER THE LUBRICANT MUST BE CHANGED IMMEDIATELY TO AVOID THE POSSIBILITY OF EARLY AXLE FAILURE RESULTING FROM CON TAMINATION OF THE LUBRICANT BY WATER DRAWN INTO THE VENT HOLE SPECIFICATIONS 7 114 Axle TYPE Semi Floating Hypoid 7 250 2 Ring Gear Diameter Number of Differential Pinions Adjustment by Spacer Washer DIFFERENTIAL BEARINGS 254 284 inch in 002 inch graduations 004 007 ...

Page 119: ...ivalent be used 8 314 Axle TYPE Semi Floating Hypoid PINION BEARINGS Ring Gear Diameter 8 750 Type Tapered Roller Number Used 2 Adjustment Small Stem Step Type Pinion Selected Shims Pre LoadTorque Seal Removed Large Stem TaperedPinion Collapsible Spacer 20 to 30 inch pounds DIFFERENTIAL BEARINGS Type Tapered Roller Number Used 2 Adjustment Adjusting Nut Serviced in Matched Sets Ring Gear Runout 00...

Page 120: ... E P 5 1 2 Pts 4 1 2 Imperial LUBRICATION Multi Purpose Gear Lubricant as defined by MIL L 2105B API GL 5 should be used on all rear axles such a lubricant is available under Part No 2933565 Chrysler Hypoid Gear Lubricant or an equivalent be used TIGHTENING REFERENCE Differential Bearing Cap Bolts Ring Gear to Differential Case Bolts Left Hand Thread Drive Pinion Flange Nut Carrier Cover Bolts Axl...

Page 121: ...Nuts Wheel Stud Nuts Shock Absorber Stud Nuts Lower Differential Bearing Cap Bolts Differential Case Half Retaining Bolts Ring Gear To Differential Case Bolts Drive Pinion Flange Nut Carrier Cover Bolts Axle Shaft Retainer Nuts Propeller Shaft Bolts Rear Spring Clip U Bolt Nuts Wheel Stud Nuts Shock Absorber Stud Nuts zyxw 8 314 Axle Pounds Foot Inch zy 90 55 240 Min 170 Min 45 35 15 45 65 50 9 31...

Page 122: ...ake line f Leaking or worn master f Recondition or replace master cy1inder and bleed hydraulic system 9 Excessively worn brake lining 9 Reline and adjust brakes a Air in hydraulic system a Fill master cylinder and bleed hydraulic system b Improper brake fluid low b Drain flush and refill with c Excessively worn or cracked c Replace all faulty brake drums d Broken pedal pivot bushing d Replace nylo...

Page 123: ... ADJUST b Weak hold down springs b Adjuster screw corroded at thrust washer c Adjuster lever does not engage star wheel d Adjuster installed on wrong wheel f Replace brake shoes 9 Replace support plate h Blow out brake assembly with compressed air and reface brake drums a Repair as necessary and lubricate support plate contact areas 6 places a Adjust brakes and check fluid b Release parking brakes...

Page 124: ...are adjusted before the service brakes TESTING APPLICATION ADJUSTER OPERATION Place the vehicle on a hoist with a helper in the driver s seat to apply the brakes Remove the plug from the rear adjustment slot in each brake support plate to observe the adjuster star wheel Then to exclude the possibility of maximum adjustment that is the adjuster refuses to operate because the closest possible adjust...

Page 125: ...h thoroughly and replace all rubber parts WHEEL STUD NUT TIGHTENING The tightening sequence and torquing of the wheel stud nuts is of great importance to insure efficient brake operation The use of an impact NY1371A Fig 3 Cutting and Flaring Steel Tubing or long handled wrench may distort the drum A criss cross tightening sequence should be used Fig 2 Tighten all the stud nuts to one half the spec...

Page 126: ...5 Stop Light Switch Adjustment Satellite and Barracuda Models junction block to both rear wheel cylinders All fittings tubing and hoses should be inspected for rusted damaged or defective flaring seats The steel tubing is equipped with a double flare or in verted seat to insure more positive seating in the fitting To repair or reflare tubing proceed as follows 1 Using Tool C 3478 or equivalent cut...

Page 127: ...dal blade or brake push rod 2 Push brake pedal down and allow to return to free position do not pull brake pedal back at MANUAL BRAKES any time 3 Place proper spacer gauge on pedal blade or push rod 4 Slide switch assembly toward pedal blade or push rod until switch plunger is fully depressed Fig 6 Stop Light Swifch Adjustment Fury Chrysler against spacer gauge on heavy duty or stop and Imperial M...

Page 128: ...PLATE DUSTBOOT I RETURN2PRING S H O E T A B S 3 move wheel and drum assembly from spindle to expose brake linings Figs 1 2 3 or 4 5 Inspect brake lining for wear shoe alignment or contamination from grease or brake fluid Removing Rear Brake Drums 1 Remove rear plug from brake adjusting ac cess hole 2 Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of ...

Page 129: ... Inch Brake Assemblies WHEEL ANCHOR C Y L I N D E PLATE BOOT SECONDARY I SECONDARY RETuRL g RETURN SPRlNG SHOE RFTAINERS AND SPRING PRIMARY SHOE AND LINING LEVER SPRING OVERLOAD LEFT FRONT LEFT REAR SPRING P B m AUTOMATIC SUPPORT PLATE AWTMBL1 Fig 3 Eleven Inch Brake Assemblies MyMopar com ...

Page 130: ...ad spring cable guide and anchor plate 3 Disengage adjusting lever from spring by sliding forward to clear pivot then working out from under spring Remove spring from pivot Re move automatic adjuster spring from secondary shoe web and disengage from primary shoe web PB509 RETAINER Fig 6 Removing or Installing Shoe Retainers Springs and Nails Right Front Remove spring Eleven inch brake only 4 Remov...

Page 131: ...brake lever strut and anti rattle spring Fig 12 7 Remove brake shoe retainers springs and nails Using Tool 2 4070 Fig 8 and remove from support 8 Disengage parking brake cable from parking brake lever CLEANING AND INSPECTION Wipe or brush clean dry the metal portions of the brake shoes Examine the lining contact pat tern to determine if the shoes are bent The lining should show contact across the ...

Page 132: ...plated The right is black and the adjusting stud end is not stamped PRIMARY t AND LINT I ZONDARY SHOE AND LINING Fig I Installing Brake Shoes Left Front 3 Install adjuster spring in primary shoe and hook other end in web of secondary Eleven inch brake only Install adjusting lever spring over pi vot pin on shoe web Install adjusting lever under spring and over pivot pin Slide lever slightly rear wa...

Page 133: ...lat against shoe web and that secondary spring overlaps primary Fig 1 Using pliers squeeze ends of spring loops around anchor until parallel PLATE f WASHER lORSESHOE LIP PRIMAp cii r A i r u n n RETL SPRl Fig 13 Installing Brake Shoes Left Rear 7 Install adjusting star wheel assembly between primary and secondary shoes with star wheel next to secondary shoe Fig 1 The left star wheel adjusting stud...

Page 134: ...inder with power brakes with one exception the master cylinder for power brakes does not include the push rod The disc brake master cylinder is different than the standard drum brake master cylinder and is covered in the disc brake section of the brake group SERVICE PROCEDURES panel and or power brake unit if so equipped MASTER CYLINDER R E M 0VAL 1 Disconnect front and rear brake tubes from maste...

Page 135: ...PISTON RETAINER RESIDUAL PRESSU VALVE AND SPRl SCRE PISTON RESIDUAL PRESSURE VALVE AND SPRING PB514 Fig 4 Removing or Installing Residual Pressure Valve springs Fig 4 C LEANING AND INSPECTION Clean master cylinder thoroughly using a suita ble solvent and dry with compressed air Wash the cylinder bore with clean brake fluid and in spect for scoring or pitting Master cylinder bore walls that have li...

Page 136: ...ake fluid Rear Piston 1 Carefully work secondary cup over rear end of rear piston with lip of cup toward piston Fig 5 2 Center spring retainer of rear piston assembly over shoulder of front piston Push piston assem blies into bore up to center piston cup Carefully work cup into bore then push piston in up to the rear cup Carefully work lip of rear cup into bore then push in on piston until seated ...

Page 137: ...ke warning switch Figs 9 and 10 is used to warn the vehicle oper ator that one of the hydraulic systems has failed A failure in one part of the brake system does not result in failure of the entire hydraulic brake system As an example failure of the rear brake system will leave the front brake system still operative As pressure falls in one system the other system s normal pressure forces the pist...

Page 138: ...ct brake tube from wheel cylinder rear wheels 3 Djsconnect brake hose or tube from wheel cylinder front Remove wheel cylinder attaching bolts front or rear then slide wheel cylinder as sembly out of support DISASSEMBLING WHEEL CYLINDERS Front or Rear To disassemble the wheel cylinders Figs 2 or 3 proceed as follows 1 Using a suitable tool pry boots away from cylinders and remove Remove push rods i...

Page 139: ...ylinder using a new gasket Torque to 25 foot pounds before attaching brake hose to frame bracket Should hose be connected to P U S H ROD wheel cylinder last tightening of the hose into wheel cylinder will twist hose and can result in suspension interference Valiant only Connect jumper tube into wheel cyl inder and torque to 115 inch pounds Attach brake hose to frame bracket and connect brake line ...

Page 140: ...d retainer into hous ing and install axle retainer nuts and washers Tighten retainer nuts to 35 foot pounds 4 Attach brake line to wheel cylinder and tight en to 115 inch pounds 5 Insert parking brake cable into support plate and attach cable to parking brake lever 6 Install brake drum and wheel Bleed and ad just brakes PARKING BRAKES INDEX INDEX Page Page Adusting Parking Brake 20 Installing Rear...

Page 141: ...le Adjust brakes and cable as necessary Replace the brake lining Replace pedal assembly SERVICE PROCEDURES threads with wire brush and lubricate with grease ADJUSTING PARKING BRAKE 2 Tighten cable adjusting nut until a slight The service brakes must be properly adjusted drag is felt while rotating wheel loosen cable ad before adjusting the parking brake justing nut until both rear wheels can be ro...

Page 142: ...LE Fig 2 Parking Brake Cable Routing Barmcuda and Satellite DIMMER SWlTC PARKING BRA AINER e PLAINWAS I FRONT CABLE ASSY SCREW AND WASHER YRETAINER FRONT CABLE NK508A Fig 3 Parking Brake Cable Routing Fury Chrysler Imperial MyMopar com ...

Page 143: ...aining clip from brake cable 4 Remove brake drum from rear axle 5 Remove brake shoe return springs 6 Remove brake shoe retaining springs 7 Remove brake shoe strut and spring from brake support and disconnect brake cable from operating arm 8 Compress retainers on end of brake cable housing Fig 4 and remove cable from support bracket INSTALLING REAR PARKING BRAKE CABLE When installing a new brake ca...

Page 144: ...clip ent size slot for corresponding cable end fitting cable TANK ASSEMBLY POWER BRAKE ACUUM LINE INSTALL TANK S O THAT HOSE ANGLE FALLS BETWEEN LIMITS SHOWN BE BRAKE LIGHT NU161 Fig 7 Parking Brake Pedal Fury and Chrysler REMOVING FRONT PARKING BRAKE CABLE equalizer bar Figs 1 2 or 3 1 Disengage front parking brake cable from 2 Disengage cable from guide clip 3 Using a screwdriver force cable hou...

Page 145: ... 2 Move transmission shift selector lever into Park position 3 Place valve in position on steering column jacket and install attaching screws DO not tighten Rotate valve clockwise viewed from driv ers position until actuating arm contacts tab in side steering column jacket Tighten screws securely 4 Remove drill from locating hole 5 Install vacuum hoses Be sure hose from en gine manifold is attache...

Page 146: ...rts in hydraulic system a Inspect for a leak and replace lining as required a Inspect self adjuster operations b Bleed brakes c Locate and correct leak d Add brake fluid e Smooth and lubricate platforms f Check wheel bearing adjustment a Replace check valve b Replace hose c Clean out fittings d Replace unit e Replace unit f Replace unit MIDLAND ROSS POWER BRAKE Small Tandem Diaphragm SERVICE PROCE...

Page 147: ...o 2 Disconnect vacuum hose from power brake 3 From under instrument panel remove nut and attaching bolt from power brake input push rod and brake pedal blade On linkage type power brake unit remove lower pivot retaining bolt Fig 2 4 Remove four power brake attaching nuts and washers 5 Remove power brake and linkage if so equipped from vehicle INSTALLING POWER BRAKE 1 Install power brake assembly i...

Page 148: ...bolt from power brake link and brake pedal Fig 3 4 From under instrument panel remove four brake unit attaching nuts and washers 5 Withdraw brake unit assembly from vehicle INSTALLING POWER BRAKE 1 Install power brake and linkage assembly if so equipped into dash panel Install attaching nuts and washers Tighten nuts to 150 inch pounds 2 Using lubriplate coat the bearing surface of bolt that connec...

Page 149: ... 5 Withdraw brake unit assembly from brake support bracket INSTALLING POWER BRAKE 1 Install power brake and linkage assembly if so equipped into dash panel Install attaching nuts and washers Tighten nuts to 150 inch pounds 2 Using lubriplate or equivalent coat the bear ing surface of bolt that connects power brake pe dal link with brake pedal linkage Install bolt and nut Tighten to 30 foot pounds ...

Page 150: ... and brake vot bolt if so equipped pedal On linkage type power brake remove low er pivot bolt 4 Install master cylinder on power brake 4 From under instrument panel remove four Tighten mounting nuts to 200 inch pounds With brake unit attaching nuts and washers power brake attached to dash panel and vacuum 5 Withdraw brake unit assembly from brake supplied to unit the master cylinder should com sup...

Page 151: ...ylinder bores of 1 5 8 inch diameter Each cylin der contains a seal piston and externally attached molded rubber dust boot to seal the cylinder from contamination The pistons are sealed by Page General Information 30 Installing Brake Disc and Hub 39 Installing Caliper 39 Installing Master Cylinder 5 9 Removing Braking Disc and Hub 39 Removing Caliper 36 Removing Master Cylinder 5 7 Routine Mainten...

Page 152: ...a The shoes slide axially in the abutments and ride metal plate called the shoe and is replaced as a on machined ledges bridges when hydraulic pres unit Brake torque is absorbed by the reaction of EXTERNAL TRANSFER STEERING A R M NUT L O C K C O T T E R PIN tGREASE CAP Fig I Disc Brake Assembly Sectional PISTON PISTON SEAL n NN423D DUST BOOT B L E E D SCREW I SHOF 4 Fig 2 Disc Brake Caliper Assemb...

Page 153: ...g running clearance Automatic adjustment is achieved by the pistons sliding outward from the cylinder bore as the lining wears The piston assumes a new position relative to the seal and maintains the cor rect adjustment location at all time Fig 4 There is no residual pressure in the disc brake hydraulic system since the residual pressure valve normally used in drum brake system is located only in ...

Page 154: ...in thickness of disc If roughness or vibration is encountered during high way operation or if pedal pumping is experienced at low speeds the disc may have excessive thick ness variation To check for this condition meas ure the disc at 12 twelve points with a microme ter at a radius approximately one inch 1 in from edge of disc If thickness measurements vary by more than 0005 inch the disc should b...

Page 155: ...ure h Brake fluid oil or grease on Iinings i Restricted hose or line j Rear brakes out of adjustment k Unmatched linings I Distorted brake shoes a Not detrimental to function of disc brakes no corrective action required Indicate to operator this noise may be eliminated by slightly increasing or decreasing brake pedal efforts adjustment braking disc a Check and adjust rear brakes b Check system for...

Page 156: ...c Disassemble caliper and hone cylinder bore If neccessary install new pistons a Corrections listed under Pull Power brake malfunction b Replace unit Air in hydraulic system or a Bleed system improper bleeding procedure Leak in system or caliper Pistons pushed back in cylinder bores during servicing of caliper shoe and lining not properly positioned Leak past piston cups in master cylinder Damaged...

Page 157: ... lining into caliper with ears of shoe resting on bridges of caliper Fig 7 Be sure shoe is fully seated and lining is facing disc 3 Slide remaining shoe and lining into caliper using same procedure as described above 4 Place shoe retainer spring assemblies in posi tion on caliper 5 Pump brake pedal several times until a firm pedal has been obtained and shoe and lining have been properly seated 6 I...

Page 158: ...e the caliper for the installation of new parts Fig 9 proceed as follows 1 Remove shoe ratiner spring clips Remove transfer tube armored at caliper 2 Mount caliper assembly in a vise equipped with protector jaws Use caliper mounting lugs Remove transfer tube 3 Remove shoe and lining assemblies Fig 77 Removing Pistons from Caliper 4 Remove bridge bolts that hold two halves of caliper together Make ...

Page 159: ...es from damage After honing the bore carefully clean the seal groove with a stiff non metallic rotary brush Use extreme care in cleaning the caliper after honing Remove all dust and grit by flushing the caliper with brake fluid wipe dry with a clean lintless cloth and then clean a second time in the same manner ASSEMBLING CALIPER To reassemble the disc brake caliper Fig 9 BORE NN435B F Fig 13 Honi...

Page 160: ...bling caliper unit be sure and check for fluid tightness under maximum pedal pressures Recheck master cylinder reservoir lever Check and be sure that lower shock ab sorber mounting bolt has been installed from rear and nut toward front of vehicle This is important Fig 3 7 Install wheel and tire assembly and tighten wheel stud nuts in a star pattern to 30 foot pounds then to 55 foot pounds This is ...

Page 161: ...en wheel stud nuts in a star pattern to 30 foot pounds then to 55 foot pounds Install wheel cover 6 Remove jackstands or lower hoist OM R E A R MASTER YLINDER OUTLET O R T MARKED F LEFT FRONT B R A K E OUTLET T O RIGHT FRONT B R A K E T U B E PLUGGED IF METERING VALVE IS USED PROPORTIONING Fig 1 7 Brake Warning Switch Proportioning Valve Sectional BLEEDING DISC BRAKE The disc brake hydraulic syste...

Page 162: ...wheel slide is obtained on brake application it usually is an indication that the fluid pressure to the rear brakes is above the reduction ratio for the rear line pressure and that a malfunction has occurred within the pro portioning valve which should be tested To test the proportioning valve proceed as follows 1 Install one of gauge set C 4007A and T between brake line from master cylinder port ...

Page 163: ...ly increasing or decreasing brake pedal efforts emanating at low speeds on rough roads front wheels only a Shoe anti rattle spring missing or not properly positioned b Excessive clearance between shoe and caliper Rattle Brake noise or rattle Scraping a Mounting bolts too long a Check system for leaks and bleed b Install new shoe and linings c Check disc for runout with dial indicator Install new o...

Page 164: ...r The cast iron braking disc has cooling fins or louvres that are cast integrally between the two machined braking surfaces Fig 2 When the wheel is in motion the rotation of the disc cool ing tins supplies air circulation between the brak ANTI RATTLE SPRING BRAKE SHOES A CALIPER TOR PIN POSIT ON ER BLEED SCREW PB519 Readjust wheel bearings to correct specifications Instruct owner how to drive with...

Page 165: ...bber dust boot installed in a groove in the cylinder bore and piston keeps con tamination from the cylinder wall and piston The boot has a wiping lip Fig 6 that prevents con tamination in the bore area As the brake pedal is depressed hydraulic pres sure is applied against the piston This force is transmitted to the inboard brake shoe and lining and the inboard braking surface of the disc As force ...

Page 166: ...DISC BRAKE FLOATING CALIPER 5 45 MOUNTING BOLT WHEEL STUD MOUNTING BOLT STEERING KNUCKL BRAKING DISC SPLASH SHIELD JL Fig 4 Disc Brake Assembly Sectional NWA MyMopar com ...

Page 167: ...for Automatic Adiustment reading in the center When an assembly has been worn to a thickness of 230 inch it should be replaced If a shoe and lining does not require replacement reinstall making sure each shoe and positioner is returned to their original positions See Brake Shoe Installation paragraph It is normal for the inboard lining to show slightly more wear than the outboard CALIPER Brake Rou...

Page 168: ...w may occur when the piston is pushed back into the new lining position Over flowing can be avoided in this case by removal of a small amount of fluid before overflow occurs SERVICE PROCEDURES BRAKE SHOE REMOVAL age flexible brake hose 1 Raise vehicle on a hoist or jackstands 5 Slide outboard shoe and lining assembly out 2 Remove front wheel covers and wheel and of caliper Slide inboard shoe and l...

Page 169: ...utboard side of caliper Fig 18 3 Slide new shoe and lining assemblies into position in adaptor and caliper Fig 8 being sure that metal portion of shoe is fully in recess of caliper and adaptor 4 Holding outboard lining in position carefully slide caliper down into position in adaptor and over disc Align guide pin holes of adapter in board and outboard shoes Fig 3 5 Install new positioners over gui...

Page 170: ...d lining assembly Remove in board shoe and lining from adaptor P CAI Fig 13 Removing Outer Bushings DISASSEMBLING CALIPER 1 Mount caliper assembly in a vise equipped with protector jaws Fig 10 Caution Excessive vise pressure will cause bore distortion and binding of piston 2 Remove Dust boot Fig 11 3 Using Tool C 4087 and SP 5518 for Barra cuda and Satellite Models remove piston from caliper Fig 1...

Page 171: ...time in the same manner or until clean cloth shows no signs of discoloration ASSEMBLING CALIPER 1 Clamp caliper in vise with protector jaws Fig 15 Installing Piston Seal CALIPER U34A Fig 17 Installing Piston Through Boot Fig 10 Caution Excessive vice pressure will cause bore distortion and binding of piston 2 Dip new piston seal in lubricant supplied with kit Ucon LB1145Y24 or equivalent and insta...

Page 172: ... caliper and anti rattle spring 5 Press IN ON END GUIDE PINS AND THREAD PINS INTO ADAPTOR USING EXTREME CARE SO AS NOT TO CROSS THREADS Tighten from 30 to 35 foot pounds Be sure tabs of posi tioners are over machined surfaces of caliper Fig 1 6 Remove plug from brake tube and install flexible brake hose Tighten securely Avoid twist ing hose 7 With bleeder screw open allow caliper to Fig 19 Checkin...

Page 173: ...05 inch disc should be removed and re surfaced or a new disc and hub assembly installed Fig 19 4 Light scoring and or wear is acceptable if DISC THICKNESS RUNOUT MAX ALLOWABLE T 1 R SURFACE FINISH MICRO INCHES TOTAL VARIATION IN THICKNESS 12 EQUAL POINTS NU99 I Fig 21 Disc Specifications heavy scoring or warping is evident the disc must be refinished or replaced See Refinishing Refacing Braking Di...

Page 174: ...due to piston knockback and increase seal bushing wear due to necessity of cali per to follow the disc wobble Thickness variation in a disc can also result in pedal pulsation chatter and surge due to variation in brake output when disc section is uneven Dishing or distortion can be caused by extreme heat and abuse of the brakes Resurfecing Breking Disc This operation can be used when the disc sur ...

Page 175: ...nding on models as follows 1 Satellite and Barracuda Models use a dual W TO FRONT BRAKES FROM MASTER CYLINDER TO REAR BRAKES PORT F FROM MASTER CYLINDER PORT R I PROPORTIONING VALVE UNIT T L E F T FRONT BRAKE TO RIGHT FRONT BRAKE PB532 Fig 23 Brake Warning Switch Proportioning Valve and Metering Valve Assembly FROM MASTER SWITCH ASSEMBLY CYLINDER MARKED OUTLET R OM MASTER CYLINDER MARKED F BRAKES ...

Page 176: ...be 360 405 p s i If proportioning valve pressure readings do not meet specifications the valve should be removed and a new valve installed PRESSURE METERING VALVE All disc brake vehicles except Valiant models are equipped with a pressure metering valve Figs 27 and 28 The valve is located on the left frame Fig 28 Holding Valve open Metering Valve rail The use of the metering valve is to better matc...

Page 177: ...ated Before driving the vehicle check the operation of the brakes to be sure that a firm pedal has been obtained 1 Raise vehicle using a hoist or jackstands 2 Bleed brakes in usual manner starting with right rear then proceeding to left rear right front and left front in order After bleeding the brakes proceed as follows 1 Remove jackstands or lower hoist 2 Test drive vehicle to be sure brakes are...

Page 178: ...o one side and remove cover and gasket Empty brake fluid from reservoirs 2 Remove front piston retainer screw from in side reservoir Fig 2 then remove snap ring from outer end of cylinder bore Fig 3 Slide rear piston assembly out of cylinder bore 3 Upend master cylinder and tamp open end down on bench to remove front piston and spring If front piston sticks in bore of cylinder use air pressure to ...

Page 179: ...e than 002 inch If master cylinder bore does not clean up at 002 inch when honed the master cylinder should be discarded and a new master cylinder installed If master cylinder pistons are badly scored or corroded replace them with new ones The piston cups and seals should be replaced when recondi tioning a master cylinder When overhauling a master cylinder use all parts furnished in repair kit Dis...

Page 180: ...rn under pres sure of springs Do this several times or until bubbles cease to appear Fig 9 4 Remove bleeding tubes from cylinder and in stall plug in rear outlet As tubes are removed fluid remaining in tubes will syphon out 5 Place cover and gasket over reservoirs and secure with bail 6 Remove master cylinder from vise and install PB527 REAR PISTON ASSEMBLY Fig 8 Installing Rear Piston Assembly BS...

Page 181: ...n occurs and a new terminal unit installed If a new warning switch body assembly is installed bleed the brake system TESTING BRAKE WARNING SWITCH The brake warning light flashes only when the parking brake is applied with the ignition key turned ON The same light will also illuminate should one of the two service brake systems fail when the brake pedal is applied To test the sys tem turn the ignit...

Page 182: ... one side and remove cover and gasket Empty brake fluid from reservoirs 2 Remove piston retaining screw and gasket Fig 4 then slide rear piston assembly out of cylinder bore 3 Upend master cylinder and tamp open end down on bench to remove front piston and spring If front piston sticks in bore of cylinder use air pressure to force piston out of cylinder New cups must be installed at reassembly if ...

Page 183: ...em with new ones The piston cups and seals should be replaced when recondi tioning a master cylinder When overhauling a master cylinder use all parts furnished in repair kit Discard all used rub ber parts REASSEMBLING MASTER CYLINDER Front Piston Before assembling master cylinder dip all com ponent parts in clean brake fluid and place on a clean shop towel or paper assembling seals dry can ruin th...

Page 184: ...linder on vehicle as follows INSTALLING MASTER CYLINDER 1 Install master cylinder on vehicle aligning power brake push rod with master cylinder piston 2 Slide over mounting studs Install attaching nuts and tighten to 200 inch pounds 3 Connect front and rear brake tubes and tighten to 150 inch pounds 4 Bleed brakes at wheel cylinders using regular procedure being sure fluid level is maintained See ...

Page 185: ...onnected wire at the switch To test the service brake warning system raise the car on a hoist and open a wheel cylinder bleeder while a helper depresses the brake pedal and observes the warning light If the light fails to light inspect for a burned out bulb disconnect ed socket a broken or disconnected wire at the switch If the bulb is not burned out and the wire continuity is proven replace the b...

Page 186: ...s Primary 3116 3116 WHEEL CYLINDER Rear Wheel Cylinder Bore 15116 15 16 MASTER CYLINDER BORE FURY MODELS TYPE Duo ServoSingle Anchor DRUM DIAMETER 11 in Police Heavy Duty 11 in NUMBER OF BRAKE SHOES 8 in WIDTH Secondary 114 114 Front Wheel Cylinder Bore 1 3 16 1 3 16 1 1 32 1 1 32 2 314 in Manual Transmission 2 112 in Front 3 in Rear 2 112 in Stirtion Wagon Front Disc Station Wagon Rear 2 112 in F...

Page 187: ... CYLINDER Front Wheel Cylinder Bore Drum 1 3116 Disc 2 314 Rear Wheel Cylinder Bore 15 16 MASTER CYLINDER BORE Drum or Disc 1 1132 DISC BRAKE FIXED CALIPER VALIANT Typeof Brake Location Master Cylinder Reservoir Proportioning Valve Location Brake Adjustment Residual Valve Location CALIPER ASSEMBLY Shoe and Lining Removal Number of Pistons Piston Diameter Piston Bore Diameter Maximum Allowable Afte...

Page 188: ... PressureControl P S I 3OOP S I Reduction in Rate of Rear Line Pressure Build Up After 300 P S I Actuation Pressure DISC BRAKE Floating Caliper IMPERIAL CHRYSLER FURY SATELLITE BARRACUDA Typeof Brake Location Master Cylinder Metering Valve Location ProportioningValve Satellite Barracuda Models Brake Adjustment Residual Valve Location Rear Brakes Only CALIPER ASSEMBLY Shoe and Lining Removal Number...

Page 189: ...ine Tube Nuts 3 8 or 7 16 1 2 or 9 16 Flexible Brake Hose To Brake Line Tubes All To Brake T Rear To Wheel Cylinders All Ventilated Cast Iron 11 75 10 97 7 725 7 04 0025 15 to 80 Micro Inches 1 250 1 240 1 ooo 1 010 0005 Bonded 400 Nominal 1 80 At Center 6 02 10 0 Square inches per pad Not less than 030 lining at any point or a minimum shoe and lining thickness of 230 Inch TIGHTENING REFERENCE 1 1...

Page 190: ...el rotating WHEEL STUD NUTS All except Valiant Valiant DISC BRAKE FIXED CALIPER Caliper Mounting Bolts Caliper Assembly Bridge Bolts Disc Splash Shield Bolts Caliper Bleeder Screw Shoe Clips Retainers ProportioningValve to Frame Screw DISC BRAKE FLOATING CALIPER Adapter Mounting Bolts Guide Pins Disc Splash Shield Screws Proportioning MeteringValve Assembly to Frame Screw 55 120 55 100 35 90 70 65...

Page 191: ...y The three pressure plate release levers are preset during manufacture and no attempt should be made to adjust them in service The clutch sizes for the various car models are described in specification charts at end of this section The Semi centrifugal type clutch Fig 2 com bines the feature of low pedal effort with that of a clutch capable of transmitting the full torque of the engine Some model...

Page 192: ...rque pedal bracket on two needle bearings or nylon shaft through a vertically positioned rod A non bushings These bearings do not require periodic adjustable over center spring is provided between lubrication E M B L Y NY7OA Fig 2 Clutch Disassembled Semi Centrifugal PEDAL STOP PLAIN WASHER BUSHING FRAME SIDE RAIL BOOT L BUSHING 1 r CLUTCH PEDAL 4 HOOK NP131B Fig 3 Clutch Pedal and Linkage Valiant...

Page 193: ...TER SPRlN BOOT D A P E R WASHER Fig 4 Clutch Pedal and linkage Valiant Heavy Duty NR180A SEALING W A S H E R 2 STUD PLATE PEDAL BRACKET BUSHING 6 CYL F w NUT 5 1 Y OVER CENTER SPRING BOOT W u Fig 5 Clutch Pedal and linkage Barracuda and Satellite NR181 MyMopar com ...

Page 194: ...lutch linkage Worn release bearing Worn disc assembly Worn release levers Worn or dry pilot bushing Dry contact pressure plate lugs in cover Replace disc assembly Replace disc assembly and correct cause of contamination Replace cover assembly Replace or tighten mounts Align clutch housing Replace disc assembly and correct cause of contamination Adjust release fork rod Replace cover assembly Adjust...

Page 195: ... Interlock A 903 trans only pawl Fig 7 1 Disconnect clutch rod swivel from interlock 2 Adjust clutch pedal free play as specified 3 When first reverse lever on transmission is in neutral middle detent position the interlock pawl will enter the slot in first reverse lever 4 Loosen swivel clamp bolt and slide swivel on rod to enter pawl Install washers and clip Hold interlock pawl forward and tighte...

Page 196: ...point where it may be CLUTCH HOUSING SPRING WASHER 6 CYL MODELS TORQUE SHAFT PLAIN WASHER K RETURN SPRING NR185C Fig 9 Torque Shaft and Linkage Barracuda and Satellite A318 AND 360 CU IN ENGINE AALL EXCEPT 318 AND 360 cu IN ENGINE SPRING WASHERA DASH PANEL RK RETURN SPRINGLA SPRING WASHER DAMPENER WASHER MPENER WASHER TORQUE SHAFT RETURN SPRING SIDE RAIL FORK RETURN SPRIN Fig 10 Torque Shaft and L...

Page 197: ...y light contact 180 degrees from that portion flywheel may be improperly mounted or sprung In either case a dial indicator mounted on clutch housing with Fig 1 2 Marking Clutch and Flywheel plunger in contact with wear circle should show no more than 003 inch runout throughout a com plete rotation of flywheel 3 Friction face of flywheel should also be free from discoloration burned areas small cra...

Page 198: ...ITY RETAINING SPRING PADS CONTACT AREA NR133 Fig 14 Clutch Lubrication Points on 11 inch clutches for 383 cu in and larger engines require no lock washers The use of lock washers would create interference problems 5 To avoid distortion of the clutch cover bolts should be tightened a few turns at a time alternately until they are all snug Tighten 5 16 inch bolts to 200 inch pounds 3 8 inch bolts to...

Page 199: ...ork and engage groove of seal in clutch housing Install housing pan 5 Insert threaded end of fork rod assembly in hole of release fork Figs 8 9 or 10 Install eye end of fork rod on torque shaft lever pin and se cure with spring washer or return spring 6 Install return spring to clutch release fork and clutch housing or torque shaft lever CLUTCH RELEASE BEARING Removed from Clutch Removal 1 Examine...

Page 200: ...hould also be smooth and free from surface scratches or embed ded foreign material The wear pattern should be uniform over the entire surface 4 Replace worn or cracked rubber seals Installation 10 1 Install new seals on ball studs Figs 8 9 or 2 Coat counterbored ends of torque shaft tor que shaft bearings and ball studs with Multi Mile age Lubricant Part Number 2525035 or Automo tive Multi Purpose...

Page 201: ...se 014 in dowel No 1736348 and 036 in through 050 in use 021 in dowel No Fig 18 Measuring Clutch Housing Face Squareness 1736353 8 To install dowels remove clutch housing and old dowels from rear face of engine block 9 Install both dowels with slots parallel and aligned in direction to correct bore runout Slot indicates direction of maximum dowel eccentricity Both dowels must be inserted into engi...

Page 202: ...LATE ASSY IDENTIFICATION CHART Size 9 114 9 112 10 112 10 112 l a l 2 8 r 11 11 11 11 Part Number 2525464 2800827 3515301 2409688 3515150 2409682 3410157 3410158 3410159 Springs No Color 3 Red Stripe 3 White 3 White 6 Plain 6 White 6 Tan 6 White 6 Tan 3 White 6 Plain 6 Green 6 Tan 9 Green 3 Purple 9 Green 3 Purple Mounting Bolt Circle Dia 10 518 10 518 11 518 11 518 11 518 12 518 11 518 11 518 11 ...

Page 203: ...sing to Engine Bolts 3 8 Clutch Housingto Engine Bolts 7 16 Clutch Housing Pan Bolts POUNDS FOOT INCH 200 200 30 30 50 200 POUNDS FOOT INCH 55 85 40 40 50 Flywheel Bolts All except 426 Hemi Flywheel Bolts 426 Hemi Torque Shaft Ball Stud Torque Shaft Ball Stud Nut Transmission to Clutch Housing Bolts Torque Shaft Ball Stud Bracket Bolts 200 MyMopar com ...

Page 204: ... 6 WATER PUMP 5 heating for unusual operating conditions is available The maximum cooling system consisting of a larger radiator and on some models radiator shrouds and or hood to yoke and bumper to yoke seals are used to provide protection against over heating for unusually severe operation requirements The trailer towing package is a combination of the maximum cooling package and the high capac ...

Page 205: ...Circulation b Incorrect ignition timing 9 Replace the cylinder head gasket and torque head in correct sequence h Clean the heater connections and replace the hoses and clamps if necessary i Tighten the water temperature sending unit j Tighten the water pump attaching bolts to zyx 30 foot pounds k Seal and re drive the stud I Replace the thermostat housing m Straighten the radiator inlet or outlet ...

Page 206: ...g due to insufficient corrosion inhibitor c Blown head gasket d Broken or shifted lower hose spring a Use of water containing large concentration of lime and minerals b Insufficient corrosion inhibitor c Use of antifreeze for extended length of time a Faulty thermostat b Flush the radiator and add antifreeze as required c Replace the head gasket d Replace lower hose a Use only clean soft water wit...

Page 207: ...th zyx 2 7 6 l or Lower Axle Ratio shroud from radiator position shroud rearward on engine Fan attaching screws can now be removed 2 On models equipped with fluid fan drive re move fan drive attaching screws The fan and fluid fan drive are removed as a unit Insfallation Use correct fan spacer if required so clearance between fan blades and radiator is 3 4 to 1 1 4 inches No fan spacer permitted wi...

Page 208: ...e water pump is serviced only as an assembly When replacing the water pump do not install a standard water pump on any air conditioned vehicle or vice versa See specifica tions for proper pump PB449 Rem0V a l 1 Drain the cooling system Remove fan shroud if so equipped and set back on engine 2 Loosen power steering pump idler pulley and alternator Remove all belts 3 Remove fan spacer or fluid drive...

Page 209: ...rm up and add oil as required Cleaning 1 Drain cooling system and refill with clean soft water and a reliable cooling system cleaner 2 Operate engine according to directions on Cleaner label 3 After cleaning operation flush entire cooling system until water runs clean 4 Regardless of climate the cooling system should be refilled with sufficient permanent type anti freeze for 20 degrees F protectio...

Page 210: ...holding the cooler fittings to the bottom tank and remove the cooler 5 Install a new cooler or repair the old cooler 6 Position oil cooler in bottom tank and install 7 Use soft solder to secure the cooler in the 8 Attach bottom tank to radiator using soft 9 Install radiator as described in Paragraph 10 Fill cooling system and test for leaks If the transmission operates properly after repair ing th...

Page 211: ...ning a copper impregnated wax as shown in Fig 7 As the temperature of the pellet increases the wax expands and opens the valve A 185 degrees thermostat is standard equipment The use of al cohol type anti freeze is not recommended If the thermostat does not close completely when cold the engine will warm up slowly or not at all and heater performance will also be impaired Poor heater performance ma...

Page 212: ...ed has not increased 100 rpm or more before gauge indicator reaches top of normal bar or warning light has come on valve is defective and should be replaced 10 Idle engine radiator uncovered until temp erature is normal reconnect distributor solenoid wire at carburetor and re adjust idle rpm RADIATOR HOSES The hoses are removed and installed using hose clamp pliers C 3250 A hardened cracked swolle...

Page 213: ...7 10 COOLING SYSTEM I L I MyMopar com ...

Page 214: ...dicate a serious internal leak in the engine If there is an internal leak the engine must be disassembled the leak located and neces sary new parts installed ally a head gasket WARNING Pressure builds up fast Any exces ENGINE WATER TEMPERATURE GAUGE sive amount of pressure built up by continuous For Removal Installation and Testing procedures engine operation must be released to a safe of the wate...

Page 215: ...ned by torque wrench using the square hole of torque wrench should be approximately vertical in the brackets to obtain proper tension Tighten all mounting To tighten belts by the torque method loosen all bolts while torque is applied to the accessory If it mounting bolts and apply specified torque to the is difticult to use the torque wrench because of clearance use an extension MyMopar com ...

Page 216: ... Yes Yes 3443978 19 3443977 22 3443976 22 3443976 22 3443976 22 IO 10 IO 12 12 12 None Yes None Yes Yes Yes Yes Yes 3443975 22 Yes Yes FAN Diameter Number Blades Width Standard 17 4 1 1 2 17 4 1 1 2 18 7 2 18 7 2 1 4 Automatic 17 4 1 1 2 17 4 1 1 2 18 7 2 18 7 2 1 4 Air Conditioning N A 17 7 1 1 2 18 7 2 1 4 18 7 2 1 4 High Capacity 17 7 1 1 2 17 7 1 1 2 18 7 2 1 4 N A Spacer Standard 1 0 6 1 06 1...

Page 217: ...ts a l Y zyxwvuts 0 Y zyxwv iu iubb N N N N N c iubb b b b N N N k iuiu N N I I I k I I I W 9 I I 0 0 m m Jrn m W L 0 2 _ o r a m m o Y U W Z g f LT E E 5 l z G a m c n c C L 5 a 7 5 u 3 I v i m r m c f I a L u U MyMopar com ...

Page 218: ...Z zyxwvuts al I n c 2 0 3 5 Z al 3 E Z w Y b b b hlhlhl zyxwvutsr c P zyxwvutsr W b I zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONM Y Y m WCD 1 I 0 0 u m m iuiviu c c c 5 I U t J m L u s m w o 4 1 2 m MyMopar com ...

Page 219: ... zyxwv 0 b iubb i u Y N b I N I m 4 rn rn D b b b N h l h l I l l N iubb N N N a z 5 o zyxwv 3 Y m c MyMopar com ...

Page 220: ... Y F 7 a PI 2 a b b z m q m 9 9 m h l m 9 r 2 6 5 5 7 a G Z G b b b b N N N N b I Ln N x m zyxwvutsrqponmlkjih Y Y a z i I W 0 I j 2c E x m U m I iv N k I I D I 5 m z v N h l VI L a l S q V I U z m 5 MyMopar com ...

Page 221: ...W W h m m cow 5 m E zyxwvuts 3 3 m v I 8 8 hr hrbb N N N N I I I h l h l y 7 r n q r n zyxwvut 9 9 v I E 3 L io iobb N N N N I I l l z F m r 5 MyMopar com ...

Page 222: ...6 12 12 12 Yes Yes Yes Yes N A 3443946 28 3443946 28 3443946 28 12 12 Yes Yes Yes All FAN Diameter Number Blades Width Standard 18 7 2 N A N A N A Automatic 18 7 2 18 7 2 18 7 2 18 1 2 7 2 1 2 A C 18 1 2 7 2 1 2 18 1 2 7 2 1 2 18 1 2 7 2 1 2 18 112 7 2 112 High Capacity 18 7 1 11 8 18 7 2 1 1 8 18 7 2 1 1 8 N A Standard 1 60 1 60 1 60 Torque A C Thermal Thermal Thermal Thermal High Capacity 1 6 0 ...

Page 223: ... Lbs Gauge Reading USED BELT All 70 Lbs Gauge Reading 50 35 90 10 70 80 30 10 25 40 15 20 20 TORQUE METHOD TIGHTENING REFERENCE Inch Pounds Water Pump Bolts Fan Attaching Bolts Thermostat Housing Bolts Shroud Mounting Bolts Radiator Mounting Bolts Drain Cock Oil Cooler Fittings To Radiator Lines to Fittings Lines to Auxiliary Cooler Lines to Connector 12 75 95 150 110 85 85 50 Foot Pounds 30 30 15...

Page 224: ...ine battery case and cover for cracks 9 Install battery 10 Tighten battery hold down screw nuts to 3 foot pounds Observe polarity of battery termi nals to be sure the battery is not reversed 11 Connect cable clamps to battery posts and tighten securely Coat all connections with light mineral grease or petrolatum after tightening clamp terminals with Cleaning Tool MX 75 12 If electrolyte level is l...

Page 225: ... Fahrenheit is zero Add zyxwv 004 specific gravity points for every 10 degrees NP165 Q 8 Fig 2 Testing Battery Cells with Cad rip Battery Cell Analyzer over 80 degrees F and subtract 004 specific grav ity points for every 10 degrees under 80 degrees F All readings must be corrected at 80 degrees Fahrenheit Refer to Figure 1 and examples one and two as follows Example 1 Hydrometer Reading 1 260 Aci...

Page 226: ... to FOURTH CELL etc until all cells have been REPLACEMENT RECOM VARY BY 5 OR MORE D IF CELL READINGS 0 A 0 zyxwvutsr oo C tested Note each cell reading so that CELL COMPARISONS CAN BE MADE Always store probe assembly in the space provided in the meter case TEST READING INTERPRETATIONS Fig 3 A If the readings of any two cells vary FIVE scale divisions or more on the TOP scale regardless of the colo...

Page 227: ...ngs as warm electrolyte will read low and this might be mistaken for failure of the battery to rise normally in gravity It could also NY838B Fig 5 Three Minute Charge Test be falsely concluded that the battery would not take a full charge HIGH RATE DISCHARGE TEST OF BATTERY CAPACITY Satisfactory capacity tests can be made only when battery equals or exceeds 1 220 specific grav ity at 80 degrees Fa...

Page 228: ...s not show a significant change in specific gravity after one hour of FAST charge the slow charge method should be used Remember to use temperature correction when checking specific gravity The manufacturers of high rate charging equipment generally outline the necessary precautions and some models have thermostatic temperature limiting and time limiting controls WARNING When batteries are being c...

Page 229: ...mation 6 Ground Circuit Test 9 Assembling the Starter 13 Brushes and Springs Replacement 12 Bushings Replacement 13 Field Coils Replacement 12 GENERAL INFORMATION The starter has a 3 5 to 1 reduction gear set Page Insulated Circuit Test 8 Installing the Starter 16 Removing the Starter 9 Resistance Test 9 Service Diagnosis 7 Servicing the Starter Clutch Unit 13 Specifications 123 Testing the Starte...

Page 230: ...st specific gravity Recharge or replace battery as required b Test and replace switch if necessary c Clean terminals and clamps replace if necessary Apply a light film of petrolatum to terminals after tightening d Inspect and test all the wiring e Test relay and replace if necessary f Test and repair as necessary 9 Test and repair h Test and replace solenoid if necessary a Test for specified gravi...

Page 231: ...epair e Test and replace relay if necessary SERVICE PROCEDURES ballast resistor or primary wire from either side AMPERAGE DRAW TEST with Starter of coil to prevent engine from starting Tester Crank engine with a remote control starter Check battery electrolyte gravity with a reliable switch and observe Exact reading on Voltmeter hydrometer Gravity should be not less than 1 220 Stop cranking engine...

Page 232: ...cates there is high resistance caused from loose circuit connections a faulty cable burned starter relay or burned solenoid switch contacts A cur rent that is high and is combined with slow cranking speed indicates starter should be re moved and repaired GROUND CIRCUIT TEST 1 Connect test voltmeter positive lead to starter housing and voltmeter negative lead to battery negative post 2 Crank engine...

Page 233: ...gh to expose terminal screw SOLENOID LEAD WIRE L n NU431A Fig 3 Unwinding or Winding Solenoid lead Wire Fig 5 Removing Dust Cover and wire wrap connection of shunt field at brush terminal Place two wood blocks between starter frame and starter gear housing to facili tate removal of terminal screw Fig 2 4 Support brush terminal by placing a finger behind the terminal and remove terminal screw 5 Unw...

Page 234: ...ion and zyxwvu a cloth 5 Fig 7 Removing or Insfalling Pinion Shaft Retainer Ring PINION SHAFT DRIVEN GEAR Fig 9 Removing or Insfalling Clutch Assembly SHIFTING F O R K PIN SHIFTING FORK ND213A Fig zyxwv I1 Removing or Installing Shifting Fork Pin should be placed over the retainer to prevent it from springing away after removal 16 Release retainer ring at front of pinion shaft Fig 7 Do not spread ...

Page 235: ... 3 Measure brush spring tension with a spring scale hooked under the spring near the end Pull scale on a line parallel to the edge of brush and take a reading just as spring leaves brush Spring tension should be 32 to 36 ounces Replace springs that do not meet specifications TESTING ARMATURE Testing Armature for Short Circuit Place armature in growler and hold a thin steel blade parallel to the co...

Page 236: ...leaning solvent Starter clutch is pre lubricated at the fac tory and a solvent will wash lubricant from the clutch The starter clutch outer housing and pinion gear may be cleaned with a cloth moistened with a cleaning solvent and wiped dry with a clean dry cloth Rotate the pinion Pinion gear should rotate smoothly in one direction not necessarily easily but should not rotate in opposite direction ...

Page 237: ...d pinion assembly thrust washer retaining and thrust washer Fig 9 5 Complete installation of pinion shaft engag ing shifting fork with clutch actuators Figures 16 and 17 show correct relation of parts at assembly The friction washer must be positioned on shoul der of splines of the pinion shaft before driven gear is positioned 6 Install driven gear snap ring Fig 6 7 Install pinion shaft retaining ...

