Chrysler CHRYSLER New Yorker 1972 Chassis Service Manual Download Page 638

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Summary of Contents for CHRYSLER New Yorker 1972

Page 3: ...al for the subject can be found at the beginning of the particular section Example M T S C 71 3 may be called out in the beginning of the subject matter This refers to the year 1971 and the session is...

Page 4: ...ic inch engines have the serial numbers stamped on the cylinder bore 440 cubic inch engines have the serial numbers stamped on the left bank pad adjacent to front tappet rail On all engines informatio...

Page 5: ...P 0 m c E I 5 n 0 L a 0 u C 0 zC 0 m zy c i z MyMopar com...

Page 6: ...12 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 15 15 112 16 16 112 16 314 17 17 112 18 18 112 19 19 112 20 20 112 21 21 112 22 22 112 23 23 112 24 24 112 25 25 112...

Page 7: ...n any particular relation to the hexagon The manu facturer s trade mark shall be legible in the center of the bolt head and not over of the cross flats dimen sion HEAD MARKINGS GRADE3 I GRADE5 I GRADE...

Page 8: ...g conditions Since these conditions vary with the individual car owner s driving habits the area in which the car is Page HEADLIGHTS 9 HOISTING 5 HYDRAULIC BRAKE SYSTEM 25 LUBRICATION AND MAINTENANCE...

Page 9: ...ion Both the SAE grade and the API designation must be found on the container Gear 1ubricants The SAE grade number also indicates the viscosity of Multi Purpose Gear Lubricants The API classification...

Page 10: ...ICATION AND MAINTENANCE SCHEDULE SERVICE Every 12 Months PointsthatShould Not Be Lubricated I I I Vehicles equipped with Fresh Air Induction System Replace lining if necessary After First 24 000 Miles...

Page 11: ...5 gals 340 4 qts 15qts AlC x 16 3 pts 4 75 pts 7 5 pts 4 4 pts 4 4 pts 4 4 pts 16 5gals MIC xxx SATELLITE 225 4qts 13qts xx 17 pts 6 5 pts 2 pts 2 pts 21 gals 340 4 qts 15qts AlC Auto Trans x 16 3 pt...

Page 12: ...gearshift or selector lever is in neutral and the distance to be traveled does not exceed 15 miles or the towing speed does not exceed 30 mph If the transmission is not operative or the car is to be...

Page 13: ...0 6 LUBRICATION AND MAINTENANCE I z a 4 u V J T 7 x MyMopar com...

Page 14: ...ant level at approximately l 1 4inches below the bottom of the filler neck Overfilling will cause loss through the overflow tube Once a year preferably in the fall the cooling sys tem should be draine...

Page 15: ...against corrosion and boiling A convenient ratio of 50 ethylene glycol type anti freeze and 50 water will provide protection to 34 degrees F TOWING SLING PD257 Fig 8 Rear Towing Pickup Barracuda Satel...

Page 16: ...nd if necessary re aimed properly every six months Changes in front and rear suspension such as front suspension height and or deflection of rear springs due to heavy loading will change the head ligh...

Page 17: ...n and carbon deposits in addition to dust and other abrasive materials tend to con taminate engine oil If permitted to remain in the crankcase for too great a period of time the con taminants reduce t...

Page 18: ...each stop for gasoline Oil should be added only when level on oil level indicator is at or below ADD OIL mark Frequently a new engine will consume some oil during its first few thousand miles of oper...

Page 19: ...GAS RECIRCULATION FLOOR J ING FUEL AIR MlXT INTAKE MANIFOLD PD133 Fig 20 Exhaust Gas Recirculation Floor Jet MANIFOLD HEAT CONTROL VALVE Freedom of movement of the heat control valve by removing lead...

Page 20: ...r Remove cleaner from carburetor and remove filter element from cleaner Examine filter element If the filter element is sat urated with oil for more than one half its circumference replace the element...

Page 21: ...retor and intake manifold Also apply same type of cleaner to fast idle cam and pivot pin to remove dirt oil and any other de posits that may have collected and cause sticking or erratic motion This se...

Page 22: ...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 VENTILATION SYSTEM OPERATION The ventilating syst...

Page 23: ...arburetor turn a 1 4 inch drilI by hand through the passages to dislodge the solid NOT ATTEMPT TO CLEAN THEVENTILA particles then blow clean If necessary use a small er drill so that no metal is remov...