Page 238: ...minal stud in brush holder Inspect condition of the contacts in brush hold er plate If contacts are badly burned replace brush holder with brushes and contacts as an assembly 1 1 Position seal on brush holder plate 12 Enter solenoid lead wire through hole in NU435A Is c _ I Fig 19 Soldering Solenoid Winding lead to Brush Terminal L Fig 21 Soldering Shunt Coil Lead Wire brush holder Fig 18 and inst...

Page 239: ...ing the Starter Parts 1 9 Disassembling the Starter 18 Drive Unit Servicing 2 2 Drive Gear Pinion Clearance Adjusting 2 2 Field Coils Replacement 21 Free Running Test 17 Installing the Starter 2 2 Insulated Circuit Test 17 Page Removing the S Jrter 1 7 Resistance Test 17 Specifications 123 Starter Circuit Tests 17 Ground Circuit Test 17 Insulated Circuit Test 17 Testing Armature 20 Armature for Sh...

Page 240: ...ve the voltmeter lead from the solenoid connector and connect to the following points re peating test at each connection Starter terminal of solenoid battery terminal of solenoid battery cable terminal at solenoid starter relay and cable clamp at battery b A small change will occur each time a nor mal portion of the circuit is removed from the test A definite change in voltmeter reading indi cates...

Page 241: ...facturer and test the locked resistance of the start er as follows zyxwvuts NB 19 I With applied battery voltage adjusted to 4 volts current draw should be as shown in specifications DISASSEMBLING THE STARTER tap commutator end head from field frame 1 Refer to Figure 1 remove through bolts and 2 Remove thrust washers from armature shaft 3 Lift brush holder springs and remove brushes 4 Remove brush...

Page 242: ...ay from field frame Fig 7 Re move pole shoe screws with special pole shoe im pact screwdriver Tool C 3475 CLEANING THE STARTER PARTS 1 Do not immerse parts in cleaning solvent Immersing the field frame and coil assembly O R K Fig 5 Removing Shifter Fork Pivot Pin INSULATED BRUSH NK512A Fig 7 Brush Repfacement and or armature will damage insulation Wipe these parts with a cloth only 2 Do not immers...

Page 243: ...ring end leaves the brush Spring tension should be 32 to 36 ounces Replace springs that do not meet specifications 12 Brush springs can be removed by spreading the retainers and disengaging the springs from re tainer legs TESTING THE ARMATURE Testing Armature for Short Circuit Place armature in a growler Fig 8 and hold a thin steel blade parallel to the core and just above it while slowly rotating...

Page 244: ...ne test probe while holding other test probe against brush ring Two brush holders that are 180 de Fig 12 Tesfing Insulated Brush Holder for Ground grees apart should cause test lamp to light as they are intentionally grounded The other two brush holders Fig 12 should not cause lamp to light when tested as they are insulated If insulated brush holders cause lamp to light when tested it indicates th...

Page 245: ...ve end pinion housing on arma ture shaft indexing shifting fork with slot in drive end housing 5 Install shifter fork pivot pin Fig 5 6 With clutch drive shifter fork and pinion housing assembled to the armature slide armature into field frame until pinion housing indexes with slot in field frame 7 Install solenoid and boot assembly Fig 4 Tighten bolts to 60 70 inch pounds 8 Connect field coil lea...

Page 246: ... INFORMATION output BAT terminal The main components of the alternator are the an A C current generator with six 6 built in rotor stator rectifiers the end shields and the silicon rectifiers that convert A C current into drive pulley Bench Tests 2 9 Regulator Testing 2 7 General Information 2 3 Service Diagnosis 2 3 Output Tests 25 Specifications 1 2 3 The alternator Figs 1 and 2 is fundamentally ...

Page 247: ...and correct as required f Inspect all connections in charging circuit and correct as required 9 Remove alternator and disassemble Test stator windings Install new stator if necessary h Remove alternator and disassemble Test the recitfiers Install new recitfiers if necessary a Tighten ground lead connections Install new ground lead if necessary b Adjust alternator drive belt c Clean and tighten bat...

Page 248: ...ernator Assembly the on state continuously One other important feature of the electronic regulator is the ability of its control circuit to vary the regulated system voltage up or down as the temperature changes This provides the best charging conditions for the batttery throughout the seasons of the year ISOLATED FIELD ALTERNATOR CHARGING CIRCUIT RESISTANCE TEST AND CURRENT OUTPUT TEST 1 Disconne...

Page 249: ...8 26 Z W W I E L 3 Lu 3 m I 3 MyMopar com ...

Page 250: ...ter the regulator is working properly if the voltage readings are in accordance with the fol lowing chart It is normal for the car ammeter to show an im mediate charge and then gradually return to nor mal position The duration the ammeter hand re mains to the right will be dependent on the 19 Connect the battery ground cable AMBIENT TEMPERATURE NEAR VOLTAGE REGULATOR VOLTAGE RANGE 20 F 14 3 15 3 8...

Page 251: ...LD BALLAST RESISTOR TO IGNITION 2 ISOLATED FIELD ALTERNATOR ISOLATED FIELDzyxw y ALTERNATOR Y BLUE 5 TOR GREEN 3 NU651B fig 4 Current Output Test SPARK PLUGS LEFT BANK Fig 5 Voltage Regulator Test Without Tester Tool C 4133 NU6526 MyMopar com ...

Page 252: ... BLACK BUTTON A Fig 7 Voltage Regulator Test Depressing Test Button 6 1 Connect a wire between one field terminal of the alternator and the positive terminal of a fully charged battery Connect test ammeter positive lead to the other field terminal of the alternator and the negative lead to the battery negative terminal 2 Slowly rotate alternator rotor by hand Ob serve ammeter reading Field coil dr...

Page 253: ...Drive End Shield From Stator NEGATIVE CASE RECTIFIERS TESTER TO END HOUSING NU353A Fig 1I Testing Negative Rectifiers Testing the Rectifiers with Tool C 3829 The Rectifier Tester Tool C 3829 provides a quick simple and accurate test of the alternator rectifiers without the necessity of disconnecting soldered rectifier leads With alternator rectifier end shield separated from drive end housing pro ...

Page 254: ... a test lamp equipped with a number 67 bulb 4 can dle power by connecting one side of test lamp to positive battery post other side of test lamp to a test probe with other test probe connected to the negative battery post c Contact outer case of rectifier with one probe and other probe to wire in center of recitifier Fig 13 d Reverse the probes moving probe from recti fier outer case to rectifier ...

Page 255: ... must be replaced unsolder the rectifier wire from the sta Fig 16 Removing the Rectifiers Fig 18 Disengaging Beoring Retoiner from End Shield tor lead wire at the soldered joint When remov ing rectifiers it is necessary to support end shield and or heat sink to prevent damage to these castings 4 Place Rectifier Removing and Installing Press in a vise and support end shield on clamp anvil under rec...

Page 256: ...inside capacitor The heat sink is also held in place by the ter minal screw 11 Remove insulator Fig 20 12 The needle roller bearing in rectifier end shield is a press fit If necessary to remove rectifi Fig 22 Solder Poinfs Slip Ring lnsfalled er end frame needle bearing protect end shield by supporting shield with Tool C 3925 when pressing bearing out with Tool C 3770A Fig 21 Make sure notches in ...

Page 257: ...ip ring on shaft I k LEAD WIRE SLIP RING LUG J 3 NP366A Fig 24 Aligning Slip ring with Field lead Wires SI NP368 Fig 26 Soldering Field Coil leads When slip ring is bottomed on rotor fan the field lead wire insulated brush ring should clear the access hole the fan and pole piece 6 Tin field coil lead wires k Coil each field lead wire around the slip ring lug starting first wrap against shoulder of...

Page 258: ... collar of rectifier bottom against casting Fig 28 Make sure installer support adapter fits square around the rectifier inner boss and N F 44A Fig 28 Installing a Rectifier CAPACITOR STATOR Fig 30 Installing Rectifier End Shield Bearing that pressure is applied on outer rim of rectifier CAUTION DO NOT USE a hammer to start the rectifier into its bore in end shield DO NOT HAMMER OR SHOCK the rectif...

Page 259: ...ressure Do not hammer 10 The alternators have the capacitor mounted internally Make sure heat sink insulator is in ROTOR SHAFT PULLEY ROTOR ND117 Fig 32 Installing Alternator Pulley 11 Install output terminal screw and capacitor 12 Install insulating washers lockwashers and 13 Make sure heat sink and insulator are in 14 Position stator on rectifier end shield 15 Position rotor and end shield assem...

Page 260: ...ermine cause and correct condition Clean distributor cam of dirt and grease apply a light film of distributor cam lubricant to cam lobes wipe off excess See Distributor Lubrication Replace contact set and adjust as necessary b Test alternator voltage regulator setting adjust as necessary Replace contact set and adjust as necessary c Align and adjust contacts d Test and replace coil if necessary Re...

Page 261: ...ll the proper adapter between cable and the spark Plug Fig 2 Installing Secondary Cable and Nipple at Coil Tower b Lift distributor cap from distributor with ca bles intact Do not remove cables from the cap c Connect the ohmmeter between spark plug adapter and the corresponding electrode inside the cap making sure ohmmeter probers are in good contact If resistance is more than 30 000 ohms remove c...

Page 262: ...osed This is also commonly referred to as dwell angle or cam angle Correct distributor contact dwell is essential for good ignition performance and contact life Test procedures are as follows 1 Disconnect vacuum line 2 CONNECT Tach Dwell red lead to distribu tor terminal of coil and black lead to a good ground 3 Turn Selector Switch to 6 LOBE position 4 Start engine and operate at idle speed 5 Obs...

Page 263: ...battery positive post 1 Connect C 744 test lamp between distributor 2 Turn engine until number 6 exhaust valve is just closing continue turning the engine slowly until mark on the crankshaft pulley is at specified degree mark at case cover 3 Loosen distributor clamp bolt so distributor housing can be rotated with a slight drag then turn distributor in the normal rotation until test lamp lights 4 T...

Page 264: ...on the highest point of the cam lobe during this test If the plunger movement exceeds 006 inch replace the distribu tor housing or shaft assembly see Distributor Disassembly DISTRIBUTOR DISASSEMBLY Fig 4 NUT CONTACT PLATE SHAFT ASSEMBLY 1 Remove distributor rotor 2 Remove the two screws and lockwashers at taching the vacuum control unit to distributor housing and remove vacuum control unit 3 Disco...

Page 265: ...of Rotor Electrode as shown in Figure 5 zyxwv Do not Scribe completely across the shaft c Remove rollpin and gear Use a fine file to clean burrs from around pin hole d Install new gear with thrust washer in place Drill hole in gear and shaft approximately 90 de grees from old hole in shaft and with scribed line centered between the two gear teeth as shown If it appears that the new pin hole may in...

Page 266: ...esence of oil or other foreign material defective condenser and improper contacts adjustment High voltage causes an excessively high current flow through the contacts which burns through them rapidly High voltage can re sult from an improperly adjusted or inoperative voltage regulator Oil or crankcase vapors which work up into the distributor and deposit on the contact surfaces will cause them to ...

Page 267: ...b utor at speeds called for under Specifications and observe arrow flashes opposite tester degree ring to determine degrees of advance 6 If advance is not according to specifications replace with correct distributor shaft assembly shaft cam yoke governor weights as complete assembly or distributor assembly less cap and rotor Vacuum Diaphragm leak Test With distributor mounted in Distributor Tester...

Page 268: ...cause of a burned tower carbon tracking or any evi dence of arcing at the tower the nipple or boot on the coil end of the secondary cable replace cable Any arcing at the tower will carbonize the nipple so that placing it on a new coil will invari ably cause another coil failure If secondary cable shows any signs of damage cable should be replaced with a new cable with a neoprene nipple since the o...

Page 269: ...s and at the spark plugs Terminals should be fully seated The nipples and spark plug covers should be in good condition Nipples should fit tightly on the coil cap towers and spark plug covers should fit tight around spark plug insulators Cable con nections that are loose will corrode and increase the resistance and permit water to enter the tow ers causing ignition malfunction To maintain proper s...

Page 270: ...the cable resistance If resistance is more than 30 000 ohms on cables under twenty five inches long or zyxwvu 50 000 ohms on cables over twenty five inches long re place cable assembly Test all spark plug cables in same manner To test coil to distributor cap high tension cable remove distributor cap with the cable intact Do not remove cable from the coil or cap Connect Fig Blnstalling Secondary Ca...

Page 271: ...eds with the fast curb idle ad justing screw resting on the solenoid plunger DISTRIBUTOR CONTACT DWELL The degrees of distributor dwell are the degrees of rotation through which the contacts remain closed This is also commonly referred to as dwell angle or cam angle The correct distributor point dwell is essential for good ignition performance and contact point life Test procedures are as follows ...

Page 272: ...ad of specified degree mark on the timing plate The timing is advanced To adjust turn distributor housing Not Vacuum Chamber Counter clockwise Do not use vacuum chamber as a turning handle If the timing light flash occurs when the timing mark on the vibra tion damper is located past the specified degree mark on the timing plate The timing is retarded To adjust turn distributor housing clockwise Ti...

Page 273: ...ary terminal and battery positive post 2 Turn engine until number 6 exhaust valve is just closing continue turning engine slowly until ND326 specified degree mark on the crankshaft pulley is at specified degree mark at timing case cover 3 Loosen distributor clamp bolt so distributor housing can be rotated with a slight drag then turn distributor in the normal rotation until test lamp lights 4 Turn...

Page 274: ... ROTOR CONDENSER LEAD SCREW ___ CONTACT S R WASHER SCREW BREAKER PLATE WASHER SCREW FELT LEAD i SNAP RING c d zyxw r CAM CLAMP BEARING LOCKWASHER V A C U M CHAMBER SPRING PIN PY927 Fig 6 Distributor Disassembled View Chrysler Built Typical MD31OB Fig 7 Distributor Disassembled View Prestolite MyMopar com ...

Page 275: ... built distributors are held in place by peened metal around the open ings and should not be removed 2 Remove the retainer attaching vacuum ad Fig 9 Installing Upper Bushing vance unit to the contact plate advance arm Prestolite 3 Remove the two screws and lockwashers at taching vacuum advance unit to distributor hous ing and remove the advance unit 4 Remove primary lead wire and rubber grom met a...

Page 276: ...ect all bearing surfaces and pivot pins for roughness binding or excessive looseness 3 Install cam spacer chamfered end down on distributor shaft Prestolite only 4 Slide cam and yoke on distributor shaft en gage weight lugs with slots in the yoke Install cam retaining spring clip Be sure it is properly seated in the groove of distributor shaft Prestolite only 5 Lubricate and install flat thrust wa...

Page 277: ...contacts If the contact opening is too small cam angle too large arcing will occur between the contacts resulting in low secondary voltage and engine miss High series resistance in the condenser circuit will prevent normal condenser action so the con tacts will burn rapidly This resistance may be caused by a loose condenser mounting or lead connection or by poor connections inside the condenser Pi...

Page 278: ...ap and rotor For Prestolite distributors corrections can be at tempted by bending the primary and secondary spring tabs on the cam yoke to increase or de crease spring tension DO NOT attempt calibration of Chrysler built distributors VACUUM Diaphragm Leak Test With distributor mounted in distributor tester and with vacuum unit attached to distributor pro ceed as follows 1 Place thumb over end of v...

Page 279: ...ble shows any signs of damage the cable should be replaced with a new cable with a neoprene nipple since the old cable can cause arcing and therefore ruin a new coil Fig 75 Cold Fouling BALLAST RESISTOR The ballast resistor is a compensating resistance in the ignition primary circuit During low speed operation when the primary circuit current flow is high ballast resistor temperature rises increas...

Page 280: ...FORMATION The fuel and temperature and oil pressure gauges operate on the constant voltage principle through a voltage limiter On models equipped with the low fuel warning system the voltage limiter is part of the low fuel relay and supplies power for the fuel gauge only FUEL LEVEL INDICATING SYSTEM A hinged float arm in the fuel tank raises or lowers dependent on the fuel level The float arm cont...

Page 281: ...itch mounted on the engine is controlled by engine oil pressure When engine oil pressure is high normal operat ing condition of the engine the switch is held in the OFF or OPEN position allowing no cur rent to flow to the oil pressure warning lamp on instrument panel When engine oil pressure is low the switch is in the ON or CLOSED position allowing current to flow to the oil pressure warning lamp...

Page 282: ...the voltage limiter is operating The Imperial model has an in line choke for radio noise suppression The choke is built in the low fuel relay FUEL GAUGE CIRCUIT With Low Fuel Warning Some models incorporate a Low Fuel Warning Part of the Sentry Signal on Imperial on the in strument panel A relay is used in the circuit to feed the fuel gauge separately The tank unit is a standard tank unit connecte...

Page 283: ...nk ground strap on the fuel line at the tank is making a good ground Should the gauge perform properly and the ground strap be properly installed remove the fuel tank sending unit as outlined in Fuel System Group 14 and test as COOLANT TEMPERATURE follows 1 Using an ohmmeter with a OIL PRESSURE 0 NK698C I 100 ohm scale connect one lead to body of sending unit and the other lead to terminal in cent...

Page 284: ...ator light should not light With the gauge tester in the M position the indicator light should show a dull glow With the gauge tester in the H position the indicator light should show full brilliance Should the oil pressure warning light fail to re spond to the above tests indications are of possi ble loose connections broken wire or burned out lamp OIL PRESSURE GAUGE If so equipped Disconnect wir...

Page 285: ... and allow switch to remain connected to wire harness 9 Roll cluster out from panel opening face down and to the right Installation 1 Work cluster in to place from right of steer ing column face down in front of panel opening Reaching around behind connect ammeter wires right printed circuit board connector wiper emer gency warning switch connectors and vacuum gauge hose or tachometer wire if so e...

Page 286: ... Removal and Installation Barracuda 2 Position cluster bezel and connect stereo con trol wiring harness if so equipped CAUTION When installing cluster bezel be sure stereo control harness is tucked into panel to avoid being trapped by bezel Install bezel mounting screws 3 Connect speedometer cable and install clock reset knob and odometer reset knob 4 Raise steering column into position and in sta...

Page 287: ...ft trim bezel and or spot cooler if so equipped 6 Remove left air conditioner duct and center air conditioner connector if so equipped 7 From under instrument panel disconnect elec trical leads to switches and clocks lamp assem blies from cluster and speedometer cable from speedometer head 8 Remove gear shift indicator pointer from column 9 Tape steering column to protect paint finish 10 Remove th...

Page 288: ...r shift indicator pointer SCRE t 6 I SCREW 5 zyxwvu ACLUSTER AND BEZEL Fig 10 Instrument Cluster and Bezel Removing and Installing Imperial 6 Lower the steering column by removing the 3 duffy plate mounting screws the steering col umn ground nut and wire and the 3 upper steer ing column attaching nuts Allow the steering wheel to rest on the seat cushion NU560 7 Disconnect the speedometer cable 8 R...

Page 289: ...nt Chrysfer Ammeter Gauge 1 Remove the instrument cluster 2 Remove the tripmeter reset knob 3 Remove 2 wiper washer switch assembly mounting screws and the switches 4 Remove 2 accessory switch bezel mounting screws and remove the switch and bezel assembly 5 Remove the 4 center A C spotcooler assem bly mounting screws and the center A C spotcool er assembly mounting screws and remove the cluster be...

Page 290: ...p pin re tainers and lift lens from housing 3 Remove two speedometer mounting screws with attached insulators Remove speedometer from cluster housing Installation install mounting screws and insulators secure with snap pins 1 Position speedometer on cluster housing and 2 Assemble cluster lens to cluster housing and SPEEDOMETER Satellite Removal To replace the speedometer it is necessary to remove ...

Page 291: ...rom a 12 volt bat tery will damage the gauges or printed circuit boards 0 30 AMPERE CIRCUIT BREAKER 15 AMPERE CIRCUIT BREAKER WINDOW LIFT SAFETY RELAY NU558 Fig 1 2 Removing and Installing Circuit Breakers or Relays FUEL TANK SENDING UNIT Before removing any unit of the fuel level indi cating system the panel fuel gauge should be test ed first See Tests in Vehicle If the panel gauge performs prope...

Page 292: ...CH REPLACEMENT Barracuda Removal Before performing this operation it is advisable to put a protective cover over the top of the instrument panel and steering column to prevent damage 1 Disconnect battery ground cable 2 Remove the six lamp panel mounting screws Carefully slide lamp panel out and lay on top of instrument panel It is not necessary to disconnect wiring harness 3 Remove the four switch...

Page 293: ...Remove center A C connector assembly 2 From under the panel disconnect the vacu um and or wiring connectors from the accessory switches 3 From under the panel remove the 2 screws which attach the accessory bezel to the instrument cluster 1 screw at upper left comer and 1 at lower right corner of accessory bezel 4 Remove accessory bezel and switches from the front of the instrument panel Roll top o...

Page 294: ...de lamp panel out and place of instrument panel It is not necessary to nect wiring harness 8 73 screws on top discon 3 Remove the four switch bezel mounting screws Carefully slide assembly out and to the right overlapping cluster then lower it until free from instrument panel Disconnect wiring harness and remove switch bezel 4 Remove left trim bezel by removing the four exterior screws and one fro...

Page 295: ...ing connectors while removing the controls from un der the panel AIR CONDITIONER OUTLET Center Fury Removal center only two 1 Remove air conditioner distribution duct 2 Remove center outlet bezel mounting screws 3 Remove center outlet from panel Installation 1 Position center outlet and install bezel mounting screws 2 Install center distribution duct Reach up un der instrument panel and install ce...

Page 296: ...cable 2 Remove cluster assembly 3 Remove clock CLOCK Fury Removal 1 Remove clock reset knob 2 Roll cluster bezel down and towards you NOTE It is not necessary to remove the bezel assembly only roll it far enough to gain access to clock wiring and mounting screws 3 Disconnect clock wiring 4 Remove 2 clock mounting screws 5 Remove clock from bezel CLOCK Chrysler Removal 1 Remove the center A C conne...

Page 297: ...f trim pad to instrument panel and secure with 4 Remove steering column cover mounting screws screws Remove steering column cover from in INSTRUMENT PANEL TRIM PAD Satellite 5 Lower steering column see Section 19 in Fig 16 The instrument panel trim pad on Satellite is 6 Remove lamp panel mounting screws Lower attached with stud type retainers and nuts lamp panel assembly slightly to disconnect lam...

Page 298: ...over instru ment cluster release remaining harness from wir ing clips also disconnect left stereo speaker elec trical leads 14 Remove instrument panel trim pad from lower sheet metal carefully so components mount ed on underside of trim pad are not damaged INSTALLATION 1 Place trim pad on lower instrument panel sheet metal 2 Working through glove box opening replace 6 upper trim pad to lower panel...

Page 299: ... at speedometer 14 Remove brake release handle pin at rear of assembly push handle forward 15 Remove left A post moulding screw and left upper corner windshield moulding screw 16 Loosen upper left corner of windshield moulding and remove left A post moulding 17 Remove right A post moulding screw and right upper corner windshield moulding screw 18 Loosen upper right corner of windshield moulding an...

Page 300: ...top moulding and remove left A post moulding 15 Remove right A post moulding screw and right upper corner moulding screw 16 Loosen upper right corner of top moulding and remove right A post moulding 17 Remove two screws from right and left sill plates 18 Remove two screws from right and left cowl trim panels and remove trim panels 19 Disconnect fresh air door control cables at the fresh air doors ...

Page 301: ...n circuit The relay is designed for intermittent duty Con tinuous operation will cause it to overheat The key warning buzzer is energized whenever the key is in the ignition switch regardless of position Accessories Off On and the driver s zer switch and door switch contacts are closed completing the buzzer circuit The headlamp On warning buzzer is a sepa rate unit It is energized whenever the hea...

Page 302: ...Before installing ignition switch and key cylinder make sure the shift housing is in a lockable posi tion park with automatic or reverse with manual transmission When installing the key cylinder it must be turned to lock position key removed Insert cylinder insert key and turn to Off position Make sure ignition switch is turned to the Off position to index its cam with the lock cylinder position 1...

Page 303: ...reo Speakers 95 AM or FM can be selected by moving the slide switch above the push buttons to the right or left Station selection is accomplished either manually by pressing the push buttons fully in or by turn ing knob at right With the search tune radio in addition station selection is accomplished by auto matically by pressing the bars marked Loc local or DIST distant or by foot operated button...

Page 304: ...the custom er understands what to expect from FM reception The factors governing FM automobile reception are listed below with a brief description of the design features which minimize reception difficulties These reception difficulties are restrict ed primarily to the fringe area and metropolitan reception is excellent Range Normal range for Chrysler AM FM radio is ap proximately 35 miles There a...

Page 305: ...opolitan areas or within approxi mately 25 miles of the station The four Intermediate Frequency stages and FM Detector circuit in the Chrysler AM FM radio keep motor noise pickup in the fringe area to a minimum Combination AM FM and AM Radio with Stereo 8 Track Tape Player Fig 3 Acc position To operate Ignition switch must be at On or The operating controls consist of two knobs and a tape program ...

Page 306: ...ided PB217 Fig 4 AM FM Multiplex Thumbwheels AM FM Multiplex Knobs Fig 5 To operate Ignition switch must be at On or Acc position Turn the left hand knob clockwise to On position This same knob adjusts the volume level The ring behind left knob provides selection of tone quality PB218 Fig 5 AM FM Mulfiplex Knobs SELECTOR KNOB EJKTIC BAK Fig 6 Sfereo Casseffe Tape Recorder Operation of the Stereo T...

Page 307: ...rts you that you are in the record mode This helps prevent accidental erasing of the tape Caution To preclude the possibility or foreign matter accidentally entering the Recorder it is recommended that a cassette be left in cassette holder at all times Store cassettes in a cool dry and clean place away from direct sunlight Fader Control Optional The fader control is used only when the vehicle is e...

Page 308: ...e an ohmmeter test Step b Radio Inoperative If static is heard check for a loose or faulty capacitor If capacitor is zyx OK remove antenna plug from radio receiver and bummp receiver with heel of hand If no static is heard start engine turn on headlights and slowly accelerate engine speed If a whining noise is heard turn off headlights and if whining noise is still present tune in AM to a weak sta...

Page 309: ...tor lead wires are making good contact on their re spective terminals and are securely mounted Faulty or deteriorated spark plug wires should be replaced ANTENNA TRIMMING All radios are trimmed at the factory and should require no further trimmer adjustment However Y POST COJ I MOI BRA MOU BOLT KP 439 B Fig 9 Ignition Coil Capacitor whenever a radio is being installed after repair or if verificati...

Page 310: ...er fender remove the lower adapter mounting collar and antenna lead and body assembly lnsfa hfion A I Models 1 Assemble mounting collar to antenna body if removed 2 Enter antenna body from underneath fender and insert through mounting hole in fender 3 Install gasket adapter and capnut Tighten capnut to 155 inch pounds plus or minus 25 inch pounds with Tool C 4085 Fig 13 4 Install antenna mast into...

Page 311: ...ping mast rods Clean and straighten the telescoping mast rods 2 Occasionally poor recption can be corrected by proper adjustment of radio antenna trimmer If this fails to produce desired results a substitute antenna known to be satisfactory may be plugged into radio with extended mast held out of car window Do not ground mast Upon establishing that the fault is in antenna assembly it may be traced...

Page 312: ...ECTRICAL 8 91 n CLAMP MSCREW Fig 15 Removing or Instolling Power Antenna Chrysler FENDER REFERENCE ANTENNA AND CA ANTENNA FERRULE CONNECTOR NU534 Fig 16 Removing or Instolling Power Antenna Imperial Service Only MyMopar com ...

Page 313: ...sembly 6 Apply 12 volts D C to yellow up power lead and ground until entire length of nylon cord has been expelled from the drive To prevent a kink or bend in nylon cord keep it taut by pull ing on mast CAUTION DO NOT DISASSEMBLE MOTOR AND DRIVE ASSEMBLY FOR ANY PURPOSE In order to remove nylon cord from disabled motor and drive assembly place assembly in a vise so that normal plane of nylon cord ...

Page 314: ...inner glass surface One wire starts at the Fig 20 Windshield Mounted Antenna with Antenna Pigtail Disconnected ANTENNA WIRES CABLE AND WIN1 BRACKET ASSEMBLY SH IELD Fig 22 Antenna Lead and Radio Cable and Bracket Installation right top corner of the windshield glass the other wire starts at the left top corner and run along the upper part of the windshield glass approxi mately two inches from the ...

Page 315: ... Disconnect battery ground cable 2 Remove control knobs from front of radio On air conditioned models remove the two outlet duct retaining nuts and remove duct It is also necessary to remove the right defroster hose and hose bracket from back of radio 3 Remove bottom screw from radio mounting bracket 4 Remove left defroster tube 5 Loosen top screw on radio mounting bracket 6 Disconnect speaker and...

Page 316: ...ews 2 Remove the radio speaker mounting screws two and lift the speaker from the top instrument panel 3 Disconnect the speaker leads and remove the speaker STEREO SPEAKER LEFT Removal 1 Remove the instrument cluster 2 Remove the four stereo speaker grille mount 3 Remove the stereo speaker grille from top of 4 Remove four mounting screws and remove ing nuts from under the instrument panel instrumen...

Page 317: ...unted in the passenger compartment under the instrument panel at left pad or on the fuse block Battery current fram the B terminal of the starter relay flows to the B terminal of the horn relay When the horn ring or steering wheel rim horn switch is depressed the horn ring com pletes a ground circuit to the horn relay closing a Page Service Diagnosis 97 Service Procedures 97 Testing 97 set of poin...

Page 318: ...inals If horns horns operate the horn relay is faulty and should If the test light fails to light reconnect the con be replaced nector to the horn terminal and connect one lead of test light to the horn relay B terminal and 6 Horns sound continuously the other test light lead to a good body ground Should the horns sound continuously disconnect If the light fails to illuminate inspect for corroded ...

Page 319: ...will only clear up sound and cannot change horn tone frequency 5 Connect a test ammeter between positive post of a 12 volt battery and horn terminal post Con nect a jumper lead from negative battery post to horn base Clean paint from horn bracket where connection is made Turn adjusting screw to ob tain a reading of four amperes minimum to six amperes maximum Amperage must be within the range of 3 ...

Page 320: ...ry Fully rotating the control ring in the OFF direction or turn INTAKE PIN ing the ignition OFF also disengages the system and in addition erases the speed memory TO RESUME Rotate control ring fully in the RESUME direction Vehicle will resume to the previously memorized speed TO VARY SPEED SETTING To increase speed de press accelerator to desired speed and momentarily depress and release SPEED SET...

Page 321: ...lamp and speed control switch adjustment f Faulty electrical circuit a Insufficient rotation of control b Faulty electrical circuit a Speed control cable kinked or ring damaged b Replace fuse c Check vacuum lines d Connect and adjust control e Adjust stop lamp and speed f See Electrical Tests a Rotate ring fully toward b See Electrical Tests a Repair or replace cable cable See Tests and Adjustment...

Page 322: ...n Screw Adjustment The Lock in Screw Adjustment Fig 3 controls the accuracy of the speed control unit When the SPEED SET button is depressed and released at speeds above approximately 30 M P H the speed control system is activated the system locks in and should hold the vehicle at virtually the same speed at which it is traveling IMPORTANT lock in accuracy will be affected by a Poor engine perform...

Page 323: ...onnect the four wire electrical connec tor at the steering column b Connect a twelve volt positive source to the black wire terminal in the speed control harness connector male c With the lever rotary switch in the ON position attach one lead of a test lamp to the connector yellow wire other lead to a good ground test lamp should light and should go off when the Speed Set button is depressed d Mov...

Page 324: ...SPEED CONTROL SYSTEM ELECTRICAL 8 103 MyMopar com ...

Page 325: ...8 104 SPEED CONTROL SYSTEM ELECTRICAL MyMopar com ...

Page 326: ...pin and install retaining clip attaching nuts Tighten nuts securely 1 Position servo on mounting bracket studs and 2 Install vacuum hose and clamp Make sure 3 Connect speedometer and transmission drive 4 With choke in full open position align throt 5 Install cable cover on servo studs and install 6 Install electrical connectors at servo IFig Removing or Installing Throttle Cable Cover Servo Thrott...

Page 327: ...n the proper connector at reassembly See Figures 5 6 and 7 6 Tape terminals then turn direction indicator lever sideways and pull lever up and wires out through opening between column and tube C 4135 Installation 1 Make a guide wire and thread the harness through the opening in column Make guide wire Removal 1 Disconnect battery negative terminal at bat tery negative post and speed control harness...

Page 328: ...ent cluster or on the front fender flashes in unison with the turn signal lights indicating to the driver that the sys tem is operating If only momentary signalling is desired such as indication of a lane change the switch should be moved to an intermediate detent which causes the light to flash but returns to neutral when the le ver is released On tmperial and Chrysler The turn signal flasher is ...

Page 329: ...r 3 Install steering wheel on steering shaft with 4 Install washer and nut Tighten nut to 27 5 Install horn switch parts previously removed 6 Connect horn switch wires 7 Connect wiring connectors at steering 8 Install wiring trough cover and steering col 9 Connect battery ground cable test operation master splines aligned foot pounds from steering wheel column umn cover of turn signals and horns E...

Page 330: ... when the motor is turned On and reverses the action The two speed wiper system used on concealed wiper systems accomplishes its depressed parking action by reversing the rotation of the motor and the use of a parking cam on the motor crank pin When the wiper switch is turned Off the motor direction is reversed and at the same time the parking cam rotates 180 degrees lengthening the drive link sli...

Page 331: ... at the end of the wiper arm where the blade is attached to the arm With the force applied pull the wiper blade away from the windshield glass once or twice to prevent glass friction from affecting upward movement of the wiper arm and blade With the force applied the clearance between the side of the wiper blade and the blade should be as follows MODEL Clearance in Barracuda 1 25 to 3 00 Satellite...

Page 332: ...osition it correctly CAUTION The use of a screwdriver or other prying tool to remove an arm may distort it in a manner that will allow it to come off the pi vot shaft in the future regardless of how care fully it is installed NEVER under any circum stances push or bend the spring clip in the base of the arm in an attempt to release the arm PANEL SWITCH TESTS Two Speed To test the switch disconnect...

Page 333: ...n ohmmeter test for continuity no resistance between the contact terminals of the switch as shown in the following chart For test purposes the Park position is the switch zyxwv Off position The Low speed is the position immediately past the Off detent and the High position is at the extreme position of the switch travel In the test chart the reference Ground means to attach one lead of the con tin...

Page 334: ...t The ground circuit is completed through the car body be certain of a good connection at the motor ground strap The motor should run continuously If motor does not run but appears to be shorted analyse the exces sive current draw as follows while the motor is still on the car Unsolder the two green leads at the park switch Fasten the two green leads together isolated from the motor frame Connect ...

Page 335: ...st be ground ed when bench testing 13 Install motor MOTOR REMOVAL With Non Concealed Wipers 1 Disconnect the battery ground cable 2 Disconnect the wiper motor wiring harness 3 Remove the three wiper motor mounting nuts OR vehicles without air conditioning it is easier to remove crank arm nut and crank arm from under instrument panel first and omit steps 4 and 5 4 Work motor off mounting studs far ...

Page 336: ...R PIVOT PINS BUSHING PIVOT PINSzyxwv u NP74B Fig 8 Pivot Arm and link Assemblies with Non Concealed Wipers motor mounting nuts pull motor away from bulk head and remove motor crank arm retaining nut After crank arm is removed from motor shaft remove drive link assembly from under left side of panel In heater equipped models remove motor drive crank arm retaining nut and pry crank arm off of motor ...

Page 337: ...rovide adequate facing instrument panel side Press each link bush sealing at the gaskets to prevent water leakage ing fully into place on the pivot crank pins 1 Install bushing on motor crank arm pin pos 5 Reconnect battery cable and test the opera ition drive link on bushing so large side of pivot tion of the wiper system Reinstall glove box if bushing faces away from drive crank arm Large necess...

Page 338: ...rn WINDSHIELD WIPER AND WASHER ELECTRICAL 8 1 17 I 9 MyMopar com ...

Page 339: ... mounting nut to 140 inch pounds 4 Connect battery ground cable 5 Test wiper system operation 6 Install cowl screen 7 Carefully install wiper arm and blade assemblies See Wiper Arm Adjustments WINDSHIELD WASHERS control the direction of fluid flow from the reser GENERAL INFORMATION voir to the pump and from the pump to the nozzles a foot operated pump as standard equipment or Electric pump equippe...

Page 340: ...les b Poor electrical connections c Pinched or leaky hoses d Defective motor grille Correction a Repair as necessary b Replace switch c Replace motor and pump assembly a Clean nozzle jets b Replace hose c Replace motor and pump assembly d Adjust nozzles a Clean ground wire terminal and tighten mounting screw b Tighten terminals c Clean and tighten terminals d Repair or replace the wires e Replace ...

Page 341: ...UPPER TARGET UPPER TARGET IMPACT POINT IMPACT POINT ELKTRIC PUMP ONLY FOOT PUMP ONLY just the nozzles while the wipers are operating Note On cars equipped with the deluxe wiper system the wipers are automatically turned on when the washer button is pushed ELECTRIC PUMP MODELS VALIANT DUSTER BARRACUDA CUDA SATELLITE ROAD RUNNER GTX FURY SUBURBAN CHRYSLER IMPERIAL Removal 1 Remove reservoir mounting...

Page 342: ...diagonal cutters and then peening using a center punch and hammer 4 Install pump and reservoir in vehicle with mounting screws making sure motor ground wire is installed under one of the mounting screws On Barracuda models equipped with air condi tioning reposition horn and tighten mounting screw 5 Connect motor feed wire connector and rub ber hose to pump Fill reservoir inspect for leaks and test...

Page 343: ...8 122 WINDSHIELD WIPER AND WASHER ELECTRICAL MyMopar com ...

Page 344: ...9 2642969 Capacity Amperes 46 59 70 70 70 80 Special Equipment Battery Part Number 2875320 2444564 2875320 2444564 2875320 2444564 2444564 2642967 2642967 2642967 Number Plates Per Cell 9 1 1 13 1 1 13 13 All Batteries are 12Volts with Negative Ground Terminal REDUCTION GEAR STARTING MOTOR Starting Motor Model Make Voltage Number of Fields Number of Poles Brushes SpringTension Drive 2875560 Chrysl...

Page 345: ... Poles Brushes SpringTension Drive 6nd Play Cranking Amperage Draw Free RunningTest Voltage Amperage Draw Minimum Speed RPM Voltage Amperage Draw Pull In Coil Hold InCoil Locked ResistanceTest Solenoid Switch Engine should be a t operatingtemperature ALTERNATOR Rotation Voltage Current Output Voltage output Brushes Field Condenser Capacity Field Current Draw Rotating Rotor by Hand 12 Volts 1 88910...

Page 346: ...e Voltage is controlled by variable load carbonpile across the battery ELECTRONIC VOLTAGE REGULATOR Part Number 3438150 The battery specific gravity should be above 1 200 when checking the regulated voltage The voltage regulator is working properly if the voltage is in accordance with the following chart Ambient Temperature 1 4 From Voltage Regulator 20 F 80 F 14OoF Above 14OoF Title on Fuse Block...

Page 347: ...oid Headlamp Delay Relay Headlamp Dimmer Headlamp Wash Relay On Imperial includes Rear Defoger Rear Heater and Rear Air Conditioning if so equipped Heater Air Con ditioning Blower Motor Tilt Column Spot Light Wiring Tail Gate Lock Solenoid Fury Chrysler 20 zyxwv 20 20 20 20 5 20 20 20 20 20 20 20 20 20 5 20 20 20 FUSES In line Car Model and Ampere Rating Valiant Barracuda 20 20 Satellite 20 20 20 ...

Page 348: ...0 I F F h l m m m I I n 9 u C D b I I 0 I I I N o o v l m m 9 D I O I I h l 0 0 0 I I m I I c 6 I I I I I Lo I I I F L 0 L r W Q Y 0 0 m Y V 0 m Y u 0 m Y 0 0 W m Y 0 0 m Y 0 0 m Y 0 0 m W 3 LL 8 v 0 W v 3 LL W 3 LL C v 0 3 LL C 0 3 U C 0 W 3 U VI W 3 LL S v 0 2 LL C 0 C 0 C 0 MyMopar com ...

Page 349: ... Stereo Indicator Switch Lighting Tachometer Tail Stop and Turn Signal 1157 2 Trunk and or Under Hood Lamp Turn Signal Indicator Panel 158 2 Heat Control 1004 Barracuda Barracuda RaIlye Satellite 1815 1815 53 2 1445 1445 1445 1156 2 1156 2 1156 2 57 57 158 89 89 211 1 or 1004 211 1 or 1004 1004 1892 330 2 1157NA 2 161 57 1891 15 5 OHMS 57 1816 3 1445 67 1892 89 57 90 1816 1815 53 4001 4000 1892 33...

Page 350: ...p Sealed Beam Hi Beam No 1 Sealed Beam Hi Low Beam No 2 Sentry Signal Side Marker Stereo Indicator Switch Lighting Tail Light only Tail Stop and Turn Signal Temperature Indicator Trunk and or Under Hood Light Turn Signal Indicator Panel License Light Included in Instrument Cluster Lighting Headlamp Reostat Dimming Fury 1445 1156 57 1293 90 211 2 90 53 330 2 57 57 1891 1445 1892 1893 3 1445 67 57 5...

Page 351: ...Spark Plug Type Size Gap Firing Order Coil Identification Number Primary Resistance 70 8OOF Secondary Resistance zyxwvutsrq 7 0 8OOF Resistance 70 8OOF Ballast Resistor Current Draw Coil and ballast resistor in circuit EngineStopped Engine Idling 017 to 023 017 to 023 41 to 46O 41 to 46O 17 to 20 oz 17 to 20 02 25 to 285 mfd 25 to 285 mfd OOO to 003 OOO to 003 003 to 017 003 to 017 Clockwise Clock...

Page 352: ...on Timing Spark Plug Type Size Gap Firinn Order Coil Identification Number Primary Resistance 70 8OoF Secondary Resistance 70 80 F Resistance 70 80 F sistor in circuit Engine Stooped Engine Idling Ballast Resistor Current Draw Coil and ballast re 017 to 023 41Oto 46 41 to 46 17 to 20 oz 25 to 285 mfd zyxw OOO to 003 003 to 017 Clockwise 2 1 2 BTC N14Y Championor N14Y Championor P 6 6PMopar P 6 6PM...

Page 353: ...fter Assembly Rotation Timing Spark PlugType Size Gap Firing Order Coil Identification Number Primary Resistance C 3 7Oo 8O0F Secondary Resistance 70 80 F Resistance 70 80 F sistor in circuit EngineStopped Ballast Resistor Current Draw Coil and ballast re Engine Idling 017 to 023 41 to 46 017 to 023 41 to 46 17 to 20 02 25 to 285 mfd OOO to 003 003 to 017 CIockwise Clockwise TDC TDC N14Y Championo...

Page 354: ...or Rebuilt Shaft End Play After Assembly Rotation Clockwise CIockwise Timing 2 5 BTC 2 5 BTC Spark PlugType N14Y Championor N14Y Championor 17 to 20 oz 25 to 285 mfd zyxw OOO to 003 003 to 017 17 to 20 oz 25to 285 mfd OOO to 003 003 to 017 P 6 6PMopar P 6 6PMopar Size 14MM 3 4 Reach 14MM 3 4 Reach Gap 035 035 Firing Order 1 5 3 6 2 4 1 5 3 6 2 4 CoiI Chrysler Essex or Chrysler Prestolite 1 65 to 1...

Page 355: ...oil 1 to 4 10 5 8 25 to 10 75 15 014 to 019 30 to 34 17 to 20 02 25 to 285 mfd 000 to 003 003 to 017 Clockwise TDC N14Y Championor P 6 6PMopar 14MM 3 4 Reach 035 Chrvsler Essex or 1 8 4 3 6 5 7 2 Identification Number 2444241 Secondary Resistance 70 80 F Resistance 70 80 F Primary Resistance 70 80 F 1 41 to 1 55 Ohms 9200 to 10700 Ohms 9400 to 11700 Ohms Batlast Resistor 2095501 Current Draw Coil ...

Page 356: ...smission 318 Cu In 3438453 zyxwv 0 to 4 600 RPM 8Oto 10 5 1000 RPM 14Oto 16O 2100 RPM LA 318 2 BarrelCarburetor Automatic Transmission 318 Cu In 3438453 0 to 4 600 RPM 8 to 10 5 1000 RPM 14 to 16 2100 RPM lo to 4 O 9 5 8 to 10 5 15 014 to 019 30 to 34O 17 to 20 oz 25 to 285 mfd 000 to 003 003 to 017 CIockwise TDC N14Y Championor P 6 6PMopar 14MM 3 4 Reach 035 Chrysler Essex 2444241 1 41 to 1 55 Oh...

Page 357: ...xw OOO to 003 003 to 017 Clockwise 5 BTC N9Y Champion 14MM 3 4 Reach 035 1 8 4 3 6 5 7 2 Coil Chrysler Essex or Identification Number 2444241 Primary Resistance 70 80 F Secondary Resistance 70 80 F 1 41 to 1 55 Ohms 9200 to 10700 Ohms Batlast Resistor Current Draw Coil and ballast re Resistance 70 80 F sistor in circuit Engine Stopped Engine Idling 340 4 Barrel Carburetor Automatic Transmission 34...

Page 358: ...elCarburetor ManualTransmission Automatic Transmission 340 Cu In 3438615 I BS4018D 340 Cu In 3438617 I BS4018E 0 5 to 4 700 RPM 13 to 15 C 3 2200 RPM 0 5 to 4 700 RPM 13Oto 15O 2200 RPM go to 1lo 1100 RPM go to iio 1100 RPM 0 5 to 3 5O 7 7 to loo 11 0 5 to 3 5 9 7 O to 10 12 5 014 to 019 One set points 27 32 both sets points 37 42 17 to 21 5 02 25 to 285 mfd OOO to 003 003 to 017 CIockwise Clockwi...

Page 359: ...ion Condenser Capacity 25 to 285 mfd 25 to 285 mfd 17 to 20 02 zyxwvu 000 to 003 003 to 017 Shaft Side Play New or Rebuilt Shaft End Play After Assembly Spark Plug Type N13Y Champion N13Y Champion Rotation Clockwise CIockwise Timing 2 5 BTC 2 5 BTC Size Gap Firing Order CoiI Identification Number Primary Resistance 70 80 F Secondary Resistance 70 80 F Resistance 70 80 F sistor in circuit Engine St...

Page 360: ...rburetor 2 Barrel Carburetor Manual Transmission Automatic Transmission 360 Cu In 3438453 360 Cu In 3438453 zyx 0 to 4 600 RPM 8 to 10 5 1000 RPM 14Oto 16O 2100 RPM 0 to 4 600 RPM 8 to 10 5 1000 RPM 14O to 16O 02100 RPM lo to 4 O 9 5 8 to 10 5 15 014 to 019 30 to 34 17 to 20 oz 25 to 285 mfd 000 to 003 003 to 017 Clockwise 2 5 BTC N13Y Champion lo to 4 O 9 5 8 to 10 5 15 014 to 019 30 to 34 17 to ...

Page 361: ... Resistor Current Draw Coil and ballast r e 383 Cu In 3438534 383 Cu In 3438534 lo to 4 5 600 RPM 5 O to 7 800 RPM 12 to 14 2000 RPM lo to 4 5 600 RPM 5 O to 7 800 RPM 12O to 14O 2000 RPM lo to 3 50 9 lo to 3 50 9 8 O to 10 zyxwv 63 15 016 to 021 28 5 to 32 5 8O to 10 15 016 to 021 28 5 to 32 5 17 to 200z 25 to 285 mfd OOO to 003 003 to 017 Counterclockwise Counterclockwise TDC 2 5 BTC J 14Y Champ...

Page 362: ... OOO to 003 003 to 017 Counterclockwise TDC J 14Y Champion or P 3 6PMopar 14MM 3 8 Reach 035 Chrysler Essex or 2444241 1 41 to 1 55 Ohms 1 8 4 3 6 5 7 2 383 2 Barrel Carburetor Automatic Transmission 383 Cu In 3438544 0 5 to 3 5 700 RPM 5 to 7 5 900 RPM 12Oto 14 63 2000 RPM 1O to 3 5O 9 8O to 10 15 016 to 021 28 5 to 32 5 17 to 20 02 25 to 285 mfd OOO to 003 003 to 017 Counterclockwise 2 5 BTC J 1...

Page 363: ...ark Plug Type Size Gap Firing Order Coil Identification Number Primary Resistance 70 80 F Secondary Resistance 70 80 F Resistance 70 80 F sistor in circuit EngineStopped Engine Idling BaIlast Resistor Current Draw Coil and ballast re 17 to 20 oz 25 to 285 mfd OOO to 003 003 to 017 Counterclockwise Counterclockwise TDC 2 5 BTC J 11Y Champion or P 3 4PMopar P 3 4PMopar 14MM 3 8 Reach 035 035 1 8 4 3...

Page 364: ...n 3438559 0 5 to 3 5 700 RPM 3 5 to 5 5 900 RPM 10 to 12 2400 RPM lo to 4 50 12 8 O to 10 16 016 to 021 28 5O to 32 5 17 to 20 02 25 to 285 mfd zyx OOO to 003 003 to 017 Counterclockwise 5 BTC J 13Y Champion or Mopar P 3 5P 14MM 3 8 Reach 035 1 8 4 3 6 5 7 2 or Chrysler Prestolite 24444242 1 65 to 1 79 Ohms 9400 to 11700 Ohms Primary REsistance 70 80 F Secondary Resistance 7Oo 8O0F 1 41 to 1 55 Oh...

Page 365: ...5 800 RPM 8 to 10 2200 RPM 0 5O to 4 3 10 5 9 7Oto 12O 15 5 016 to 021 28 5O to 32 5 17 to 20 02 25 to 285 mfd zyxw OOO to 003 003 to 017 Counterclockwise TDC J l1Y Champion or P 3 4PMopar 14MM 3 8 Reach 035 Chrysler Essex or 2444241 1 41 to 1 55 Ohms 9200 to 10700Ohms 1 8 4 3 6 5 7 2 440 Special Cam 4 Barrel Carburetor Automatic Transmission 440 Cu In 3438694 0 5 to 4 0 700 RPM 5 to 7 900 RPM 8 t...

Page 366: ...F Resistance 70 80 F sistor in circuit EngineStopped Engine Idling Ballast Resistor Current Draw Coil and ballast re lo to 4 10 5 7 5Oto loo 15 014 to 019 One set points 27O 32 both set points 37O 42 17 to 21 5 oz 25 to 285 mfd zyxw OOO to 003 003 to 017 Counterclockwise Counterclockwise 5 BTC 5 BTC J l1Y Champion or P 3 4PMopar P 3 4PMopar 14MM 3 8 Reach 14MM 3 8 Reach 035 035 Chrysler Essex or C...

Page 367: ...mbly Rotation Timing Spark PlugType Size Gap Firing Order Coil Identification Number Primary Resistance 70 80 F Secondary Resistance 70 80 F Resistance 70 80 F sistor in circuit EngineStopped Engine Idling Condenser Capacity Ballast Resistor Current Draw Coil and ballast re oo to 3 50 9 oo to 3 50 9 6 7 to 9 2 13 5 6 7 to 9 2 13 5 014 to 019 Individual Contacts 27O 32 Total Dwell 37O 42 17 to 21 5...

Page 368: ... Rallye Cluster Valiant 162 163 Instrument Panel Wiring Standard Cluster Barracuda 168 169 Instrument Panel Wiring Rallye Cluster Satellite 176 177 3 Page Instrum n P ne1 Wiring Standard Clus w Valiant 160 161 Instrument Panel Wiring Rallye Cluster Barracuda 166 167 Instrument Panel Wiring Standard Cluster Satellite 174 175 Instrument Panel Accessory Wiring Valiant 164 165 Instrument Panel Accesso...

Page 369: ...8 148 WIRING DIAGRAMS Fig 2 Bulkhead Disconnect Boracuda Satellite P6358 Fig 3 Bulkheod Disconnect Fury Chrysler ond Imperial MyMopar com ...

Page 370: ...WIRING DIAGRAMS 8 149 PB359 Fig 4 Fuse Block Valiant Fig 5 Fuse Block Barracuda Satellite MyMopar com ...

Page 371: ...50 WIRING DIAGRAMS a z I Fig 6 Fuse Block LEGEND I m MALE FE FEMALE INSULATORS VIEWED FROM TERMINAL SIDE Fury Chrysler and Imperial P PINK R I RED YELLOWzyxwvu PB361 Fig 7 Color Code and legend MyMopar com ...

Page 372: ...WIRING DIAGRAMS 8 151 I zyx V I L 3 WLu c l n L n MyMopar com ...

Page 373: ... 6 5 7 2 6666 SPARK PLUGS LEFT BANK EIGHT CYLINDER DISTRIBUTOR COUNTER CLOCKWISE ROTATION FOR 383 AND 440 CUBIC INCH ENGINES FIRING ORDER 1 5 3 6 2 4 BULKHEAD CONNECTOR Btik P I B2 18BK P SWITCH B1 18BK BACK UP 1 LAMP THREE SPEED TRANSMISSION BULKHEAD CONNECTOR TO B2A l8BK I INSTRUMENT I I FOUR SPEED TRANSMISSION PANEL J MANUAL TRANSMISSION SWITCH 9 H2A l6DGN R H2 16DGN R WINDSHIELD WASHER MOTOR R...

Page 374: ...a 440 CU IN ENGINE WITH THREE TWO BARREL CARBURETORS TO NO 1 SPLICE R3 18DGN R3 18DGN 18DBL J2D l8DBL CARBURETOR V10 18BR 383 CU IN ENGINE WITH DISTRIBUTOR SOLENOID J2A 1608L IGNITION J3A 14BR BALLAST I J3 14BR LOW OIL PRESSURE SWITCH I TACHOMETER WIRING G6 18GY G6B 24GY RESISTANCE CABLE LOW OIL PRESSURE SWITCH IF SO EQUIPPED R6 12BK R6 8BK I LG6 18GY I AlC lOR zyxwvutsrqp 0 INSTRUMENT PANEL WIRIN...

Page 375: ...DGN s ALTERNATOR J3 14BR 1 1 j3A 14BR J3A 14BR IGNITION COIL I l l SPEED CONTROL UNIT CI BULKHEAD I V4 18R w I TWO SPEED WINDSHIELD WIPER MOTOR THREE SPEED WINDSHIELD WIPER MOTOR V6 18DBL V6 lBDBL V5 18DGN V3 18BR V3 18BR V4 18R V4 18R A1C 1OR A1E lOR I A11 18R SPARK PLUGS RI EIGHT CYLINDER DISTRIBUTOR WISE ROTATION FOR 383 AND 440 JBlC INCH ENGINES COUNTER CLOCK FIRING ORDER 1 8 4 3 6 5 7 2 SPARK...

Page 376: ...ALLAST SOLENOID VALVE zyxwv e J2A 18DBL V ASSEMBLY SPEED SWITCH 0 18BK D z S6 188R NOX WITH AUTO TRANSMISSION DBL y BK DASH R6A 1 OBK J2D l8DBL R3 18DGN VOLTAGE J3A l4BR J3 148R IGNITION TEMPERATURE BALLAST GAUGE SEND UNIT J2D W I I I E B L I I I I MANUAL TRANSMISSION SWITCH TO INSTRUMENT DASH 3PANEL WIRING I I I I L L I 1 l l l l 1 l I l R6B 8BK R6A lOBK yvf R6 lOBK I 18BK 2 Rl6 18BK BULKHEAD DIS...

Page 377: ...STOR CONNECTOR ALTERNATOR TO DISTRIBUTOR SOLENOID I R6A 12BK I I I I R6C 8BK R6B 8BK z A I AlA 1OR A1 12R 1 FUSIBLE LINK DASH PANEL AMMETER h P B 3 Fig 11 Engine Wiring 65 Ampem leere Neville Alternator Satellite PART OF ALTERNATOR TEMPERATURE 2 1 v GAUGE PB112 Fig zyxwvutsr I 2 Engine Wiring 65 Ampere leere Neville Alternator Fury MyMopar com ...

Page 378: ...WIRING DIAGRAMS 8 157 L I I r adc zyx 1 I MyMopar com ...

Page 379: ...TRIBUTOR WISE ROTATION FOR 383 AND 440 JBlC INCH ENGINES FIRING ORDER COUNTER CLOCK 1 8 4 3 6 5 7 2 THREE SPEED WINDSHIELD WIPER MOTOR V6 18DBL V6 18DBL V5 18DGN V3 18BR V3 18BR V4 18R V4 18R A1E 10R I All l8R R6B 8BK A2A 1OG BK 1 A1 68 R A2 4G BK BATTERY ION ENGINE GROUND STARTER MOTOR S5 12BR Al l4R PB42 SPARK PLUGS LEFT BANK Fig 14 Engine Wifing Chrysler MyMopar com ...

Page 380: ...LENOID VALVE J2A 18DBL SPEED SWITCH ASSEMBLY 18BK S6 18BRzy 2 NOX WITH AUTO TRANSMISSION 1 DASH I I I TO INSTRUMENT PANEL WIRING AUTOMATIC FLD TRANSMISSION S4 18BRIY LR6 10BK BULKHEAD DISCONNECT LGMBGY I I R6 1OBK MANUAL TRANSMISSION SWITCH B1 l8BK DASH E L TO INSTRUMENT WIRING pt TNUAL ITRANSMISSION STARTER RELAY A1C 1OR I 52 18Y S2 18Y A I E OR 2 8GA 60AMP pB42 FUSIBLE LINK A1 14R A1 14R Fig 14 ...

Page 381: ...RD FLASHER 181RIGHT FRONT 18LGN LEFT FRONT IBBK HORN 4 M28 20Y I D7 18BR DB 18DGN D4 18W D32 18P TURN SIGNAL SWITCH ACCESSORY LAMPS AND TIME DELAY CONNECTOR Xl2 1BR Cl 14BK X1 16R X1 16R Q2A 14BK E2A 18 0 P2 20BK P2 2OBK A1 12R P5 20BK M620Y M16B 20BK rM Z C Z O Y m 17A lBBK LL6 18Y HEADLAMP BUZZER I RELAY CONNECTOR 1 rM6A 20Y I M 6 2 0 Y HORN RELAY 1 M 1 6 2 0 B K 4 7 w AND KEY IN BUZZER TO RIGHT...

Page 382: ... C1 14EKn D8 18DGN P2 20BK A1 12R M6 20Y D7 18BR M2 20Y J1 12R H1 16V H l 1 6 V l L Q 3 1 4 R 62A 14BK ACCESSORY FEED I f 1 I Cl l4BK HEATER X12 18R RADIO M2B 20Y f TO BODY WIRING xi I R CIGAR LIGHTERJ LE 1EP TAIL LAMPS zyxw I M1 18P M2A 20Y VSTRUMENT LAMPS HAND BRAKE RELEASE SWITCH P2 zyxw B T L4 18V TO HEADLAMP DELAY RELAY WIRING FOOT DIMMER SWITCH zyxwvu e BATTERY L2A 16LGN HIGH P873 L3 18R L3 ...

Page 383: ... CONNECTOR M 2 A F 2OY L 1 M6 20 c b c RIGHT FRONT DOOR AUTO MATIC SWITCH MOTOR X 1 2 1 8 R A 3 Ql8R 18 0 4 1 RADIO E2D 18 0 I Y V 3 1 8 B R q V6 18DBL WINDSHIELD WIPER w SWITCH V5 18DGN SEE ACCESSORY Vl lpP WIRING I I V4 18R I R6A 12BK rP4 20DBLC D9 18T 3 18DBL G1 18BK G2 18V t R6 12BK H2 CIGAR LIGHTER I 1 J2 16DBL J2A 16DBL aP P4 20DBL C zyxwvuts on A nr B Y HANDBRAKE RELAY SWITCH DISCONNECT Fig...

Page 384: ...WIRING DIAGRAMS 8 163 Fig 16 Instrument Panel Wiring Rallye Cluster Valiant MyMopar com ...

Page 385: ...INSTRUMENT LAMPS TERMINAL ACCESSORY LAMPS AND TIME DELA TO FRONT SPEAKER n I F24 18BK I F26 188K F23 18DGN WIRING u ToCASSETTE SHIELDED SEVEN WIRE y INSULATED CABLE pv 18BK I I18bGN 1 I I I F25 18V I A M DUAL AUDIO TO INSTRUMENT PANEL MAIN HARNESS RADIO CONNECTOR IBK WIRING BODY STEREO WIRING WYY BULKHEAD DISCONNECT RELAY WIRING L2B 16LGN HEADLAMP Q Q2B 18BK DELAY RELAY Q3A 16R z j L Q2B 18BK HEAD...

Page 386: ...CK ACCESSORY TERMINAL SWITCH WIRING 18DGN DASH LINE MOLDED GROMMET TO STARTER RELAY ENGINE COMPARTMENT CLUTCH START SWITCH MANUAL TRANSMISSION ONLY ACCESSORY TERM1NAL TO FUSE BLOCK INSTRUMENT LAMPS TERMINAL 4 1 R I E 2 C 1 8 CONDITIONING WIRING 0 4 PART OF INSTRUMEN PANEL MAIP HARNESS ACCESSORY LAMPS BUZZER CONNECTOR M6E 18Y M2D 20Y 176 18BK RELAY TO FUSE BLOCK ACCESSORY TERMINAL M2D 20Y HEADLAMP ...

Page 387: ...CATOR LAMP INSTRUMENT SPEEDOMETERzy r R6A 12BK1 I I I I I I I I I I 1 CIGAR LIGHTER V6 18DBL PARK I I I I I I I r t zyxwvut I T ACCESSORIES FEED Q4 16T aP5 18BK p I I Fig 18 Instrument Panel Wiring Rallye Cluster Barracuda MyMopar com ...

Page 388: ...8P zyxwvutsrq 1 3 f V3 18BR A VARIABLE SPEED F1 2 SPEED 6P L6 18BK Y HEADLAMP SWITCH L2A 16LGN L7 18BK L8 18P L7A 18BK I U I I Ll 16BK D1 18B zyxwvutsrqp K HEATER I 18R TURN SIG 18T RIGHT FRO 18LGN LEFT FRONT BRAKE 4 SWITCH TO HEADLAMP DELAY RELAY WIRING LEFT FRONT TO BODY I SWITCH I I I I L6A l8BK Y J FLASHER D5 1BT HIGH 1 D6 18LGN L3 16R L4 16V r 82 18W L3 l6R 1 PB30 L4 16V LOW Fig 18 Instrument...

Page 389: ... BGY WARNING r M5118P X1 16R CIGAR LIGHTER 18R F1 VARIABLE SPEED 2 SPEED 3 18BR A VARIABLE SPEED 1 2 SPEED V lEDBL PARK 18R F1 VARIABLE SPEED 1 3 18BR A VARIABLE SPEED 1 2 SPEED V lEDBL PARK 1 V5 18DGN F2 I P5A 18BK DUAL BRAKE D9 18T S2 18Y IGNITION START r r DlO ILGN I I I I I I I I I Fig 19 Instrument Panel Wiring Standard Cluster Bamcudo MyMopar com ...

Page 390: ... 18Y 16DBl J 1 12 R E2 18 0 D31 18P 18 18P 1 2BK Q2A I 1 I 1 I I I PANEL DIMMER SWITCH El 18T L6 18BKIY L8 LI I BK 44 t HEATER BLOWER SWITCH C 5 1 4 D G N p C5 14DGN HIGH 18Y START BRAKEzyx 4 SWITCH TO HEADLAMP DELAY RELAY WARNING LEFT FRONT DOOR SWITCH I TO BODY 3K L2A 6LGN D L 6LGN G4 Ir Y Fig 19 Instrument Panel Wiring Standard Cluster Barracuda MyMopar com ...

Page 391: ... PART 1 OF 4 ROAD LAMP WIRING BARRACUDA1 PART OF INSTRUMENT PANEL MAIN HARNESS CLOCK C RCUIT FOR RALLYE ONLY GLOVE BOX LAMP yylBlNG PART OF INSTRUMENT PANEL MAIN HARNESS E2B 1801 E2C 18 INSTRUMENT PANEL LAMP FEED ASH RECEIVER LAMP WIRING CLOCK CLOCK WIRING STANDARD I CLUSTER ONLY zyx 1 SEAT BELT SWITCH TITLE PART OF INSTRUMENT LAMP LAMP PANEL MAIN HARNESS 18 M6A M6C 20Y M6D 2oV 18Y J S A Z Q Y q J...

Page 392: ...3 0 A 2 0 D B L1 l r PART OF INSTRUMENT PANEL MAIN HARNESS C J L J L 8 YELLOW Y T2 12BR UP TO BODY WIRING SIDE COWL T3 12Y DOWN FUSE BLOCK TOP LIFT WIRING THIGH C 1 1 1 8 B K TO BODY WIRING SIDE COWL BLOWER SWITCH tALOW C12 18W A PART OF INSTRUMENT ACCESSORY FEED REAR WINDOW DEFOGGER SWITCH WIRING PUSH BUTTON ACTUATOR n STOP LAMP SWITCH 22 DBL PART 2 OF 4 PW SPEED CONTROL WIRING ACCE S S R Y FEED ...

Page 393: ...W LIFT ART O F INSTRUMENT ANEL MAIN HARNESS _ X12 18R w2 14y d W L F W 2 2 1 4 V 4 1 W12 14P 835 PART 3 OF 4 WINDOW LIFT SAFETY RELAY WIRING I COURTESY LAFP GROUND OF lNSTRUMENT MAIN HARNESS 2 RED M5 18P COURTESY LAMP FEED CLOCK CIRCUIT FOR RALLYE ON1 COURTESY LAMP WIRING RACKET DASH LINE CLUTCH START SWITCH TO STARTER RELA EVER SCHEMATIC DIAGRAM ENGINE COMPARTMENl SWITCH OPEN CLUTCH PEDAL RELEASE...

Page 394: ...EED FUSE BLOCK PART OF INSTRUMENT PANEL MAIN HARNESS 8 l8BK PART OF INSTRUMENT PANEL MAIN HARNESS TO CONSOLETTE WIRING SIDE COWL ACCESSORY FEED CONSOLETTE WIRING ACCESSORY FEED HEADLAMP DELAY RELAY WIRING PART OF INSTRUMENT PANEL MAIN HARNESS INSTRUMENT PANEL LAMP FEED E2B 18 0 E2 180 TO BODY WIRING SIDE COWL CONSOLE GEAR SELECTOR LAMP INSTRUMENT PANEL WIRING E2C 18 0 WITHOUT STEREO F23 18DGN F21 ...

Page 395: ...ASH RECEIVER HEATER BLOWER MOTOR RESISTOR 16DGN MEDIUM 16LGN HIGH 16BR LOW 618LGN LEFT TURN 2 18w BACK UP LAMPS BACK UP LAMP 1 14BK J3 14BR 05 18T 6 18LGN Fig 21 Instrument Panel Wiring Standard Cluster Satellite MyMopar com ...

Page 396: ...WIRING DIAGRAMS 8 175 STEERING COLUMN GROUND CABLE 20Y 18R KEY BUZZER L2 16LGNH 13 16R PB49 Fig 21 Instrument Panel Wiring Standard Cluster Sateffjte MyMopar com ...

Page 397: ...LGN LEFT TURN SIGNAL INDICATOR LAMP R6 12BK ALTERNATOR BATT It PRESSURE INDICATOR LAMP 16DBL IGNITION R WITHOUT CONCEALED HEADLAMP H2 16DGNIR H L6A l8BK Y PARKING LAMPS FEE D5 18T RIGHT TURN SIGNAL D5 18T Db18LGN LEFT TURN SIGNAL D6 18LGN 82 18W BACK UP LAMPS L3 16R HEADLAMP HI BEAM U16V HEADLAMP LOW BEAM 13 16R Fig 22 Instrument Panel Wiring Rallye Cluster Satellife MyMopar com ...

Page 398: ...WIRING DIAGRAMS 8 177 CLUSTER WITH TACHOMETER L7 181 BK Y 1 I 1 PB48 Fig 22 Instrument Pone1 Wiring Rallye Cluster Satellite MyMopar com ...

Page 399: ... LEFT CHANNEL OU 8 AD10 I C C C A D D l l P A D l C r STEREO CASSEllE UNIT C RADIO CHASSIS FRONT SPEAKER 1 8 B K wb X54A 20BK I I XS A l RnGN _ 1 I I TLEFT CHANNEL I 18DGN X52 18DGN II _ 18BK p TO REAR SPEAKER CHANNEL rF1 20v d WIRING BODY I RAD lo CoNNECTIoN STEREO WIRING X53 20BK 4 I I SCHEMATIC DIAGRAM SWITCH OPEN CLUTCH PEDAL RELEASED BRACKET MOLDED GROMMET A 1 II SWITCH CLOSED i CABLE 18GA DA...

Page 400: ...18W D4 18W HORN LEFT FRONT HAZARD FLASHER LEFT REAR RIGHT REAR STOP LAMPS RIGHT FRONT D5 18T TURN SIGNAL FLASHER D2 18R NOT USED WITH CONSOLE PART OF INSTRUMENT PANEL MAIN HARNESS E2 18 0 TO INSTRUMENT PANEL MAIN HARNEB TURN SIGNAL SWITCH CONNECTOR GEAR LAMP TILT STEERING COLUMN WIRING PANEL MAIN HARNESS L6 18BK Y L6A l8BK PART OF INSTRUMENT M16A 20BK M16B MBK LAMP ON BUZZER HEADLAMP WARNING BUZZE...

Page 401: ...HARNESS M5 18P L8 18P OPEN DOOR BATTERY FEED INDICATOR LAMP M2 20Y M2 18Y DOOR SWITCH CIRCUITPART O F INSTRUMENT PANEL MAIN HARNESS TAXI OPEN DOOR INDICATOR LAMP t Ql l2R I AMMETER KEY BUZZER RbA 12BKA A1 12R I W10 18BK XlOA 12BK 0 LOWERGROUND REINFORCEMENT PART OF INSTRUmciri PANEL MAIN HARNESS W5 20T E2 18 0 E2 18 0 18 0 RADIO WIRING PB50 PART 3 OF 4 V TO POWER WINDOV W15 12BR UP W5B 12R WINDOW ...

Page 402: ...TLE LAMP ORANGE q 1 8 0 E2 18zy 0 PART OF TAIL GATE LOCK X34 14P ANEL MAIF BODY WIRING X33 14 0 UNLOCK 20 AMP X 3 2 1 4 B K e I G N FEED TAIL GATE LOCK UNLOCK SWITCH WIRING X42B 14LGN 20 AMP DECK LID SWITCH ELECTRIC DECK LID SWITCH WIRING 4 TO LEFT SIDE COWL BODY WIRING TO CONSOLE WlRlNC E2 18 0 R I G H T SIDE COWL TO GEAR SELECTOR LAMP WIRING I CONSOLE GEAR SELECTOR LAMP WIRING C 12 18W LOW TO BO...

Page 403: ...R LAMP YELLOW YELLOW 12BK TILT WHEEL l G G i FRONT AUTOMATIC SWITCH zyxwvutsrq L P5 20BK X12 18R I I l l I I l l I I 1 Dl 18BK 1 I X1 16R f Rl 18BK Q2 12BK TURN SIGNAL FLASHER v1 16 D 1 1 8 B K a 1l i g l Cl l2BK HEATER p B 1 1 8 W BACK UP LA X12 18Rf RADIO Q2A 12BK ACCESSORY L R1 1RW I Fig 24 Instrument Panel Wiring Fury MyMopar com ...

Page 404: ... 1 12R 18LGN 18DGN G4 H1 16V M1 18P H2 16DGN R 33 14BR 42A 16DBL 1 1 I l l I I 7 I I I I I I I I I I I 1 zyxwvutsrqpo e L2 1 LGN RELAY FEED L2A 1 1 HEADLAMP DELAY LOW L4 16V FOOT DIMMER SWITCH E gt Dy L7 18BK 2 1 4 5 WIRING D8 18DGN 3 6 M1 18P rM11 18P M2C 20Y TO LEFT REAR DOOR LEFT FRONT SWITCH PB36 Fig 24 Insfrunrent Panel Wiring Fury MyMopar com ...

Page 405: ...8 184 WIRING DIAGRAMS MyMopar com ...

Page 406: ... WIRING ON INSTRUMENT PANEL I U System Wiring TO RIGHT REAR SPEAKER A CHANNEL 4F24 18BKzyxwv a F25 18DGN zyxw a B CHANNEL STEREO SPEAKER WIRING STATION WAGONS F24 18BK TO REAR SPEAKER TO FADER SWITCH INSTRUMENT WIRING PANEL ON f f F 2 4 1 8 B K p l 9 F25 18DGN F25 18DGN a REAR SPEAKER WIRING MONAURAL STATION WAGONS X 5 2 1 8 D G N d TO RIGHT REAR SPEAKER A CHANNEL X54 18 R n a REAR SPEAKER B CHANN...

Page 407: ...R TO AUXILIARY SWITCH LAMP GI1A 1BY ilGNAL LAMP LOW FUEL RELAY G7 18T SIGNA LAMP TO TIME DELAY GBA lBBK RELAY WIRING YELLOW GB IBBK TO ACCESSORY FEED PB115 ART 1 OF 4 LOW FUEL AND LOCK DOOR INDICATOR WIRING PART OF POWER ASSIST WIRING 15 AMP 4TTERY CIRCUIT BREAKER 4p Q 3 A 1 4 R iED zyxwvuts 1 BODY O X42 14LGN WFUS SIDE DOOR LOCK RELAY O R BLOC RED RIGHT FRONT SEAT BACK LATCH WIRING TO FUSE X42A 1...

Page 408: ... WIRING TO BODY WIRING Q 0 BODY WIRING W1B 12T OWER WINDOWS W1 12T b 0 RADIO WIRING W9 20T 7 W9A 20T 0 MAIN cd 4ARNESS N5 CIRCUIT BREAKER FEED TO I BULKHEAD W 5 C m DlSCONNECl CAVITY 28 L W 5 A 1 2 R 6 T RCUIT BREAKER FEED CABLE WINDOW LIFT SAFETY RELAY LOWER REINFORCEMENT WINDOW LIFT SAFETY RELAY WIRING TO WINDOW LIFT W1 12T SAFETY RELAY TAIL GATE WINDOW LIFT SWITCH TO WINDOW W5 12R INSTRUMENT zy...

Page 409: ...N L318 1BDBL V208 1BDGN 0 INSTRUMENT VlOC 18BR ANEL MAIN HARNESS I V WITCH CIRCUIT V1OA 18BR HEADLAMP WASHER RELAY WINDSHIELD WIPER VlOC m Q 2 D l E W G4A l8GY R G2A lBBK J A 4 1BDBL R16 18BK 5 v zyxwvutsrqp 1 WITH LOW FUEL RELAY G6A 18GY I NOTE PULL OUT EXISTING CIRCUIT G6 AT BULKHEAD AND REPLACE WITH CIRCUIT 1 _ v G6A CAVITY 15 011 PRESSURE GAUGE WIRING FRONT SPEAKER F21 1BDGN F23 18DGN 1 8 R D ...

Page 410: ...AR D8 18DGN RIGHT REAR D7 18BR D7 18BR zyxw d STOP LAMPS D4 18W D4 18W D27 1BV D29 18 T F D 2 8 1 8 L G N 4 FEED D27 18V TO CORNERING LAMPS WIRING IF SO EQUIPPED TILT STEERING COLUMN WIRING RIGHT SPEAKER I 4 1 1 x 1 181 X50 18BK I I 1 STEREO 4D TAPE 9SSOVER STEREO TAPE WIRING WITHOUT REAR SPEAKER RIGHT LEFT FRONT OOR COURTESY LAMP LAMP A g r fCONNECTOR LAMP TO INSTRUMENT PANEL MAIN HARNESS COURTES...

Page 411: ... I I I I r I A1IA lBR G9 1iGY M6A 20Y X12 18R CI 12BK START AND IGNITION SWITCH LAMP I PB114 VlO l8BR V6 18DBL M2A 20Y VS 18DGN sib V3 188R VI lRP I I 14 16V I XI 1bR Q3 12R CIOA 16LGN M16A mBK X32 18BK 13 16R B2 18w D7 18BR M16 20BK D32 18P Dl 18BK D2 18R B1 18w Al 10R FLASHER STARTER AND IGNITION SWITCH S2 l8Y STAR 12Y START 12BK ACCESSORY 12R BATTERY 0 1 8 R TURN SIGNAL SWITCH BUZZER I8P HAZARD...

Page 412: ...HIELD WASHEF WITCH V3 188R RESISTANCE CABLE CIRCUIT ____V7 24 GAUGE BR NOT REQUIRED FOR I I I I HEADLAMP SWI M16A 208K 1 I i I I I P2 18BK BRAKE SYSTEM SWITCH HEADLAMP DELAY RELAY FEED rn L2A 16LGN1 LEFT FRONT DOOR AUTOMATIC SWITCH M16B ZQBK M2C 20Y r L2A 16LGN BATTERY W 16R FOOT DIMMER SWITCH T O CONSOLE BODY TO DOME LAMP MX ZQY MIA 18P Mll 18P L B2 18W zyxw I G E D B L L7 18BK TO WIRING BODY L D...

Page 413: ...W Cll 168K E2E 180 X18 20R M168 20BK L6A 18Y C12 16W Cl OB 16LGN LEFT ASH RECEIVER H46 20BK i281180 1 E 2 1 8 O E Z E l E O E2A 180 E2E 180 HEAD LAMP ON REMINDER XIA 16R CIGAR LIGHTER r i BUZZER RELAY WITHOUT GROUND LOWER Q 0 REINFORCEMENT ClF 12BKi AND HEATER WIRING CONNECTOR WITHOUT ATC MA 18Y HAZARD FLASHER D32 18P D32 18P E2 180 G4A 18DBL W 10 20BK I I I 1 1 1 I l l E2D 180 I I 1 1 1 C9 161 C6...

Page 414: ...A 20Y P5A 20BK X1B 20R IGNITION SWITCH LAMP STARTER AND IGNITION 1 8 Y a m J 5 2 0 Y SWITCH I I y J 3 1 2 B R J 2 1 2 D B L E r1 1 2 D B L l G N l l l O N l J5 2OY J1 12R 12R BATTERY 12BR IGNITION 2 I CB l2GY ATC IN CAR SENSOR 7 18 V IER KEY IN BUZZER 18BR RIGHT REAR 18DGN LEFT REAR 18P HAZARD FLASHER 181 RIGHT FRONT IBLGN LEFT FRONT 18BK HORN I H3 20BK C2 16Y E2 18 zy 0 v1 12P D6 1BLGN D5 18T I I...

Page 415: ...Y D27 18V D29 181 028 18LGN L ClOB l6LGN ClI l6BK C12 l6W 02 1 8R w TURN SIGNAL FLASHER G6 18GY GI A 188K G4 18DBL P5A 20BK G11 2OY V20A V2OA 18DGN X I B 20R AII lOR G I 1 20Y DI IBBK G6 18GY D2 18R Ic G 2 1 8 V I E1 181 J5 20Y G7 I8GY S2 12Y Cl OA I6LGN G7A 20GY I I DZR 18LGN C2 16Y Ip X32 16B I I 1 I I PSR 1ARK I I I 1 I D7 18BR Fig 30 Instrument Panel Wiring Imperial MyMopar com ...

Page 416: ... 1O B K 1 G11 2OY D29 18T D28 18LGN J2A J2C 12DBl 12DBL L6 18Y 18 1 2P 4 3 12R zyxwvutsrqponmlk I Ill Ill A I IOR J U lBR 1 SWiTCH I I 1 I I I TO LEFT FRONT DOOG AUTOMATIC SWITCH TO BODY C12 l6W WIRING I REAR BLOWER CONNECTOR TO BODY W 5 B 1 2 R a WIRING POWER SEAT TO BODY WIRING D7 1B B R 17C lBBK I WINOOW IIFT Fig 30 Instrument Panel Wiring Imperial MyMopar com ...

Page 417: ... T O PRINTED CIRCUIT BOARD G4A 1BDBL GAUGE G7 18GY TO PRINTED CIRCUIT INSULATOR GBA 18BK LOW FUEL INDICATOR LAlAP CAVITY ACCESSORY FEE C l O A 2 LOW FUEL SIGNAL p 16DGN RELAY YELLOW PART OF INSTRUMENT PANEL MAIN HARNESS LOW FUEL SIGNAL RELAY WIRING CHRYSLER ACCESSORY FEED PART OF INSTRUMENT PANEL REAR BLOWER HOTOR SWITCH MAIN HARN_ESS YELLOW REAR WINDOW DEFOGGER O R HEATER SWITCH WIRING CHRYSLER S...

Page 418: ... STATION WAGONS I H5 1BBK 4 HORN GROUND CABLE CHRYSLER AND IMPERIAL r o HEATER VACUUM SWITCH 3 R AIR CONDITIONING WITHOUT ATC i C lE 12 B K l I f CORNERING LAMPS I D27 TO FUSE BLOCK HEATER ci0 C1 12BKl AIR CONDITIONING FUSE 12BK HEADLAMP CAVITY 9 HORN RELAY Hl Q3 12R Q 3 A 1 6 R 1 INSTRUMENT PANEL WIRING WITH ATC PART OF INSTRUMENT PANEL MAIN HARNESS IMPERIAL 18DGN TAIL LAMPS FUSE IGNITION 2OLGN P...

Page 419: ...T PANE CLUTCH START SWITCH CABLE CLUSTER LAMPS WIRING FADER MAP LAMP SWITCH TO STEREO WIRING REAR SPEAKER CONNECTOR SAME AS CHRYSLER TO BODY WIRING FADER CONNECTOR SHOWN ABOVE SPEAKER FADER FRONT SPEAKER Fig 31 Instrument Panel Accessory Wiring Chrysler Imperial MyMopar com ...

Page 420: ...A 1 2 R zyx 1 RED W5E 12T 1 W5C 12R Xb2 14LGN I 1 WPA ZOT GROUND LOWER REINFORCEMENT I Th Dlo TO BODY WIRING RIGHT SIDE PART OF INSTRUMENT PANEL MAIN HARNESS WSB 12R y q 30 AMP CIRCUIT BREAk ON FUSE BLOCK X42 14LGN I 1 FRONT SEAT BACK LATCH OR POWER DOOR LOCKS WIRING CHRYSLER TO STARTER AND IGNITION SWITCH HEADLAMP RE1 CIRCUIT BREAKER CONCEALED HEADLAMP RELAY WIRING CHRYSLER PART OF INSTRUMENT PAN...

Page 421: ... 1BR rLEFT REAR RIGHI FRONT D5 181 1 2 3 4 5 6 RIGHT REAR D7 18BR STOP LAMPS DC18W C l 1 2 B K d PART OF HEATER AND AIR CONDITIONING ACCESSORY FEED WIRING ASSEMBLY CHRYSLER PART OF INSTRUMENT PANEL MAIN HARNESS IMPERIALI P Q 1 3 A l B R 4 1 TO INSTRUMENT PANEL MAIN HARNESS TURN SIGNAL SWITCH CONNECTOR s2 12Y TURN SIGNAL SWITCH 12BR IGNlTl 12R 12DBL IGNITION 1 Q2 1ZBK ACCESSORIES 2 3 4 5 6 7 8 TO I...

Page 422: ...H c 9 1 6 T I 1 Cdl6DBl C8 12GY FEED FEED ClC lZBK I C l B 12 B K C17A 16R C17 16R r CAR IN SENSOR CIA 12BK C1B 12BK I MAIN HARNESS ACCESSORY FEED CID lZBK TO INSTRUMENT PANEL CONNECTOR CHRYSLER I 1 I I I I I I I I I r _ _ l C7C 12DGN zyxwvuts 2 C 7 C 1 2 D G N m I I FUSE TO FUSE BLOCK BATTERY BUSS BAR _ _ _ _ _ DASH LINE CHRYSLER FEED SEE PART2OF6 FOR IMPERIAL FEED SERVO ENGINE COMPARTMENT RIGHT ...

Page 423: ...Console Wiring Fury 203 Instrument PaneI Wiring VaIiant 203 Instrument Panel Wiring Barracuda 204 Instrument Panel Wiring Fury 208 Instrument Panel Wiring Chrysler 209 Instrument Panel Wiring Imperial 210 Overhead Console Wiring Barracuda 204 Air Conditioner Heater and Windshield T O INSTRUMENT PANEL CONSOLE WIRING G E A R SHIFT S E L E C T O R BULB PY811 Fig I Console Wiring Barracuda PY432 MyMop...

Page 424: ...WIRING ADAPTATIONS 8 203 PY715 Fig 3 Console Wiring Fury Fig 4 Instrument Panel Wiring Valiant MyMopar com ...

Page 425: ...IRING ADAPTATIONS W WHEELHOUSE ANEL OVERHEAD INNER PANEL ONSOLE WIRING PY810 WARNING BULB UPPER FRAME WARNING LAMP IN DIRECTION VIEW Y VIEW z BULB OF ARROW X Fig 6 Overhead Console Wiring Barracuda MyMopar com ...

Page 426: ...WIRING ADAPTATIONS 8 205 Z w I I r MyMopar com ...

Page 427: ...8 206 WIRING ADAPTATIONS MyMopar com ...

Page 428: ...WIRING ADAPTATIONS 8 207 I z h s P I a Y m MyMopar com ...

Page 429: ...8 208 WIRING ADAPTATIONS 4 e szy t d H Y a n Y a X ii a MyMopar com ...

Page 430: ...WIRING ADAPTATIONS 8 209 MyMopar com ...

Page 431: ...8 210 WIRING ADAPTATIONS MyMopar com ...

Page 432: ...ced by the oil pump to a series of oil passages in the engine Fig 49 The semi series flow cooling system contains an aluminum water pump body with a pressed in ball bearing and seal assembly and steel stamped impeller The water pump housing is integral with the cylinder block Compression Ratio Remarks 8 4 to 1 8 4 to 1 8 8 to 1 10 5 to 1 10 5 to 1 8 8to 1 8 7 to 1 8 7 to 1 9 0 to 1 9 7 to 1 10 5to...

Page 433: ...r contacts Incorrect spark plug gap Incorrect ignition timing Dirt or water in fuel line or carburetor Carburetor flooded Test battery specific gravity Recharge or replace as necessary Clean and tighten battery connections Apply a coat of petroleum to terminals Refer to Starting Motor Wipe wires and cap clean and dry Replace any cracked or shorted cables Test and replace if necessary Clean or repl...

Page 434: ...ncorrectly gapped spark plugs Dirt or water in fuel line carburetor or filter Incorrect carburetor float setting Faulty fuel pump Incorrect vaIve timing I Adjust float level check m Install new fuel DumD seats Measure float level Adjust bowl vent Inspect operation of manifold control valve Adjust carburetor Adjust choke Adjust carburetor Adjust float setting Inspect intake manifold gasket and repl...

Page 435: ...ring clearance e Excessive end play f Crankshaft journal out of round 9 Loose flywheel or torque worn converter Correction i Install new head gasket j Test compression of each cylinder k Install new valves I Install new parts as necessary m Replace any cracked or shorted cables n Test and replace as necessary a Replace contacts and adjust b Clean spark plugs and set gap c Refer to Ignition Timing ...

Page 436: ... Oil Seal and Chain 12 Installing Piston and Connecting Rod Tune up 5 Assembly 19 Valves and Valve Springs 10 Measuring Connecting Rod Bearing Valve Timing 12 Clearance 19 SERVICE PROCEDURES 5 Clean or replace spark plugs as necessary TUNE UP and adjust gap to 035 inch Tighten to 30 1 Test battery specific gravity add water if foot pounds necessary clean and tighten battery connections 6 Test resi...

Page 437: ...ect crankcase ventilation system as out TRANSMISSION EXT HOUSING wv KBJ 40 FT LBS I KC 90 FT zy LBS 1 Fig 6 Front Engine Mounts Valiant lined on page 92 14 Inspect and adjust accessory belt drives ref erring to Cooling System Group 7 for proper adjustments 15 Road test vehicle as a final test ENGINE ASSEMBLY Removal move hood carburetor air cleaner move radiator rative control system from cylinder...

Page 438: ...ansmission filler 13 Lower vehicle 14 Tighten front engine mount bolts to speci fied torque 15 Connect exhaust pipe at the manifold using a new gasket 16 Connect fuel lines carburetor linkage and wiring to engine 17 Install closed ventilation system and evapo rative control system on cylinder head cover 18 Install hood using scribe marks for proper alignment 19 Close all drain cocks and fill cooli...

Page 439: ...head Fig 10 is held in place by 14 bolts Spark plugs are located at the wide edge of the combustion cham bers and aluminum spark plug tubes serve as spark plug gaskets hsfulhtion 1 Rocker arms and shaft assembly must be in stalled Fig 9 so the flat on the end of rocker shaft is on toD and point toward front of engine This is necessary to provide proper lubrication to rocker assemblies Removal 2 In...

Page 440: ... arms and shaft assembly with FLAT on end of rocker shaft ON TOP and TOOL CYLINDER HEAD ASSEMBLY Fig 7 2 Compressing Valve Spring pointing toward front of engine Fig 9 to pro vide proper lubrication to rocker assemblies Install rocker shaft retainers between rocker arms to the seat on rocker shaft and not on extended bushing on rocker arm Be sure to install long retainer in center position only In...

Page 441: ...earance as follows a install sleeve Tool C 3973 over valve stem and install valve Fig 13 The special sleeve places the valve at the correct height for measur ing with a dial indicator b Attach dial indicator Tool C 3339 to cylinder head and set it at right angle to the valve stem being measured Fig 14 c Move valve to and from the indicator The total dial indicator reading should not exceed 017 inc...

Page 442: ...tisfactory If the blue is transferred to the top edge of valve face lower the valve seat with a 30 degree stone If the blue Tesfing Valve Springs Fig 17 1 Whenever valves have been removed for inspection reconditioning or replacement valve springs should be tested As an example the com pressed length of the spring to be tested is 1 5 16 inches Turn table of Tool 2 647 until the surface is in line ...

Page 443: ...tor to zero Rotate crankshaft clockwise normal running direction until valve has lifted 029 inch The timing of the crankshaft pulley should now read from 12 degrees before top dead center to dead center Readjust lash 3 If reading is not within specified limits a Inspect sprocket index marks b Inspect timing chain for wear c Inspect accuracy of DC mark on timing indicator TIMING CHAIN COVER OIL SEA...

Page 444: ...LLING P L A T E T O O L REMOVER SCREW Fig 25 Removing Oil Seal with camshaft sprocket 7 Turn crankshaft to line up the centerline of camshaft and crankshaft with the timing mark on crankshaft sprocket 8 Install camshaft sprocket and timing chain 9 Line up timing marks on the sprockets with the centerline of crankshaft and camshaft Fig 23 10 Tighten camshaft sprocket lock bolt to 35 foot pounds Sli...

Page 445: ...ning inside of chain case cover facing up 7 Place the seal in cover opening with neo prene down Place seal installing plate into the new seal with the protective recess toward lip of seal retainer Fig 26 8 Install flat washer and nut on the remover screw hold screw and tighten nut Fig 27 9 Seal is properly installed when the neoprene is tight against face of cover Try to insert a 0015 inch feeler ...

Page 446: ...tributor time the engine The distributor rotates clockwise 1 Rotate crankshaft until the mark on inner CFMSHAFT BEARING OIL HOLE Fig 32 Removing Camshaft Bearings Tool edge of crankshaft pulley is in line with the 0 TDC mark on the timing chain case cover No 1 cyl compression stroke both valves closed 2 With distributor 0 rings in position hold the distributor over mounting pad 3 Turn the rotor to...

Page 447: ...AN BE EQUAL O R DIAMETER AT D CAN B E 0015 IN GREATER THAN C NY221B Fig 34 Piston Measurements taper of more than 010 in or if the cylinder walls are badly scuffed or scored the cylinder block should be rebored and honed and new oversize pistons and rings fitted Whatever type of boring equipment is used boring and honing oper ation should be closely coordinated with the fitting of pistons and ring...

Page 448: ...mal room temperature 70 degrees F 2 Measure piston diameter at the top of skirt 90 degrees to piston pin axis 3 Measure cylinder bores halfway down cylin der bore and transverse to engine crankshaft cen ter line Fitting Rings 1 Measure piston ring gap about two inches from the bottom of the cylinder bore in which it ANVIL TOOL PILOT TOOL SCREW TOOL ONNECTING ROD KR195B GUIDE LARGE TOOL Fig 36 Tool...

Page 449: ...press to prevent damage to bottom of the anvil 6 Remove tool from piston Insfatlafion 1 Measure piston pin fit in the piston It should be a sliding fit in piston at 70 degrees F Piston pins are supplied in standard sizes only 2 Lubricate piston pin holes in piston and con necting rod I N D E N T A S S E M B L E T O W A R D S F R O N T O F ENGINE 1 A S S E M B L E RIGHT SIDE N Y1428 Fig 39 Connecti...

Page 450: ...1 main bearing is 001 inch undersize CONNECTING RODS Installing Connecting Rod Bearings 1 Install connecting rod bearings so small formed tang fits into machined groove in connect ing rod 2 The limits of taper or out of round on any crankshaft journal should be held to 001 inch Bearings are available in standard 001 002 003 010 and 012 inch undersize 3 Install bearings in pairs Do not use a new be...

Page 451: ... car ry the crankshaft thrust loads and are not interchangeable with any other main bearings in the engine Bearings that are not badly worn scored or pitted should be reinstalled in the same bearing bore Fig 44 Removing or Installing Upper Main Bearing The bearing caps are not interchangeable and the numbers should be marked at removal to insure correct assembly Bearings are available in stand ard...

Page 452: ...seals make it possible to replace the upper rear seal without removing the crankshaft The seal must be used as an upper and lower set and cannot be combined with the rope seal 1 With oil pan removed remove rear seal re tainer and rear main bearing cap 2 Remove lower rope oil seal by prying from the side with a small screw driver Fig 45 3 Remove upper rope seal by turning in Tool C 4148 into the en...

Page 453: ... removed until the tool is se ated in the line bearing bore 3 Hold tool in this position and cut off the portion of the seal that extends above the block on both sides lower Seal ends protrude Fig 47 down into position until tool is seated 1 Install a new seal in seal retainer so that 2 Install the bridge on the tool and tap seal 3 Trim off portion of seal that protrudes above ENGINE OILING SYSTEM...

Page 454: ...e en gine crankshaft to clear counterweights and re move oil pan 225 Cubic Inch Engine Barracuda Satellite Fury 1 Remove oil dipstick disconnect negative ground cable Raise vehicle on hoist and drain oil pan 2 Remove center link from steering arm and idler arm ball joints see Front Suspension 3 Disconnect exhaust pipe from manifold and tie out of way 4 Remove oil pan attaching bolts rotate engine ...

Page 455: ...move pump assembly lnsf0thfion tighten to 200 inch pounds front engine mount bolts stall fan shroud if so equipped 1 Using new zyxwvuts 0 rings install oil pump and 2 Lower engine to its original position install 3 Connect upper and lower radiator hoses In 4 Install oil filter 5 Refill radiator Disassembly Fig 51 1 Remove pump cover and seal ring 2 Press off drive gear Support gear to keep Fig 52 ...

Page 456: ... plunger for scoring for free operation in its bore Small scores Fig 57 Measuring Clearance Between Rotors may be removed with 400 grit wet or dry paper 9 For 198 225 cubic inch engines the relief valve spring has a free length of 2 9 32 to 2 19 64 inch and should test 14 85 to 15 85 Ibs when compressed to 1 19 32 inch Discard spring that fails to meet specifications 10 If oil pressure is low insp...

Page 457: ...pounds for 318 line disconnected Ignition timing should be set to or 360 Cubic Inch Engine or 110 pounds for 340 compensate for altitudes and or gasoline grades Cubic Inch Engine and not vary more than 40 9 Set carburetor idle mixture adjustment Ad pounds The recommended compression pressures just throttle stop screw to specifications Perform are to be only as a guide to diagnosing engine a combus...

Page 458: ...stem Group 7 for proper adjustments 15 Road test vehicle as a final test FRONT ENGINE MOUNTS Figs 2 3 and 4 Removal hose and radiator top tank 1 Raise hood and position fan to clear radiator 2 Disconnect throttle linkage at transmission I z b yz d x LEFT SIDE PY603 Fig 4 Fronf Engine Mounfs 340 Cubic Inch Barracuda Safellife 360 Cubic Inch Fury Fig 6 Engine Rear Supporf Barracuda Safellife Fury an...

Page 459: ...t crossmember and remove transmission from vehicle 10 Lower vehicle and attach a crane or other suitable lifting tool to fixture eyebolt 11 Remove engine front mounts Raise engine with lifting tool and work engine out of chassis 12 Place engine in repair stand C 3167 and adapter C 3662 for disassembly using transmission mounting bolts Installation 1 Attaching engine lifting fixture to carburetor f...

Page 460: ...reason to suspect leakage If out of flatness exceeds 00075 times the span length in any direction either replace head or lightly ma chine the head gasket surface As an example if a 12 inch span is 004 in out of flat allowable is 12 x 00075 009 in Head is OK The cylinder head surface finish should be 70 180 micro inches 3 Coat new gaskets lightly with number 1057794 Sealer and install on cylinder b...

Page 461: ...ll distributor cap and wires 16 Install fuel line alternator and drive belt Tighten alternator mounting bolt to 30 foot pounds and and adjusting strap bolt to 200 inch pounds See Cooling Section on adjusting belt tension 17 Place new cylinder head cover gaskets in position and install cylinder head covers Tighten to 40 inch pounds 18 Install closed crankcase ventilation system and evaporative cont...

Page 462: ... Valve Guide 005in 379 380 in 2 3433 C 3430 015in 389 390 in C 3427 030in 404 405 in 6 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Do not at tempt to ream the valve guides from standard directly to 030 inch Use step procedure of 005 015 and 030 inch so the valve guides may be reamed true in relation to the valve seat Refacing Vafves and Valve Seats 1 The intak...

Page 463: ...e wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on Fig 78 Installing Valve Cup Seals Spring and Retainer the table for finer adjustments Refer to specifica tions to obtain specified height and allowable tensions Discard the springs that do not meet specifications 2 Inspect each valve spring for squareness wit...

Page 464: ...pecifications and installvalve covers 318 340 360 ENGINE 9 33 HYDRAULIC TAPPETS Preliminary to Checking the Hydraulic Tappets Before disassembling any part of the engine to correct tappet noise read the oil pressure at the gauge Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and check the oil level in the oil pan The pressure should be between 45 and 65 poun...

Page 465: ...osits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger flat check valve check valve spring check valve retainer and plunger spring Cleaning and Assembly remove all varnish and carbon 1 Clean all tappet parts in a solvent that will CLEAN KEROSENE NR69 Fig 20 Testing Tappet Using Tool c 3160 2 Replace tappets that are unfit for further service with new...

Page 466: ...ront Fig 22 Measuring Timing Chain Stretch bolt at each side 6 Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket It is normal to find particles of neoprene col lected between the crankshaft seal retainer and crankshaft oil slinger 7 Slide crankshaft oil slinger from end of crankshaft Measuring Timing Chain for Stretch 1 Place a scale next to timing chain so ...

Page 467: ...t for 002 to 006 inch end play with a new thrust plate and up to 010 inch end play with a used thrust plate If not within these limits install a new thrust plate 14 If within limits slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket Fig 24 Alignment of Timing Marks REMOVING AND INSTALLING PLATE R E M O V E R S C R E W TOOL1 CHAIN CASE C O Fig 26 Removing ...

Page 468: ...n 1 Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs 2 Using a new gasket carefully install chain case cover to avoid damaging oil pan gasket Fig 29 Inspecting Seal for Proper Seating Fig 37 Positioning of Distributor Drive Gear Tighten chain case cover capscrews to 30 foot pounds first than tighten oil pan capscrews to 200 inch pounds 3 Lubricate seal l...

Page 469: ...o the left cylinder head and Number four bearing must index with the oil passage to the right cylinder head If the camshaft bearing shell oil holes are not in exact alignment remove and reinstall them correctly Install a new core hole plug at the rear of camshaft Be sure this plug does not leak 1 Remove rocker arm and shaft assemblies 2 Remove push rods and tappets identify so each part will be re...

Page 470: ...he distributor and engage the shaft in the slot of distributor drive shaft gear 5 Turn distributor clockwise until breaker con tacts are just separating and install hold down clamp CYLINDER BLOCK Piston Rem0Val 1 Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block Be sure to keep tops of pistons covered during this operation Pistons and con n...

Page 471: ... SHOULD BE PISTON SKIRT SHOULD BE 0 1 0 OOOO TO 001 INCH TO 013 IN LESS AT DIAMETER A THAN ACROSS THE THRUST FACES AT DIAMETER B LARGER THAN C NU249A Fig 38 318 Cubic Inch Piston Measurement 021 to O BIN LESS V 8 B PISTON 4 A F T H A N DIAMETER AT C 1 360 CUBIC INCH DIAMETER D SHOULD BE THE ELLIPTICAL SHAPE OF THE PISTON SKIRT SHOULD BE 010 TO 013 IN LESS AT DIAMETERzyxw oooO TO 01 INCH A THAN ACR...

Page 472: ... lock rings On 360 cubic inch engines the piston pin ro tates in piston only and is retained by the press interference tit of the piston pin to the small end of connecting rod Fig 42 Removing Piston Pin 318 340 Cubic Inch Only 1 With new piston and new pins at room temperature 70 degrees F pin should be a light thumb push fit in the piston and connecting rod Replacement is necessary if there is ex...

Page 473: ... and piston pin in piston Fig 43 8 Install nut on puller screw to hold assembly MAIN SCREW TOOL1 ANVIL TOOLI Fig 44 Installing Piston Pin PISTON RING RING GROOVE NK31 Fig 46 Measuring Piston Ring Clearance together Place assembly on a press Fig 4 4 9 Press piston pin in until piston pin bottoms on the pilot This will position pin in connecting rod 10 Remove tool and arrange tool parts and pis ton ...

Page 474: ...ller Tool C 3586 for 318 cu bic inch engine Tool C 3672 for 340 cubic inch engine Tool C 3562 for 360 cubic inch engine Be sure the mark Top on each compression ring is to the top of piston when ring is installed CRANKSHAFT IDENTIFICATION A crankshaft which has one or more connecting rod or main bearing journals undersize will be steel stamped on the milled flat on the 8 crank shaft counterweight ...

Page 475: ...om 009 to 017 inch two rods INSTALLING PISTON AND CONNECTING ROD ASSEMBLY 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Figure 48 3 Immerse the pisto...

Page 476: ...nserting Tool C 3059 Fig 51 into the oil hole of crankshaft 3 Slowly rotate crankshaft clockwise forcing out upper half of bearing shell SEAL Fig 52 Removing Upper Oil Seal with Tool C 4748 Installation Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened When installing a new upper bearing shell slightly chamfer the sharp edges from the plain...

Page 477: ...r Main Upper Oil Seal crankshaft if necessary while sliding seal into groove Care must be exercised not to damage the sealing lip 6 Install other half of the seal into the rear main bearing cap with paint stripe to the rear 7 Install rear main bearing cap tighten to 85 foot pounds Do not use sealer or cement on seal ends or lip REAR MAIN BEARING OIL SEAL Crankshaft Removed Upper Seal 1 Install a n...

Page 478: ...318 340 360 ENGINE 9 47 a MyMopar com ...

Page 479: ...remove cap by tapping pump body using a soft hammer Discard cap and remove spring and relief valve Fig 57 2 Remove oil pump cover bolts and lockwashers and lift off cover 3 Discard oil seal ring 4 Remove pump rotor and shaft and lift out 5 Wash all parts in a suitable solvent and in outer rotor spect carefully for damage or wear Fig 58 Inspection 1 The mating face of the oil pump cover should be s...

Page 480: ...re than 004 inch can be inserted between rotors and straightedge replace pump body Fig 64 9 Inspect oil pump relief valve plunger for scoring and for free operation in its bore Small scores may be removed with 400 grit wet or dry paper 10 The relief valve spring has a free length of 2 1 32 to 2 3 64 inch and should test 16 2 to 17 2 lbs when compressed to 1 11 32 inch Dis card springs that fails t...

Page 481: ...rd spring that fails to meet specifications 6 Install the relief valve spring a new retainer cap Spring seats inside retainer cap Press re tainer in housing so that top of retainer cap is within the relief valve bore diameter as shown in Figure 65 Install cotter pin 383 440 CUBIC INCH ENGINES INDEX Page Camshaft 6 2 Camshaft Bearings 6 2 Connecting Rods 67 Crankcase Ventilation System 9 2 Cranksha...

Page 482: ...9 Set carburetor idle mixture adjustment Ad just throttle stop screw to specifications Perform a combustion analysis 10 Test the fuel pump for pressure and vacuum Refer to Fuel System Group 14 Specifications 11 Inspect the manifold heat control valve in NR42A Fig 2 Front Engine Mounts Barracuda Safellife Fury Chrysler Imperial the right exhaust manifold for proper operation and apply Manifold Heat...

Page 483: ...nes at the transmission 10 Remove engine rear support crossmember and remove transmission from vehicle 11 Lower vehicle and attach chain hoist to fix ture eyebolt 12 Remove engine front mounting bolts Raise engine with a chain hoist and work engine out of chassis 13 Place engine in repair stand Tool C 3167 and adapter C 3662 for disassembly using trans mission mounting bolts Installation flange st...

Page 484: ...ing sure to install the long stamped steel retainers in the number two and four positions 2 Install rocker shafts so that 3 16 inch diame ter rocker arm lubrication holes point downward into the rocker arm so that the 15 degree angle of these holes point outward towards the valve end of the rocker arms Fig 5 This is necessary to provide proper lubrication to the rocker assemblies The 15 Degree ang...

Page 485: ... 6 Install push rods in the tappets maintaining alignment using rod Fig 7 7 Install rocker arm and shaft assembly start I REPATSTAND TOOL KRl4lA Fig 8 Compressing Valve Spring ing each push rod into its respective rocker arm socket making sure to install the long stamped steel retainers in the number two and four positions tighten bolts to 25 foot pounds 8 Place new cylinder head gasket in positio...

Page 486: ...05 in Tool Number Oversize Size 8 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Do not at tempt to ream the valve guides from standard directly to 030 inch Use step procedure of 005 015 and 030 inch so the valve guides may be reamed true in relation to the valve seat Refacing Valves and Valve Seats The intake and exhaust valve faces have a 45 degree angle Always...

Page 487: ...d the spring seat 9 If the tip exceeds the maximum grind sten zyxwvu L Fig 14 Inspecting Valve Spring Squareness tip to within gauge limits Clean tappets if tip grinding is required resfing the Valve Springs Fig 13 1 Whenever valves are removed for inspection reconditioning or replacement the valve springs should be tested As an example the compressed length of the spring to be tested is 1 15 32 i...

Page 488: ...ons Fig 16 Insfalling Valve Spring Cup Seal and Refainer could be responsible for noisy tappets Oil Level Too High If oil level is above the full mark on dipstick it is possible for the connecting rods to dip into the oil while engine is running and create foam Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily Oil Lev...

Page 489: ...et on a dirty work bench Disassembly Fig 17 1 Pry out plunger retainer spring clip 2 Clean varnish deposits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger flat check valve check valve spring check valve retainer and plunger spring NR66 Fig 18 Testing Tappet Using Tool C 3160 Cleaning and Assembly 1 Clean all tappet parts in a solvent that will remo...

Page 490: ... Cover Rem0Val and water pump assembly ing bolt 1 Drain cooling system and remove radiator 2 Remove crankshaft vibration damper attach TORQUE WRENCH Fig 20 Measuring Timing Chain Stretch 3 Remove two of the pulley bolts install Tool C 3688 and pull damper assembly off end of crankshaft Fig 19 4 Remove chain cover and gasket lt is normal to find particles of neoprene collected between seal retainer...

Page 491: ...lignment of timing marks Fig 22 13 Install washer and camshaft sprocket bolt tighten to 35 foot pounds Check to be sure that rear face of aluminum camshaft sprocket is flush with end of camshaft Slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket Fig 22 Alignment of riming Marks R E M O V E R S C R E W T REMOVING A N D INSTALL1NG PLATE TOOL W Fig 24 Removi...

Page 492: ... View 7 Place seal in cover opening with neoprene down Place seal installing plate into the new seal with protective recess tmvard lip of seal retainer Fig 25 The lip of the neoprene seal must be toward source of oil 8 Install flat washer and nut on remover screw hold screw and tighten nut Fig 26 9 The seal is properly installed when the neo Cover Installation 1 Be sure mating surfaces of chain ca...

Page 493: ...aced all of tappet faces must be inspected for crown with a straight edge If any contact surface is dished or worn tappet must be replaced BUSHING KR159 Fig 31 Removing Distributor Drive Shaft Bushing CAMSHAFT BEARINGS Engine Removed From Vehicle Removal 1 With engine completely disassembled drive out camshaft rear bearing welch plug 2 Install proper size adapters and horse shoe washers part of To...

Page 494: ...ar with engine oil Install the shaft so that after gear spirals into place it will index with the oil pump shaft so slot in top of drive gear will be parallel with cen ter line of crankshaft Fig 34 Insfallation o f Disfribufor 1 Hold distributor over mounting pad on cylin der block with vacuum chamber pointing toward center of engine 2 Turn rotor until it points forward and to ap proximate locatio...

Page 495: ... MENT IS MADE hzyxw IN BE LOW LOWER RING GROOVE NU258 DIAMETERS AT C AND D CAN BE EQUAL OR DIAMETER AT D CAN BE 0015 IN GREATER THAN C Fig 36 Piston Measurements 1 Used carefully the cylinder bore resizing hone C 823 equipped with 220 grit stones and 390 extensions necessary with 383 and 440 cubic inch engines is the best tool for this job In addition to deglazing it will reduce taper and out of g...

Page 496: ...nd the following oversizes 005 020 and 040 inch Fitting Rings 1 Measure piston ring gap about two inches from bottom of cylinder bore in which it is to be fitted An inverted piston can be used to push rings down to insure positioning rings squarely in cylinder bore before measuring 2 Insert feeler stock in the gap Ring gap should be between 013 to 052 inch for the com SCREW TOOL ONNECTING ROD KR19...

Page 497: ...ance engines only for installation of piston pin Fig 40 4 Install spring inside the pilot and install spring and pilot in the anvil Install piston pin over main screw 5 Place piston with front up over the pilot so pilot extends through piston pin hole 6 Position connecting rod over the pilot which extends through piston pin hole Assemble rods to pistons of the right cylinder bank 2 4 6 and 8 with ...

Page 498: ...k shaft journals should be held to a maximum of 001 inch Bearings are available in 001 002 003 010 and 012 inch undersize Install the bearings in pars Do not use a new KK 162 Fig 44 Showing location of Infernal Marking of Counferweighf bearing half with an old bearing half Do not file the rods or bearing caps MEASURING CONNECTING ROD BEARING CLEARANCE Shim Stock Method 1 a 383 engine with 2 barrel...

Page 499: ...EGULARLY SCHEDULED OIL CHANGE REFER TO LUBRICATION GROUP 0 FOR SUBSEQUENT USE OF THIS ADDITIVE IN HIGH PERFORMANCE ENGINES ADDED TO THE ENGINE OIL TO AID BREAK IN CRANKSHAFT MAIN JOURNALS Crankshaft main bearing journals should be in spected for excessive wear taper and scoring Journal grinding should not exceed 012 inch un der the standard journal diameter DO NOT grind the thrust faces of the NO ...

Page 500: ...ring shell with one 001 inch undersize shell Always use the smaller diameter bearing half as the upper Never use an upper bearing half more than 001 inch smaller than the lower bearing half and never use a new bearing half with a used bearing half REAR MAIN BEARING 011 SEALS Service seals are of split rubber type composition The seals make it possible to replace the upper rear seal without removin...

Page 501: ... or diesel fuel to the side seals 2 Install seals immediately in the seal retainer grooves 3 Install seal retainer and tighten screws to 25 foot pounds Failure to pre oil the seals will result in an oil leak ENGINE OILING SYSTEM Fig 51 Removal 1 Disconnect battery cable and remove dipstick 2 Raise vehicle on a hoist and disconnect steer 3 Disconnect exhaust pipe branches from right 4 Remove clamp ...

Page 502: ... PUMP Removal Remove oil pump attaching bolts and remove pump and filter assembly from bottom side of engine Disassembly 1 Remove filter base and oil seal ring 2 Remove pump rotor and shaft and lift out outer pump rotor 3 Remove the oil pressure relief valve plug and lift out the spring and relief valve plunger Fig 52 Inspedon and Assembly 1 Clean all parts thoroughly The mating face of filter bas...

Page 503: ...uter rotor into pump body press to one side with fingers and measure clearance be tween outer rotor and pump body Fig 56 If OUTER ROTOR PUMP BODY Fig 56 Measuring Outer Rotor Clearance OUTER ROTOR INNER ROTOR Fig 58 Measuring Clearance Between Rotors measurement is more than 014 inch replace oil pump body 6 Install inner rotor into pump body and place a straightedge across the face between bolt ho...

Page 504: ...Do not use tool 2 To obtain an effective seal tighten filters by hand the additional number of turns indicated on the replacement fjlter Start engine and inspect for leaks 426 CUBIC INCH HEMI ENGINE INDEX Page Camshaft 84 Camshaft Bearings 84 Connecting Rods 87 Crankcase Ventilation System 9 2 Crankshaft Identification 87 Crankshaft Main Bearings 88 Crankshaft Main Journals 88 Cylinder Block 8 5 C...

Page 505: ...e in the right exhaust manifold for proper operation and apply Manifold Heat Control Valve Solvent Number 3419129 or equivalent to the bushing and shafts 12 Every oil change remove filter element and blow out dirt gently with air hose Direct air from inside out and keep nozzle 2 inches away from element to avoid damaging Clean the metal Fig 2 Engine Rear Support housing and replace the element Eve...

Page 506: ...g hooks to lifting straps and remove engine from repair stand 2 Lower engine into chassis until the front en gine mounts line up with K member support Install attaching bolts and stud nuts do not tight en at this time 3 Install engine support fixture C 3487A en gaging the hooks in holes in frame side members Be sure support ends are up against the underside of the oil pan flange 4 Remove hydro cra...

Page 507: ...ls at each end of NN1034 Fig 5 Hemi 426 Engine Combustion Chamber Cross Section manifold 5 Remove intake manifold with ignition coil both carburetors fuel lines fuel filters throttle linkage and upper bellcrank as an assembly 6 Disconnect exhaust headers from cylinder heads and tie out of way 7 Remove the lower eight cylinder head bolts Fig 3 8 Remove the four stud nuts 9 16 inch hexagon from cy1i...

Page 508: ...ean cylinder head cover gasket surface In spect cover for distortion and straighten if necessary 7 Place new cylinder head cover gaskets in position and install cylinder head covers Tighten nuts to 40 inch pounds NN1036 Fig 7 Cylinder Head Tightening Sequence Fig 9 Compressing Valve Spring 8 Adjust spark plug gaps to zyx 035 inch Slide spark plug tube seals over tubes With a six inch extension on ...

Page 509: ...rd burned warped or cracked valves 2 Measure valve stems for wear New intake valve stem diameter should measure 3085 to 3095 inch and exhaust valve stem diameter should measure 3075 to 3085 inch If wear ex ceeds 002 inch replace valve 3 Remove carbon and varnish deposits from inside of valve guides with a reliable valve guide cleaner 4 Measure valve stem guide clearance as follows a Install sleeve...

Page 510: ...nch mark on the threaded stud and the Fig 14 Inspecting Valve Spring Squareness zero mark to the front Place spring over stud on the table and lift compressing lever to set tone device Pull on torque wrench until ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fractional measurements are indicated on the table f...

Page 511: ... the oil pump causing them to lose length and allow valves to seat noisily Oil Level Too Low Low oil level may allow oil pump to take in air which when fed to the tappets causes them to lose length and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same tappet action When tappet noise is due to aeration it may be intermittent or consta...

Page 512: ...inch CAUTION Do not turn crankshaft any further clockwise as the valve spring might bottom and result in serious damage positions I E TORQUE WRENCH Fig 16 Measuring Timing Chain Stretch Typical The timing of the crankshaft pulley should now read from 10 degrees before top dead center to 2 degrees after top dead center 6 If reading is not within specified limits a Check accuracy of DC mark on crank...

Page 513: ... engine block Remove dis tributor and oil pump distributor drive gear Lo cate tool against rear side of cam gear and at tach tool with distributor retatiner plate bolt Fig 17 Fig 18 Alignment of Timing Marks REMOVER SCREW T REMOVING AND INSTALLING PLATE TOOL f CHAIN CASE k COVER Fig 20 Removing Oil Seal 7 Place camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imagi...

Page 514: ...g 21 The lip of the neoprene seal must be toward source of oil 8 Install flat washer and nut on remover screw hold screw and tighten nut Fig 22 9 The seal is properly installed when the neo REMOVER SCREW fHAlN CASE COVER SEAL RETAINER KR155B Fig 22 Instolling New Seal NP292 Fig 24 Installing Vibration Domper Assembly prene is tight against face of cover Try to insert a 0015 inch feeler gauge betwe...

Page 515: ...with zyxwvu a straight edge If any contact surface is dished or worn tappet must be replaced CAMSHAFT BEARINGS Engine Removed From Vehicle BUSHING Fig 26 Removing Distributor Drive Shaft Bushing Removal 1 With engine completely disassembled drive out camshaft rear bearing welch plug 2 Install proper size adapters and horse shoe washers part of Tool C 3132A at the back of each bearing to be removed...

Page 516: ...h cen ter line of crankshaft Fig 29 nstallation of Distributor 1 Hold distributor over mounting pad on cylin der block with vacuum chamber pointing toward center of engine 2 Turn rotor until it points forward and to ap proximate location of No 1 tower terminal in the distributor cap 3 Place distributor gasket in position 4 Lower the distributor and engage the shaft in the slot of distributor drive...

Page 517: ... as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required limits 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone Tool C 3501 equipped with 280 grit stones 3501 3810 if the cylinder bore is straight and round 20 to 60 strokes depending on the bore condition will be sufficient to provide a satisfactory ...

Page 518: ...row indicating front is to the left of the operator and the connecting rod insert locating tang or number is facing the operator Install pis ton pin and lock rings with the bevel edge away from the piston pin using Tool C 3915 3 Assemble the right cylinder bank 2 4 6 8 so the arrow is to the right of the operator with the connecting rod insert locating tang or number is facing the operator Install...

Page 519: ...EQUENT USE OF THIS ADDITIVE IN HIGH PERFORMANCE ENGINES O f To01 C 385 ADDED TO THE ENGINE OIL TO AID BREAK IN 1 THRUST BEARING a OWER NY412 Fig 32 Main Bearing Identification CRANKSHAFT MAIN JOURNALS Crankshaft main bearing journals should be in spected for excessive wear taper and scoring Journal grinding should not exceed 012 inch un der the standard journal diameter DO NOT grind the thrust fac...

Page 520: ... 2 Install bearing in center main bearing cap bearing tang in groove in cap lubricate bearing and position shim stock across the bearing install cap and horizontal tie bolts Tighten cap bolts to 100 foot pounds then horizontal tie bolts to 45 foot pounds 3 If a slight drag is felt as crankshaft is turned moved no more than 1 4 turn in either direction clearance is 002 inch or less and is considere...

Page 521: ...nd disconnect steer 3 Drain crankcase oil 4 Remove converter dust shield 5 Remove oil pan bolts Turn flywheel until counterweight and connecting rods at front end of crankshaft are at their highest position to provide clearance and lower the pan Turn pan counter clockwise to clear oil screen and suction pipe as it is lowered ing linkage from idler arm and steering arm Insfallation 1 Inspect alignm...

Page 522: ...an 014 inch replace oil pump body 6 Install inner rotor pump body and place a straightedge across the face between bolt holes KB 67A Fig 39 Measuring Inner Rotor Thickness OUTER ROTOR PUMP BODY Fig 40 Measuring Outer Rotor Clearance OUTER ROTOR INNER ROTOR Fig 42 Measuring Clearance Between Rotors Fig 41 If a feeler gauge of more than 004 inch can be inserted between the rotors and straightedge re...

Page 523: ...awn into the crank case from the air cleaner and through the crank case inlet air cleaner by means of a hose Fig 1 Air is circulated through the engine and drawn out of the cylinder head cover by manifold vacu um into the combustion chambers and dispelled with the exhaust gases The system consists of a ventilation valve in stalled in the outlet vent of the cylinder head cover and a hose The hose i...

Page 524: ...block and the neces See the Lubrication and Maintenance section sary tools and inserts for the repair of damaged Group 0 of this manual for proper service or worn thread Heli Coil tools and inserts are procedures ELI COIL INSERT IN Fig 2 Heli Coil Installation readily available from automotive parts jobbers Inserting Extracting Heli Coil Insert Drill Tao Tool Tool Thread Part Insert Part Part Part...

Page 525: ... Rear Seal Surface Interchangeability of Bearings MAIN BEARINGS service All available in Standard and the following Undersizes CONNECTING RODS AND BEARINGS Type Length Center to Center Weight Less Bearing Shells Bearings Diameter and Length Clearance Desired Maximum Allowable before Reconditioning Side Clearance Bearings for Service Piston Pin Bore Diameter In line OHV 6 3 40 3 640 4 125 198 225 c...

Page 526: ...e Piston Length overall Ring Groove Depth No 1 No 2 No 3 Pistons for Service PISTON PINS Type Diameter Length Clearance in Piston Chain Steel Backed Babbitt 4 Cylinder Block 001 to 003 005 1 998 to 1 999 1 982 to 1 983 1 967 to 1968 1 951 to 1 952 2 000 to 2 001 1 984 to 1 985 1 969 to 1 970 1 953 to 1 954 50 50 88 Mechanical 0012 to 00025 9040 to 9045 010 Intake 020 Exhaust Horizontal Slot w Stee...

Page 527: ...Stem to Guide Clearance Valve Face Angle Adjustment Maximum Allowable Before Reconditioning Lift VALVES Exhaust Material Head Diameter Length to gauge dim Line Stem Diameter Stem to Guide Clearance Maximum Allowable Before Reconditioning Valve Face Angle Adjustment Lift zyx 3 2 1 3 piece steel rail chrome face 0775 0780 025 010 020 0 1 5 055 0015 0030 0002 005 0 1 0 047 0 1 5 062 0015 004 0002 005...

Page 528: ...rive Shaft Bushing press fit in block Ream to Shaft to Bushing Clearance Pump Type Capacity qts Pump Drive Operating Pressure at 1000 RPM Pressure Drop Resulting from Clogged Filter CYLINDER BLOCK ENGINE LUBRICATION 0IL FILTER Type Spin On 12 1 92 49 57 Ibs 1 11 16 137 150 Ibs 1 5 16 1 010 to 1 030 1 5 8 1 11 16 Wedge Type 002 45Ozy 070 to 090 45O 040 to 060 022 3 4000 005 010 001 040 9051 9059 00...

Page 529: ... indicating Crankshaft counterweight No 2 3 main bearing journal and or R 1 4 etc indicating No 1 4 connecting rod journals Maltese Cross and X M 10 indicates 010 Crankshaft counterweight U S all main journals and or R 10 indicates 010 U S all rod journals _ 010 U S Crankshaft Top of front pad Right side of block zyx 020 O SCylinder A Top of front pad Right Bores side of block 008 O STappets Top o...

Page 530: ...a C m zyxwvut c a a s 0 zyxwvu iu o M o M 0 9 a Ln 0 0 I O b q 09 0 o o m 0 o m 0 06 9 1 2 0 a MyMopar com ...

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Page 533: ...102 SPECIFICATIONS zyxwvu 0 b 9 0 zy a s 0 0 0 0 0 0 0 0 0 0 z z z z z z z z z z m zyxwvuts E 0 E a 1 2 S a 0 C C a a 3 Z z I W 3 a c MyMopar com ...

Page 534: ...I SPEClFlCATtONS 9 1 z 03 b P zyxwvut co b P d F vi s 0 0 03 zyx a E x F zyx E n m _ E a t l m _ u v E E m L h E n E a v Q v m 0 n E z 3 Q 0 0 E 3 o v C a Q o a m Y W z u z W MyMopar com ...

Page 535: ...9 104 SPECIFICATIONS zyxwvu 0 cc zyxwvutsrqpo L Q L m 0 CT c ci L a VI C E a w L a I L C a f z 0 I c L 1 0 L L E B Q o E 0 MyMopar com ...

Page 536: ...appets 3 8 diamond shaped stamp Top pad Front of engine and flat ground on outside surface of each O S tappet bore 3 8 tapped holes on each end of cvlinder head 005 O S Valve Stems X Milled pad adjacent to two ENGINE zyxwvutsr 383 440 Type 9oov 9oov Number of Cylinders 8 8 Bore 4 25 4 320 Stroke 3 375 3 75 zy 0 Piston Displacement 383 cu in 440 cu in Compression Ratio 8 7 to 1 9 0 to 1 Minimum Com...

Page 537: ...insfor Service PISTON RINGS Number of Rings per Piston Compression Oil Oil Ring Type 1 3 5 7 2 4 6 8 4 2495 4 2515 005 010 001I f 040 9050 9058 0005I f 0040 I 4865 4880 007 0027 Autothermic W Steel Struts 021 029 OO03 0013 770 gms 3 874 220 220 208 Std 005 020 040 Oversize Press Fit in Rod 1 0935 1 0937 3 555 3 5 75 00045 I 00075 0007 0012 Standard Only 3 2 1 3 piece Chrome plated rails with Stain...

Page 538: ...owing undersizes CONNECTING ROD JOURNALS Diameter Maximum Allowable Out of Roundand or Taper Drive Bearings Number Diametral Clearance Maximum Allowable before Reconditioning Thrust Taken By CAMSHAFT 0015 0030 OOOO 005 013 023 015 062 0015 004 0000 005 6 356 6 360 8 1224 gms 009 017 1 0923 1 0928 None Steel Backed Babbitt Tri metal Steel Backed 2 376 927 005 002 001 002 0025 Std 001 002 003 010 01...

Page 539: ...TC 20 25 200 25 Valve Overlap 38 46 38 46 Intake Valve Duration 260 268 260 268 Exhaust Valve Duration 268 284 268 284 Number of Links 50 50 Pitch 50 50 Width 75 75 Type Hydraulic Hydraulic Body Diameter 9035 9045 9035 9045 Clearance in Block 0011 0024 0011 0024 ServiceTappets Available Std 001 I 008 030 Std 001 008 030 Clearance Between Valve Stem and Rocker Arm Pad Dry Lash 060 210 060 210 TIMIN...

Page 540: ...458 Number 16 16 Free Length 2 58 2 23 Load When Compressed to Valves Exhaust Stem to Guide Clearance Valve Springs Valve Closed 121 129 1 55 64 100 110 1 55 64 Valve Open 192 208 1 7 16 236 256 1 23 64 Valve Spring I D 1 01 1 03 1 07 1 09 Maximum Allowable Out of Plumb zyxw 060 080 Valve Spring Installed Height spring seat to retainer Use 1 16 Spacer to ReduceSpring Height 1 53 64 1 57 64 1 53 64...

Page 541: ...GS Engine Displacement Condition ldentification Location of Identification 383 cu in 440 cu in 001 U S Crankshaft Maltese Cross Top of front pad Right side of block M 2 3etc indicating Crankshaft counterweight No 2 3 main bearing joumal and or R 1 4etc indicating No 1 4 connecting rod journals Maltese Cross and X Top pad Front of engine M 10 indicates 010 Crankshaft counterweight U S all main jour...

Page 542: ...er Distributor Lower Drive Shaft Bushing pressfit in block Ream to Shaft to Bushing Clearance PISTONS TypeMaterial Land Clearance diametrical Clearance a t Top of Skirt Weight Std through 040 oversize Piston Length overall Ring Groove Depth No 1 No 2 No 3 Pistonsfor Service PISTON PINS Type Diameter Length Weight Clearance in Piston Tight Thumb Push 7OoF End Play Clearance in Rod Pins for Service ...

Page 543: ...e Clearance Desired Clearance Allowed Finish a t Rear Oil Seal Surface Diameter Maximum Allowable Out of Round Maximum Allowable Taper Bearings for Service Available in Standard and the following undersizes CRANKSHAFT MAIN BEARING JOURNALS CONNECTING ROD JOURNALS Diameter Maximum Allowable Out of Round Maximum Allowable Taper 3 2 1 3 Piece Chrome Plated Rails with Stain less Steel Expander Spacer ...

Page 544: ...Valve Seat Runout maximum Intake Valve Seat Angle Seat Width Finish Exhaust Valve Seat Angle Seat Width Finish Cylinder Head Gasket thicknesscompressed Combustion Chamber Volumes with valves and plugs Type Guide Bore Diameter Head Diameter Length to center of valve face Stem Diameter Standard CYLINDER HEAD VALVE GUIDES VALVES Intake Roller Chain Steel Backed Babbitt 5 001 zyx 003 005 Cylinder Bloc...

Page 545: ...nimum Pump Pressure 1000rpm Operating Pressure at 2000 rpm Pressure Drop Resultingfrom Clogged Filter Oil Filter Type With Tools C 3973 and C 3339 using wobble method When Filter Element is Replace Add 1 U S Quart or 3 4 Imperial Quart ENGINE LUBRICATION 002 004 017 45O Std zyx 005 015 030 Oversize Stem Diam 490 1 940 4 7543 4 7693 3075 3085 003 005 017 Std 005 015 030 Oversize Stem Diam 48 1I A 5...

Page 546: ...Cross Top pad Front of engine Crankshaft countew eight M 2 3etc indicating No 2 3 main bearing journal and or R 1 4etc indicating No 1 4 connectingrod journals Maltese Cross and X M 10 indicates 010 U S all main journals and or R 10 indicates 010 U S all rod iournals OIOrr U S Crankshaft Top pad Front of engine Crankshaft countew e i ght zy 020 O S Cylinder Bores A Top pad Front of engine 008 O S ...

Page 547: ...Alternator Bracket Bolt Alternator Mounting Nut Alternator Adjusting Strap Bolt Alternator Adjusting Strap Mounting Bolt Intake to Exhaust Manifold Bolt Oil Pan Drain Plug Oil PanScrew Oil Pump Cover Bolt Oil Pump Attaching Bolt Oil Filter Attaching Stud Oil Pressure Gauge Sending Unit Rocker Shaft Bracket Bolt Starter Mounting Bolt Temperature Gauge Sending Unit Water Pump to Housing Bolt Torque ...

Page 548: ...to Cylinder Block Flywheel Housing Cover Intake Manifold Oil Pan Drain Plug Oil PanScrew Oil Pumpcover Bolt Oil Pump Attaching Bolt Rocker Arm Adjusting Screw Lock Nut Rocker Shaft Retainer Bolt Spark Plug Vibration Damper Pulley Bolts Water Pump Torque Foot Pounds 45 95 85 35 210 in lbs 35 30 100 in lbs 35 100 40 in lbs 24 50 55 55 270 in lbs 50 100 in lbs 35 20 200 in lbs 95 in lbs 30 25 200 30 ...

Page 549: ... Bolt Alternator Mounting Bolt Alternator Adjusting Strap Bolt Alternator Adjusting Strap Mounting Bolt Intake Manifold Bolt Oil Pan Drain Plug Oil PanScrew Oil Pump Cover Bolt Oil Pump Attaching Bolt Rocker Shaft Bracket Bolt Vibration Damper Pulley Bolts Starter Mounting Bolt Water Pump to Housing Bolt Water Pump Housingto Cylinder Block Bolt A C Compressorto Engine Bolt Torque Foot Pounds 45 70...

Page 550: ...t Main Bearing Cap Tie Bolt Oil PanScrew 0 1 1Pan Drain Plug Oil Pump Attaching Bolt Oil Pump Cover Bolt Rocker Arm Adjusting Screw Lock Nut Rocker Shaft Bracket Bolt Sparkplug Starter Mounting Bolt Torque Converter to Flex Plate Bolt Water Pump to Housing Bolt Water Pump to Cylinder Block Bolt Torque Foot pounds 30 200 in lbs 30 40 200 in lbs 15 18 15 18 75 135 30 70 75 70 75 40 in lbs 200 in lbs...

Page 551: ...ines to meet these new standards and maintain or im prove vehicle driveability Fig 1 Page IDLE SPEED SOLENOID 5 LOWER COMPRESSION RATIOS 5 NOx SYSTEM 7 VAPOR SAVER SYSTEM 6 HEATED AIR SYSTEM All engines except the 340 CID 426 Hemi and 440 CID 3 2V or engines equipped with the fresh air scoop option have a heated air intake system This system provides a faster more efficient engine warm up with imp...

Page 552: ...es the heat control downward decreasing the heated air flow from the stove and increases the air flow through the snorkel The vacuum diaphragm is simply a bellows type diaphragm mounted in a housing with a spring between the diaphragm and the top of the housing and a hose nipple in the side of the housing to connect to the vacuum hose from the sensor Per manently connected to the piston of the vac...

Page 553: ... the gauge and the vacuum source Apply 20 inches Hg to the vacuum diaphragm and stop off the line and check for diaphragm leaks Fig 5 The diaphragm should hold 20 in Hg for five minutes Next release the vacuum on the vacuum diaphragm Then with the use of the bleed valve build the vacuum slowly and observe the door operation The door should lift off the bottom of PY948 Fig 6 Opening Front Lock Tab ...

Page 554: ...operating rod into heat control door then slide rearward engaging the rear lock tab when front lock is in position press forward edge down 2 While holding vacuum diaphragm down ap ply 9 inches of vacuum to diaphragm hose nipple door should operate freely If door operates freely bend lock tab forward While supporting snorkel and the lock tab with a piece of flat steel held securely under lock tab f...

Page 555: ... vacuum advance mechanism to retard the ignition timing when the throttle is closed At closed throttle electrical contacts on the carburetor throt tle stop and with idle adjusting screw in the closed position causes the distributor solenoid to energize This retards the ignition timing to pro vide reduced exhaust emissions under hot idle conditions Cold or part throttle starting is not penalized be...

Page 556: ...case ventilation system which is an ex isting part of the Cleaner Air System CAS into the base of the carburetor to be burnt by engine combustion increase hold down screw stop distributor 7 Stop the engine and tighten the distributor 8 Reconnect the wire at the carburetor throttle 9 Reconnect the vacuum hose to the 10 Remove the timing light SAVER The possible expansion of fuel in a full fuel tank...

Page 557: ...uel or into the hole in the release valve housing An im vapor from the fuel filler cap would indicate one mediate leak with light blowing or lack of release or more of the following with hard blowing indicates a defective or incor 1 An unsatisfactory seal between cap and filler rect unit neck 3 All lines plugged between fuel tank and va 2 A malfunction of the Vapor Saver cap re por separator lease...

Page 558: ...lected the circuit will be broken by opening the trans mission switch This de energizes the solenoid vac uum valve and restores normal vacuum spark advance This means that if the temperature is above 70 degrees F you will not have normal vacuum spark advance in any of the lower gears but you will have it whenever high gear is selected When the temperature drops below 70 degrees F the NOx System wi...

Page 559: ...ce and allows any vacu um that may be trapped in the distributor spark advance chamber to be bled off cancelling any TO VOLTAGE REGULTOR T BALLAST CONTROL UNIT TEMPERATURE SWITCH TO IGNITION1 y GROUNDAT MOUNTING BOLT VACUUM SWITCH SPEED SWITCH I I I A N Q U E TO 150 IN LBS aCO TROL MODULE SOLENOID VACUUM AT INSTALLATION PB409 Fig zyxwvu I S Wiring Schematic of Automatic Transmission Installation s...

Page 560: ...h vacu um gauge should indicate normal vacuum spark advance when about 30 mph is reached Due to variations in speedometer and speed switches this is only an approximate speed reading If no solenoid action occurred in the foregoing procedures replace control unit assembly Repeat tests to be sure problem was corrected Reconnect vacuum lines as before test and be CONTROL UNIT ASSEMBLY TO AIR CLEANER ...

Page 561: ...aust with the 318 V 8 engine has an exhaust pipe which is one piece from en gine to tail pipe support Fig 13 Barracuda 340 4V 383 2V single 383 4V 440 4V and 440 Page INTAKE MANIFOLD 383 440 Cu In Engines 19 INTAKE MANIFOLD 426 Hemi Engine 20 INTAKE MANIFOLD HEAT TUBES 426 Hemi Engine 20 MANIFOLD HEAT CONTROL VALVE 21 6 Cylinder Engine 21 318 340 and 360 Cubic Inch Engine 22 360 383 440 Cubic Inch...

Page 562: ...11 2 EXHAUST SYSTEM rn Fig 2 Valiant Exhaust System 318 cubic inch engine MyMopar com ...

Page 563: ...er block type support at the end of the system Satellite models with the 440 cubic inch Power Pak engine or the 426 Hemi engine use chrome plated extensions clamped to the ends of their systems Fig 8 Barracuda models equipped with 340 383 4V 440 and 426 Hemi and also the Duster with the 340 cubic inch engines use a chrome plated exten sion clamped on at the end of their systems Figs 3 8 and 1 4 Ba...

Page 564: ... On all V 8 models a similar valve is located in the right hand manifold On all V 8 models except those equipped with the 426 Hemi engine the valve directs exhaust gases to the heat chamber beneath the carburetor mounting flange in the intake manifold to help vaporize the fuel mixture during the warm up period On the 426 Hemi engine a heat tube arrange ment incorporated with the exhaust header the...

Page 565: ...8 MyMopar com ...

Page 566: ...11 6 EXHAUST SYSTEM W VIEW F VIEW G z PB178 Fig 7 Satellite Dual Exhaust System 3834V cubic inch engine MyMopar com ...

Page 567: ...I EXHAUST SYSTEM 11 7 MyMopar com ...

Page 568: ...11 8 EXHAUST SYSTEM Fig 9 Fury Exhaust System 225 cubic inch engine TIGHTENING PLAIN WASHER 2 VIEW D NRWB S T A T I O N N ONLY Fig 10 Fury Exhaust System 318 and 360 cubic inch engines MyMopar com ...

Page 569: ...EXHAUST SYSTEM 11 9 MyMopar com ...

Page 570: ...11 10 EXHAUST SYSTEM Fig zyxwvutsrq I 2 Fury Chrysler Dual Exhaust System 383 41 440 4V cubic inch engines and 440dV cubic inch engine Fury only MyMopar com ...

Page 571: ...EXHAUST SYSTEM 11 1 1 MyMopar com ...

Page 572: ...11 12 EXHAUST SYSTEM I MyMopar com ...

Page 573: ...EXHAUST zy tr Y U zyxwvu 2 m SYSTEM 11 13 MyMopar com ...

Page 574: ...11 14 EXHAUST SYSTEM rn I n I n 4 w zyxw 5 n L I MyMopar com ...

Page 575: ...T CONTROL a Thermostat broken a Replace thermostat VALVE RATTLE broken cylinder head connections LEAKING EXHAUST GASES a Leaks at pipe joints gaskets pipe or replace as necessary b Broken weak or missing b Replace spring anti rattle spring SERVICE PROCEDURES at exhaust pipe flanges discard gaskets and care EXHAUST PIPES MUFFLERS AND TAIL PIPES fully clean manifold flanges of any gasket particles R...

Page 576: ... exhaust headers but do not tighten ball joint nuts at this time 3 Adjust muffler and tail pipe supports to pro vide proper clearance with underbody and adjacent parts Do not fully tighten attaching bolts and nuts at this time 4 Tighten front muffler resonator in Barracuda slip joint U bolt nuts to 150 inch pounds 5 Tighten muffler and tail pipe support attach ing bolts to 150 inch pounds at same ...

Page 577: ...re 17 install carburetor air heat er with two screw and washer assemblies Tighten to 200 inch pounds 2 Attach exhaust pipe to manifold flange using a new gasket Tighten stud nuts to zyxwvu 35 foot pounds 3 Install air cleaner and connect air cleaner to breather cap line 4 Install air cleaner to carburetor vacuum line NIFOLD AIR CLEAN Fig 18 Carburetor Air Heater 318 cubic inch engines CONNECTOR UP...

Page 578: ...ortion 4 Test operation of manifold heat control valve If shaft is binding apply a suitable manifold heat control valve solvent Then work valve back and forth until it turns freely lnstallation 1 Install a new gasket between the two mani folds and install the three long screws securing the manifolds Do not tighten screws at this time 2 Position manifold assembly on cylindei head using a new gasket...

Page 579: ... applying sealer on the coarse thread ends If this precaution is not taken water leaks may develop at the studs 1 Position two outboard arms of manifolds on the two studs on cylinder heads using new gaskets Install conical washers and nuts on studs Fig 21 inch engines Typical Fig 21 2 Install two screws and conical washers at inner ends of outboard arms of manifold Install two screws without washe...

Page 580: ...ne Servicing compressed air any leakage into intake passages 1 Clean manifold in solvent and blow dry with 2 Inspect exhaust passages and pressure test for 3 Inspect mating surfaces for parallelism 4 Use new gaskets when installing manifold Reinstall manifold as outlined in Group 9 Engine INTAKE MANIFOLD HEAT TUBES 426 Hemi Engine Removal Inlet Tube 1 To remove inlet tube remove two stud nuts and ...

Page 581: ...inutes to dissolve deposits Then work valve back and forth until it turns freely Installation 1 Place headers in position on cylinder heads using new gaskets Install conical washers and screws Position washers with concave side toward bolting flanges Tighten screws to 35 foot pounds 2 Assemble exhaust pipes to exhaust headers Secure ball joints with bolts and nuts Tighten nuts to 20 foot pounds 3 ...

Page 582: ...Arc weld valve plate to shaft with stainless steel rod Arc welding ground must be made at counterweight 10 Test for free operation Install anti rattle spring 11 Complete assembly and installation as out lined on page 318 AND 340 CUBIC INCH ENGINES Removal 1 Remove exhaust pipe from manifold 2 Remove exhaust manifold from engine 3 Position valve plate grind off spot welds from valve plate and shaft...

Page 583: ...rol Valve Disassembled 426 Hemi Engine Installation 1 Press in cup seals until seals extend into ma nifold lo0 inch on each side with curved ends facing outward Fig 25 2 Press in bushings flush with outer edge of exhaust manifold 3 Line ream bushings and seals zy 3095 to 3110 inch diameter Test for free tit of shaft in bush ings and seals 4 Mark one end of shaft with a suitable dye at 1 240 inches...

Page 584: ...pin Fig 28 5 Tighten clamp bolt to 50 inch pounds with NN967 Fig 28 Installing Counterweight 426 Hemi Engine C 3380 Torque Wrench Test operation of valve for freedom of movement MANIFOLD HEAT CONTROL VALVE REPLACEMENT HEMI ONLY Removal 1 Remove alternator 2 Remove exhaust pipe from manifold 3 Remove exhaust manifold from engine 4 Remove counterweight thermostat shaft re 5 Grind welds off valve pla...

Page 585: ...e Clamp Bolt Nut 426 Hemi Engine Heat Tube Screw and Stud Nut 426 Hemi Engine 318 340 360Cu In Engine 383 440 Cu In Engines Intaketo Exhaust Manifold Screw Rear Muffler Support Bolt and Nut Rear Muffler Support to Underbody Bolt Except Fury Tail Pipe Front Clamp Screws Fury Models Tail Pipe Support to Underbody Bolt Except Fury Tail Pipe Support to Crossmember Screws Fury Models Tail Pipe U Bolt N...

Page 586: ...3 440 cu in tricarb installation This new design allows faster opening of the choke mechanism re sulting in leaner fuel mixtures during the warm up period for reduced emissions and fuel consumption Fig 1 To function properly it is important that all parts be clean and move freely Other than an occasional cleaning the automatic choke control requires no servicing However it is very impor tant that ...

Page 587: ...uretor fuel bowl vent valve is also included by a tube from the vent valve to the breather cap or fuel pump 6 cylinder engines This completely seals the fuel system SERVICING THE CARBURETOR Often the carburetor is blamed for a great varie ty of trouble which is classed as POOR CAR PERFORMANCE Therefore be definitely sure that the trouble is not located elsewhere before disassembling the carburetor...

Page 588: ...s and indicates a richer mixture as the carburetor is leaned out if carburetor is set not in park position Off too lean c When it has been established that the meter is indicating a lower reading richer mixture when the idle mixture screws are turned in the richer direction proceed to adjust the carburetor to give 14 2 air fuel ratio turning the screws counterclockwise richer to lower the meter re...

Page 589: ...lve shaft for wear If excessive wear is apparent replace throttle body assembly d Replace throttle body assembly e Test fuel level in carburetor Adjust as necessary to obtain correct float level f Tighten main body to throttle body screws securely to prevent air leaks 9 Clean and inspect needle valve and seat If found to be in questionable condition replace assembly Then test fuel pump pressure Re...

Page 590: ...e Disassemble carburetor Replace worn metering jet using a new jet of the correct size and type c High float level d Worn needle valve and seat e Excessive fuel pump pressure c High float level c Adjust float level as necessary d Excessive fuel pump pressure d Test fuel pump pressure Refer CARBURETOR MIXTURES a Air leak bypassing carburetor a Repair LEAN ENGINE RUNS EXCESSIVELY RICH AFTER COLD STA...

Page 591: ...hoke valve or linkage incorrect viscosity incorrect rich LOW ENGINE OUTPUT 10 a Engine lubricating oil or degrees F or lower b Valve lash incorrect c Choke thermostat adjustment Correction a Instruct owner a Adjust b Replace assembly c Repair clean or replace d Reseat valve e Reinstall gasket properly a Recommended 5W 20 b Readjust c Adjust to correct setting ENGINE RUNS LEAN FIRST HALF MILE SERVI...

Page 592: ...bling Carburetor 8 General Information 7 Inspection and Reassembly 9 Specifications 137 is a thermostatically operated air bleed to relieve an overrich condition at idle This condition is the result of excessive heat Since the service procedures are identical on all BBS carburetors the illustrations showing the vari ous disassembly procedures will not always show any one specific carburetor ACCELE...

Page 593: ... up and away from main body Discard gasket Separate bodies Dis card gasket 8 Remove bowl vent valve plunger to operating E clip Remove accelerator pump rocker arm pivot screw Fig 2 Push up on bottom of plun ger and disengage from rocker arm Remove rock er arm and bowl vent valve lever Slide plunger spring and seat out of air horn If inspection shows plunger can be used again place in a jar of clea...

Page 594: ...p Jet Remove screw and spring from throttle body The carburetor now has been disassembled into three main units air horn main body and throttle body and the component parts of each disassem bled as far as necessary for cleaning and inspection INSPECTION AND REASSEMBLY Throttle Body 1 Check throttle shaft for excessive wear in the throttle body If wear is extreme it is recom mended that throttle bo...

Page 595: ...n throttle and poor acceleration Checking Float Setting The carburetors are equipped with a synthetic rubber tipped fuel inlet needle The needle tip is a rubber material which is not affected by gasoline and is stable over a wide range of temperatures To correctly set the float height when the car buretor is being overhauled proceed as follows 1 Install floats with fulcrum pin and pin re tainer in...

Page 596: ...he assembly must be replaced Install the diaphragm on the carburetor as follows 1 Place diaphragm on mounting surface Install and tighten attaching screws securely 2 Install choke operating link in position be tween the diaphragm plunger stem and choke lever Install clip to secure 3 Inspect rubber hose for cracks before placing it on correct carburetor fitting Do not connect vacuum hose to diaphra...

Page 597: ...MyMopar com ...

Page 598: ...MyMopar com ...

Page 599: ...le Speed On Vehicle 19 GENERAL INFORMATION The Holley single throat carburetor models R 4655A R 4656A and Taxi application R 4659A are used on the 225 cu in engines when the ve hicles are equipped with manual or automatic transmissions respectively Fig 1 These carbure BOWL VENT VALVE OPERATING LEVER ECONOMIZER COVER CHOKE VALVE BOWL VENT VALVE PLUNGER STEM as described previously Page Idle Speed A...

Page 600: ...al on all Holley carburetors the illustrations showing the various disassembly procedures will not always show any one specific carburetor SERVICE PROCEDURES DISASSEMBLING CARBURETOR 1 Place carburetor assembly on repair stand 2 Remove vacuum hose between carburetor To01 C 3866 throttle body fitting and vacuum diaphragm BOWL VENT VA CHOKE VACUUM DIAPHRAGM TUBE FITTING VENT ROD SPRING S 3 Remove ch...

Page 601: ...emove fast idle cam retaining screw then remove cam and at same time disengage fast idle cam rod 14 Remove plastic limiter cap from idle air mixture screw Be sure and count number of turns to seat the screw as the same number of turns from the seat must be maintained at installation Remove screw and spring from throt tle body Discard plastic cap 15 Remove fast idle and curb idle speed screws ETERI...

Page 602: ...heck float setting as described above after adjustment 1 Slide economizer diaphragm and stem assem bly into position making sure vacuum holes are aligned and that stem is on power valve Fig 4 Install cover and retaining screws Tighten screws securely 2 Slide baffle into position in fuel bowl place fuel bowl gasket on cover Place fuel bowl in position install screws and washers and tighten alternat...

Page 603: ... zyxwvu t i A MINIMUM Or10 INCHES O F VACUUM REQUIRED A DIAPHRAGM STEM RETRACTED BY VACUUM 2P b T 1 PYSllA Fig 11 Adjusting Choke Vacuum Kick Setting er a distributor test machine with a vacuum source or vacuum supplied by another vehicle Adjust as follows 1 If adjustment is to be made with engine running back off fast idle speed screw until choke can be closed to the kick position with engine at ...

Page 604: ...ixture then proceed as follows 1 With engine off and transmission in PARK or NEUTRAL position open throttle slightly 2 Close choke valve until fast idle screw can be positioned on second highest speed step of fast idle cam Fig 12 3 Start engine and determine stabilized speed Turn fast idle speed screw in or out to secure specified speed See Specifications 4 Stopping engine between adjustments is n...

Page 605: ... BBD 4957s is equipped with a dash pot which retards the return of the throttle to idle position Manual Transmission Only The proper adjustment of the dash pot is very important See carburetor adjustments Since the service procedures are identical on all BBD carburetors the illustrations showing the var ious disassembly procedures will not always show any one specific carburetor FAST IDLE FAST IDL...

Page 606: ... horn retaining screws and lift air horn straight up and away from main body Fig 2 Discard gasket Remove dash pot and bracket if so equipped 8 Remove E clip and washer from plunger stem slide accelerator pump plunger out of air horn Remove screws attaching bowl vent housing to air horn Remove housing vent valve spring and vent valve If the old plunger can be used again or if a new plunger is to be...

Page 607: ... throttle body assembly be replaced throttle body rather than installing a new shaft in old body main body Separate bodies body The tapered portion must be straight and horn The choke shaft must float free to operate new idle mixture screw should be installed to in pears to be gummed from deposits in air horn a NOT USE A SCREW DRIVER Turn screws thorough cleaning will be required lightly against t...

Page 608: ... idle compensator valve gasket in position in recess in main body followed by valve Be sure valve is positioned with legs toward out side of main body Fig 3 Place cover over opening and install attaching screws Tighten securely Checking Float Setting The carburetors are equipped with a synthetic rubber tipped fuel inlet needle The needle tip is a rubber material which is not affected by gasoline a...

Page 609: ...oves more than 1 16 inch in 10 seconds the leakage is excessive and the assembly must be replaced Install the diaphragm assembly on the air horn as follows 1 Assemble to air horn and tighten the attach ing screws securely 2 Install choke operating link in position be tween diaphragm plunger stem and choke lever PB374 Fig 12 Adjusting Accelerator Pump Stroke Install clip to secure 3 Inspect rubber ...

Page 610: ...th engine at curb idle If an auxiliary vacuum source is to be used open throttle valves engine not running I LL OR GAUGE CHOKE VALVE A MINIMUM DIAPHRAGM STE RETRACTED BY VACUUM Fig 14 Aa justing Choke Vacuum Kick and move choke to closed position Release throt tle first then release choke 2 When using an auxiliary vacuum source dis connect vacuum hose from carburetor and connect it to hose from va...

Page 611: ... SECOND HIGHEST STEP FAST IDLE CAM I PY497 Fig 16 Fast Idle Speed Adiustment On Vehicle 1 With engine off and transmission in PARK or NEUTRAL position open throttle slightly 2 Close choke valve until fast idle screw can be positioned on second highest speed step of fast idle cam Fig 16 3 Start engine and determine stabilized speed Turn fast idle speed screw in or out to secure specified speed See ...

Page 612: ...d idle tubes are suspended in the fuel in the main well of the float bowl This pro vides good insulation from possible excessive en gine heat The main metering jets are of the fixed type Metering calibration is accomplished through a system of calibrated air bleeds which give the cor rect air fuel mixtures throughout all operational ranges The Model 2GV carburetor employs the use of a vacuum opera...

Page 613: ...fuel flow into the carburetor bowl A float needle pull clip connecting the float arm to IDLE AIR BLEED IDLE A RESTRIT A d q zy 5 IDLE COMPENSATOR AIRPASSAGE k BI METAL STRIP Fig 3 Idle System the needle valve keeps the needle from sticking closed in the needle seat The fuel bowl is internally vented by a cored hole which leads from inside the air horn bore to the top of the fuel in the float bowl ...

Page 614: ... carburetor venturi to a point below the throttle valves The hot idle compensator valve is operated by a POWER PISTON POWER PISTON POWER VALVE PB431 I RESTRICTIONS MAIN WELL Fig 5 Power System bi metal strip which senses temperature During extreme hot engine operation excessive fuel vapors entering the engine manifold cause richer than normally required mixtures resulting in rough en gine idle and...

Page 615: ...strictions and on into the main fuel wells As the engine load decreases the resulting high er vacuum overcomes the spring tension on the power piston and raises the power piston closing PLUNGER VACUUM U U I V I I UBE VAC IUM LINK THERMOSTATIC CHOKE COIL PB433 Fig 7 Choke System the power valve A two step power valve is used In the first position fuel is metered by the valve itself This is during t...

Page 616: ...atic coil working against the bucking spring allows the choke valve to be further closed during severe cold starting to provide richer mix tures and yet allow the choke valve to open fur ther after start in warmer temperatures to provide the engine with slightly leaner mixtures As the engine continues to warm up the choke coil continues to relax its tension until the choke valve is fully opened an...

Page 617: ... seat 2 Remove air horn gasket 3 Remove power piston by depressing shaft and allowing spring to snap repeatedly thus forcing the power piston retaining washer from casting Note If heavy staking is encountered remov ing staking from around power piston retaining washer 4 Remove pump lever and shaft assembly by loosening set screw on inner arm and removing outer lever and shaft assembly and plastic ...

Page 618: ... For this reason efficient carburetion depends upon careful cleaning and inspection while servicing 1 Thoroughly clean all carburetor castings and ATTACHING SCREWS co ASSEMBLY zy d COVER PB438 Fig 12 Removing or Installing Hot Idle Compensator Valve metal parts in an approved carburetor cleaning solvent Caution Pump plunger choke diaphragm as sembly or any fibre rubber or plastic parts should not ...

Page 619: ...eck ball or seat Clean passage again and repeat test T RETAINER PLASTIC AIN WELL INSERTS DISCHARGE SPRING STEEL BALL HOT IDLE COMPENSATOR VALVE t zyx 4 4 PR440 Fig 14 Installing Pump Discharge Steel Ball Spring and T Retainer with new check balls Remove fuel from bowl be ing careful not to lose check balls Float Bowl Assembly 1 Install hot idle compensator gasket into re cess in bowl Then install ...

Page 620: ...t to obtain the correct drop setting See Figure 17 Assembly of Air Horn to Float Bowl 1 Carefully place air horn assembly on float bowl making certain that the pump plunger is properly positioned in the pump well Lower the cover gently straight down then install the eight MEASURE FROM LIP AT TOE OF FLOAT TO AIR HORN GASKET I BEND HERE PB442 Fig 76 Adiusting Float level 1 FROM GASKET SURFACE TO NOT...

Page 621: ...are made externally The follow ing adjustments can be made on or off the car except for fast idle speed and the idle vent valve adjustment which should be checked on the vehicle Accelerator Pump Rod Adjustment Back out the idle speed screw and completely close the throttle valves in the throttle bores Place the pump gauge across the air cleaner mounting surface Figure 18 with leg of gauge pointing...

Page 622: ...when removing the drill Shorten or lengthen diaphragm link to obtain correct choke valve opening Length changes should be made by carefully opening or closing the U bend provided in the link Improper bending causes contact be tween the U section and the diaphragm assembly BENDTANGON 4 Fig 21 Adiusfing Choke Unloader CAUTION DO NOT APPLY TWISTING OR BEND ING FORCE TO DIAPHRAGM 5 Reinstall the vacuu...

Page 623: ... vent valve is just closed on the second step rotate the fast idle cam so that the fast idle screw will be on the next lower step At this point the vent valve should just begin to open To adjust turn the adjustment screw in the plas tic valve until it just closes with the fast idle screw on the second step of the fast idle cam Fig 22 CARTER THERMO QUAD CARBURETOR INDEX Page Automatic Choke Well Ty...

Page 624: ...operated air bleed to relieve an overrich condition at idle in case of abnormally high temperatures A fast curb idle speed solenoid is mounted on the intake manifold on the throttle lever side This solenoid is used to maintain a higher idle speed when the engine is running and allows the throttle to close to a low idle speed position when the ig nition key is turned off to prevent after running Th...

Page 625: ...ke con nector rod to choke countershaft then disengage rod and swing rod at an arc to disengage choke shaft lever assembly 7 Remove step up piston cover plate attaching screw and cover plate then remove step up piston and link assembly with step up rods Remove step up piston spring 8 Remove pump jet housing screw housing with gasket Invert carburetor and remove dis charge check needle 9 Remove 10 ...

Page 626: ...Y fi THROTTLE VALVFS PB542 Fig 4 Ports in Relation to Throftle Valves ber of turns from seat must be maintained at installation Remove idle mixture screws and springs It is not advisable to remove the throttle shafts or valves unless wear or damage necessitates the installation of new parts During the manufacture of the carburetor the location of the idle transfer ports and the idle discharge port...

Page 627: ...s For adjustment See Secondary Throttle Adjustment 7 Install idle mixture screws and springs in the CHECK SEAT 66544 Fig 6 Accelerator Pump Assembly Disassembled View throttle body The tapered portion must be straight and smooth to insure having correct idle mixture control Do not use a screw drive Turn screws lightly agains their seats with fingers Back off the number of turns counted at disassem...

Page 628: ...check needle Retest for leakage 9 If discharge check needle leaks after above test attempt to reseat as follows a Insert a piece of drill rod down on needle Lightly tap drill rod with a hammer to form a new seat Remove and discharge needle and install a new one Retest as described previously If serv ice fix does not correct the condition a new car buretor will have to be installed b Install accele...

Page 629: ...ge choke connector rod with hole in choke shaft lever then swing rod at an arc until rod can engage choke countershaft Install rod retainer 21 Engage fast idle connector rod with slot in fast idle operating lever then swing rod at an arc SHOULD JUST START TO OPEN PB549 Fig 1I Checking Secondary Throttle Adiustment until lever can engage choke countershaft with choke valve held in open position ins...

Page 630: ...clockwise until air valve contacts stop lightly test an additional 1 1 4 turn 3 Hold adjustment plug with tighten lock plug securely with sure adjustment does not move for freedom of movement Accelerator Pump Stroke 1 Move choke valve to wide with finger then screwdriver and Tool C 4152 Be Check air valve open position to m AIR VALVE STOP COUNTER CLOCKWISE PB55 Fig 73 Adjusting Air Valve Spring Te...

Page 631: ...aphragm Connector Rod Secondary Air Valve Control The diaphragm must be energized to adjust the choke diaphragm connector rod Use an auxiliary source like a distributor test machine Perform this adjustment before Vacuum Kick Adjustment 1 Be sure diaphragm is securely mounted on carburetor Apply a vacuum of 10 or more inches of HG to diaphragm to fully depress diaphragm stem 2 With air valve closed...

Page 632: ... be provided by a screwdriver placed in U shaped opening between lever and shaft Caution Do not load the link connecting the two choke shafts because Choke Control lever Quali THROTTLEIN WIDE BEND TO OPEN POSITION ADJUST PB557 Fig 19 Adjusting Choke Unloader fication will change 6 Reinstall vacuum hose on correct carburetor fitting Return fast idle screw to its original ad justment if on vehicle a...

Page 633: ...nts have been made reinstall car buretor on engine using a new gasket It is suggested that the carburetor be filled with clean gasoline This will help prevent dirt that is trapped in the fuel system from being dislodged by free flow of fuel as the carburetor is primed Fast Idle Speed Adjustment On Vehicle Fast idle engine speed is used to overcome cold engine friction stalls after cold starts and ...

Page 634: ... Unloader Wide Open Kick 5 7 Fast Idle Speed and Cam Position 5 6 Fast Idle Speed On Vehicle 58 Idle Speed 5 8 GENERAL INFORMATION The Holley dual throat 2210 series carburetor models R 4665A and R 4666A are used on the 360 cu in engines when the vehicles are equipped AUTOMATIC TRANSMISSION FAST IDLE CAM I MANUAL 1 TRArSMlSSlON 1 BOWL VENT I CH KE VALVE VAI VF Page Vacuum Kick 5 6 Cleaning Carbure...

Page 635: ...haft then disen gage accelerator pump rod from center slot in ACCELERATOR PUMP FLATS ON SHAFT ROCKER ARM Fig 2 Removing or Installing Accelerator Pump Rocker Arm EVER LtNK CHOKE DIAPHRAGM PB379 arm and from hole in throttle lever Fig 2 3 Remove nut and washer that attaches choke lever to choke shaft Disengage fast idle connector rod from lever and fast idle cam Fig 3 4 Remove choke vacuum diaphrag...

Page 636: ...EME CARE WHEN HANDLING AIR HORN SO AS NOT TO BEND OR DAMAGE MAIN WELL TUBES Fig 6 8 Disengage accelerator pump plunger from pump shaft by pushing up on bottom of plunger Fig 9 Removing or Installing Fuel Baffle then tilting slightly toward center then slide off pump shaft Slide plunger stem out of air horn and remove compression spring Fig 7 9 Slide accelerator pump shaft out of air horn Fig 8 10 ...

Page 637: ...parts are not striking these tubes UMP DISCHARGE CHECK NEEDLE I e MAIN METERING JET z65 PY846A JET 63 POWER VALVE Fig 13 Removing or Installing Main Metering Jets 16 Remove screws attaching bowl vent valve cover to fuel bowl Lift off cover and remove vent valve spring and seal Fig 1 Remove seal from bottom of valve 17 Remove screws that attach hot idle compen sator valve cover to main body Lift of...

Page 638: ...ped screw threads damaged or marred mating surfaces on all major castings The passages in the castings should be free of restrictions Install new castings as required Check float assembly for damage or any condition that would impair this item from further service The choke and throttle valves should be replaced if the edges have been nicked or if the protective plating has been removed Be sure th...

Page 639: ...d by valve Be sure valve is positioned with legs toward out side of main body Fig 12 Place cover over opening and install attaching screws Tighten to 15 inch pounds Air Horn 1 Test freeness of choke mechanism in air horn The choke shaft must float free to operate a415 Fig 18 Installing Vacuum Power Piston correctly If choke sticks in bearing bores or ap pears to be gummed from deposits in air horn...

Page 640: ...face of air horn Fig 21 If an adjustment is necessary bend tang on float arm until parallel surfaces have been obtained Installing Air Horn 1 Place a new gasket on air horn then check FLOAT FLOAT RAISED ADJUSTING LIP Fig 20 Bending Float Adiusting Lip PB419 PB417 Fig 22 Installing Vent Valve Seal and Cover to be sure main well tubes are straight Lower air horn straight down on main body guiding ac...

Page 641: ... 1 16 inch in 10 ten seconds the leakage is excessive and the assembly must be replaced Install choke diaphragm assembly on the air horn as follows PRESSURE ON CHOKE LEVER FASl IDLE SPEED ADJUSTING SCREW BEND ROD AT ANGLE FOR ADJUSTMENT Fig 24 Fast Idle Cam Position Adjustment 1 Engage free end of choke operating link in slot of choke lever 2 Install choke diaphragm and mounting brack et on air ho...

Page 642: ...g the drill Shorten or lengthen diaphragm link to obtain correct choke valve opening Length changes should be made by carefully opening or closing the U bend provided in the link Improper bending causes contact be tween the U section and the diaphragm assembly HOLLEY 2210 FUEL SYSTEM 14 57 DRILL O R GAUGE CHOKt L C V C K O N THROTTLE LEVER TO ADJUST PB423 Fig 26 Choke Unloader Adiustment Wide Open...

Page 643: ...ed as follows 1 With the throttle valves at curb idle it should be possible to insert a 015 inch gauge be tween the bowl vent valve plunger stem and oper ating rod Fig 28 2 If an adjustment is necessary bend the tang on pump lever to change arc of contact with throttle lever using Tool T 109 213 until correct clearance has been obtained Idle Speed Adjustment Curb Idle Section Refer to General Info...

Page 644: ...OPERATING FAST IDLE SPEED ADJUSTING SCREW 1T7ROTTLE LEVER I BOWL VENT Page Fast Idle Speed On Vehicle 6 5 Choke Unloader Wide Open Kick 64 Idle Speed Adjustment 6 5 Cleaning Carburetor Parts 2 Disassembling Carburetor 60 Inspection and Reassembly 61 Specifications 137 which retards the distributor when the carburetor is at curb idle for better emission control Since the service procedures are iden...

Page 645: ... as a PY500 Fig 2 Removing or Installing Hot Idle Compensator Valve SPECIAL TOOL M E T CLUSTER NR380A Fig 4 Removing or Installing Main Metering Jets special item A liquid cleaner may damage the diaphragm material 7 Remove screws that attach hot idle compen sator valve cover to main body Remove cover and lift out hot idle compensator valve and gasket Fig 2 8 Remove air horn retaining screws and li...

Page 646: ... in the throttle body Any clearance over 010 inch a new throttle shaft and or throttle body should be installed GUIDE SIZE INTERMEDIATE POWER STAGED MIXTURE STEP zy N YA17 Fig 7 Step up Rods Free Play INSPECTION AND ASSEMBLY Throttfe Body 1 Inspect the throttle shaft and throttle body for excessive wear If either or both are worn to the point where the carburetor operation will be affected replace...

Page 647: ... fuel bowl to crown of each float at center If an adjustment is necessary hold the floats on bottom of the bowl and bend float lip toward or away from needle Recheck the 5 16 inch setting again and repeat the lip bending operation as required CAUTION When bending the float lip do not allow the lip to push against the needle as the synthetic rubber tip can be compressed suffi ciently to cause zyxw ...

Page 648: ...AGAINST FACE OF NEXT STEP OF LIGHT CLOSING FAST IDLE CAM AGAINST CHO PY502 Fig 10 Fast Idle Cam Position Adiustment can be made on the bench This adjustment is im portant to assure that the speeds of each step of the cam occur at the proper time during engine warm up 1 With fast idle speed adjusting screw contact ing second highest speed step on fast idle cam move choke valve toward closed positio...

Page 649: ...itting Return fast idle linkage to its original con dition if disturbed as suggested in Step No 1 6 Make following check With no vacuum ap plied to diaphragm the CHOKE VALVE SHOULD MOVE FREELY between open and closed positions If movement is not free examine linkage for misa lignment or interferences caused by bending operation Repeat adjustment if necessary to pro vide proper link operation CAUTI...

Page 650: ...e Speed Adiusfmenf On Vehicle ficient to force additional fuel into bowl add nec essary fuel from a clean container WARNING Since the manifold may be hot it is dangerous to spill fuel onto these surfaces Take the necessary precautions to avoid spillage 4 With only pressure from buoyant float hold ing lip against inlet needle check float setting us ing Tool T 109 280 or a T scale There should be 5 ...

Page 651: ...l Holley four barrel carburetors the illustrations showing the various disassembly procedures will not always show any one specific carburetor Page Idle Speed Curb Idle 83 Idle Speed Solenoid Adjustment Fast curb Idle 83 Secondary Throttle 8 2 Vacuum Kick On or Off Vehicle 8 2 Disassembling the Carburetor 7 3 Cleaning Carburetor Parts 7 6 General Information 66 Inspection and Reassembly 76 Servici...

Page 652: ...NDARY FUEL BOWL DISTRIRUT R GROUND SWITCH LFAD CHOKE VALVE DISTRIRIJTOR VACUUM ADVANCE TUBE CONNECTION FUEL TRANSrER TtJRE UUM DISTRIBUTOR FAST CURB SPEED GROUND ADJUSTING SCREW SWITCH LEAD zyx PB467 Fig I Carburetor Assembly Manual Transmission MyMopar com ...

Page 653: ...CLOSE VENT 1 Fig 2 Carburetor Assembly Automatic Transmission P6468 MyMopar com ...

Page 654: ...nted internally by the vent tube at all times At curb idle or when the engine is stopped the chamber is also vented by the external vent on top of the primary fuel bowl This external vent provides a release of excess fuel vapors from the bowl Idle System Fig 5 At idle and low speeds the air flow through the carburetor is not sufficiently strong enough to draw fuel through the primary venturi for t...

Page 655: ...increased This creates an in creased vacuum in the venturi to bring the main metering system into operation The flow from the idle transfer system tapers off as the main meter ing systems begin discharging fuel The two sys tems are engineered to provide smooth gradual transition from idle to cruising speeds Main Metering System As the engine is running the intake stroke of each piston draws the ai...

Page 656: ...es in the side of the valve through the diagonal restrictions in the main metering body and then into the main well In the main well the fuel joins the DIAPHRAGM PUMP INLET CHECK BALL NP603C Fig 8 Accelerating Pump System fuel flow in the main metering system enriching the mixture As engine power demands are reduced manifold vacuum increases The increased vacuum acts on the diaphragm overcoming th...

Page 657: ...s reduced venturi vacuum in the bores become weaker As the vacuum act ing on the diaphragm is lessened the load on the diaphragm spring will commence closing the sec Fig 10 Secondory Fuel Metering System ondary valves The diaphragm spring is assisted by the design of the secondary valves Each secondar y valve is slightly offset When the valves are closing the combined force of manifold vacuum and ...

Page 658: ... Each step permits a slower idle rpm as engine temperature rises and choking is reduced Spark Advance The distributor utilizes changes in air pressure within the carburetor to control spark timing to satisfy all engine speed and load conditions In order to obtain a vacuum to operate the spark advance as dictated by the engine speed and load conditions a port is located in the throttle bore just ab...

Page 659: ...ring body plate and gaskets off balance tube Fig 14 8 Remove balance tube washers and 0 rings by sliding out of main body either end 9 Disconnect choke diaphragm hose from throt tle body fitting then remove diaphragm assembly at the same time disengaging link from fast idle cam lever Fig 13 Removing or Installing Primary Metering Body and Plate VALVE COVER PBd70 Fig I S Removing or Installing Hot ...

Page 660: ...the fuel inlet needle may drop out of seat assembly Remove float baffle 3 Remove fuel inlet needle valve seat Discard the gasket 4 Remove screws attaching accelerator pump TOOL NY41B Fig 17 Removing or Installing Power Valve MAIN METER RESTRICTION PB472 Y WELL BLEED Fig 19 Secondary Metering Body cover Remove cover then carefully remove dia phragm and spring 5 Remove fuel inlet fitting and discard...

Page 661: ... but should not be con nected to the vacuum inlet fitting IMPORTANT If the commercial solvent or clean er recommends the use of water as a rinse it should be HOT After rinsing all trace of water must be blown from the passages with air pressure It is further advisable to rinse all parts in clean gasoline or kerosene to be certain no trace of moisture remains Never clean jets with a wire drill or o...

Page 662: ...en securely Slide fuel inlet needle into seat 4 Install float baffle in position then slide float hinge over pivot and secure with E clip float spring Install FUEL lNLET SEAT PRIMARY FUEL BOWL SPiiNG ASSEMBLY PB474 Fig 21 Float Needle and Baffle Disassembled View 5 Install new gasket over fuel inlet fitting then install fitting in primary fuel bowl Tighten securely 6 Install seal on bottom of vent...

Page 663: ...MyMopar com ...

Page 664: ...MyMopar com ...

Page 665: ...o change arc of contact with throttle lever using Tool T109 213 until correct clearance has been obtained Checking Accelerator Pump 1ever Clearance To check accelerator pump lever clearance Fig 27 proceed as follows 1 With throttle valves wide open and the pump lever held down it should be possible to insert a 015 inch gauge between adjusting nut PUMP OVERRIDE SPRING ADJUSTING SCREW pB479 Fig 27 C...

Page 666: ...icated tang until correct opening has been obtained Fig 29 FASTI DLE SPEED ADJUSTING TANG FAST IDLE CAM zyx i FOR ADJUSTMENT NP772B Fig 30 Fast Idle Speed Adiustment On Vehicle Fast Idle Speed Adjustment zyx On Vehicle Fast idle engine speed is used to overcome cold engine friction stalls after cold starts and stalls because of carburetor icing Set this adjustment after the vehicle odometer indica...

Page 667: ...ce dis connect the vacuum hose from the carburetor and connect it to the hose from the vacuum supply XJ v D R l L L OR GAUGE PB483 Fig 32 Vacuum Kick Adiustment with a small length of tube to act as a fitting Removal of the hose from the diaphragm may re quire forces which damage the system Apply a vacuum of 10 or more inches of hose 3 Insert the specified drill see specifications between the chok...

Page 668: ...rect specifications are obtained Fuel level will vary 1 32 inch for every pround of fuel pump pressure under or over specifications See Specifications AVS CARBURETOR INDEX Page Automatic Choke well type 1 Carburetor Adjustments 89 Accelerator Pump and Bowl Vent 90 Air Valve Secondary 91 Bowl Vent Valve 91 Choke Unloader Wide Open Kick 90 Choke Vacuum Kick 89 Fast Idle Cam Position 89 Fast Idle Spe...

Page 669: ...irements The AVS air valve secondary carburetor con tains many features some of which are the loca tions for the step up rods and pistons The step up rods pistons and springs are accessible for service without removing the air horn or the carburetor from the engine The primary venturi assemblies are replaceable and contain many of the calibra tion points for both the high and low speed system One ...

Page 670: ...n body Lift air horn straight up and away from main body When removing air horn use 10 Remove hot idle compensator and gasket Disassembling Air Horn Place air horn in an inverted position on bench to protect the floats then proceed to disassemble as follows 1 Using a suitable tool remove float fulcrum pins left and right then lift float up and out of bosses on air horn It is suggested that the flo...

Page 671: ...rge ports to the valve is carefully established for one particular IDLE TRANSFER PORTS NR517 VALVES Fig 5 Ports in Relation to Throttle Valves assembly Fig 5 The valves are milled to give proper port relation If new throttle shafts should be installed in an old 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 ...

Page 672: ... intake check assembly from the throttle body Install a new check assembly then retest as described previously Fig 3 Discharge Check Needle 1 With discharge check needle installed insert a piece of drill rod down on needle Lightly tap drill rod with a hammer to form a new seat Re move and discard old needle and install a new one Retest as described previously If service fix does not correct the co...

Page 673: ...rn in upright position 1 With air horn inverted upside down place air horn in upright position and measure the dis tance floats move from inverted to upright position This measurement should be 1 2 inch Fig 8 Air horn gasket installed If an adjust ment is necessary bend stop tabs on float levers until correct drop setting has been obtained Bend tab toward needle seat to lessen drop or away from se...

Page 674: ...MENTS The following adjustments should be made with LEVER DIAPHRAGMGEM RETRACTED 7 2 8 Fig 11 Checking Choke Vacuum Kick Setting the carburetor on the bench for ease of working and should be made in the following order Fast Idle Speed Cam Position Adjustment The fast idle engine speed adjustment should be made on the vehicle as described in the Fast Idle Speed Adjustment On Vehicle Paragraph Howev...

Page 675: ...ed to diaphragm CHOKE VALVE SHOULD MOVE FREELY between open and closed positions If movement is not free examine linkage for misa CAUTION DO NOT APPLY TWISTING OR BEND I CURB IDLE SPEED ADJUSTING A SCREW BACKED OFF TO ALLOW VALVES TO FULLY SEAT PY729 Fig 73 Checking Accelerator Pump Adjustment THROTTLE CLOSED lignment or interferences caused by bending operation Repeat adjustment if necessary to p...

Page 676: ...n manually open and close the choke valve The tang on the sec ondary throttle lever should freely engage in the notch of the lockout dog Fig 14 If an adjustment is necessary bend the tang on the secondary throttle lever until engagement has been made Use Tool T 109 22 for this operation After adjustments have been made reinstall car buretor on engine using a new gasket It is suggested that the car...

Page 677: ...open throttle slightly 2 Close choke valve until fast idle screw can be positioned on the second highest speed step of fast idle cam Fig 18 3 Start engine and determine stabilized speed HOKE VALVE WIDE OPEN FAST IDLE SPEED ADJUSTING SCREW ON SECOND HIGHEST STEP OF CAM Fig 18 Fast Idle Speed Adjustment On Vehicle Fig 19 Idle Speed Solenoid Adiustment Fast Curb Idle Turn fast idle speed screw in or ...

Page 678: ...s are connected to the center carburetor s slotted throttle lever by two adjustable connector rods The slotted throttle lever of the center car buretor allows the throttle valves to open on the outboard carburetors as vacuum requires and close mechanically with the controlling center carburetor Fig 1 Page Idle Speed Curb Idle 107 Outboard Carburetor Throttle Rod 106 Qualifying Choke Control Lever ...

Page 679: ...ENOID SOLENOID PLUNGER VACUUM CENTER REAR OUTBOARD DItL EfFM CARBURETOR FRONT I TUBE I zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA e L fl CARBYRETOR OUTBOARD THROTTLE CONTROL VACUUM 1 I DIAPHRAGM DlSTRlEUfOR VACUUM DIAPHRAGM zyxwvutsrq 1 VACUUM JCE TUBE PI3485 Fig 7 Tri Carburetor Installation MyMopar com ...

Page 680: ...ing the fuel inlet needle valve to immediately restore or hold the proper fuel level The fuel inlet system must constantly maintain the specified level of fuel as the basic fuel metering systems are calibrated to deliver the proper mix ture only when the fuel is at this level A float spring is incorporated under the float to THERMOSTATIC COIL SPRING NU944 Fig 3 Choke System assist in minimizing fl...

Page 681: ...er venturi The air passing through the throat of a venturi creates a low pressure called a vacuum The strength of this low pressure is determined primarily by the velocity of the air flowing through throat of the venturi This in turn is regulated by the speed and power output of the engine The difference between the pressure in the booster venturi and the normal air pressure in the float chamber c...

Page 682: ...g the main metering system into operation The flow from the idle sys tem tapers off as the main metering system begins discharging fuel The two systems are engineered to provide smooth gradual transition from idle to cruising speeds This fuel is discharged into the booster venturi and then in the air stream of the carburetor venturi The throttle valve controls the amount of fhel air mixture admitt...

Page 683: ...disassemble the carburetor Fig 8 for clean ing or overhaul proceed as follows 1 Install four elevating legs Tool T109 287s in mounting flange holes in throttle body or use Carburetor stand C 3886 These tools are used to protect the throttle valves from damage and to provide a suitable base for working 2 Remove screws and seal washers that attach fuel bowl and metering body to main body Re move fue...

Page 684: ... shaft and at the same time disengage choke rod from bottom hole of lever Fig 12 Note position of fast idle cam in choke control lever 7 Remove accelerator pump discharge nozzle retaining screw then lift out discharge nozzle Fig 13 Remove nozzle and retaining screw gaskets and discard Remove vacuum diaphragm hose To outboard carburetors 8 Invert main body and drop out accelerator pump check needle...

Page 685: ... AND SEAT ASSEMBLYzyxwv 0 RING ADJUSTING NUT GASKET e LOCK S C R E W PB490 Fig I 7 Removing or Installing Fuel Inlet Needle and Seat Remove throttle body and discard gasket Disassembling Fuel Bowl 1 Remove screw that retains bowl vent valve plate spring and rod to fuel bowl Fig 16 Re move bowl vent valve assembly 2 Remove fuel level adjusting nut lock screw then remove adjusting nut Slide needle v...

Page 686: ...e num ber of turns to seat screws as the same number of turns from the seat must be maintained at SPECIAL TOOL POWER VALVE Fig 20 Removing or Installing Power Valve NU1016 Fig 22 Removing Idle Air Mixture Screws and Gaskets installation Fig 22 Disassembling Throttle Body Caution In normal routine cleaning and over haul of the carburetor do not remove throttle valves unless they are nicked or damag...

Page 687: ...s are not bent or scored Replace any broken or distorted springs Replace all screws and lockwashers that show signs of stripped threads or distortion ASSEMBLING CARBURETOR Center Unit Throttle Body damage install new valves as follows If the throttle valves were removed because of MAIN METERING BODY IDLE AIR M XTURE GASKET f2 SCREW IDLE AIR MIXTURE SCREW 2 NU1018 Fig 24 Installing Idle Air Mixture...

Page 688: ...om hole of lever Secure with E clip 10 Slide fast idle cam lever over flats on throt tle shaft Be sure lever is installed in such man ner so that tab rides on cam steps Fig 11 11 Engage choke link in slot on choke control lever then place choke diaphragm on main body Install attaching screws and tighten securely I VACUUM DIAPHRAGM HOSE PLASTIC T NU1021 Fig 26 Installing Vacuum Diaphragm Hose 12 In...

Page 689: ...ump lever clearance Fig 28 proceed as follows 1 With throttle valves wide open and the pump lever held down it should be possible to insert a 015 inch min 0625 max gauge be tween adjusting nut and lever 2 If an adjustment is necessary adjust pump over ride screw until correct clearance has been obtained PUMP OVERIDE THROTTLEzy c t Fig 28 Adiusting Accelerator Pump lever Clearance ADJUST AT TO TOP ...

Page 690: ...p on fast idle cam move choke valve toward the closed position with light pressure on choke control lever Fig 30 3 Insert specified drill between the choke valve and wall of the air horn See specifications An adjustment will be necessary if a slight drag is not obtained as the drill is being removed 4 To adjust bend the indicated tang Fig 30 until the correct choke valve opening has been obtained ...

Page 691: ...n the lever to which the choke rod attaches to provide a minimum choke valve opening without distortion of the diaphragm link Note that the cylindrical stem of the diaphragm will extend as an internal spring is compressed This spring must be fully compressed for proper measurement of the vacuum kick adjustment 4 Adjustment is necessary if slight drag is not obtained when removing the drill Shorten...

Page 692: ... PLUG SIGHT PLU GASKET zyx NU957A Fig zyxwv 3 5 Adiusfing Fuel Level On Vehicle Checking Wet Fuel Level On Vehicle Before checking wet fuel level check the fuel pump pressure to be certain 5 pound reading is obtained 1 To check fuel level in bowl start engine and then remove sight plug from fuel bowl Fig 35 2 Using a wrench and screwdriver turn adjust ing nut either up or down until fuel just drib...

Page 693: ...STEM LOCK SCREW I FUEL BOWL VENT TUBE THROTTLE CONTROL VACUUM DIAPHRAGM ADJUSTING NUT F U E L BOWL FUEL INLET VACUUM TUBE FITTING LOCK SCREW FUEL VENT zyxwvu P E Fig 36 Carburetor Assembly Outboard Front or Rear P W MyMopar com ...

Page 694: ...Bowl Screws CLUTCH HEAD SCREWDRIVER CLUTC HEAD BODY Fig 38 Removing or Installing Fuel Bowl SCREWS 6 PB494 r i x c CLUTCH HEAD i SCREWS PB495 Fig 39 Removing or Installing Metering Body Screws CLUTCH HEAD SCREWS 6 Fig 40 Removing or Installing Metering Body Plate and Gaskets P8497 Fig 47 Metering Body MyMopar com ...

Page 695: ...or Instolling Vocuum Diaphrogm MAIN BODY NU1002A Fig 45 Removing or Installing Main Body AFB CARTER CARBURETOR INDEX Page Page Secondary Throttle Lever 118 Secondary Throttle Lockout 118 Cleaning Carburetor Parts 2 Disassembling Carburetor 112 General Information 111 Inspection and Reassembly 115 Specifications 137 Carburetor Adjustments 117 Accelerator Pump 117 Bowl Vent Valve 119 Fast Idle Speed...

Page 696: ...condition is the result of excessive heat and resultant overrich mixtures These carburetors also work in conjunction with an idle speed solenoid which is used to maintain a higher idle speed when the vehicle is running and allows the throttle to close to a low idle speed throttle position when the ignition key is turned off to prevent after running The idle solenoid is mounted between the two carb...

Page 697: ...s allows an overall height reduction in the carburetor The section containing the accelerator pump is termed the primary side of the carburetor The rear section is the secondary The five conventional systems used in previous four barrel carburetors are also used in this unit The five conventional systems are two float systems two low speed systems primary side only on front carburetors only two hi...

Page 698: ...ade screw driver remove needle valve seats Be sure each needle valve is returned to its original seat at reassembly 3 Remove spring clip that holds throttle con nector rod in center hole of pump arm Remove pump arm pivot screw and lift off pump arm at same time disengage link from arm and pump stem Slide accelerator pump plunger and spring out of air horn Remove gasket 4 Place accelerator pump plu...

Page 699: ...asting The component parts of Fig 8 Removing or Installing Secondary Venturi Cluster SPARK lDlE DISCHARGE PORTS ADVANCE A IDLE TRANSFER PORTS PB457 Fig zyxwv IO Ports in Relation to Throttle Valves each have been disassembled as far as necessary for cleaning and inspection It is usually not advisable to remove the throttle shafts or valves unless wear or damage necessitates the installation of new...

Page 700: ...n gasoline into carburetor bowl approximately 1 2 inch deep Remove accelerator pump plunger from jar of gasoline Flex leather several times then slide into pump cylinder 2 Install accelerator pump discharge check nee dle in discharge passage Raise pump plunger and press lightly on plunger shaft to expel air from pump passages Using a small clean brass rod hold discharge check needle firmly on its ...

Page 701: ... applying pres sure to end of float shell with thumb To avoid damage to the float apply only enough pres sure to bend the float lever 3 After aligning floats remove as much clear ance as possible between arms of float lever and lugs of air horn To do this bend float lever The arms of float lever should be as parallel as possi ble to inner surfaces of lugs of casting GAUGE OUTFR _ _ e ENDOF FLOAT I...

Page 702: ... idle cam then swing in an arc to lock Fig 7 5 Fast Idle Cam Position Adjustment in cam Slide other end of rod into choke shaft lever and secure with hairpin clip and AFB 4970s Carburetors Only The following adjustments should be made with the carburetor on the bench for ease of working and should be made in the following order CARBURETOR ADJUSTMENTS AFB 4969s Fast Idle Speed Cam Position Adjustme...

Page 703: ...dary throttle levers Fig 18 If an adjustment is necessary bend the shoe on the secondary throttle lever using Tool T 109 22 until correct clearance has been obtained Secondary Throttle Lock Out Adjustment Crack the throttle valves then manually open and close the choke valve The tang on the sec ondary throttle lever should freely engage in the notch of the lockout dog Fig 17 PRIMARY SHOE PB460 Fig...

Page 704: ...lve opening has been obtained 4 Install new plug and rap lightly to seat us ing a hammer Fig 21 Idle Speed Solenoid Adiustment Idle Speed and Mixture Adjustment A FB 4969s and A FB 4970s Rear Carburetors A FB 4971s Front Carburetor Connect a tachometer and warm up the engine to normal operating temperature Be sure the choke is fully off and that the engine is at curb idle transmission in Neutral P...

Page 705: ...S 4587SA Fig 2 is used on the 318 340 and the 360 cu in engines Model MS 4589SA Fig 3 and Model Page Service Diagnosis 121 Specifications 137 Testing Fuel Pump On Vehicle 122 RD 267A Fig 4 optional is used on the 383 and 440 cubic inch engine Model MA 4024s is used on the 426 cu in engine Fig 5 Model MS 4845s is used on the 440 cu in zy H P engine Fig 3 The fuel pumps are driven by an eccentric ca...

Page 706: ...UEL PUMP LEAKS OIL a b C 4 INSUFFICIENT FUEL DELIVERY a Worn ruptured or torn diaphragm Loose diaphragm mounting plates Loose inlet or outlet line fittings Cracked or deteriorated pull rod oil seal Loose rocker arm pivot pin Loose pump mounting bolts Defective pump to block gasket Vent in tank restricted This will also cause collapsed fuel tank Leaks in fuel line or fittings Dirt or restriction in...

Page 707: ...rate at full capacity and low pressure reading will result If fuel pump does not perform to above test 4 Connect a tachometer then start engine and run at idle The reading should be as shown in specifications depending on pump and remain constant or return to zero very very slowly when engine is stopped An instant drop to zero indi cates a leaky outlet valve If pressure is too low a weak diaphragm...

Page 708: ...s open If clogged bend a paper clip and insert through re stricted orifice to clear If necessary use air pres sure to clear return line to fuel tank after remov ing filler cap FUEL TANK VAPOR SAVER SYSTEM INDEX Page General Information 123 Installing Fuel Tank 131 GENERAL INFlORMATlON All Chrysler Corporation Vehicles are equipped with a Vapor Saver System to reduce the loss of fuel from the fuel ...

Page 709: ... nected into the crankcase via a connecting nipple on the fuel pump This fuel pump also incorpo rates a bleed device which prevents buildup of pressure in the fuel supply line between the pump and the carburetor This feature aids hot starting In event of fuel pump replacement it is impor tant that the correct pump is used The fuel tank on all models except Station Wag on Models is located at the r...

Page 710: ...FUEL TANK FUEL SYSTEM 14 125 Z 2 I 4 4 V MyMopar com ...

Page 711: ...14 126 FUEL TANK FUEL SYSTEM zyxwvu Q a E 9 C P I 3 MyMopar com ...

Page 712: ...FUEL TANK FUEL SYSTEM 14 127 MyMopar com ...

Page 713: ...14 128 FUEL TANK FUEL SYSTEM z C P I r MyMopar com ...

Page 714: ...rn FUEL TANK FUEL SYSTEM 14 129 z d m MyMopar com ...

Page 715: ...acing against the mouth and blowing into the maintenance in normal service Any loss of fuel or hole in the release valve housing zyx An immediate vapor from the fuel filler cap would indicate one leak with light blowing or lack of release with or more of the following hard blowing indicates a defective or incorrect 1 An unsatisfactory seal between cap and filler unit neck 3 All Vapor Saver lines p...

Page 716: ...new rubber grommet in tank Insert a new gasket in fuel gauge opening recess then slide gauge into tank Align the positioning tangs on gauge with those in tank Install lockring then tighten securely using Tool C 3582 If tank insu lator was torn or damaged during removal of tank be sure and install a new insulator at reassembly 2 Locate insulation pad on top of tank Slide tank under car and up in po...

Page 717: ...ain tank into a safety can then disconnect 2 Remove keystone keystone clamps and vent hoses from vapor separator Fig 6 3 Remove screw that attaches filler tube brack et to rear crossmember 4 Remove nuts that hold ends of fuel tank hold down straps to frame Lower front end of tank far enough to disengage filler tube from rear panel and slide out from under vehicle 5 Remove tank gauge unit using spa...

Page 718: ... pounds in sequence er vehicle to floor Electrical Group 8 Gauges THROTTLE LINKAGE ADJUSTMENT Aufomatic Transmission Transmission Section of this Manual For adjustment of throttle linkage refer to Manual Transmission Fig 1 6 Cylinder Engines 1 Apply a thin film of multi purpose grease on accelerator shaft where it turns in bracket antirat tle spring where it contacts shaft ball end and pocket at r...

Page 719: ...14 134 THROTTLE LINKAGE FUEL SYSTEM W BRACKR Fig I Throttle linkoge Adiustment zyxwvu 6 Cylinder Engines Fig 2 Throttle linkoge Adiustment V 8 Engines MyMopar com ...

Page 720: ...r carburetor at wide open throttle adjust length of connector rod 4 so that front carburetor is also at wide open throttle To lengthen this rod 4 turn adjusting stud 17 clockwise as viewed from front of engine Tighten lock nut 18 6 Remove choke valve blocking fixture CARBURETOR AIR SYSTEM The carburetor air system Fig 1 is available on Plymouth Road Runner GTX is the Air Grabber a vacuum operated ...

Page 721: ...14 136 THROTTLE LINKAGE FUEL SYSTEM MyMopar com ...

Page 722: ...tting 2 Notches Rich HOLLEY 1920 SERIES SINGLE THROAT CARBURETOR Taxi Model Manual Trans Automatic Trans Engine Displacement Cu In Bore Venturi Standard One Step Lean Two Steps Lean Flost Setting Float Level Height Wet Main MeteringJet ADJUSTMENTS Vacuum Kick Drill Size Cam Position Adjustment Drill Size Choke Unloader See Fast Idle Bowl Vent Valve Idle Speed Curb Idle rpm Fast Idle Speed Engine H...

Page 723: ...Miles if necessary Ball and Ball Dual Downdraft 318 318 BBD 4957s BBD 49588 1 7116 1 7 16 1 3 16 1 3 16 120 309s 120 3098 120 299s 120 299s 120 300s 120 300s 75 1849 75 1549 031 x 026 032 x 027 114 1 4 200 200 1 4 1 4 750 700 No 20 No 20 No 41 No 41 1600 1900 Well Thermostatic Coil Spring On Index ROCHESTER MODEL 2GV CARBURETOR Type Engine Displacement cu in Automatic Transmission Bore Venturi Mai...

Page 724: ...1 1 4 turn 1 1 4 turn top of plunger to top of bowl cover 31 64 31 64 Accelerator Pump Stroke Choke Control Lever Adjustment Off vehicle 3 27 64 3 27 64 On vehicle 5 41 64 5 41 64 clearance between air valve and stop 040 040 Choke Diaphragm Connector Rod Vacuum Kick 110 or 35 drill 110 or 35 drill Fast Idle Cam and Linkage 110 or 35 drill Choke Unloader Wide Open Kick 190 or 11 drill Seconclary Th...

Page 725: ... 4962s Bore 1 911 6 1 9 16 Venturi 1 511 6 1 5 16 Main MeteringJet Standard 120 4373 120 437s Step Up Wire Standard 75 1843 75 i88i Accelerator Pump Setting 1 OO 1 OO Diameter 2Stage zyxw 040 x 036 042 x 039 ADJUSTMENTS Float Setting at Center of Floats 5116 5116 Vacuum Kick Adjustment No 20 No 28 Fast Idle Cam Position Adjustment No 20 No 20 Bowl Vent Valve at curb idle 3 16 3 16 114 114 Choke Un...

Page 726: ... 9 16 13116 13 16 015 Min 015 Min 65 65 Well Coil Spring 2 Notches Rich CARTER AVS SERIES CARBURETORS Type Model AVS 6125s AVS 4966s AVS 4967s AVS 4968s Carter 4 Barrel Downdraft Transmission Type Engine Displacement Cu In Primary Secondary Primary Primary Secondary Standalrd Accelerator Pump top of plunger to air horn Fast Idle Cam Position drill size Choke Unloader Vacuum Kick drill size Bowl Ve...

Page 727: ... Kick Adjustment No 28 No 39 Adjustments No 53 No 53 Center float in bowl with fuel bowl inverted Fast Idle Cam Position Float Setting Dry Adjustment wide open throttle 015 min 015 min Fuel Level Wet Accelerator Pump Override With bowl sight plugsremoved fuel level should be at bottom edge of sight plug hole but not over flowing Note that floats are externally adjustable Choke Type None Well None ...

Page 728: ...utomatic Manual Engine Displacement Cu In 426 Hemi 426 Hemi THROTTLE BORE Primary 1 7116 1 7116 Secondary 1 11 16 1 11 16 Primary 1 3116 1 311 6 MAIN VENTURI Secondary 1 911 6 1 9 16 MA1N JET Primary 089 089 L 089 R Secondary 089 092 L 077 R STEP UP ROD 2stage ADJUSTMENTS Standard 16 28X 16 543L 16 544R Accelerator Pump top of plunger to air horn 31164 31 64 Fast Idle Cam Position drill size No 50...

Page 729: ...Cu In H P 360 Cu In Make Carter Carter Carter Carter Airtex Carter Model MS 4844s MS 4587SA MS 4589SA MS 4024s RD 267A MS 4845s Type Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Number of Valves 2 2 2 3 2 2 Driven by Camshaft Camshaft Camshaft Camshaft Camshaft Camshaft Pumo Pressure oounds 3 1 2 to 5 5 to 7 3 1 2 to 5 7 to 8 1 2 3 1 2 to 5 6 to 7 m MyMopar com ...

Page 730: ...sed to exclude road splash and other foreign material Fig 1 The universal joints and sliding spline yoke are permanently lubricated The joints should be in spected every time the vehicle is serviced for ex ternal seal leakage Figs 2 and 3 The joints need not be disassembled or relubricated unless seal leakage is evident If the cross and roller universal joints are repacked with the recommended lub...

Page 731: ...ft and universal joints are the same which the centering balls are located between the in all respects yokes of each joint to maintain the relative posi A single one piece propeller shaft will be used tion of the two joints The centering balls cause RETAINER zyxwvutsrqpo c _ _ BUSHING NUT WASHER zyxwvut 1 NF571B Fig 3 zyxwv Cross and Roller Universal Joint Rear FLANGE WASHER I BEARING ASSEMBLY BEA...

Page 732: ...t and tighten U bolts to specified torque f Recondition universal joint 9 Install new propeller shaft h Replace rear spring i Reindex propeller shaft 180 a Tighten nuts to specified b Recondition universal joint degrees reride and correct as necessary torque SERVICE PROCEDURES PROPELLER SHAFT ANGULARITY All joint angle measurements on the vehicle The increased emphasis on the need for a quiet shou...

Page 733: ...igs 18 or 19 for front joint angle A normal joint angle will cause bubble to position itself within the acceptable range If bubble is found to be slightly forward of the acceptable tolerance range this means that the angle is actually small er than that specified and does not need correcting If bubble in spirit level is found to be rearward of the acceptable range the angle is too large and must b...

Page 734: ... Observe position of bubble in spirit level and compare the position with that shown on Chart Figs 18 or 19 for rear joint angle A normal joint angle will cause the bubble to position itself within the acceptable range 5 If bubble in spirit level is found outside the I ADAPTER C 4050 sp R T LEVEL ADJUSTING SCREW h Fig 11 Adiusting Gauge on Differential Models with 9 314 in Ariel Rem Joint Angle Re...

Page 735: ... CAUTION It is important to protect the ma chined surface of the sliding yoke from damage after propeller shaft has been removed lnstollotion Front Joint 1 Before installing propeller shaft wipe sliding yoke clean and inspect machine surface for scratches nicks burrs and correct as necessary 2 Engage the yoke splines on end of output shaft being careful not to burr the splines Fig 2 Rear Joint Ins...

Page 736: ...nt universal joint from sliding yoke to remove propeller shaft When rein stalling install in same manner os propeller shaft was removed CAUTION Under no circumstances should propel ler shaft be allowed to drop or hang by either unicersal joint during removal a s this can dam age the centering ball arrangement Tie up or h l Fig 14 Rear Constant Velocity Universal Joint otherwise support propeller s...

Page 737: ...ring rollers from center ing ball assembly 3 Fill cavity behind centering ball and inside the ball with Multi Purpose Grease NLGI grade 2 EP Multi Mileage Lubricant Part Number SHAFTYOKE Fig 1 7 Removing Centering Ball and Socket Assembly 2525035 is suitable for this application 4 Insert a rod slightly smaller than inside di ameter of centering ball into ball and strike it sharply with a hammer Fi...

Page 738: ...ner 6 Install the two bearings in rear bores of ten ter yoke and on cross as previously described Install two snap rings 7 Install centering stud spring on centering stud large end first Apply a film of Multi Pur pose Grease NLGI grade 2 EP Multi Mileage Lu bricant Part Number 2525035 is suitable for this application on stud 8 Install two slip spline yoke bearing assemblies on cross and assemble i...

Page 739: ... AUTOMATIC TRANS PLYMOUTH 117 W B 424 OR 440 C I ENG 9 AXLE PLYMOUTH STATION WAGON 117 W B PLYMOUTH 119 W B EXCEPT STATION WAGON II I T1 PLYMOUTH 121 W B STATION WAGON 1 7 1 1 1 1 I 1 ACCEPTABLE REGION FRONT OF CAR ADD SHIMS AT REAR AXLE HOUSING PRING SEATS 1 WEDGE SHIM MOVE BUBBLE 3 TO 4 GAUGE DIVISIONS TO EDUCE ANGLE INSTALL THICK END 0 1 WEDGE TO FRONT OF CAR ACCEPTABLE REGION ANGLE LOW ANGLE H...

Page 740: ...ANGLE lNSTALL THICK END OF WEDGE TO FRONT OF CAR PY269A Fig 19 Universal Joint Angularify Reference Chart CHRYSLER Model Application PROPELLEFl SHAFT Length Inches Diameter Inches Type Tubular AXLE RATIO 2 76 2 94 3 23 MANUA L TF 1ANSMI zyxwvu SSION 3 SPEED A 230 383 CI Engine 2BBL Except Station Wagon 57 86 3 25 IVA AUTOMATIC TRANSMISSlON A 727 383 CI Engine 2BBL Except Station Wagon 57 86 3 25 I...

Page 741: ... 9 1 MANUAL TRANSMISSION 3 SPEED 198 CI Engine 7 1 4 Axle 3 00 IVA 3 00 IVA 2 75 3 00 LVA 2 75 2 75 225 CI Engine 7 1 4 Axle 318 CI Engine 7 1 4 Axle 2 75 198 225 CI Engine 8 3 4 Axle 2 75 318 340 CI Engine 8 3 4 Axle 2 75 2 75 2 75 AUTOMATIC TRANSMISSION 198 225 318 CI Engine 7 1 4 Axle 2 75 198 225 CI Engine 7 1 4 Axle 3 00 IVA 3 00 IVA 3 00 IVA 198 225 CI Engine8 3 4 Axle 2 75 318 CI Engine 8 3...

Page 742: ... a x a Do0 DMhl b b b 9L9 4 a x a 0 zyxw c Lo M u d x 0 M a o o o o b b b b d d zyxw yszzz a e x I l l a Y Lo 1 1 a w Lo I 1 2 I l l a a a I LoLoLo M M M a 1 Lo 1 I I a 1 Lo 1 I a I a 12 I a a 1 I I a Y Lo 1 2 I a a L o a I I l l a x Y Lo l l l l 1 I I I I I I a x MyMopar com ...

Page 743: ...I I I I I I I I I l l I I I I a a 2 2 I B m E 2 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 1 I I I I 2 35 o o w Y w o m o w o o o o m C b t n f m u u h o o o o m m m m m o m m o i u K K o o r i r i o o m m o oori ocj zyx 0 9 e y u L L m y 9 c L z e c c c e c g g z z m 1 MyMopar com ...

Page 744: ...INTS 16 15 A a I n n a a a zyx 003 zyxw m 99 I I M O O m I n a a m i x zyxwvu ix k I Z 1 I I I I I I I h l O l i l I I I I I I I I I I I I I I I I I I I I I I I u I l xl 1x1 I I I I I I I I I I I c E 2 g o E m t a I m E W 1 MyMopar com ...

Page 745: ...ion Flange Clamp Screw 7 1 4 8 1 4 8 3 4 Axles 170 Pinion Flange Clamp Screw 9 3 4 Axle 170 Rear Spring U Bolt Nut 8 1 4 8 3 4 9 3 4 Axles Pinion Bumper Plate Screw 7 1 4 Axle 150 Rear Spring U Bolt Nut 7 1 4 Axle 40 45 Pinion Bumper Plate Screw 8 1 4 8 3 4 9 3 4 Axles zy 200 MyMopar com ...

Page 746: ...ional on others Zinc interleaves are used between the leaves of all springs to reduce corrosion and improve spring life The double acting shock absorbers do not help support the load but are a means used to control ride motion The shock absorbers are matched to the particular suspension of the vehicle It is not usually necessary to replace shock absorbers in pairs Their action does NOT change with...

Page 747: ...HOCK ABSORBERS Front Removal Figs I 2 3 and 4 1 Loosen and remove nut and retainer from On Imperial models to remove the front shock absorbers you may find it necessary and also 2 Raise car so wheels are clear of floor and more convenient to remove the tire and wheel loosen and remove lower attachement bolt nut assembly and perform the removal from under Remove this bolt from lower shock absorber ...

Page 748: ...t Do not extend unit while inverted 6 Repeat steps 4 and 5 several times to expel any air trapped in cylinder 7 Should lost motion persist replace shock absorber Repeat operation 4 and 5 prior to instal lation of a new shock absorber New shock ab sorbers may have a greater resistance than an old one due to friction of new seal insfallafion 1 To install upper rubber bushing remove in ner steel slee...

Page 749: ...ber 5 Inspect appearance of shock absorber mount ing bushings and if they appear damaged or deteriorated remove and replace 6 Test and expel air from shock absorber be fore installation see Testing and Expelling Air procedure tnstattation 1 Position and align upper eye of shock absor Fig 8 Rear Shock Absorber Fury Chrysler Imperial BUSHING 5 SHACKLE HANGER U BOLT BOLT Fig 9 Reor Spring Valiant ber...

Page 750: ...g front spring hanger to body mounting bracket 6 Loosen and remove rear spring hanger bolts and let spring drop far enough to pull front spring hanger bolts out of body mounting bracket holes Barracuda models loosen and remove rear shackle nuts plate and remove shackle which will let spring be easily removed 7 Loosen and remove front pivot bolt from front spring hanger zyxwvuts Y Fig 1 2 Rear Spri...

Page 751: ...vot bushing remove rear tighten pivot bolt nut until full weight of vehicle is on wheels 7 Attach spring hanger to body bracket and tighten mounting bolts to 30 foot pounds 8 To replace rear spring shackle bushings re move rear spring hanger from body bracket Re move shackle then slide bushings out of spring and hanger 9 Insert new bushings in spring and hanger then assemble shackle and hanger on ...

Page 752: ...1I 2 LENGTH Inches 55 57 58 62 62 62 62 62 MOUNTING WIDTH Inches 2 112 2 112 2 1I2 2 112 2 112 2 112 2 112 2 112 Front Rubber Bushing Rear Shackle Rubber Bushing Type Double Acting Mounting Rubber Bushing Models equipped with 426 Hemi or 440 CI Satellite Only High PerformanceEngine use 6 full spring leaves on left side and 5 leaves plus two 112 leaves forward of axle on right side Chrysler 300 and...

Page 753: ...nut assembly is supprot ed in the gear housing by an adjustable ball thrust type upper and lower bearing The lower bearing cup is pressed into the gear housing and the upper bearing cup is pressed into the worm shaft bearing adjuster The cross shaft is integral with the sector gear The sector gear meshes with the rackteeth on the re circulating ball nut Adjustment at this point is controlled by th...

Page 754: ...gn the front wheels See Front Suspension Group h Replace rear springs i Replace parts necessary a Inflate tires to recommended pressures b Lubricate as necessary c Inspect and repair as necessary d Replace shock absorbers as necessary a Replace worn parts and adjust according to instructions b Replace worn parts See Front Wheel Alignment c Adjust according to instructions d Inspect for damage to g...

Page 755: ...en ball nut rack and sector gear teeth then tighten adjusting screw lock nut GEAR a J PY1075 Fig 3 Removing Steering Gear Arm to 35 foot pounds 3 Turn steering wheel about 1 4 turn away from center of high spot position Then using torque wrench Tool 2 3380 at steering wheel nut measure torque required to rotate steering wheel through high spot at center position The reading should be between 8 and...

Page 756: ...to avoid contaminating wormshaft and ball ball nut assembly with dirt or grit 1 Attach steering gear to holding fixture Tool C 3323 and install holding fixture in a vise Fig 2 Loosen cross shaft adjusting screw lock nut and back out screw about two turns to relieve load caused by close mesh between ball nut rack and sector gear teeth Remove cross shaft seal as outlined in Cross Shaft Oil Seal Repl...

Page 757: ... 5 Fig 8 Removing Lower Bearing Cup Tool C 3868 Fig 8 behind the bearing cup and expanding remover head by pressing down on cen ter plunger of tool Withdraw bearing cup by turning remover screw nut in clockwise direction while holding center screw 14 Wash all parts in clean solvent and blow dry with compressed air 15 Test operation of ball nut assembly on wormshaft If ball nut does not travel smoo...

Page 758: ...sing 26 Hold ball nut from turning Fig 6 and insert wormshaft and ball nut assembly into hous ing with end of worm resting in thrust bearing 27 Place upper thrust bearing on wormshaft Thoroughly lubricate threads on adjuster and threads on housing 28 Place a protective sleeve of plastic tape over wormshaft splines so splines do not damage seal Slide adjuster assembly over shaft 29 Thread adjuster ...

Page 759: ... contacts end of housing Re move tool 42 Turn worm shaft about 1 4 turn away from center of high spot position Using torque wrench C 3380 and 3 4 inch socket on worn shaft spline check torque required to rotate shaft through high spot at center position The reading should be between 8 and 11 inch pounds Read just cross shaft adjusting screw as necessary to obtain proper torque reading Tighten lock...

Page 760: ...h the cross shaft sector and a wormshaft connecting the steering wheel to the power piston through a CROSS SHAFT ADJUSTING SCREW Page Tests and Adjustments 21 Gear Reconditioning 15 Gear Installation 2 2 Gear Removal 15 Worm Shaft Oil Seal Replace 15 Specifications 60 Tightening Reference 62 pot type coupling The wormshaft is geared to the piston through recirculating ball contact The steering val...

Page 761: ...9 9 I z cy MyMopar com ...

Page 762: ...ot properly inflated b Steering linkage binding c Improper wheel alignment d Damaged steering tube bearing e Steering wheel column jacket and steering nut improplerly aligned f Steering gear malfunctions a Inflate tires to recommended pressures b Repair and lubricate as necessary c See Front Wheel Alignment Front Suspension Group 2 d Remove jacket tube and replace bearings e See Gear Installation ...

Page 763: ... Engine idle too slow f Air in the system STEERING WHEEL TO THE c oil on pump belts 9 Power steering pump output h Gear malfunction low NOISES 9 Replace the steering gear valve body assembly a See Fluid Level b See Group 7 Cooling c Replace the belt and adjust d Lubricate and repair as necessary e See Fuel Specifications Group 14 f Work the steering wheel from right to left until the air is expell...

Page 764: ...e the worm and piston d Reaction seal missing d Remove the steering gear and piston assembly repair as necessary LACK OF ASSIST Both Directions b Pump output low b Pressure test pump a Pump belt slipping c Broken or worn ring on worm c Recondition steering gear d Piston end plug loose a See Group 7 piston d Replace the worm and piston assembly SERVICE PROCEDURES screw until backlash just disappear...

Page 765: ...trol valve body being sure it seats in counterbore at bottom of housing Lubricate piston and insert nose end of pistion into body bore Test for smooth operation Be sure cushion spring is not cocked 11 Install spring on top of piston and install copper washer and fittings Tighten to 20 foot pounds 12 Position two new zyx 0 rings on control valve body and attach to steering valve body Tighten the tw...

Page 766: ...ip down lubricate inside diameter with power steering fluid and insert seal protector sleeve SP 1601 7 Position seal with protector over cross shaft with lip of seal toward housing 8 Place tool adapter SP 5148 with long step of adapter against new seal Fig 6 Install tool nut on cross shaft and tighten tool nut until shoulder of tool adapter contacts gear housing 9 Remove tool nut adapter and prote...

Page 767: ...ill now slide out of the T slot in the end of the shaft 5 Remove and discard cover zyxwvu 0 ring from VALVE ASSEMBLY RINGS Fig IO Removing Valve Body Assembly inside housing 7 Lubricate new 0 ring with power steering fluid and place it in housing 8 Place the head of the adjusting screw in the T slot in the end of the cross shaft and place cover over the adjusting screw Insert an Allen wrench throu...

Page 768: ...both cylinder head and housing head It will prohibit center spacer from becoming separated from center race and becoming cocked in housing which may make it impossible to remove power train without damaging the spacer the housing To01 C 3988 ASSEMBLY Fig 1 2 Removing Power Train or both 10 Place power train vertically in a vise equipped with soft jaws to avoid damaging piston assembly See Fig 13 f...

Page 769: ...I POWER STEERING 19 17 I 2 MyMopar com ...

Page 770: ...r oil seal ring from cylinder head counterbore Fig 16 25 Test operation of wormshaft The torque required to rotate wormshaft throughout its travel in or out of piston must not exceed 2 inch pounds with a 15 pound side load The worm should run in and out of piston under its own weight The worm and piston is serviced zyx as a complete as sembly and should not be disassembled 26 Test for excessive si...

Page 771: ...justing nut WORM SHAFT ADJUSTINGNUTLL 1 OUTER RACE CENTER RACE CYLINDER HEA Fig 20 Staking Worm Shaft Bearing Adj usting Nut do not tighten 34 Turn wormshaft clockwise one half turn Hold wormshaft in this postion with splined nut Tool C 3637 and socket wrench and hold in this positon thru items 35 and 36 then tighten to 50 foot pounds to prestretch wormshaft threads 35 Loosen adjusting nut Place s...

Page 772: ...rt Tool 2 3875 or C 3786 in steering housing place housing in a press and press out bearings and oil seal REACTION SEAL WORM SHAFT BALANCING RING DFACTIAN SPP REACTION0 RING zyxwvu 5 0 RING d __ PY195 Fig 22 Reaction Rings Installed Cut Away View 48 To install gear shaft lower needle bearing place bearing on end of Tool C 3875 or C 3786 Press bearing into steering gear housing 1 32 inch below end ...

Page 773: ...nsmission fluid 2 Connect test hoses with proper adapters to hydraulic pump on vehicle with pressure gauge I t PB28 Fig 24 Adiusting Steering Gear Mesh C 3309D installed between pump and steering gear 3 Start the engine 4 Center valve until unit is not self steering Tap on the head of valve body attaching screws to move valve body up on steering housing and tap on end plug to move valve body down ...

Page 774: ...e steering gear in its normal upright position remove one tooth of the spline at the 12 o clock postion with a suitable file Fig 25 Gear Installation 1 Position gear on frame and install three gear to frame retaining bolts and lock washers Tighten to specifications 2 Rotate worm shaft by hand and center cross shaft to mid point of its travel Align master ser ration on cross shaft with splines in s...

Page 775: ...side surface of the cam ring As the rollers follow the eccentric Specifications 60 Tightening References 62 Reconditioning 27 h THREP 312 Fig 2 1 06 Pump pattern of the cam ring oil is drawn into the in let ports and exhausted through the discharge ports as the rollers are forced into vee shaped cavities of the rotor A flow control valve permits a regulated amount of oil to return to the intake si...

Page 776: ...ump rattling noise d Foreign material blocking pump housing oil inlet hole e Vanes improperly installed f Vanes sticking in rotor 9 Faulty flow control valve h Pressure plate thrust plate or rotor scored i1 Pressure plate thrust plate cam rotor or rollers scored j Pump hose interference with sheet metal or brake lines k Pulley loose a Pump hose interference with sheet metal or brake lines a Tighte...

Page 777: ... Checking Fluid Level 1 06 Model 1 Start engine turn steering wheel from stop to stop several times to expel air frbm system then shut off engine 2 Wipe reservoir filler cap free of dirt remove cap and visually inspect oil level in reservoir Engine at room temperature Oil should just cover filler neck reservoir joint 1 3 4 inches to 2 inches from top of filler neck Engine Hot Oil level should be o...

Page 778: ...stallation All Models ing and locking bolts 1 Position pump on engine and install mount TOP VIEW END VIEW NU343 PUMP RETURN HOSE Fig 5 Hose Routing 7 06 Pump 6 Cylinder Engines 2 Install drive belt and adjust See Cooling System Group 7 Tighten mounting bolts to 30 foot pounds 3 Connect pressure and return hoses Use new pressure hose zyxw 0 ring 1 06 pump only See Hose Installation 4 Fill pump rese...

Page 779: ...SCREW Fig 9 Oil Seal Removal shaft down in vise between square boss and shaft housing Fig 6 6 Remove two mounting studs and pressure hose fitting Gently tap reservoir filler tube back and forth with plastic hammer to loosen Work reservoir off pump body Fig 6 Discard 0 rings from reservoir two mounting studs and pressure fitting 7 Using a punch tap end cover retainer ring around till one end of rin...

Page 780: ...n solvent blow out all passages with compressed air and air dry cleaned parts 2 Inspect drive shaft for excessive wear and SEAL 1 NNlOlO Fig I7 Oil Seal Installation 4 TOOL C 4090 ROTOR LOCK RING 6 Fig 73 Installing Rotor lock Ring seal area for nicks or scoring Replace if necessary 3 Inspect fit of vanes in rotor Vanes must slide freely in slots of rotor without binding Ex cessively loose vanes r...

Page 781: ...shaft end down 3 Install end cover and pressure plate 0 rings in grooves in pump cavity These rings are the same size Lubricate with power steering fluid 4 With drive shaft clamped splined end up in soft jawed vise install thrust plate on drive shaft smooth ported side up Fig 12 5 Slide rotor over splines with the counterbore of rotor facing down Install rotor lock ring mak ing sure ring is seated...

Page 782: ...ef outlet orifice 16 Install pressure hose fitting and tighten mounting studs Tighten pressure hose fitting to 20 foot pounds and rear mounting studs 25 35 PRESSURE FLOW RELIEF CONTROL NN1003 Fig 20 Flow Control Valve 94 Pump foot pounds 17 Remove pump assembly from vise and in stall mounting brackets and drive shaft key 18 Install pulley on shaft and secure with re taining nut Tighten nut to 45 5...

Page 783: ...th lip toward pump Use Tool C 4061 to drive seal flush with housing Fig 23 8 Install drive pulley See Pulley Installation Figs 33 and 34 9 With installer shaft clamped securely in vice tighten drive nut against thrust bearing and press pulley onto shaft CAUTION Do not attempt to press pulley on to shaft without the use of special tool as serious damage will result to interior of pump TOOL Fig 22 R...

Page 784: ...embled with brass plates only The fibre gasket may be found stuck to housing floor it can easily be lifted or pulled away Insure that all portions of gasket are removed and that housing floor is not scratched or damaged 11 Discard pressure plate and end cover zy 0 rings 12 Remove snap ring bore plug flow control valve and spring from housing Discard 0 ring 13 If necessary to disassemble flow contr...

Page 785: ...re gasket Align index notches in plate and gasket I r L I DOWEL PIN Fig 27 Installing Cam Ring 118A Fig 29 Instolling Rollers in Rotor with dowel pin hole in housing cut out sections of gasket and plate should be in line with core pockets on side of housing bore Fig 26 Caution Pump will not operate properly if either gasket or seal plate are improperly installed 6 Carefully install front plate in ...

Page 786: ...ket and plastic hammer Figs 31 and 32 Remove drill Inspect pressure plate at both oil passage slots to insure that plate is squarely seated on cam ring end face A Fig 3 7 Installing Pressure Plate NU277 II A Fig 33 Pulley Installation 6 Cylinder Engines 12 Place large coil spring over raised portion of installed pressure plate 13 Position end cover lip edge UP over spring Press end cover down belo...

Page 787: ... RELIEF BALL NR327 Fig 35 Flow Control Valve Disassembled View Disassembly 1 Remove pump from engine and reservoir from pump 2 Remove snap ring and plug from flow bore Discard 0 ring from plug 3 Depress control valve against spring pressure and allow to spring back The valve should pop out of bore far enough to be lifted out Light tap ping on rear face of pump body may be necessary to remove a stu...

Page 788: ... piece telescoping steering shaft with upper and lower sections connected by plastic fric tion collars and shear pins 4 A mounting bracket connecting steering col umn to the instrument panel which allows the column to slide forward but blocks its rearward movement toward the driver The center section of the column jacket has dia mond shaped perforations and is formed with ac cordion pleats These p...

Page 789: ...is removed special care must be take in handling this assembly When the column is removed from the car such actions as a sharp blow on the end of the steering shaft or shift levers leaning on the column assembly or dropping of the assembly could shear or loosen the plastic shear joints that maintain column rigidity It is therefore suggested that the removal and installation and the disas sembly an...

Page 790: ... then remove horn ring and switch 7 Remove steering wheel retaining nut and washer Remove steering wheel with Tool C 3428B Do not bump or hammer on steering shaft to remove wheel Barracuda models remove three nuts fastening steering wheel to corruglated cylinder remove nut and washer from steering shaft and install Tool C 3428B to pull cylinder from shaft splines zy L 8 Remove turn signal lever Fi...

Page 791: ...retaining roll pin out with a punch 5 Remove turn signal switch and upper bearing COLUMN STANDARD 19 39 COVER PBNl IGNITION KEY LAMP Fig 6 Ignition Key Lamp STEERING SHAFT REMOVING TOOL A Fig 8 Pressing Shaft Out of Bearing retainer screws Remove retainer and lift switch upward out of the way Fig 5 6 Remove retaining screw and lift the ignition key lamp assembly out of the way Fig 6 7 Remove snap ...

Page 792: ... and the lock lever guide plate which will expose the lock cylin der release hole Fig 11 4 Place cylinder in lock position and re move key Insert a small diameter screwdriver or similar tool into lock cylinder release hole and J IGNITION SWITCH PY887 Fig 10 Ignition Key Buzzer Switch LOCK CY1 RELEASE IGNITION SWITCH CAM AND PIN PYaa9 Fig 1 2 Removing Lock Cylinder LOCK LEVERS AND SPRING ASSEMBLY T...

Page 793: ...straighten the tabs at top of shift tube which are bent outward against shift housing casting If so equipped remove shift indicatior bracket from shift tube Remove shift tube support retaining clip from slots at bottom of jacket Loosen shift tube set screw in shift housing and remove parts from jacket 2 To remove shift tube from column shift man ual models remove the three bearing support screws a...

Page 794: ...wer hub of gearshift housing so that the cen ter of the curved washer surface bears against the CROSSOVER SPRING SHIFT TUBE AND zy 7 LEVER ASSEMBLY COLUMN JACKET ND530C Fig 20 Shift Tube Assembfy Removal or fnstallation COVER MASTER SPLINE MARK SHOE SPRIN IDOWEL P N HOLE I STEERING SHAFT PY22 IN Fig 21 Steering Shaft t Coupling Disassembled housing hub Position the housing and washer on the column...

Page 795: ...W STEERING COLUMN STANDARD 19 43 MyMopar com ...

Page 796: ...19 44 STEERING COLUMN STANDARD MyMopar com ...

Page 797: ...he holes in bushing are aligned with adjustment slots in column jacket Slide shift tube and lever assem bly through jacket and into gearshift housing Start the bushing retainer screws through slots in SHIFT L E V E R P R N D 2 1 POSITIONS ON GATE LOCK HOUSING Fig 25 Lock Housing and Shift Gate VIEW A PB202 Fig 27 Gear Selector Pointer Bracket INSULATOR RING SHIFT LEVER PY099A Fig 29 Install Shift ...

Page 798: ...nto place locking the cylinder into the housing Sfeering Shaff Coupling Assembly Fig 31 mately 1 2 inch from top 1 Fill coupling body with grease to approxi 2 Place cover and seal on shaft 3 Press shoe pin into steering shaft so that it 4 Place spring on side of shaft straddling the projects an equal distance on each side of shaft SHAFT lNS ALLlNG TOOL Fig zyxwv 3 2 Pulling Shaft Into Bearing shoe...

Page 799: ...IMITS FOR ADJUSTMENT PY1189 Fig 34 Adjusting Steering Shun in Coupling c If hole in tool is too large to grip steering shaft add the split insert to adapt tool to smaller shaft diameter d On floor shift columns with no shift tube place tool C 4157 over steering shaft and slide up into lower end of jacket to keep shaft centered while column is installed 2 Position bracket assembly on steering colum...

Page 800: ...inal location Slowly move gearshift lever from 1 low to P park pausing briefly at each selector position The indicator pointer must align with each selector position If necessary loo sen the bolt and readjust to align pointer correctly Floor Shifl Column The Steering Column used on Valiant Barracuda and Satellite models with a floor mounted gearshift is basically the same as previ ously described ...

Page 801: ...STEERING COLUMN TILT WHEEL 19 49 I MyMopar com ...

Page 802: ...e tool lock plate cancelling cam and spring 7 Remove three turn signal switch attaching screws place shift bowl in low 1 position and remove switch and wiring Fig 1 8 The buzzer switch can be pulled straight out of the housing A flat spring wedges the switch toward the lock cvlinder Fig 4 This mav be RETAINING RING z LOCK PLATE DEPRESSING TOOL PY918A Fig 3 Removing lock Plate Retaining Ring PY920 ...

Page 803: ...ion switch Fig 7 14 Place Pivot Pin Remover C 4016 over pivot ETAINING CLIP BEARING ADAPTER PY923 fig 70 Shaft Lower Bearing Adapter pin and thread small portion of screw firmly into the pin Hold screw from turning with one wrench turn nut clockwise with a second wrench to withdraw pivot pin from the support Fig 8 Remove opposite pivot pin in same manner 15 Use tilt release lever to disengage lock...

Page 804: ...scratches and wear 1 Inspect all bearings and race seats for STEERING SHAFT PY925 Fig 1 2 Steering Shaft Disassembled 2 Inspect centering sphere for nicks damage or wear If damage is found check shaft couplings for nicks burrs or rough spots 3 Inspect actuator housing shift lever bowl and support for cracks or other damage 4 Inspect turn signal switch unit for distortion broken or damaged parts 5 ...

Page 805: ...ll switch and tighten screws to 35 inch pounds 15 Install hazard warning knob and pull knob out Install cancelling cam spring canceling cam and shaft lock Depress shaft lock and install re taining ring with Tool number C 4156 Fig 3 16 Install tilt release lever and signal switch lever 17 To install ignition lock turn key to LOCK position and remove key This will cause buzzer operating lever to ret...

Page 806: ...move tilt spring retainer us ing screw driver blade that just fits into slot opening Insert screw driver in slot press in ap proximately 3 16 inch turn approximately 1 8 turn counterclockwise until ears align with grooves in housing and remove spring and guide Fig 6 12 Remove seat and upper bearing race Fig 1 13 With ignition switch in LOCK position remove two ignition switch mounting screws and i...

Page 807: ...I STEERING COLUMN TILT A SCOPE 19 55 MyMopar com ...

Page 808: ...e lever pin with punch and hammer Remove lever and release lever spring To relieve load on release lever hold shoes in ward and wedge block between top of shoes over SHAFT LOCK I zi I SPECIAL TOOL w C RING PY941 Fig 3 Removing or Installing Lock Plate zy C Ring LOCK RELEASE SLOT PY920 Fig 5 Removing Lock Cylinder IGNITION SWITCH ACTUATOR ROD I RACK SLIDER DETENT POSITIONS IN SWITCH P Y m Fig 7 Ign...

Page 809: ...d Remove separator and balls from bearing Place housing on work surface With a pointed punch against back sur face of race carefully hammer race out of housing until bearing puller can be used Repeat for other race lnspecfion 1 Inspect all bearings and race seats for brinelling nicks scratches and wear 2 Inspect centering sphere for nicks damage or wear If damage is found check shaft couplings for...

Page 810: ... Install pivot pins 9 Place housing in full UP position and in stall guide tilt spring and tilt spring retainer zy us ing screw driver in retainer slot Turn retainer clockwise to engage Fig 6 10 Install tilt lever opening shield and turn sig nal lever opening shield in housing 11 Remove tilt release lever install housing cover and tighten three screws to 45 inch pounds Fig 4 12 Assemble buzzer swi...

Page 811: ...teering wheel with Tool C 3428B Do not bump or hammer on steering shaft to remove wheel Disassembly ing and telescoping steering wheel tact and spring assembly Figure 14 shows a disassembled view of the tilt 1 Remove 2 spring clips and remove horn con 2 Remove 3 screws and lift off cover Assembly 1 Place cover on bottom of steering wheel and fasten with 3 screws 2 Position horn contact assembly st...

Page 812: ...secures wheel in any telescoped position to 35 inch pounds TlNG SCREW 4 MOUNTING STUD HORN CONTACT HORN RING SPRING SPRING CLIP 2 HORN CONTACT STUD I COVER MOUNTING SCREW 3 NU522 fig 14 Telescoping Steering Wheel Disassembled SPECIFICATIONS MANUAL STEERING Type Ratio Cross Shaft Bearings Valiant 6 Cyl Worm Shaft Bearings Cross Shaft Adjusting Screw End Play Worm Bearing Pre Load Sector Mesh Adjust...

Page 813: ...0 CID Engine Imperial 1 06 pump Pump Output 94 pump 1 06 pump High level Low level Typeof Fluid Constant Control Full Time Power 15 7 to 1 2 Needle Bearingsand 1 Direct Bearingon Gray Iron Cover Tighten Adjusting Screw 3 8 to 1 2 turn past Zero Back Lash Center of High Spot 4 Pints Power Steering Fluid Part No 2084329 or equivalent Do not use Automatic Transmission Fluid 3 112 16 24OZS Constant Di...

Page 814: ...liant Barracuda and Satellite 80 Housing Head Spanner Nut 150 Fury Chrysler Imperial Models Cross Shaft Adjusting Screw Lock Nut 28 Valve Body End Plug 50 Cross Shaft Cover Nut 150 Steering Wheel Nut 28 High Pressure Hose Fitting 30 8 100 Valve Body Attaching Bolts PUMPS Foot Location Pounds High Pressure Hose Fitting Gear End All Models 13 Pump End All Models zyxwv 24 Bracket Bolts 94pump 35 1 06...

Page 815: ...e the transmis sion model number The following four numbers PY627A Page Assembling Transmission 9 Cleaning and Inspection 6 Disassembling Transmission 3 Extension Housing Bushing Replacement 12 Transmission Installation 13 Transmission Removal 2 Specifications 133 Tightening Reference 136 are a date of manufacture code The last four numbers are a sequence number The main drive pinion input shaft i...

Page 816: ...ift rods out of c Synchronizer clutch teeth worn d Clutch housing bore or face out of alignment a Excessive end play in countershaft gear b Loose synchronizer hub spline fit on mainshaft c Damaged broken or excessively worn gear teeth d Rough or pitted bearing races or balls installed stop rings adjustment a Refer to Clutch Group for corrections b Perform linkage adjustment as outlined in Gearshif...

Page 817: ... interlock levers are cracked proceed as follows Pull shift forks out of shafts 4 Remove nuts attaching operating levers to the shafts Disengage levers from flats on shafts and remove 5 Remove burrs from shafts before removal from housing to avoid scoring the bores or dam aging the lip seals which would cause leakage af ter reassembly 6 Push gearshift lever shafts through housing bores and remove ...

Page 818: ...21 4 3 SPEED A 230 MANUAL TRANSMISSION I MyMopar com ...

Page 819: ...ed remove snap ring and press bearing off the pinion gear shaft Fig 12 MAINSHAFT DRIVE PINK ASSEMBL PY631 Fig 5 Tap Drive Pinion Forward for Mainshaft Pilot Clearance 4 SHAFT A N D KFV MAlNanAri A X X M D L T ARBOR FOR ROLLERS PY633 Fig 7 Reverse Idler Gear Removal or Installation 6 Lift countershaft gear and arbor assembly out through rear of case Fig 13 Mainshaft Disassembly 1 Remove the snap ri...

Page 820: ... synchronizer assembly off splines and remove from mainshaft Fig 22 10 Remove 1st gear and its stop ring from mainshaft Fig 23 20 PY635 Fig 9 Countershaft Removal LUUIY Irnannt T GEAR AND ARBOR SSEMBLY LYING IN BOTTOM OF CASE PY637 Fig 11 Drive Pinion and Bearing Assembly Removal or Installation CLEANING AND INSPECTION Clean transmission case thoroughly using a suit able solvent dry with compresse...

Page 821: ...ect bearings zyxwv v HOLE FOR PINION BEARING RETAINER DRAIN Fig 13 CountershaH Gear and Arbor Removal or Installation 2ND GEAR PY638 Assembly STOP RING LUG 2Nd 3RD SYNCHRONIZER ASSEMBLY P Y W Fig 15 2nd 3rd Synchronizer Assembly and Stop Ring Removal or Installation BEARING RACE PY646 MAINSHAFT BEARING RETAINER Fig 17 Snap Ring Spread to Remove or Install Retainer on Mainshaft Bearing for pitting ...

Page 822: ...TOP R I N ON REVERSE SIDE OF SYNCHRONIZER PY653 MAINSHAFT BEARING REVERSE GEAR Fig 20 Reverse Gear and Mainshaft Bearing Removal or Installation STOP RING iST REVERSE SYNCHRONIZER ASSEMBLY PY655 I MAINSHAFT Fig zyxwvutsrq 22 1st Reverse Synchronizer Assembly Removal or Installation PRESS RAM SUPPORT MAINSHAFT WHEN CLEAR OF BEARING TO AVOID FALL 1 Fig 19 Using Press to Remove Mainshaft Bearing SNAP...

Page 823: ...vely worn a new mainshaft should be installed Inspect snap ring grooves for burred edges If rough or burred remove condition using a fine file or crocus cloth Inspect synchronizer clutch gear splines on shaft for burrs ASSEMBLING TRANSMISSION Countershaft Gear 1 Slide assembly arbor Tool C 4112 into countershaft gear 2 Slide one roller thrust washer over arbor and into gear followed by 22 Greased ...

Page 824: ...and mainshaft bearing in place and take to press to force bearing on shaft Fig 20 8 Support inner race of bearing and press shaft through to shoulder Fig 31 Be sure snap ring groove on outer race is forward CLUTCH GEAR SNAP RING POSITION LONG HUB FORWARD b CLUTCH SLEEVE STRUT S RINGS 2 P Y r n Fig 28 1st Reverse Synchronizer Disassembled CLUTCH GEAR SLEEVE STRUT SPRINGS 2 CLUTCH GEAR FORWARD POSIT...

Page 825: ...ess to Install Mainshaft Bearing ROLLERS PY639 Fig zyxwv 3 2 Reverse Idler Gear Roller and Arbor Assembly not check to see if a strut pinion roller or ring is out of position Reverse Idler Gear gear along with 22 greased rollers Fig 32 with grease to retain them 1 Place assembly arbor Tool C 464 into 2 Position reverse idler thrust washers in stop idler case 3 h o w position reverse idler gear wit...

Page 826: ...l slot in housing then drive bushing into place Fig 35 4 TO install a new seal position seal in open ing of extension housing and drive it into housing with Tool C 3972 Fig 36 NN125 __ Fig 36 Installing Extension Housing Seal EXHAUST EMISSION SWITCH WHEN S O EQUIPPED A 2 3SHIFT SHAFT I Y lST REVERSE SHIFT FORKS SHIFT SHAFT PB263 BACK UP LIGHT SWITCH Fig 38 Gearshift Mechanism and Housing Disassemb...

Page 827: ...e of adapter representing number of teeth on gear is in 6 zyxwvuts 0 clock position Exhaust Emission Confro System Switch Some models have a switch mounted in the shift cover adjacent to the 2 3 shift lever for the Emis sion Control System It is actuated by a flat on the 2 3 lever shaft when in third gear Fig 38 In those vehicles not equipped with the Emission System a plug is installed in the swi...

Page 828: ...1 I CROSSMEMBER CENTER zy 9 4 b Fig 40 Center Crossmember and Rear Engine Mount Valiant TRANSMISSION EXTENSION HOUSING REARMOUNT V NU45A SPACER 2 I CENTER CROSSMEMBERI TIGHTENING TORQUE VI Fig 41 Center Crossmember and Rear Engine Mount Barracuda and Satellite MyMopar com ...

Page 829: ...ing Fig 42 3 With cable housing connected carefully work adapter and pinion out of extension housing 4 If transmission fluid is found in cable housing replace seal in the adapter Fig 43 5 Start seal and retainer ring in adapter then push them into adapter with Tool C 4004 until tool bottoms Fig 4 4 6 Note number of gear teeth and install spee OIL SEAL BOLT AND WASHER RETAINER RING Fig 43 Speedomet...

Page 830: ... Reverse rod swivel by loosening clamp bolt and sliding swivel along rod so it will enter 1st reverse lever at transmission Install washers and clip Tighten swivel bolt to 100 inch pounds 7 Remove gearshift housing locating tool un lock ignition switch and shift column lever to neutral position 8 Adjust 2nd 3rd rod swivel by loosening clamp bolt and sliding swivel along rod so it will enter 2nd 3r...

Page 831: ...imensions shown in fig ures 49 50 or 51 3 Insert lever alignment tool into slots in levers and mechanism frame to hold levers in nuetral crossover position 4 Place transmission levers in neutral middle detent position and adjust shift rod swivels so rods will install freely to levers 5 Secure rods with proper washers and clips and remove alignment tool If so equipped work flange portion of lower b...

Page 832: ... TRANSMISSION 2ND 1ST REVERSE ROD HING FOR 6 CLIP W zyxwvuts V 1ST RE CLAMP BOL PY695 1ST REVERSE ROD DETAILS A T STEERING COLUMN Fig 47 Column Shift A 230 Satellite Fig 48 Holding Crossover Node in Neutral Position MyMopar com ...

Page 833: ...AND REVERSE ROD FLOOR PAN PY691A Fig 49 Floor Shift 3 Speed Valiant GEARSHIFT KNOB SELECTOR LEVER SCREW AND WASHER ASSEMBLY 3 TRANSMISSION EXTENSION SPACER 3 Y HOUSING ROD SECOND AND THIRD zy 1 zyxwvu c c R U U FlKbl A N U K t V t K 3 C SWIVEL LEVER AFLOOR PAN ALIG NMENT SLOT LEVER ALIGNMENT TOOL SHEET METAL PY692A Fig 50 Floor Shift 3 Speed Barracuda MyMopar com ...

Page 834: ...numbers are the transmis sion model number The following four numbers are a date of manufacture code The last four numbers are a sequence number PB244 Page Service Out of Vehicle 25 Assembling Transmission 32 Disassembling Transmission 27 Extension Housing Bushing Replacement 33 Transmission Installation 36 Transmission Removal 25 Specifications 133 Tightening Reference 136 The main drive pinion a...

Page 835: ...The service procedures covering the four speed trans mission used on all vehicles so equipped is identi cal to the following service procedures except where noted IMPORTANT Some internal transmission parts are different from standard on vehicles with high performance engines These special parts are listed in applicable Parts Catalog therefore be sure they are used when replacement is necessary SER...

Page 836: ...tion Figs 3 4 5 and 6 1 Fasten unit to extension housing mounting plate with two bolts and lock washers and tighten to 30 foot pounds 2 Install shift rods washers and clips 3 See next paragraph for adjustment procedure 4 Fasten shift lever to shift mechanism with two bolts 5 Slide boot down over lever and fasten to floor pan 6 Install console and connect wiring if so equipped See Body Book Reconne...

Page 837: ...ION 21 23 THIRD FOURTH REVERSE ROD WASHER PY167A Fig 4 Gearshift Mechanism Disassembled Satellite Typical for Valiant EMBLY BOOT ASSEMBLY LOCK WASHER REVERSE ROD PY169A Fig 5 Gearshift Mechanism Disassembled Barracuda MyMopar com ...

Page 838: ...ter Disassembled assembly make sure adapter flange and its mating area on extension housing are perfectly clean Dirt or sand will cause mis alignment rw sulting in speedometer pinion gear damage 6 Rotate the speedometer pinion gear and adapter assembly so that the number on the adapter corresponding to the number of teeth zy on the gear is in the 6 o clock position as the as sembly is installed Fi...

Page 839: ... rear axle pinion shaft yoke 6 Fill transmission to level of fill plug Refer to Lubrication Group 0 NNl25 Fig 12 Installing Extension Housing Yoke Seal SERVICE OUT OF VEHICLE TRANSMISSION REMOVAL components refer to Four Speed Gearshift 1 Remove console and 4 speed gearshift 2 Drain fluid from transmission 3 Disconnect propeller shaft at rear universal joint marking parts to reinstall in same posi...

Page 840: ...ssmember Figs 13 or 14 member Be sure support ends are up against un 8 Support transmission with a suitable jack and TRANSMISSION EXTENSION REAR MOUNT CENTER CROSSMEMBER PY171A Fig zyxwvuts I 4 Center Crossmember and Rear Engine Mount Barracuda and Satellite GEARSHIFT HOUSING MAIN DRIVE PINION I PINION BEARING RETAINER I CASE GASKET RDFATHFR 1ST AND 2ND OPERATING LEVER BACK UP LIGHT SWITCH JKV ANV...

Page 841: ... pivot pin and remove interlock levers and spring from housing Extension Housing and Mainshaft 1 Remove bolt and retainer securing speedome 51 Countershaft Gear Cluster 52 Needle Bearing Rollers 53 Thrustwasher Needle Roller 54 Thrustwasher Gear 11 55 Backup Light Switch 56 Backup Light Switch Gasket 57 Plug 58 Retainer Reverse Detent 59 Gasket 60 Spring Reverse Detent Ball 61 Ball Reverse Detent ...

Page 842: ...21 28 4 SPEED MANUAL TRANSMISSION NH74OF Fig 16 A 833 Transmission Disassembled MyMopar com ...

Page 843: ...earing Snap Ring Front Remove bearing from mainshaft by inserting steel plates on front side of 1st speed gear then press GASKET EXTENSION HOUSING NH741 Fig 18 Removing or Installing Extension Housing and Mainshaft Assembly 3RD AND 4TH SPEED SYNCHRONIZER CLUTCH GEAR NH743B Fig 20 Disassembling Mainshaft SNAP RING GROOVE MAINSHAFT NH745 EXTENSION HOUSING Fig 22 Removing or Installing Mainshaft or d...

Page 844: ...EARSHIFT FORK SHIFTER SHAFT NH749B Fig 27 Measuring Countershaft Gear End Play 25 12 Slide 1st and 2nd clutch sleeve gear and clutch from mainshaft Do not separate clutch sleeve gear and clutch unless inspection reveals a replacement part is required Remove 2nd speed gear 13 Fig 26 shows various mainshaft bearing surfaces for the gears Inspect these surfaces for signs of wear scoring or any condit...

Page 845: ...eed only be done if oil leakage is visible around reverse gearshift lever shaft 5 Remove any burrs from shaft so as not to SNAP RINGS COUNTERSHAFT GEAR IN CASE NU41 DRAIN PLUG Fig 32 Removing or Installing Drive Pinion Assembly Heavy Duty damage the case bore then carefully push rev erse gearshift lever shaft inward and remove it from case Fig 31 Retrieve detent ball from bot tom of case Remove sh...

Page 846: ...ECTION Clean transmission case thoroughly using a suit able solvent dry with compressed air Inspect case for cracks stripped threads in various bolt holes and machined mating surfaces for burrs nicks or any condition that would render the case unfit for further service The front mating surface should be smooth if any burrs are present dress them off with a fine mill file If threads are stripped in...

Page 847: ...se 10 Align countershaft arbor with bores in case then drive countershaft into the gear Install the woodruff key Continue to drive shaft into case until end of shaft is flush with rear face of the case Remove arbor Tool C 3938 11 Using Tool C 3789 or C 3801 for heavy duty model Fig 36 install a new oil seal in re tainer bore SNAP RING OUTER BEARING MAIN DRIVE I PIYION TOWARD THE FRONT ROLLER BEARI...

Page 848: ...mbled 5 Install mainshaft bearing retaining ring fol lowed by mainshaft rear bearing Using an arbor and a suitable tool drive or press bearing down into position Install a new snap ring on shaft to secure bearing Fig 24 This snap ring is a select fit for minimum end play 6 Install partially assembled mainshaft into ex tension housing far enough to engage bearing re taining ring in slot in extensio...

Page 849: ...RANCE POSITION MARKED B LESS REVERSE LEVER NEUTRAL POSITION CLEARANCE CAM CLEARANCE REVERSE POSITION REVERSE DETENT RETAINER BALL SPRING SPRING ETENT DETENT iALL SPRING PLUG Fig 4 7 Reverse Interlock 5 In the transmission position both synchroniz er sleeves in neutral Place the 1 2 shift fork in groove of 1 2 synchronizer sleeve 6 Lay transmission on it s right side and posi tion gasket using grea...

Page 850: ...in 6 o clock position Fig 8 EXHAUST EMISSION CONTROL SYSTEM SWITCH Some models have a switch mounted in the shift housing below the 3 4 shift lever for the Emission Control System It is actuated by a cam on the 3 4 lever when in fourth gear similar to the Back up Light Switch System Fig 40 In those vehicles not equipped with the Emission System a plug is installed in the switch mounting hole in th...

Page 851: ...main drive pinion and is supported by a ball bearing in the rear of the case The rear end of the mainshaft is supported by the sliding yoke and bushing in the extension housing The speedometer drive gear is integral with the mainshaft The main drive pinion input shaft is supported by a ball bearing in the transmission case and an olite bushing pressed in the end of the crankshaft SERVICE DIAGNOSIS...

Page 852: ...n gear teeth e Drive pinion bearing worn TRANSMISSION NOISES a Excessive end play in a Inspect and remove all linkage interferences b Adjust gearshift rods as outlined in Gearshift Linkage Adjustments c Disassemble transmission and replace parts as necessary d Refer to Clutch Group for correction procedures a Replace thrust washers b Inspect mainshaft and synchronizer hub and replace parts as nece...

Page 853: ...ock ignition switch 4 Place screwdriver or suitable tool between cross over blade and 2nd 3rd lever at steering col umn so that both lever pins are engaged by cross over blade Fig 6 5 Set 1st Reverse lever on transmission to rev erse position Fig 3 6 Adjust 1st reverse rod swivel by loosening clamp bolt and sliding swivel along rod so it will enter 1st reverse lever at transmission Install washers...

Page 854: ...clutch engagement Fig 8 Speedometer Pinion and Adaptor Installed A D A L 107 RING zyxw c l SEAL I TOOL NP2 Fig 10 Installing Speedometer Pinion Seal SPEEDOMETER PINION GEAR Removal and Installation Rear axle gear ratio and tire size determines pin ion gear size requirements Refer to Speedometer Pinion Chart in Specifications for pinion usage 1 Place drain pan under adapter to drain transmission 2 ...

Page 855: ... CENTER Fig 11 Center Crossmember and Rear Engine Mount Valiant TRANSMISSION EXTENSION HOUSING r 200 IN LBS NU45A CENTER CROSSMEMBER TIGHTENING TORQUE 30 FT LBS PY171A Fig zyxwvuts I 2 Center Crossmember and Rear Engine Mount Safellife MyMopar com ...

Page 856: ...over mainshaft and down against the case Install and tighten attaching bolts to 50 foot pounds TOOL INSTALLING zyx 111 1 REMOVING END NU43 Fig 14 Replace Bushing in Extension Housing TOOL NN125 _ Fig zyxwv I S Installing Extension Housing Yoke Seal 2 Install center crossmember and tighten retain ing bolts to 30 foot pounds Lower transmission install extension housing to rear engine mount bolts and...

Page 857: ...to holes in the side frame members with support ends up against un derside of oil pan flange Use Adapter Leg 2 3806 on 6 cyl engines 5 Raise engine slightly with support fixture Disconnect transmission extension housing from removable center crossmember Fig 11 or 12 6 Support transmission with a suitable jack and remove center crossmember Remove bolts that attach transmission to clutch housing 7 S...

Page 858: ...ainer securing speedome ter pinion adapter in extension housing Fig 8 Carefully work adapter and pinion out of exten sion housing 2 Remove bolts which attach extension housing to transmission case Slide extension housing off mainshaft Drive Pinion 1 Remove bolts that attach drive pinion bear 3 TEETH OMITTED TO CLEAR CLUSTER BEARING AND SNAP RING WASHER SNAP RING I I OIL SEAL SURFACE PY69 fig 19 Dr...

Page 859: ... pull assembly out of case slightly then slide synchronizer front inner stop ring from the short splines on pinion as as sembly is being removed from the case Fig 20 4 Remove snap ring Fig 19 which locks bearing on pinion shaft Remove pinion bearing washer then carefully press pinion shaft out of bearing using an arbor press Remove oil slinger 5 Remove snap ring and bearing rollers from cavity in ...

Page 860: ...toward rear of case until small key can be removed from countershaft 3 Drive countershaft remaining way out of case keeping arbor tight against end of counter shaft to prevent loss of bearing rollers 4 Remove countershaft gear and thrust washers from the case 5 Remove bearing rollers washers and center spacer from countershaft gear Ball Bearings Wash ball bearings using a clean solvent and blow dr...

Page 861: ...r of case Insert shaft key and continue to drive countershaft forward in case until key is bottomed in recess Reverse Idler Gear 1 Position arbor Tool C 464 in reverse idler gear and using heavy grease install 22 roller bear ings in gear 2 Place front and rear thrust washers at each end of reverse idler gear and position assembly in transmission case with chamfered end of gear teeth toward front F...

Page 862: ...aining snap ring groove 4 Secure bearing and washer with selected thickness snap ring Four snap rings are available to eliminate end play Be sure snap ring is prop erly seated If large snap ring around bearing was removed install at this time 5 Place pinion shaft in a vise with soft jaws then install 14 bearing rollers in cavity of shaft Fig 21 Coat bearing rollers with heavy grease then install b...

Page 863: ... LIGHT 2 3 SHIFT LEVER SWITCH SHIFT LEVER push transmission forward until seated against clutch housing Do not allow transmission to hang after pinion has entered the clutch disc 4 Install transmission attaching bolts and tight en to 50 foot pounds Remove the jack 5 Using a pointed drift align crossmember bolt holes then install attaching bolts Tighten to 30 foot pounds Fig 11 or 12 6 Remove engin...

Page 864: ...tem The converter housing and transmission case are an integral aluminum casting The transmission con sists of two multiple disc clutches an over running clutch two servos and bands and two planetary gear sets to provide three forward ratios and a reverse ratio The common sun gear of the plane Page Fluid Leakage 130 Recondition Sub Assemblies 99 Accumulator Piston and Spring 106 Extension Housing ...

Page 865: ...TORQUEFLITE TRANSMISSION 21 51 z m zy 2 Z Z N 3 z 1 CY Q n Z 2 9 3 P 2 P 0 I 4 w MyMopar com ...

Page 866: ...21 52 TORQUEFLITE TRANSMISSION rn a 3 z 3 zyxwv r z 2 I3 v v P m 9 z c Z Z P 0 t 4 2 z 5 v Y Z U w 0 MyMopar com ...

Page 867: ...P zyxwvutsrqponm 1 1 1 1 1 LINE PUMP SUCTION SELECTOR LEVER IN PARK CONVERTER 5 30pai ENGINE RUNNING LUBRICATION 5 30pri HIGH PRESSURE RELIEF VALVE I SELECTOR LEVER IN PUMP SUCTION ENGINE RUNNING CONVERTER 30 55psi 0 LUBRICATION 5 30psi Park and Neutral 6 and 8 cylinder PB1 MyMopar com ...

Page 868: ... zyx d COOLER I TO LUBRICATION VT PUMP rl I URE 1 L I E F VALVE OIL FILTER 0 PUMP SUCTION THROTTLE GOVERNOR CONVERTER U GOVERNoR L y LUBRICATION 5 30 psi 1 2 SHIFT CONTROL 25 35psi SELECTOR LEVER IN DRIVE BREAKAWAY HALF THROTTLE PB2 Drive Breakaway 8 Cylinder MyMopar com ...

Page 869: ... SERVO r f I LIMIT VALVE I 1 HIGH PRESSURE RELIEF VALVE r PUMP OR L 40 ps 5 40 psi 30 75 psi 0 GOVERNoR LUBRICATION 5 30 psi 0 1 2 SHIFT CONTROL 25 35 psi SELECTOR LEVER IN DRIVE SECOND HALF THROTTLE I PB3 Drive Second 8 Cylinder MyMopar com ...

Page 870: ...21 56 TORQUEFLITE TRANSMISSION REAR SERVO PUMP E OIL FILTER m w E SELECTOR LEVER IN DRIVE DIRECT P M Drive Direct 8 Cylinder MyMopar com ...

Page 871: ...P I rurFuT UFFVF c OIL PRESSURES LINE 55 90P PUMP SUCTION THROTTLE 2545 psi GOVERNOR 3 40psi I I CONVERTER LUBRICATION 5 30 psi 0 1 2 SHIFT CONTROL 25 35 psi SELECTOR LEVER IN DRIVE PART THROTTLE KICKDOWN BELOW 40 M P H 30 75psi 0 ve Pari irottle Kickdown 8 Cylinder PB5 MyMopar com ...

Page 872: ...O LUBRICATION w PUMP HIGH PRESSURE RELIEF VALVE D l PUMP SUCTION THROTTLE GOVERNOR CONVERTER zy 90psi 4075 psi 30 75psi I GOVERNoR 2gF Ly LUBRICATION 5 30psi I 1 2 SHIFT CONTROL 55 65 psi d Drive Full Throttle Kickdown 8 Cylinder SELECTOR LEVER IN DRIVE FULL THROTTLE KICKDOWN ABOVE 50 M P H PE6 MyMopar com ...

Page 873: ...21 59 REAR SERVO zyxwvutsrqp 4 iiiil PUMP SUCTION TO LUBRICATION HIGH PRESSURE RELIEF VALVE 1 2 SHIFT CONTROL 25 35 I SELECTOR LEVER IN TWO MANUAL SECOND CLOSED THROTTLE PB7 LIMIT VALVE Selector lever Two 8 Cylinder MyMopar com ...

Page 874: ... SERVO REAR SERVO f r 6 OIL PRESSURES 55 PI1 0 PUMP SUCTION GOVERNOR L 0 30psi TO LUBRICATION CONVERTER 30 55psi 5 30 p U 1 2 SHIFT CONTROL 45 55 psi SELECTOR LEVER IN ONE MANUAL LOW CLOSED THROTTLE Selector Lever One 8 Cylinder MyMopar com ...

Page 875: ...yxw d T LUBRICATION REAR SERVO iFLlTE TRANSMISSION 21 61 z P LUBRICATION PUMP SUCTION HIGH PRESSURE RELIEF VALVE L LUBRICATION 5 30PI I PUMP OIL FILTER SELECTOR LEVER IN REVERSE PB9 Reverse 8 Cylinder MyMopar com ...

Page 876: ...ISSION REAR SERVO TORQUE OIL PRESSURES PUMP SUCTION LUBRICATION GOVERNOR 0 20 PSI rg TILyCONVERTER 30 75 PSI LUBRICATION zyxw 5 30PSI L I r SELECTOR LEVER IN DRIVE BREAKAWAY HALF THROllLE Drive Breakaway 6 Cylinder MyMopar com ...

Page 877: ...3 b TO LUBRICATION I I 1111 u r PUMP I OIL PRESSURES LINE PUMP SUCTION THROTTLE I GOVERNOR 5 40 P S l l F LTILyCONVERTER 30 75 PSI LUBRICATION 5 30 PSI1 SELECTOR LEVER IN DRIVE 2ND HALF THROllLE Drive Second 6 Cylinder 11 MyMopar com ...

Page 878: ...21 64 TORQUEFLITE TRANSMISSION f mi2 Drive Direct 6 Cylinder MyMopar com ...

Page 879: ...utsrqpon J 21 65 7 I I LUBRICATION W M P I OIL PRESSURES LINE PUMP SUCTION THROllLE GOVERNOR L y CONVERTER LUBRICATION 40 75 P iIzyx 3 55P S I 1 Drive Port Throttle Kickdown zyxwv 6 Cylinder SELECTOR LEVER IN DRIVE PART THROTTLE KICKDOWN MyMopar com ...

Page 880: ...21 66 TORQUEFLITE TRANSMISSION zyxwv I b i i i i Drive Full Throttle Kickdown 6 Cylinder OIL PRESSURES SELMOR LEVER IN DRIVE FULL THROllLE KICKDOWN 14 MyMopar com ...

Page 881: ...N 21 67 REAR SERVO TORQUE OIL PRESSURES PUMP SUCTION GOVERNOR 3 55 PSI CONVERTER 30 55 PSI LUBRICATION 5 30 PSI LUBRICATION SELECTOR LEVER IN TWO MANUAL 2ND CLOSED THROTTLE m m I Selector lever Two 6 Cylinder PB15 MyMopar com ...

Page 882: ...QUEFLITE TRANSMISSION rn REAR SERVO b ACCUMULATOR OIL PRESSURES PUMP SUCTION LUBRICATION L y LUBRICATION 5 30 PSI1 SELECTOR LEVER IN ONE MANUAL LOW CLOSED THROTTLE PB16 Selector Lever One 6 cylinder MyMopar com ...

Page 883: ...I TORQUEFLITE TRANSMISSION 21 69 OIL PRESSURES SELECTOR LEVER IN REVERSE PB17 Reverse zyxwvu 6 Cylinder MyMopar com ...

Page 884: ...GED RELEASED RELEASED OVER RUNS KICKDOWN To Second DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 1 45 to 1 To Low DISENGAGED ENGAGED RELEASED RELEASED HOLDS 2 45 to 1 2 SECOND DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 1 45 to 1 1 LOW DISENGAGED ENGAGED RELEASED APPLIED PARTIAL HOLD 2 45 to 1 R REVERSE ENGAGED DISENGAGED R ELEASED APPLIED NO MOVEMENT D DRIVE Pressure Regulating Valves The press...

Page 885: ...has the same selector lever positions The parking lock is applied by moving the selector lever past a gate to the P position CAUTION Never apply the parking lock until the vehicle has stopped otherwise a severe ratcheting noise will occur Starting the Engine The engine will start with the selector lever in either the P park or N neutral positions 1 As a safety precaution when starting in the N neu...

Page 886: ...s required Inspect accumulator for sticking broken rings or spring Repair as required Inspect servo for damaged seals binding linkage or faulty band lining Repair as required Disassembie and inspect clutch Repair or replace as required Refill to correct level with Dexron type Automatic Transmission Fluid Adjust control linkage Perform hydraulic pressure tests and adjust to specifications Replace o...

Page 887: ... replace as required k Inspect and replace seal rings as required also inspect respective bores for wear Replace parts as required a Refill to correct level with Dexron type Automatic Transmission Fluid b Adjust throttle linkage c Adjust kickdown band d Perform hydraulic pressure tests and adjust to specifications e Remove and clean governor Replace parts if necessary f Perform pressure tests to d...

Page 888: ...control linkage e Perform hydraulic pressure tests and adjust to specifications f Remove and clean governor Replace parts if necessary 9 Replace oil filter h Perform pressure tests t o determine cause and correct as required i Remove valve body assembly and perform air pressure tests Repair as required j Perform hydraulic pressure tests adjust or repair as required k Inspect and replace seal rings...

Page 889: ...s Repair as required h Inspect servo for damaged seals binding linkage or faulty band lining Repair as required i Perform hydraulic pressure tests adjust or repair as required j Adjust idle speed to specifications and readjust transmission throttle rod a Refill to correct level with Dexron type Automatic Transmission Fluid b Perform hydraulic pressure tests and adjust to specifications c Perform p...

Page 890: ...isassemble transmission and repair overrunning clutch as required f Inspect and replace seal rings as required also inspect respective bores for wear Replace parts as required a Adjust control linkage b Perform hydraulic pressure tests and adjust to specifications c Adjust low reverse band d Perform pressure tests to determine cause and correct as required e Remove valve body assembly and perform ...

Page 891: ...eplace parts as required c Remove and recondition valve body assembly d Inspect and repair clutch as required a Drain fluid to correct level b Inspect and clean breather vent opening in oil pump housing c Replace oil filter d Inspect for air leakage into pump suction passage a Replace rubber 0 ring seal Inspect for bore porosity b Replace rubber seal c Can often be stopped by tightening the attach...

Page 892: ...m limits shown release the accelerator im mediately since transmission clutch slippage is indicated STALL SPEED ABOVE SPECIFICATION If stall speed exceeds the maximum specified in chart by more than 200 rpm transmission clutch slippage is indicated Follow the transmission oil pressure and air pressure checks outlined in the Service in Vehicle section to determine the cause of slippage STALL SPEED ...

Page 893: ... tools and in serts are readily available from most automotive parts jobbers Some thread drag may occur in Fig 3 Converter Drain Plug screwing a bolt into the installed Heli Coil insert Therefore a torque reading should be taken of the thread drag with an inch pound torque wrench and added to the specified bolt torque so that all bolts securing a particular part will be tightened to the same torqu...

Page 894: ... screws to 35 inch pounds 6 Clean the oil pan and reinstall using a new gasket Tighten oil pan bolts to 150 inch pounds 7 Pour six quarts of DEXRON type Auto NN551 Fig 5 Column Gearshift linkage Valiant Fig 7 Column Gearshift linkage Fury and Chrysler matic Transmission Fluid through the filler tube 8 Start engine and allow to idle for at least two minutes Then with parking brake on move selector ...

Page 895: ...hift lever is in park or neutral positions LINKAGE ADJUSTMENT Console Shift Figs 9 10 11 and 12 1 Assemble all linkage parts leaving adjustable rod ends free Step 2 applies to Fury and Chrys r 1 BUTTON SPRING LEVER LEVER MOUNTING Fig 9 Console Gearshift Unit Fig 11 Console Gearshiff Linkage Barracuda and Safellite ler only 2 At steering column upper end line up locat ing slots in bottom of shift h...

Page 896: ...uired disconnect battery ground cable Remove set screw and shift knob or handle Proceed as outlined in Body Book 7 After console is in place install shift knob as Fig 14 Bottom View of Transmission Pan follows with gearshift lever in NEUTRAL thread Removed button spring and knob assembly on the cable screw The T type handle requires no adjust end until dimension from top of button to top of ment a...

Page 897: ...Circuit is through the two outside terminals of the 3 terminal switch 7 To test switch remove wiring connector from switch and test for continuity between the two outside pins 8 Continuity should exist only with transmis 9 No continuity should exist from either pin to sion in Reverse position the case BAND ADJUSTMENTS Kickdown Band The kickdown band adjusting screw is located on left side of the t...

Page 898: ...t to 35 foot pounds 5 Reinstall oil pan using a new gasket Tighten oil pan bolts to 150 inch pounds 6 Fill transmission with DEXRON type Au tomatic Transmission Fluid THROTTLE ROD ADJUSTMENT With engine at operating temperature and carbu retor off fast idle cam adjust idle speed of engihe using a tachometer Refer to Fuel System Group 14 for idle speed Specifications and carbu retor linkage adjustm...

Page 899: ... forward position 7 Connect choke rod 4 or remove blocking fixture Transmission Throttle Linkage Adjustment 8 Cylinder Model with Three Section Throttle Rod Fig 17 1 Follow detailed instructions in Lubrication Section for linkage lubrication of all models 2 Disconnect choke 8 at carburetor or block choke valve in full open position Open throttle slightly to release fast idle cam then return carbu ...

Page 900: ...of slot should con tact carburetor lever pin no backlash without exerting any forward force on pin when slotted adjuster link 1 is in its normal operating position 7 Assemble slotted adjustment 1 to carburetor lever pin and install washer and retainer clip As semble transmission linkage return spring 13 in place 8 Remove Tool Assembly with spring at transmission throttle lever Check freedom of ope...

Page 901: ...tailed instructions in Lubrication Section for linkage lubrication of all models 2 Block choke valve in full open position Open throttle slightly to release fast idle cam then return carburetor to curb idle 3 Use Special Tool Assembly with spring C 4160 to hold the transmission throttle lever for ward against its stop while adjusting linkage mak ing sure that no other force is exerted against the ...

Page 902: ...ure test should be made at same time that line pressure and front servo re lease pressure are tested 1 Install a tee fitting between cooler return line fitting and fitting hole in transmission case at rear left side of the transmission Fig 22 Con nect a 0 100 psi pressure gauge Tool C 3292 to the tee fitting 2 At 1 OOO engine rpm with throttle closed and transmission in direct lubrication pressure...

Page 903: ...te turn of adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counter clock wise increases pressure and clockwise decreases pressure Throttle Pressure Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a malfunction is evident 1 Remove valve body assembly from transmis sion to perform adjustment 2 Loosen ...

Page 904: ...s that rear clutch is operating Also inspect for ex cessive oil leaks If a dull thud cannot be A D A L LOCI RINGzyxw 1 7 a SEAL I TOOL NP2 Fig 29 Installing Speedometer Pinion Seal heard in the clutches place finger tips on clutch housing and again apply air pressure Move ment of piston can be felt as the clutch is applied Kickdown Servo Front Direct air pressure into front servo apply passage Ope...

Page 905: ...ension housing CAUTION Be careful not to scratch or nick ground surface on sliding spline yoke during re moval and installation of the shaft assembly 2 Remove the extension housing yoke seal Fig 30 with Tool C 3994 or C 3985 3 To install a new seal position seal in open ing of extension housing and drive it into the housing with Tool C 3995 or 2 3972 Fig 31 4 Carefully guide front universal joint ...

Page 906: ... ING G E A R P RINGS S N A P RING GOVERNOR BODY llTS 4 NN77 Fig 34 Governor Shaft and Weight Snap Rings 2 Install and tighten extension housing bolts to 24 foot pounds 3 Install gasket plate and two screws on bot tom of the extension housing mounting pad 4 Install center crossmember and rear mount assembly tighten retaining bolts Figs 111 112 or 113 Lower transmission install extension housing to ...

Page 907: ...upport 3 Slide shaft out of extension housing to re move the parking sprag and spring Fig 36 Re move snap ring and slide the reaction plug and pin assembly out of the housing 4 To replace the parking lock control rod ref BACK UP LIGHT AND PB329 NEUTRAL STARTING SWITCH Fig 37 Parking Lock Control Rod Retaining E Clip er to Valve Body Removal and Installation Installation 1 Position sprag and spring...

Page 908: ...mission and converter must be re moved as an assembly otherwise the converter drive plate pump bushing and oil seal will be damaged The drive plate will not support a load therefore none of the weight of the transmission should be allowed to rest on the plate during removal 1 Connect a remote control starter switch Tool C 763 to starter solenoid and position switch so engine can be rotated from un...

Page 909: ...lamp from edge of bell housing then carefully slide assembly out of the transmission STARTER RING GEAR REPLACEMENT The starter ring gear is mounted directly on out er diameter of the torque converter front cover BRASS DRIFT WOOD BLOCKS zy NY1607 Fig 40 Removing Starter Ring Gem With torque converter removed from vehicle re placement of the gear is as follows Removol 1 Cut through weld material at ...

Page 910: ...flushed to insure that metal particles or sludged oil are not later transferred back into the reconditioned transmission ENT SHIELD TOOL 1D184A Fig 42 Installing Pump Oil Seal HAND Ff USHING 1 Place converter in horizontal position and pour two quarts of new clean solvent or kerosene into converter through the impeller hub 2 Turn and shake converter so as to swirl sol vent through the internal par...

Page 911: ... avoid nicks or burrs Drive Train End Play Measuring drive train end play before disassem bly will usually indicate when a thrust washer PB330 Fig 44 Transmission Installed ln Repair Stand change is required except when major parts are replaced The thrust washer is located between reaction shaft support and front clutch retainer on A 727 transmissions The thrust washer is lo cated between input an...

Page 912: ...Support 1 Tighten front band adjusting screw until band is tight on front clutch retainer This pre vents clutch retainer from coming out with pump which might cause unnecessary damage to the PB332 Fig 46 Compressing Kickdown Servo Spring 2 Remove oil pump housing retaining bolts 3 Attach Tool C 3752 to pump housing flange Fig 49 in threaded holes in the flange 4 Bump outward evenly with the two kn...

Page 913: ...nded for repairing PB335 Fig 48 Transfer and Separator Plate A 904 damaged stripped or worn threads in aluminum parts Pre sized service bushings are available for re placement for most all bushings in the Torque Flite transmission The two bushings in sun gear are not serviced because of the low cost of sun gear assembly If bushings are found worn or scored they should be replaced as outlined in th...

Page 914: ...Fig 52 2 Remove spring retainer line pressure adjust ing screw assembly do not disturb setting and the line pressure and torque converter regulator springs 3 Slide torque converter and line pressure valves out of their bores 4 Remove E clip and washer from throttle le ver shaft Fig 52 Remove any burrs from shaft then while holding manual lever detent ball and spring in their bore with Tool 2 3765 ...

Page 915: ...EMBLY THROTTLE VALVE ADJUSTING SCREW ROTTLE VALVE SPRING MANUAL VALVE zyxwv q KICKDOWN VALVE KICKDOWN DETENT F SPRING RETAINER Fig 52 Pressure Regulators and Manual Control A 904 PB340 2 3 SHIFT VALVE THROTTLE PLUG 2 SHIFT VALVE REGULATOR VALVE THROTTLE PRESSUREPLUG REGULATOR VAVE LINE PRESSURE PLUG LINE PRESSURE REGULATOR VALVE END PLATE PB341 Fig 53 Shift Valves and Pressure Regulator Valve Plug...

Page 916: ...governor plug and the 2 3 shift valve governor plug 3 Remove shuttle valve E clip and slide shuttle valve out of its bore Also remove the sec ondary spring and guides which were retained by E clip WASHER THROTTLE LEVER SHAFT AND SEAL VALVE 1 E CLIP PB337 Fig 55 Valve Body Controls A 727 and A 904 LA I SHUTTLE VALVE COVER PLATE Pressure Regulators and Manual Control 1 Hold spring retainer firmly ag...

Page 917: ...7 and A 904 la MANUAL LEVER ASSEMBLY DETENT BALL CONTROL VALVE CONVERTER PRESSURE REGULATOR SPRING LINE PRESSURE REGULATOR V A L V E LINE PRESSURE REGULATOR SPRING 4 6 SHUT LE VALVE SECONDARY SPRING TORQUE CONVERTER THROTTLE LEVER ASSEMBI THROTTLE VALVE SPRING MANUAL VALVE KICKDOWN VALVE KICKDOWN DETENS LINE PRESSURE ADJUSTING SCREW SPRING RETAINER PB342 SCREW ASSEMBLY Y PB343 Fig 57 Pressure Regu...

Page 918: ...ol lapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be removed with crocus cloth providing extreme care is taken not to round off sharp edges The sharp ness of these edges is vitally important because it prevents foreign matter from lodging between valve and valve body thus reducing possibility of sticking Inspect all valves and plugs for freedom of o...

Page 919: ... align the spring loaded ball as the 17 shorter screws are installed 3 longer screws are for oil filter 4 Starting at the center and working outward tighten screws to 35 inch pounds 5 Install oil filter and tighten to 35 inch pounds 6 Check spring engagement with tang and ad justing nut and install remaining spring retainer screws Check alignment Fig 23 and tighten to 28 inch pounds 7 After valve ...

Page 920: ...ward tighten screws to 35 inch pounds 5 Install oil filter and tighten to 35 inch pounds 6 Check spring engagement with tang and ad justing nut and install remaining spring retainer screws Check alignment Fig 23 and tighten to 28 inch pounds 7 After valve body has been serviced and com pletely assembled adjust throttle and line pressures Fig 24 and 25 However if pressures were satis factory prior ...

Page 921: ...spect lugs on support gear for broken edges or other damage Thoroughly clean all governor parts in clean solvent and test for free movement before assembly Assembly 1 If support was separated from governor body Disassembly support disassembled support and lift support off the pump flange Figure 61 shows the oil pump and reaction shaft 1 Remove bolts from rear side of reaction shaft 2 Remove rubber...

Page 922: ...SP 5117 Reaction Shaff Bushing Replacement A 904 In case of a reaction shaft bushing failure al ways inspect the support for wear from the input shaft seal ring lands If worn or grooved replace support assembly 1 Assemble remover Tool SP 5324 cup Tool SP 3633 and hex nut Tool SP 1191 Fig 64 CAUTION Do not clamp any part of reaction SHAFT SUPPORT INSTALLATION ND345A REACTION REMOVAL SHAFT Fig 64 Re...

Page 923: ...ol securely 4 Invert pump and reaction shaft support as sembly with clamping tool intact Install support to pump body bolts and tighten to 160 inch pounds Remove clamping tool pilot studs and rotor alignment tool 5 Place a new oil seal in opening of pump housing lip of seal facing inward Using Tool C 3757 drive seal into housing until tool bottoms 011 PUMP AND REACTION SHAFT SUPPORT A 727 Disussem...

Page 924: ...he removing head Fig 67 3 Drive bushing straight down and out of the bore Be careful not to cock tool in the bore 4 Position a new bushing on installing head 5 With pump housing on a smooth clean sur face hub end down start bushing and installing head in the bushing bore Install handle Tool SP 3549 in installing head Fig 67 6 Drive bushing into housing until tool bot To01 SP 5118 Fig 68 Staking Pu...

Page 925: ...n the pump housing Fig 66 2 Install reaction shaft support Install retaining bolts and tighten to 160 inch pounds 3 Place a new oil seal in opening of pump housing lip of seal facing inward using Tool C 3860 drive seal into housing until tool bottoms FRONT CLUTCH A 904 Disassembly Figure 70 shows a disassembled view of the front clutch assembly 1 Remove large waved snap ring that secures pressure ...

Page 926: ...spect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal ring grooves for nicks and burrs Inspect neoprene seal rings for deterioration wear and hardness Inspect A 904 PISTON SEAL RING INNER PISTON I I PISTON RETAINER ASSEMBLY D RING ND2A Fig 73 Measuring Front Clutch Plate Clearance piston spring retainer and sna...

Page 927: ... clutch for both six cylinder engines Four plates and discs are used in A 904 transmissions for eight cylinder engines Fig 76 Replacing Front Clutch Retainer Bushing 5 With front clutch completely assembled in sert a feeler gauge between pressure plate and snap ring Fig 73 Maximum clearance should be 048 to lo9 inch for the four plate clutch and 036 to zy 087 inch for the three plate clutch A 727 ...

Page 928: ...e Slide a new bushing on installing head Tool SP 5511 and start them in clutch re tainer bore 4 Install handle Tool SP 3549 in the installer Fig 76 Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retainer before as sembly and installation Assembly 1 Lubricate and install inner seal on hub of clutch retainer Make sure lip of seal faces down and is properly seated in ...

Page 929: ...2 3863 Fig 7 9 and seat snap ring in hub groove Remove compressor tool 4 Lubricate all clutch plates install one steel plate followed by a lined plate disc until the number given in the chart is installed Install pressure plate and snap ring Make sure snap ring is properly seated 5 With front clutch completely assembled push downward on pressure plate and insert a feeler gauge between pressure pla...

Page 930: ...oprene rings Inspect neoprene seal rings for deterioration wear and hardness Inspect piston spring wave spring and spacer for distortion or breakage Inspect interlocking seal rings Fig 83 on input Fig 85 Measuring Rear Clutch Plate Clearance shaft and piston retainer for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant Inspect rear clutch...

Page 931: ... driving discs Re place discs that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of material flaking off or if facing mate rial can be scraped off easily Inspect driving disc splines for wear or other damage Inspect steel plate and pressure plate surfaces for burning scor ing or damaged driving lugs Replace if necessary Inspect steel plate lug grooves in ...

Page 932: ...ace 5 Place clutch piston spring and spacer ring on top of piston in clutch retainer make sure spring REAR PLANETARY GEAR ASSEMBLY DRIVING SHELL NK292 Fig 88 Measuring End Play of Planetary Gear Assemblies and spacer ring are positioned in the retainer recess Start one end of wave spring in retainer groove Fig 84 then progressively push or tap spring into place making sure it is fully seated in th...

Page 933: ...Make sure all oil passages in shaft are open and clean Inspect bushings in sun gear for wear or scores replace sun gear assembly if bushings are damaged Inspect all thrust washers for wear and scores replace if damaged or worn below specifications Inspect thrust faces of planetary gear carriers for wear scores or other damage replace as required Inspect planetary gear carrier for cracks and pinion...

Page 934: ...nt planetary assem bly off the shaft 3 Slide front annulus gear off planetary gear set Fig 90 Remove thrust washer from rear side of planetary gear set 4 Slide sun gear driving shell and rear plane tary assembly off output shaft 5 Lift sun gear and driving shell off rear plan etary gear assembly Remove thrust washer from inside the driving shell Remove snap ring and steel washer from sun gear rear...

Page 935: ...f sun gear long end of gear Insert sun gear through front side of driving shell install rear steel washer and snap ring 4 Carefully slide driving shell and sun gear as sembly on output shaft engaging sun gear teeth with rear planetary pinion teeth Place thrust washer inside the front driving shell 5 Place thrust washer on rear hub of front OVERRUNNING CLUTCH Inspection Inspect clutch rollers for s...

Page 936: ...pilot studs Tool C 3288 B into the case Fig 94 Chill the support with ice preferably dry ice Quickly position support over Fig 95 Removing Overrunning Clutch Cam A 727 Fig 97 Installing Overrunning Clutch Cam A 727 the pilot studs and drive it firmly into the case with a wood block and hammer Overrunning Clutch Cam Replacement A 727 If overrunning clutch cam and or roller spring retainer are found...

Page 937: ...t for parts reference Inspect piston and guide seal rings for wear and make sure they turn freely in the grooves It is not necessary to remove seal rings unless condi tions warrant Inspect piston for nicks burrs scores and wear Inspect piston bore in the case for scores or other damage Inspect fit of guide TORQUEFLITE TRANSMISSION 21 123 SEAL RING SPRING PISTON ROD GUIDE PISTON N D A Fig 99 Kickdo...

Page 938: ...w Reverse Band and linkage ND21 Assembly in the piston and secure with snap ring 1 Lubricate and insert piston plug and spring ASSEMBLY SUB ASSEMBLY INSTALLATION The assembly procedures given here include in stallation of sub assemblies in the transmission case and adjusting drive train end play Do not use force to assemble mating parts If parts do not assemble freely investigate the cause and cor...

Page 939: ... insert output shaft through rear support Carefully work ANCHOR A 727 ONLY 4 zy u 1 ADJUSTING SCREW AND LOCKNUT ND17A Fig 105 Kickdown Band and Linkage assembly rearward engaging rear planetary carrier lugs into low reverse drum slots CAUTION Be very careful not to damage ground surfaces on output shaft during installation Front and Rear Clutch Assemblies The front and rear clutches front band oil...

Page 940: ...ace de flector over vent opening and install four pump body bolts The A 904 does not use a deflector over vent opening Remove pilot studs install re maining bolts and snug down evenly Rotate input and output shafts to see if any binding exists then tighten bolts to 175 inch pounds Check shafts again for free rotation Governor and Supporf 1 Position support and governor body assembly on the output ...

Page 941: ...ll gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by mov ing lever through all detent positions If binding exists loosen valve body bolts and re align 7 Install flat washer and throttle lever then tighten lever clamp bolt 8 Adjust kickdown and low feverse bands 9 Install oil pan using a new gasket Tighten pan bolts to 150 inch pounds TRANSMISSION CONVERTER AND DRI...

Page 942: ...t cover Fig 110 Carefully work trans mission assembly forward over engine block dow els with converter hub entering the crankshaft opening 7 After transmission is in position install bell housing bolts and tighten to 28 foot pounds 8 Install and tighten the two lower drive plate to converter bolts to 270 inch pounds 9 Install starting motor and connect battery ground cable 10 Rotate engine with re...

Page 943: ... point should now be 13 Install gearshift torque shaft and connect TRANSMISSION EXTENSION HOUSING A TIGHTENING TORQUE W CENTER CROSSMEMBER Fig 112 Center Crossmember and PY171A Rear Engine Mount Barracuda and Satellite TRANSMISSION EXTENSION f REAR MOUNT Fig 113 Center Crossmember and Rear Engine Mount Fury and Chrysler MyMopar com ...

Page 944: ...torque con verter drain plug torque prior to removal of the transmission and torque converter High oil level can result in oil leakage out the CONVERTER HOUSING AREA Fig zyxwv I15 Transmission Converter Area vent located at the top of the front pump housing If the fluid level is high adjust to proper level Oil leakage can also occur at the torque convert er drain plug Torque the drain plug to 110 ...

Page 945: ...as shown in UB SEAL CUP PLUG MADE FROM OLD FILLER TUBE PY302 Fig 117 Transmission Prepared for Test WELD O R BRAZE BREAK EDGE 1 16 I MIN 1 a SEAL THIS END AIR TIGHT OUTSIDE OF OPEN END zyx F O R THIS DISTANCE ON TUBE MATERIAL 1 7 8 INCH O D THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC Fig 119 A 727 Converter Hub Seal Cup PY304 Figs 119 through 123 The transmission should be prepared for pressu...

Page 946: ...psi If a leak source is located that part and all as sociated seals and gaskets should be replaced with new parts 1 1 3 64 14 3 16 MATERIAL 1 4 STEEL STOCK 1 1 4 WIDE PY306 Fig 121 Hub Seal Cup Retaining Strap 13 32 DRILL 2 HOLES 3 314 RADIUS w I zy 0 MATERIAL 3 16 STEEL STOCK PY308 Fig 123 A 904 Vent Plug Retainer TORQUE CONVERTER PRESSURE TEST If fluid leakage has occurred in the bell housing ar...

Page 947: ...ft Gear End Play 005 to 022 Clutch Housing Face Squareness 006 Max Clutch Housing Bore Run Out 008 Max Synchronizer Float 060 to 117 3 SPEED TRANSMISSION A 230 ALL SYNCHRONIZED 198 225 340 Engine Displacement Cu In 318 383 Gear Ratio 3 08 2 55 First Second 1 70 1 49 Third 1 oo 1 oo 2 90 3 34 Reverse 3rdto2nd 45 to 15 mph 2ndto 1st 25 to 0 mph Downshift Speed Limits Lubricant U S Pints IMP Pints 4 ...

Page 948: ...to 15 mph 15 to Zero mph TORQUEFLITE TRANSMISSIONS Transmission Models A 904 A 727 TYPE Automatic Three Speed with Torque Converter TORQUE CONVERTER DIAMETER Std 10 314inches High Stall Speed 11 314inches 10 314inches u s Imperial U S Imperial 0 1L CAPACITY TRANSMISSION AND Measure Measure Measure Measure TORQUE CONVERTER 14 Pts 19 Pts 16 Pts Std 17 Pts Use DEXRON Type Automatic COOLING METHOD LUB...

Page 949: ...2to 066 3 Disc 035to 088 4 Disc 047to 110 5 Disc 033to 075 4Disc 025to 045 440 6 340 360 383 2 383 4 440 426 3 3 3 4 4 5 3 3 3 4 4 5 3 3 3 3 3 3 4 4 4 4 4 4 2 2 2 2 2 2 2 2 2 2 1 3 3 4 2 2 2 2 2 2 2 2 THRUST WASHERS A 904 A 727 Reaction Shaft Support to Front 1 061to 063 1 Selective 061to 063 Natural 084 to 086 Red lo2to 104 Yellow Clutch Retainer Front Clutch to Rear Clutch 2 061to 063 2 061to 06...

Page 950: ... 80 29 50 31 44 32 51 32 51 34 48 32 50 27 40 25 37 27 41 28 42 27 40 27 41 20 22 17 18 20 22 21 22 18 19 20 22 56 64 49 53 54 63 55 64 53 58 54 62 80 88 66 71 78 86 80 87 71 77 78 85 P Fury C Chrysler Y lmperial TIGHTENING REFERENCE Pounds Pounds Torqueflite A 904 and A 727 Foot Cooler Line Fitting Cooler Line Nut Converter Drain Plug Converter Drive Plate to Crankshaft Bolt 55 Converter Drive Pl...

Page 951: ... 15 9 00 x 15 9 15 x 15 2 45 1 27 26 26 25 25 24 24 24 24 26 25 25 25 25 25 26 25 25 24 24 24 2 71 l 2 76 l 29 29 28 28 27 27 26 27 26 26 25 25 28 28 27 26 28 28 27 29 28 28 27 27 26 27 26 26 24 25 30 29 29 28 28 27 27 27 27 26 26 25 29 28 28 27 29 28 28 29 29 28 28 27 26 28 27 26 24 25 26 LINES ALL TRANSMISSIONS PINION GEAR LISTED UNDER EACH AXLE 2 93 1 2 94 1 3 21 1 3 23 1 3 54 1 3 55 1 3 91 1 4...

Page 952: ...ion of Tires 3 Repairing Tire Leaks 4 Tire Noise Complaints 4 Tire Wear Patterns 5 Tire Tread Wear Indicators 4 Wide Tread 70 and 60 Series Tires 3 WHEELS 6 Tire Wheel Balance 6 Tire and Wheel Runout 6 Wheel Covers 7 vehicle are designed and tested to meet all normal GENERAL INFORMATION operating requirements These tires are superior The original equipment Load Range B 4 ply tires for the vehicle ...

Page 953: ...been care Tires used at low speeds in cool climates and with light loads will have longer life than tires used for high speed driving in hot climates with heavy loads Abrasive road surfaces will accelerate tire wear Driving habits have more effect on tire life than any other factor Careful drivers will obtain in most cases much greater mileage than severe or careless drivers Rapid acceleration and...

Page 954: ...of radial tires is not recommended because of their harsh ride at low speeds and possible unfamiliar stability characteristics Should these radial tires be desired IRIGHT REAR 8 SPARE zyxwvu 2 KP23A Fig 3 Tire Rotation Diagram 5 Tires the maximum allowable size should be selected Radial ply tires must be used in sets of five 5 and under no circumstances should they be used on the front only If sno...

Page 955: ...pment manufacturers recommendations Fig 5 Tire Tread Wear Indicator Tools used for dismounting and mounting tires must be smooth free from sharp edges or burrs which could damage the tire or wheel rim The tire must be completely deflated before the tire beads are removed from the seats Before mounting the tire on the wheel make sure all rust scale is removed from the wheel rim A mild soap solution...

Page 956: ...corrected Various types of abnormal tire wear with their causes and corrective actions are shown in Fig 6 Underinflation For the maximum results in stability and handling ride quality and tire life tire inflation pressures should not be allowed to go below the recommended inflation pressures Underinflation results in much faster wear of the shoulders than the center of tread Overinflation By maint...

Page 957: ... rotate by itself An assembly that has a heavy spot is stati cally out of balance and can produce a bouncing motion Correction for static unbalance is made by first finding the location of the heavy spot then add ing sufficient weight to counterbalance it follow the equipment manufacturers recommendations Half the balance weight should be added to the inside of the wheel and the other half to the ...

Page 958: ... time of normal brake reline Lubricant should not be add ed to that already in the bearings Rem0Val without Disc Brakes floor nut lock and bearing adjusting nut cone spindle cone 1 Raise vehicle so front wheels are free of the 2 Remove wheel cover grease cap cotter pin 3 Remove thrust washer and outer bearing 4 Slide wheel hub and drum assembly off the 5 Drive out inner oil seal and remove bearing...

Page 959: ...tion Group 0 Lubricant should be even with inner diameter of bearing cups 3 Force lubricant between bearing cone rollers or repack using a suitable bearing packer 4 Install inner cone and a new seal with lip of seal facing inward Using Tool C 3893 position seal flush with end of hub The seal flange may be damaged if tool is not used 5 Clean the spindle and apply a light coating of wheel bearing lu...

Page 960: ...upe Front Seat 2 passengers Rear Seat 1 passenger Luggage 0 Total 450 Ibs D78 14 E78 14 F78 14 F70 14 E60 15 F60 15 E60 15 Front G60 15 Rear BARRACUDA 5J 5 1 2JJ 5J 5 1 2JJ 6JJ 5J 5 1 2JJ 6JJ 5 1 2JJ 6JJ 7JJ susp travel required 7JJ Hemi engine models only 7JJ Trans Am models only H D susp with sway bar required H D susp wlsway bar restricted Vehicle Maximum Capacity Sedans Hardtops and Convertibl...

Page 961: ... bucket seats without center seat Optional Reduced Vehicle Loading For Improved Ride Sedans Hardtops Front Seat 2 passengers Rear Seat 3 passengers Luggage 0 Total 750 Ibs FURY F78 15 5J 5 1 2JJ G78 15 5 1 2JJf 6JJ H78 15 5 1 2JJf 6JJ H70 15 6JJ H D susp required J78 15 6JJ 6 1 2JJ Station Wagon has ample chain clearance L 8 415 6 1 2JJ Station Wagons only Vehicle Maximum Capacity Sedans Hardtops ...

Page 962: ...l 1200 Lbs Optional Reduced Vehicle Loading for Improved Ride Sedans Hardtops Front Seat 2 passengers Second Seat 3 passengers Luggage 0 Total 750 Lbs Chain Clearance Tire Snow chains are not recommended for use with some tire sizes as indicated on the Tire Size Chart by the symbol because of possiblefender interferences In an emergency chains may be used on these tires if the vehicle is moderatel...

Page 963: ... where maximum vehicle caDacitv is carried above 75 mDh and maximum allowable load 3 4 5 6 7 8 9 range B 4 ply rating tire pressureswould be exceeded We strongly discourage excessive speed however if the vehicle must be driven at sustained speeds over 90 mps special high speed tires inflated to maximum vehicle capacity pressuresare required The use of tires smaller than the specified minimum or la...

Page 964: ... the air flow Page Blower Motor 9 FURY Control Cable Adjustment 10 Heater Removal and Installation 10 Blower Motor Removal and Installation 13 CHRYSLER AND IMPERIAL General Information 13 Service Procedure 13 Control Cable Adjustment 15 Heater Removal and Installation 15 Heater Core Removal and Installation 17 Blower Motor 17 Rear Seat Heater Removal and Installation UPPER LEVEL VENTILATION STRATO...

Page 965: ...ct only the temperature blend air door cable at the heater 2 With the control assembly removed from the instrument panel position the temperature cable on the control bottom cable mounting bracket so the cable housing is flush with edge of the bracket Install new clip AIR SHUT OFF DOOR CABLE TEMPERATURE CONTROL CABLE I Fig I Heater Control Cable Adjustment treme left COOL position connect the cabl...

Page 966: ...bly 7 Disconnect heater housing support rod from 8 Remove heater assembly Fig 2 seal from dash panel bles from heater assembly Fig 2 air duct Fig 3 Fig 4 Heater Mounting Installation 1 Position heater assembly on dash panel by sliding four mounting studs into their respective holes in dash panel Fig 4 2 Connect and adjust heater defroster cable and temperature control cables to their respective co...

Page 967: ...te heater housing halves 9 Remove screw attaching seal retainer and IO Remove heater core tube support clamp 11 Remove screws attaching heater core to 12 Remove seal retainer and seal from heater seal around heater core tubes heater housing and remove core core Assembly 1 Position heater core in heater housing 2 Slide seal retainer and seal over heater core tubes and up against housing Install att...

Page 968: ...nd four screws that hold the front cover to the assembly housing 3 Cut sponge rubber plenum to housing air seal in two places where the front cover separates cover from housing 4 Remove one core tube retaining screw from behind housing between core tubes 5 Remove two sponge rubber gaskets from core tubes and remove heater core from housing 6 Disconnect blower motor lead from blower motor resistor ...

Page 969: ...XISTING STUD IN PLENUM PANEL 4 MOUNTING SCREWS TEMPERATURE CONTROL DOOR CABLE VIEW IN DIRECTION O F ARROW A NTROL CABLE PY136A REAR VIEW VIEW IN DIRECTION O F ARROW B Fig I Heater Assembly Barracuda Models MyMopar com ...

Page 970: ...R Removal The entire heater assembly must be removed from the vehicle to service the blower motor 1 Disconnect blower motor lead from resistor block and ground wire from mounting plate 2 Remove six sheet metal screws and six re taining clips holding blower motor mounting plate to housing Separate mounting plate and blower motor assembly from housing 3 Remove blower wheel from motor shaft 4 Remove ...

Page 971: ...24 8 HEATERS t VIEW IN DIRECTION O F ARROW A TEMPERATURE CONTROL DOOR CABLE VIEW IN CIRCLE Y Fig I Heafer Assembly Satellife Models VIEW IN CIRCLE X PB255 MyMopar com ...

Page 972: ...ion front cover on housing and install mounting screws check all doors for alignment 5 Place sponge rubber gaskets on core tubes 6 Seal plenum air seal cuts with a good grade rubber cement and install assembly in vehicle as outlined in Heater Installation HEATER Removal 1 Disconnect battery ground cable 2 Drain coolant from radiator 3 Disconnect heater hoses from core tubes at dash panel Plug core...

Page 973: ...knob in leave CABLE RETAINING CLIP CABLE Y VIEW IN DIRECTIO PY668 OF ARROW A SHUT OFF B L E Fig 1 Heater Control Cable Adjustment about 1 8 inch between the knob and panel 2 Remove the kick pad at the air outlet 3 Remove the control cable clip from the vent 4 Rotate and hold the vent door firmly closed 5 Reinstall kick pad door cable bracket and attach cable clip Passenger Side Housing Removal 1 D...

Page 974: ...rn HEATERS 24 11 Fig 2 Heater Assembly Fury MyMopar com ...

Page 975: ...nnect heater hoses at core tubes 3 Remove inner fender shield See note 4 From under instrument panel disconnect blower motor feed and ground wires Push wires and rubber grommet through dash panel into en gine compartment 5 From engine compartment remove four re taining nuts and three screws from outer edge of housing and remove housing Insfallafion NOTE Before pressing housing to dash panel be sur...

Page 976: ...ondition inside the vehi cle can then be controlled using the Fan Switch and the Temperature Control Lever Summer Ventilation Two air inlets are provided to allow outside air to be brought inside the vehicle in warm weather independent of the heater The control knobs for the inlets are located on the lower edge of the instrument panel on both sides of the steering column Be sure the air inlets are...

Page 977: ...ENUM DEFROS PASSENGER SIDE HOUSING zyxwvutsr d TEMPERATURE CONTROL DOOR HEAT SHUT OFF DOOR ACTUATOR TO DEFROSTER DISTRIBUTION DUCT PASSENGER SIDE HOUSING I ENGINE SIDE HOUSING NU253 Fig I Heater Assembly Chrysler and Imperial MyMopar com ...

Page 978: ...tlet 3 Remove the control cable clip from the vent 4 Rotate and hold the vent door firmly closed 5 Reinstall kick pad door cable bracket and attach cable clip Fig 3 Heater Hose Routing HEATER REMOVAL Passenger Side Housing 1 Disconnect battery negative cable and drain radiator 2 In engine compartment disconnect heater hos es at dash panel Plug hose fittings on heater to prevent any coolant from sp...

Page 979: ...24 16 HEATERS MyMopar com ...

Page 980: ...ning nuts from right side of heater core and four screws from outside of housing top of housing 3 Remove core tube locating metal screw from 4 Carefully pull heater core out of housing Installation NOTE Examine core to housing seal for damage or misalignment before seating heater core in housing 1 Position core on studs in housing and install two retaining nuts 2 Install four core retaining screws...

Page 981: ...late to heater body and remove the core Insfallafion stall the four retaining screws 1 Remove heater from vehicle as outlined in 2 Remove the 11 metal screws from end plate 3 Remove the four screws retaining heater core 1 Poiition heater core in heater body and in 2 Install end plate and 11 metal screws 3 Install heater as outlined in Heater Installation Blower Mofor Rear Unif out removing heater ...

Page 982: ...s not replace the two lower cable operated cowl vents but is to be used in addition to these lower vents for best results Fast Cool Down 1 Place the mode lever in the Vent position On Chrysler Models push the push button mark ed Vent 2 Place the blower switch on Hi 3 Open both cowl vents 4 Place the temperature control lever in the full Heat position this will position air doors to allow fast cool...

Page 983: ... YLI STER DUCT HEATER Izyxwvu IC I N L E T HOSE VACUUM ACTUATED BLEND AIR DOOR CABLE WATER SHUT OFF VALVE rJ VALVE TURN BUCKLE ADJUSTER PUSH BUTTON CONTROL I I HEAT DEFROST DOOR ACTUATOR UPPER LEVEL VENT DOOR ACTUATOR Fig 2 Upper Level Ventilation Chrysler shown PB310 MyMopar com ...

Page 984: ...he A C button and adjusting the fan Page Chrysler Imperial and Plymouth Fury Models 73 Gauge Set Manifold Installation 22 Operating Instructions For Owners 21 Service Procedures 40 Servicing The Compressor 43 Test Procedures 24 switch to change fan blower speed If less cooling is desired move the fan switch lever to Low speed and readjust the cooling outlets for indirect cooling For warmer air mov...

Page 985: ...r 0 to 30 inches of vacuum and 0 to 150 psi This gauge is connected to the suction service port of the compressor On Valiant installations this gauge is connected to the compressor inlet service port A special service port adapter supplied with the gauge set provides the means of connecting the gauge set manifold hose to the service port When the adapter is installed at the port and tightened the ...

Page 986: ...ir conditioning instal lation is Refrigerant 12 It is transparent and col orless in both the liquid and vapor state Since it has a boiling point of 21 7 degrees F below zero at atmospheric pressure it will be a vapor at all normal temperatures and pressures The va por is heavier than air non flammable and nonexplosive It is nonpoisonous except when it is in direct contact with open flame It is non...

Page 987: ...igerant to touch bright metal Refrigerant will tarnish bright metal and chrome surfaces Avoid splashing refrigerant on any surface Refrigerant in combination with moisture is very corrosive and can cause great damage to all metal surfaces TEST PROCEDURES INDEX Page Correcting Low Refrigerant Level 28 Expansion Valve and EPR Valve Test 33 Front Unit Performance Test 30 Over All Performance Test 30 ...

Page 988: ...t required to complete a full charge may be added to the system as follows Maintaining the discharge pressure at 225 to 250 psi add refrigerant gas through the suction side of the system until foam is cleared from sight glass then add exactly one half 1 2 pound of refrigerant SIGHT GLASS Periodic inspection of the sight glass is consid ered a practical method of determining the amount of refrigera...

Page 989: ...und to be defective it must be replaced Switch lest Engine not running cut out switch and connect them together 1 Remove the two wires from the low pressure 2 Press the A C button 3 Momentarily turn the ignition switch on do not crank the engine listen for the compressor clutch engaging 4 If the clutch does not engage the clutch wiring or fuse may be defective Check the clutch circuit and clutch 5...

Page 990: ...frigerant gas drawn into the sampling or snifter hose will cause the flame to change color in proportion to the size of the leak A very small leak will prod uce a flame varying from yellowish green to bright green A large leak will produce a brilliant blue flame CAUTION Do not use the lighted detector in any place where explosive gases dust or va pors are present Do not breathe the fumes that are ...

Page 991: ...efore adding refrigerant where cause of low lev el is not known the system should be tested for leaks Assuming no leaks are present or that leaks have been corrected without discharging the system proceed with partial charge Install and connect gauge set manifold Figs 5 and 6 1 Close both of the gauge set manifold valves Open the gauge set manifold needle valve 2 Connect the suction gauge test hos...

Page 992: ...button fan switch on high On dual installation both blowers must be on high speed during charging operation 13 If necessary block the condenser to main tain a discharge pressure of 225 to 250 psi The system must be charged through the evaporator suction service port as follows a Slowly open the suction service gauge valve Meter flow of refrigerant by adjusting the suction service gauge valve so th...

Page 993: ...old Air temperature in test room must be 75 degrees F minimum for this test 84 85 86 87 88 89 90 66 68 69 70 71 72 73 FRONT UNIT PERFORMANCE TEST Start the engine open the windows temperature control lever must be in the off position Push in A C button fan switch on high Open all grille outlets When testing the front unit of a dual system leave roof unit blower turned off Adjust engine RPM as outl...

Page 994: ... Pressure Regulator z 66 57 SINGLE UNIT 67zyxwvuts 68 69 70 71 72 73 74 75 76 n 7a 79 80 58 58 59 59 60 60 61 61 62 a 64 65 66 67 INLET AIR WET BULB TEMPERATURE 60 57 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 n 78 58 59 60 61 61 61 62 62 63 63 64 64 64 65 66 67 68 69 INLET AIR DRY BULB TEMPERATURE MUST BE BETWEEN 75 AND100 F PB260 Fig 8 Performance Temperature Chart Single Unit Satellite and...

Page 995: ...87 42 43 44 45 46 47 49 50 51 52 52 52 53 53 55 55 56 56 56 5 7 57 59 60 61 62 63 63 65 67 69 71 72 73 88 89zy 90 74 75 76 DISCHARGE AIR DRY BULB TEMPERATURE INLET AIR DRY BULB TEMPERATURE MUST BE BETWEEN 75 AND 110 F NP655 Fig I I Performance Temperature Chart Front Unit Only Imperial FRONT UNIT OF DUAL INLET WET BULB TEMPERATURE VERSUS DISCHARGE DRY BULB TEMPERATURE INLET AIR WET BULB TEMPERATUR...

Page 996: ...the air flow across the condenser using cardboard or paper In high ambient temperatures and high hu midity areas it may be necessary to put an elec tric fan in front of the condenser to keep the pressure down to these limits Observe and record the Inlet Dry Bulb Temperature and Inlet Wet Bulb Temperature as registered on the psychrometer Observe and record Discharge Air Temperature registered by t...

Page 997: ...mine which is the bad component raise the engine speed to 1750 RPM If the evaporator suc tion pressure now reduces to 21 25 psi range the expansion valve is operating satisfactorily but the compressor is faulty 0 Immerse the expansion valve in 32 degrees F ice water If the evaporator suction pressure reads 21 to 25 psi the compressor inlet pressure should be 17 psi or less If the compressor inlet ...

Page 998: ...ure was greater than 28 psi step c and 25 psi step e one or possibly both of the expansion valves are stuck open The expansion valve that produced the least evaporator suction pressure change when its ther mo bulb was moved from in the 32 degree F ice water to in the hand location is stuck open and should be replaced After replacing the defective expansion valve charge the system and repeat the te...

Page 999: ...e used for discharging to the refrigerant dispensing manifold 3 Attach a single can of Refrigerant 12 to the dispensing manifold Place the refrigerant in 125 degree water For detailed instructions on attach ing refrigerant can for charging see Charging the System in this section 4 With vehicle windows open and hood up proceed with test as follows 5 Start engine and adjust R P M as indicated in cha...

Page 1000: ...fold center connection to vacuum pump Tool C 3652 as shown in Figures 1 and 2 2 Open both gauge set manifold valves and the needle valve 3 Start the vacuum pump and operate until the evaporator suction gauge registers at least 26 inches of vacuum If system is tight and pump in good condition vacuum will go as low as 28 inches 4 Allow vacuum pump to operate with the suction gauge registering 26 to ...

Page 1001: ...ockwise to open them 5 Momentarily loosen the charging hose at the gauge set manifold to allow the refrigerant gas to purge air out of the charging hose 6 Place the three cans of refrigerant into a pan containing hot water at a temperature of 125 de grees F 7 Start engine and adjust speed as outlined zy un der Discharge the System a Charge the system through the suction side of the system by slowl...

Page 1002: ...rn AIR CONDITIONING 24 39 MyMopar com ...

Page 1003: ...r connection in the refrigera tion system Open fittings with caution even after the system has been discharged If any pressure is noticed as a fitting is loosened allow trapped pressure to bleed off very slowly Use a suitable Page Radiator Pressure Cap 42 Vacuum Control System Adjustments and Tests 42 tube bender when bending the refrigerant lines to avoid kinking Never attempt to rebend formed li...

Page 1004: ...such ad verse effects the following service procedure should be followed 1 Any belt that has operated for a minimum of a half hour is considered to be a used belt Adjust air conditioning drive belts at the time of new car preparation See Chart Accessory Belt Drives 2 Measure drive belt tension at regular service intervals using torque method and adjust as needed 3 On all new belt installations new...

Page 1005: ...determines whether or not the vacuum and electrical circuits are properly connected and the controls are func tioning properly However it is possible that a vacuum control system that operates perfectly at the high vacuum provided at engine idle speed may not function properly at high engine speeds Before starting this test stop engine and make certain the vacuum source hose at engine intake i I I...

Page 1006: ...mance test If vacuum drop NY297A Fig 6 Vacuum Actuator Test is still in excess of 3 4 inch remove connector plug from the switch Insert the vacuum test prod alternately in each of the connector holes except the source hose connector hole Fig 5 Note amount of vacuum drop below 8 inches after each actuator has operated If vacuum test gauge comes back to 8 inches at each of the 6 holes the hoses and ...

Page 1007: ...Remove the three hexagon head screws atta ching the clutch field assembly to the compressor and lift off the assembly lnstallation All 1 Install clutch field coil assembly on the base of compressor bearing housing Make sure coil as sembly is positioned so lead wire points to left of compressor as viewed from the front Install the PULLER C 3787 NY896A Fig 2 Remove Hub and Shoe Assembly REMOVER TOOL...

Page 1008: ...nto the inner bearing race and press hub into position with an arbor press 4 Install bearing snap ring and hub snap ring CAUTION The pulley assembly and hub assem bly are mated parts They are burnished at the factory before shipment No attempt should be made to replace either unit separately as this may reduce the initial torque of the clutch COMPRESSOR The compressor is a two cylinder reciprocati...

Page 1009: ...cause noisy operation and possible damage to bearing CAUTION Before reassembly of any unit all contact surfaces must be liberally coated with clean refrigerant oil Refrigerant oil must be kept in a sealed container until ready for use to prevent entrance of moisture and dirt Never use engine oil as a substitute for refrigerant oil EPR Valve Evaporator Pressure Regulator Removal System Discharged 1...

Page 1010: ...for 15 minutes at lo00 engine rpm for eight cylinder engines and 1100 engine rpm for six cylinder engines These engine settings will provide a compressor speed of ap proximately 1200 rpm 2 Open car windows and keep engine hood raised 3 Press the AK button and turn blower switch to high On completion of the above operations shut the air conditioning off without changing any of the described setting...

Page 1011: ...ounds on VALVE PLATE CASKET 1vVALVE PLATE ASSEMBLY ER D I Fig 10 Installing Valve Plafe and Cylinder Heod the remaining bolts Piston and Connecting Rod Removal 1 Drain oil from compressor 2 Remove sump attaching bolts 3 Separate the sump from the case by tapping with a plastic hammer being careful not to distort the oil pressure relief spring 4 Remove oil relief spring and rubber ball from crankca...

Page 1012: ...e up Use a sleeve with the minimum inside diameter of 1 3 8 in to avoid CA CARTRIDGE 1 WAVE SPRING PY1 zy O B Fig 13 Gas Seal Identification damaging the micro finish sealing surface of the face plate Tap the sleeve lightly until the seal seat is fully seated in the housing 2 Before installing the cartridge type assembly inspect the assembly to make sure that the tangs of the carbon seal are index...

Page 1013: ...rnal before plat ing crankshaft in the crankcase 3 Rotate crankshaft to engage the oil pump shaft in the crankshaft slot 4 Install new gas seal and crankshaft bearing housing Use a suitable tool to assure free axial movement Fig 14 5 Install pistons and connecting rods 6 After pistons and connecting rods are installed turn the crankshaft to check freeness Shaft should turn without binding 7 Instal...

Page 1014: ...the blower motor circuit are common to the heat OFF MAX A C TO WATER VALVE er and air conditioner Controls and cooling air outlets are integral with the instrument panel Three cooling air outlets are contained in one unit secured to the lower edge of the instrument panel Each outlet can be adjusted independently to direct air up down or to either side Two fixed openings in the distribution duct in...

Page 1015: ...are provided one below each end of the instrument panel These doors can be opened man ually for outside air ventilation during warm weather Before using the air conditioner be sure both ventilation doors are closed and latched MAX A C With the MAX A C button pushed in all of the doors and the water valve are in the same position they are in when the OFF button is pushed The MAX A C push button mer...

Page 1016: ...er from left Low to right High Temperature Control Switch The temperature control switch controls the temperature of the evaporator by automatically cycling the compressor clutch As the clutch is cycled on and off the temperature of the evapora tor is held at the setting of the temperature con trol lever OPERATION OF ALL CONTROLS Operating controls must be tested in the follow ing sequence 1 Inspe...

Page 1017: ...he shut off valve does not close completely replace the valve EXPANSION VALVE Valiant Removal The system must be completely discharged before opening any of the refrigerant lines 1 Remove equalizer tube from evaporator suc tion line fitting Fig 3 2 Disconnect expansion valve from elbow as sembly and liquid line Use two wrenches to loo OUTSIDE RECIRCULATING AIR DOOR ACTUATOR b Fig 4 Recirculating A...

Page 1018: ... incorporated in the air conditioning temperature control cable This turn buckle is used to adjust the length of the cable housing without removing it from the instrument panel control or the blend air door crank Fig 5 Adjustment If the blend air door does not fully open or close the control cable housing may be shortened or lengthened by rotating the turnbuckle remove glove box to adjust Replacem...

Page 1019: ...lips attaching the heater housing halves together and separate the heater housing halves 12 Remove the screws attaching the heater core to heater housing and remove the core Installation 1 Place a small bead of sealer in heater hous ing flange 2 Install heater core in the heater housing and secure the four attaching screws 3 Cement the weatherseal on the inner lip of heater core flange Fig 8 4 Pla...

Page 1020: ... heater hoses Figs 9 and lo fill cooling system connect battery terminal and in stall air cleaner 14 Start engine operate until normal engine operating temperature is obtained and test opera tion of heater assembly EVAPORATOR The evaporator assembly includes the evaporator core the evaporator housing with the evaporator inlet and defroster doors To remove the evapora tor assembly it is necessary t...

Page 1021: ...NP673B Fig 9 Air Conditioning and Heater Plumbing Valiant 198 and 225 Cu In Engine EXPANSION VALVE ASSEMBLY DISCHARGE MUFFLER WATER VALVE DISCHARGE HOSE VACUUM HOSES HEATER HOSE MUFFLER CONDENSER I RECEIVER DRIER LIQUID TUBE ASSEMBLY NP672B Fig 10 Air Conditioning and Heater Plumbing Valiant 318 and 340 Cu In Engine MyMopar com ...

Page 1022: ...3 Carefully install capillary sensing tube MOUNTING STUD NUTS NK1409 Fig 13 Instolling Capillory Sensing Tube through the case into the evaporator to the tull depth Position evaporator temperature control switch and secure with attaching screws Fig 13 4 Install defroster actuator and cement and weatherseal around air outlet opening 5 Position evaporator assembly on the dash panel and install the s...

Page 1023: ...eheat air conditioner unit all the air en tering the system passes through the evaporator coil Then either through or around the heater core All output air temperatures are controlled by a single slide lever in the instrument panel which operates the heater water flow control valve The blower motor is turned on in any of the positions except Off The Barracuda and Satellite air conditioning housing...

Page 1024: ...w AIR CONDITIONING 24 61 PY182A Fig I Evaporator Heater Assembly Barracuda Installation MyMopar com ...

Page 1025: ...L CONNECTIONS VACUUM WATER VALVE VIEW IN DIRECTION O F ARROWzy 2 TO VACUUM VACUUM CONNECTIONS 7 SUPPLY ON ENGINE ENGINE COMPARTMENT VIEW IN DIRECTION OF ARROW Y PB259 Fig 2 Evaporator Heater Assembly Satellite Installation MyMopar com ...

Page 1026: ... or air conditioner the requirements of the driver and passengers The center outlets can be rotated to direct air Air Directional Vanes One at each end and Figs 3 and 4 CENTER OUTLETS RIGH SPOT COOLER LEFT SPOT COOLER B VIEW IN DIRECTION OF ARROW Z Fig 3 Air Conditioning Ducts Barracuda Installation PY162 LEFT SPOT COOLER RIGHT SP6T COOLER CENTER OUTLETS PBZ8 Fig 4 Air Conditioning Ducts Satellite...

Page 1027: ...NDICATES OPEN CLOSED SEALED HEAT DEFROSTER RESTRICTOR AIR COND RECIRCULATING OUTSIDE AIR HEAT um hoses are activated for each control position In the following illustrations air flow is indicated as the vacuum actuator hoses are activated Figs 5 and 6 OFF same as MAX A C position MAX A C The MAX A C position turns on the blower motor and engages the compressor clutch The vacuum application is as i...

Page 1028: ... VACUUM RECIRCULATING OUTSIDE AIR VACUUM REGULATOR CONTROL HEAT DEFROSTER ACTUATOR HEAT t YELLOW BY PASS ACTUATOR OPEN CLOSED RESERVOIR V A C Y SOLID LINE INDICATES ENGINE VACUUM VACUUM CONTROL SWITCH REGULATED VACUUM WHITE ACTUATOR RECIRCULATING OUTSIDE AIR VACUUM REGULATOR CONTROL AIC VENT BY PASS ACTUATOR DEFROSTER t HEAT OPEN CLOSED REGULATED VACUUM i WHITE RED ACTUAT0R RECIRCULATING OUTSIDE A...

Page 1029: ... away from the outside air inlet and closes off the recirculating inlet sup plying outside air to the blower which forces it through the evaporator coils and the heater core The amount of heat added to the air by the heat er core depends on the setting of the water flow control valve lever DEFROST When the heater section is operating on Defrost there will be a small amount of heat bleed through th...

Page 1030: ...ach button to test the over all operation of the electrical and vacuum controls The Push Button Control Chart summarizes the actions that should take place in each position pushed See Chart Also refer to Vacuum con trols and circuits CONTROL CHART Control Position Off Max AIC AIC Heat Defrost Inlet Air Door Opento Inside Inside Outside Outside Outside Air Conditioning Door Open Open Open Closed Cl...

Page 1031: ...rature and humidity If the discharge air from the air conditioning outlets is too cold the air temperature may be increased by reheating the air after it has passed through the evaporator coil The amount of reheatirlg is determined by the temperature control slide lever which controls the water flow to the heater core Any desired air temperature can be obtained from the A C outlets by adjusting th...

Page 1032: ...EMBLY Removal 1 Remove air cleaner from carburetor ATTACHING SCREW LOCATION o r PYl92 Fig IO Air Distribution Housing Removal TO A C SPOT COOLER SUPPORT PLENUM AIR SEAL I DEFROSTER OUTLET EVAPORATOR I AIR CONDITIONING ACCESS PLATE OUTLET I 1 I RESISTORzyx BLOCK TO PUSH BUTTON CONTROL PY183 Fig I 2 Heater Evaporator Assembly Front View 2 Disconnect battery negative cable 3 Drain cooling system and ...

Page 1033: ...ear actuator and by pass door actuator core tubes Fig 14 Evaporator Core Removal HEATER CORE MOUNTING HOUSING SEAL XREW LOCATION 1 d 7 PY188 Fig 16 Housing Seal Partially Removed covers together and one screw from between eva porator core tubes Fig 13 Separate housings 5 Remove three screws from evaporator core access plate remove plate this will provide access to two evaporator core mounting scre...

Page 1034: ...ation 1 Position housing up under instrument panel EVAPORATOR CORE PY190 Fig 18 Evaporafor and Heater Core Installed 2 Loosely connect housing to plenum support bracket 3 From engine compartment install four retain ing nuts on housing mounting studs tighten to 24 inch pounds then tighten the plenum support bracket securely 4 Connect vacuum harness to back of control switch Place the water valve co...

Page 1035: ...SING TUBE EQUALIZER TUBE CAPILLARY SENSING TUBE 318 AND 340 CUBIC INCH ENGINES HEATER HOSES SUCTION LINE HOSES WATERVALVE 1 198 AND zyxwvutsr 225 CUBIC INCH ENGINES SAME AS 318 AND 440 EXCEPT ACSHOWN VIEW IN DIRECTION OF ARROW A A L L ENGINES PY161 Fig 19 Air Condifioning and Heater Plumbing MyMopar com ...

Page 1036: ...e to maintain a selected interior temperature The third option is a dual installation consisting of the combination front unit and a rear unit The rear unit evaporator assembly is mounted in the Page Heater Core Removal and Installation 80 Inspection and Test Procedures 2 4 Linkage Adjustment 80 77 Vacuum Controls and Circuits 7 5 Operation of all Controls luggage compartment This deluxe installat...

Page 1037: ...4 AIR CONDITIONING I BLOWER MOTOR RESISTOR BLOCK INLET AIR DOORzyxw HOUSING ASSEMBLY TIME DELAY RELAY NU ENGINE SIDE HOUSING Fig 1 Air Conditioner Heater Assembly Plymouth Chrysler and Imperial MyMopar com ...

Page 1038: ...that can be shut off or rotated to direct air up or down adjustable vanes direct air to either side Fig 2 The air outlets at each end of the instrument panel are also adjustable or can be shut off by a knob controled damper with the exception of the Plymouth it has the vane shut off feature VACUUM CONTROLS AND CIRCUITS When testing or adjusting the doors in the dis tribution system it is necessary...

Page 1039: ...CULATING VACUUM AIR COND OFF MAX A C SOLID LINE INDICATES ENGINEVACUUM SOLID LINE INDICATES ENGINEVACUUM ACTUATOR t R E C I R C U L A T I N G AIR COND A C REGULATORzyxwvutsrq 1 HEAT PUSH BUTTON CONTROL VACUUM SWITCH PB66 DEFROST Fig 3 Vacuum Circuits Air Conditioning and Heating Plymouth Chrysler and Imperial MyMopar com ...

Page 1040: ... COMPRESSOR CLUTCH n 18DBL zyxwvutsrqp 2 63 16BR 16LGN BLOWER MOTOR RESISTOR 14DGN BLOWER MOTOR 14DGN zyxwvutsr 0 PRESSURE SWITCH P 18DBL LTIME DELAY RELAY FRONT AIR CONDITIONING RIGHT BLOWER MOTOR LEFT BLOWER MOTOR I 14DGN I LEGEND I FEMALE INSULATORS VIEWED FROM TERMINAL SIDE NU117A Fig 4 Electrical Control Circuits Plymouth and Chrysler PUSH BUTTON CONTROL CHART Button Off Max AIC AIC Heat Defr...

Page 1041: ...ct for mechanical misalignment binding or improper linkage adjustment Vacuum Actuated Water Valve The water temperature control valve is operated by engine vacuum which is modulated by a regu lator on the back of the temperature control lever Fig 5 When the control lever is in the off position 0 to 1 inch of vacuum will be present at the water valve and no water will flow through the heater core W...

Page 1042: ... restriction in the vacuum hose leading to the heater door actuator This restrictor provides some delay in the opening of the defroster door after the HEAT or DEFROST button is depressed This delay gives the blower time to expel condensation from the evaporator housing through the heater outlets be fore it can be blown onto the windshield Should it become necessary to replace the vacu um hose lead...

Page 1043: ...Remove glove box and remove center spot cooler air distribution housing and right spot cooler duct FRONT COVER NU383 Fig 13 Evaporator Removed From Front Cover 5 From glove box opening disconnect wires at resistor block and vacuum hoses from recirculating housing actuator 6 Unplug antenna wire from radio and place wire out of the way 7 From engine compartment remove seven re taining nuts surroundi...

Page 1044: ...connections and drains 5 Disconnect the suction and discharge lines Cap all refrigerant lines to prevent dirt and mois ture from entering the system 6 Remove the mounting bracket to flange bolts six and remove the evaporator assembly from the luggage compartment Fig 17 Installation 1 Position the evaporator assembly in the lug gage compartment and install the mounting brack et to flange bolts The ...

Page 1045: ...R E S S U R E VALVE CUT OFF SWITCH I I zyxwvutsrqpo c w VIEW IN DIRECTION OF ARROW NU2166 fig I S Air Conditioning and Heater Plumbing 225 Cu In Engine Plymouth ROOF UNIT VIEW IN DIRECTION OF ARROW B VIEW IN DIRECTION OF PY163 Fig 16 Roof Unit Air Conditioning Plumbing Station Wagon Only Plymouth and Chrysler MyMopar com ...

Page 1046: ... ambient temperature and control setting in varying degrees of either heating or cooling without any action on the part of the op erator other than dialing a desired comfort setting and setting the system on Lo Auto Hi Auto Page Service Diagnosis 90 Service Procedures and Component Tests 96 System Test Procedure 96 Tester Connections 96 Vacuum Circuits 106 Wiring Diagram 101 or Def The basic air c...

Page 1047: ...24 86 AIR CONDITIONING I ENGINE SIDE HOUSING Fig I Auto Temp II Housing Assemblies PB140 MyMopar com ...

Page 1048: ...slots with normal defrost bleed or the air conditioning outlets as required by the system There are five blower speeds available on the air conditioning mode of operation and four available on the heat mode the maximum blower speed on air condi tioning is higher than the maximum blower speed on heat Hi Auto Same as Lo Auto except the blower will operate at the higher blower speeds only There are t...

Page 1049: ...pen sate for any variation from the selected comfort setting Fig 3 Ambient Sensor The ambient sensor is located in the plenum panel behind the glove box Fig 3 This sensor senses the outside temperature and sends an elec trical signal to the amplifier Temperature Control Dial Thumbwheel This control is located above the push buttons in the control head It allows the operator to select any interior ...

Page 1050: ...ted on the servo assembly This switch prevents the blow er motor from starting when heat is required un til the engine coolant temperature is above 125 degrees F and the Lo Auto or Hi Auto push buttons are engaged This is accomplished by pre AIR CONDITIONING 24 89 VACUUM HARNESS ETAlNlNG SCREW NUT 10 ELECTRICAL CONNECTIONS WATER VALVE Fig 6 Servo Assembly This component plus its gasket is a separa...

Page 1051: ...d replace if a Damper linkage binding from a Re adjust linkage b Vacuum not supplied to rod a Inspect wiring repair short or b Test wiring replace or in car sensor replace sensor temperature control dial potentiometer potentiometer if necessary necessary necessary improper adjustment side of mode actuator b Check vacuum line connection plugged or disconnected at actuator fitting Check for pinched ...

Page 1052: ...TS AIR COMING OUT OF AIR CONDITIONING OUTLETS WHEN SYSTEM IS IN THE POSITION DEFROST OR HI DEFROST MOST OF THE AIR COMING OUT OF DEFROSTERS WHEN SYSTEM SHOULD BE ON HEAT MODE Correction c Connect properly d Replace harness e Replace switch f Inspect all connections repair if possible replace if necessary 9 lnpect lines h Inspect lines i Replace a Connect properly b Check by connecting directly to ...

Page 1053: ...PEED c Defective engine thermostat c Replace a Defective servo assembly a Test servo assembly replace if b Aspirator not operating properly b Test aspirator and tube Repair pinched or disconnected tube or replace if necessary SYSTEM DOES NOT ACHIEVE A COMFORTABLE pinched or disconnected tube or replace if necessary CONDITION TEMPERATURE b Frayed or bare sections in SLOWLY DRIFTS UP AND sensor lead...

Page 1054: ...ace if necessary a Route properly b Instruct owner on proper a Resistor block faulty resistors shorted b Connections at resistor block b Connect loose or disconnected a Lower speeds not provided for Hi Auto unit a Repair or replace a Instruct owner on operation of a Cold engine lockout switch faulty b Blower master switch inoperative in closed position c Vacuum bleed plugged d Check valve 2 failed...

Page 1055: ...tch failed in cIosed position c Fresh air door not sealing properly d Check valve 2 reversed or failed closed a Fresh Recirculating door in recirculating air position vacuum hoses on Fresh Air door actuator reversed a Defective vacuum reservoir tank b Vacuum leak c Check valve 1 reversed or failed open a Defrost override circuit in amplifier b Hi Defrost feed from push button switch to amplifier n...

Page 1056: ...se c Defective compressor switch d Vacuum hose yellow to e Vacuum hose to compressor compressor switch off switch pinched SYSTEM COMES ON IN A C a No defect MODE DURING COLD WEATHER SYSTEM NOISE AFTER a No defect ENGINE IS SHUT DOWN c Replace push button switch d Check servo and replace if necessary a Visually inspect switch vacuum ports and electrical terminals are located left and right side of ...

Page 1057: ...the surest route to accurate diagnosis It is recommended 2 Connect tester in series with system harness that they be followed and performed in the order 3 Attach tester white lead to a good body in which they are presented However all steps ground are not necessary for all problems 4 Tee in tester vacuum hose at the green mas Auto Temp It Tester Before performing any tests the thumbwheel The Auto ...

Page 1058: ...not c Instruct owner on positioning of directed properly outlets and or on moving control dial slightly to attain his comfort level Aspirator not operating properly d Test aspirator and tube Repair pinched or disconnected tube or replace if necessary Loose electrical connection at a Inspect connections sensors amplifier or servo assembly Defective amplifier Defective Servo Assembly c Replace if ne...

Page 1059: ...e the surest route to accurate diagnosis It is recommended 2 Connect tester in series with system harness that they be followed and performed in the order 3 Attach tester white lead to a good body in which they are presented However all steps ground are not necessary for all problems 4 Tee in tester vacuum hose at the green mas Auto Temp I1 Tester Before performing any tests the thumbwheel The Aut...

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Page 1061: ...o air should be coming out of A C outlets 2 The air temperature should have remained essentially the same as in LO AUTO Hi Defrost following 3 Blower speed increases Push Hi Defrost button and observe the 1 Blower speeds reduce in steps 2 The air temperature at defroster outlets is 3 Blower speed increases in steps to M3 4 The mode knob on tester is no longer effec rising to maximum heat blower ti...

Page 1062: ...Hi 20 Open Closed Closed AIC 20 Open Closed Closed Hi HI AUTO Blower Volts AIC 20 Open Closed Closed Hi Heat 20 Open Closed Closed HI AJC 20 Open Closed Closed Hi Heat 20 Open Closed Closed HI Closed 100 Closed Open Bleed Lo 100 Closed Open Bleed Lo Closed Hi to M3 100 Open Closed Closed M3 100 Open Closed Closed M3 to M2 100 Closed Open Bleed M2 M2 to M3 100 Closed Open Bleed Heat 100 Closed Open...

Page 1063: ...uld be read for the various driving and stabi lized conditions The voltmeter switch must be in the Servo Amp position and the engine must be running at 1100 RPM Servo Amplifier Test Mode Switch Driving Stablized Position Voltage Voltage Park 3 5 to 4 5 v Park to AIC AIC AIC to Heat 3 5 to 4 5 v Heat Heat to Park 4 to 6 v Park 0v Park to Heat 3 5 to 4 5 v Heat 3 v to 4 v 3 5 to 4 5 v Heat to AIC 3 ...

Page 1064: ...OR THUMBWHEEL IN CAR POTENTIOMETER SENSOR 1 2 3 4 zyx 5 6 7 8 zyx 9 10 GROUND SENSOR PARK T2 SERVO DRIVE T1 MOTOR FEED MEDIUM HIGH DEFROST HIGH LOW T DASH LINE C4 14LGN zyx 1 5 IT I BLOWER MOTOR RESISTOR 2 DEFROST 3 SENSOR 4 GROUND 5 PARK 6 BATTERY 7 T2 SERVO DRIVE MOTOR 8 IGNITION MPLlFlER C18 16V C17A l6R PB167 fig IO Wiring Diagram MyMopar com ...

Page 1065: ...ragm with attached electrical contact is pulled away from the magnet and the electrical circuit is completed This switch can be checked by applying 8 t 1 inch Hg vacuum to it with an external vacuum source and checking for electrical continuity and by removing the vacuum source and checking to see that it opens at less than 5 inches Hg vacuum The resistance of this switch can be checked by measuri...

Page 1066: ...ary but a 25 to 30 pound pressure differential will show during switching action of the ETR switch ETR SOLENOID VALVE The ETR valve is a precision part with ex tremely small operating clearances The presence of foreign material between the two sleeves can cause the valve to stick It is therefore imperative that every effort be made to protect the valve from contaminents Replacement 1 Discharge sys...

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Page 1068: ...I AIR COWMTlOMWG 24105 MyMopar com ...

Page 1069: ...will not work in such weather but work at room am bient temperatures CAUTION zyxw Do not use a lubricant of any type to attempt to increase the efficiency of faulty check valves as serious damage will result to the entire vacuum system System Vacuum Leak Test 1 Tee in a 0 to 30 inch vacuum gauge at the master switch green color coded vacuum connection 2 With the Lo Auto button depressed place syst...

Page 1070: ...AIR CONDITIONING 24 107 TO ENGINE VACUUM FiTilNG ROTARY VACUUM SWITCH IN POWER SERVO ASSEMBLY AIR C0ND ACTUATOR HEATING FIG i5 Vacuum Hose Color Code COMPRESSOR SWITCH TRANSFER SWITCH PB248 MyMopar com ...

Page 1071: ...24 108 AIR CONDITIONING 8 s F f 0 u zy LrY I P x V 0 Z c v 2 8 U MyMopar com ...

Page 1072: ...I AIR CONDITIONING 24 109 MyMopar com ...

Page 1073: ...24 110 AIR CONDITIONING 8 I MyMopar com ...

Page 1074: ...AIR CONDITIONING MyMopar com ...

Page 1075: ...24 112 l l t cammcmm MyMopar com ...

Page 1076: ...I AIR 24 113 MyMopar com ...

Page 1077: ... are not fulfilled refer to the diagnosis chart for should be 120 degrees F or more the causes and proceed according to the standard 21 If the requirements of either step 16 or 20 procedures If the requirements are fulfilled the calibration check out is complete MyMopar com ...

Page 1078: ...S FLOATING CALIPER 5 41 Removing Caliper from Vehicle 5 49 Testing Application Adjusters 5 3 MASTER CYLINDER DRUM BRAKES 5 13 Page Brake Warning Switch 5 16 Cleaning and Inspection 5 14 Disassembling Master Cylinder 5 13 General Information 5 13 Installing Master Cylinder 5 15 Master Cylinder Removal 5 13 Reassembling Master Cylinder 5 15 Testing Master Cylinder 5 16 Bleeding Master Cylinder 5 59 ...

Page 1079: ...SSURE TESTING COOLING SYSTEM 7 9 PRESSURE TESTING RADIATOR CAP 7 9 RADIATOR 7 6 RADIATOR HOSES 7 9 Page RADIATOR PRESSURE CAP 7 9 REVERSE FLUSHING COOLING SYSTEM 7 7 SERVICE DIAGNOSIS 7 1 SPECIFICATIONS 7 13 TEMPERATURE OPERATED VACUUM BY PASS VALVE 7 9 TIGHTENING REFERENCE 7 20 THERMOSTAT 7 8 TRANSMISSION OIL COOLER 7 6 WATER PUMP 7 5 ELECTRICAL Page ALTERNATOR AND VOLTAGE REGULATOR 8 23 Assembli...

Page 1080: ...test 8 17 Field Coils Replacement 8 21 Free Running Test 8 17 Page STARTER REDUCT1ON GEAR 8 6 Ampere Draw Test 8 8 Assembling the Starter 8 13 Brushes and Springs Replacement 8 12 Bushings RepIacement 8 13 Cleaning the Starter 8 12 Field Coils Replacement 8 1 2 General Information 8 6 Ground Circuit Test 8 9 Disassembling the Starter 8 10 Insulated Circuit Test 8 8 IGNITION 8 CYLINDER 8 45 Ballast...

Page 1081: ...arings 9 45 Crankshaft Main Journals 9 45 Crank case Ventilation System 9 92 Cylinder Block 9 39 SIX CYLINDER ENGINES 9 5 EIGHT CYLfflDER ENGINES 318 340 360 CUBIC INCH 9 25 Camshaft Bearings 9 38 Cylinder Heads 9 29 Distributor Drive Shaft Bushing 9 38 Engine Assembly 9 28 Engine Mounts 9 27 Hydraulic Tappets 9 33 Installing Piston and Connecting Rod Assembly 9 44 Page Measuring Connecting Rod Be...

Page 1082: ...XHAUST HEADERS 426 HEMI ENGINE 11 21 EXHAUST MANIFOLD 318 340 360 CU EXHAUST MANIFOLD 383 AND 440 CU EXHAUST PIPES MUFFLERS AND TAIL INTAKE AND EXHAUST MANIFOLD 6 CYL ENGINES 11 18 INTAKE MANIFOLD 318 340 AND 360 IN ENGINES 11 19 IN ENGINES 11 19 PIPES 11 15 GENERAL INFORMATION 11 1 CU IN ENGINES 11 18 Page INTAKE MANIFOLD 383 AND 440 CU INTAKE MANIFOLD 426 HEMI ENGINE INTAKE MANIFOLD HEAT TUBES 4...

Page 1083: ...1 Cleaning Carburetor Parts 14 2 Disassembling Carbureta 14 21 Inspection and Reassembly J4 22 SpeCifiCatiom 14 137 m CARER THERMOQUAO 14 38 Autanan ChokeWell Type 14 1 Carburetor Adjustments 1444 Secondary Throttle Linkagep 1444 Secondary Air Valve Opening 1445 Secondary Air Valve Spring 1 1445 Accelerator Pump Stroke 1445 Choke Control Lever Adj Off or On Vehicle 144s Choke Diaphragm zyxw connec...

Page 1084: ...le Speed Cam Posithn 14 117 Fast Idle Speed On Vehicle 14 118 Idle Speed _ _ 14 119 Secondary T h W e Lever 14 118 Secondary Throttle Lockout 14 118 Cleaning Carburetor Parts 14 2 Disassembling Carburetor 14 112 General Information 14 111 Inspection and Reassembly 14 115 Specifications 14 1 37 FUEL PUMP 14 120 Fuel Vapor Separatar 14 123 General Information 14 120 Service Diagnosis 14 121 Specific...

Page 1085: ... 24 85 General Information 24 85 Major Components 24 88 Operating Controls 24 85 Performance Tests 24 112 Push Button Control Chart 24 99 Service Diagnosis 24 90 Service Procedures and Component Tests 24 96 System Test Procedure 24 96 Tester Connections 24 96 Vacuum Circuits 24 106 Wiring Diagram 24 101 HEATERS 24 1 General Information 24 1 Service Diagnosis All Models 24 1 Service Procedure 24 2 ...

Page 1086: ...DEX Page REAR AXLE ALIGNMENT CHECKING PROCEDURE 3 5 REAR AXLE ASSEMBLY 8 1 4 IN RING GEAR 3 15 Axle Shaft and Bearings 3 17 Differential 3 19 Differential Case 3 20 Differential Bearing Preload And Drive Gear And Pinion Backlash 3 25 Drive Pinion Depth Of Mesh 3 23 Gear Tooth Contact Pattern 3 26 Lubrication 3 28 Pinion Bearing Cup Installation 3 23 Rear Axle Assembly 3 19 Removal And Replacement ...

Page 1087: ...eal 19 7 General Information 19 1 Gear Installation 19 3 Gear Reconditioning 194 Gear Removal 19 3 Service Diagnosis 19 1 Specifications 19 60 Tightening Reference 19 62 POWER STEERING GEAR 19 8 General Information 19 8 Service Diagnosis 19 1 0 Service in Vehicle 19 1 2 Cross Shaft Adjustment 19 1 2 Cross Shaft Oil Seal Replace 19 1 3 Valve Body Recondition 19 1 2 Service Out of Vehicle 19 1 5 Gea...

Page 1088: ...16 Removal Transmission and Converter Speedometer Pinion Gear 21 15 Pump Oil Seal Service Out of Vehicle 21 3 Starter Ring Gear Assembling Transmission 21 9 Torque Converter Flushing Cleaning and Inspection 21 6 Service Diagnosis Disassembling Transmission 21 3 Service In Vehicle Extension Housing Bushing Replacement21 1 2 Air Pressure Tests Transmission Installation 21 13 Aluminum Thread Repair S...

Page 1089: ...T10N 22 1 SERVICE PROCEDURES 22 2 SPECIFlCAT1ONS 22 9 TIGHTENING REFERENCE 22 11 TIRES 22 2 22 2 BEARINGS FRONT WHEEL 22 7 Care of Tires Cleaning Page Collapsible Spare Tire Inflation of Tires Radial Ply Tires Rotation of Tires Repairing Tire Leaks Tire Noise Complaints Tire Wear Patterns Tire Tread Wear Indicators Wide Tread 70 Series Tires WHEELS Tire Wheel Balance Tire and Wheel Runout Wheel Co...

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Chrysler CHRYSLER 300 1971, Chassis Service Manual

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Summary of Contents for CHRYSLER 300 1971

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