Page 24: ...VALVE See Crankcase Ventilation System Group 0 Carburetor Air Filter Paper Element Clean filter element after 12 months replace every two years Clean or replace more often when car is driven in dusty...

Page 25: ...e recommended CAUTION When filling do not use a pressure gun as high pressure may damage the seals I 3 Fig 35 Power Steering Pump Reservoir 1 06 Pump Power Steering At every engine crankcase oil chang...

Page 26: ...ivalent Frequency of 1ubricaiion 1 Normal Service Lubricate every three years or 36 000 miles whi chever occurs first Fig 38 Upper and lower Ball Joint lubrication Satellite and Barracuda Models Fig 4...

Page 27: ...de surface of the seal to permit complete inspection 2 Remove the threaded plug from each ball joint and install standard grease fittings these fittings can remain for future regularly scheduled lubri...

Page 28: ...bricant Part Number 2933565 or its equivalent is used This lubricant recom mended for conventional differentials too contains special additives necessary to provide proper differ ential durability and...

Page 29: ...ould be checked every six months The correct level is at the bottom of the filler plug hole Fig 49 If lubricant is below this specified level replenish with automatic transmis sion fluid of the type l...

Page 30: ...should be made when engine temperature gauge indicates a normal warmed up condition and transmission fluid is heated to its Fig 52 Transmission Level Indicator Markings normal operating temperature C...

Page 31: ...thoroughly clean all parts in a suitable solvent and inspect for wear Damaged bearings and or ball studs should BEARING INSIDE SURFACE RELEASE FORK PIVOT AREA NH172C Fig 54 Clutch Torque Shaft Bearin...

Page 32: ...ar equipped entirely with drum brakes low fluid level may have been caused by Fig 56 Hand Operated Parking Brake Lubrication PARKING BRAKE FRONT CABLE ASSEM hY PY366 Fig 58 Foot Operated Parking Brake...

Page 33: ...t Number 1064768 or equivalent is recommended for this purpose When the hand lever can be pulled out more than four inches or the foot pedal depressed more than four and one half inches the brake cabl...

Page 34: ...be inspected when RELEASE LEVER Fig 66 Front Wheel Bearing Adjustment ever the wheels are removed to inspect or service the brake system Brake system inspection is recom mended every 12 months or 12 0...

Page 35: ...Depress release lever on center bridge and re move blade from arm Fig 67 4 Depress release on end bridge either button or lever with screwdriver to release from center bridge 5 Withdraw rubber wiping...

Page 36: ...ARTS REQUIRING NO LUBRICATION There are many points that should not be lubricated some because they are permanently lubricated some because lubricants will be detri mental to their operating character...

Page 37: ...lloon 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 Up Page TIGHTENING REFERENCE 21 TOR...

Page 38: ...Inflate tires to correct pressure b Adjust wheel bearing c Adjust steering cross shaft d Adjust steering gear e Replace bushing f Replace bushings 9 Replace spring h Measure and adjust front wheel al...

Page 39: ...nterrelated suspension angles affecting the running and steering of the front wheels of the vehicle The importance of wheel alignment and wheel balancing is considered essential in order to maintain e...

Page 40: ...ber causes wear to the outside Toe in is measured in inches and is the distance the leading edges of the tires are closer than the trailing edges Toe in is considered the most serious cause for excess...

Page 41: ...ension height from side to side is 1 8 inch on all Models Camber and Caster 1 Prepare vehicle for measuring wheel alignment 2 Remove all foreign material from exposed Fig 3 Measuring Fronf Suspension...

Page 42: ...rsion bar adjusting bolt and swivel and replace if there is any sign of corrosion or oth er damage Lubricate for easy operation Installation 1 Insert torsion bar through rear anchor 2 Slide balloon se...

Page 43: ...t 200 inch pounds 9 Adiust front wheel alignment as necessary ALL IMPERIAL MODELS ARE EQUIPPED WITH FRONT WHEEL DISC BRAKES FOR BRAKE DISC AND CALIPER REMOVAL AND INSTALLATION SEE BRAKES GROUP 5 FOR C...

Page 44: ...embly end at the throat opening If the parts have not lost all the lubricant and are not contaminated worn or rusted use new seals and reinstall otherwise a new complete tie rod end assembly should be...

Page 45: ...r link Tighten nuts 40 foot pounds and install cotter pins CROSSMEMBER PY84 Fig 13 Sway Bar Assembly Barracuda Satellite NUT c RETAINER INSULATOR SWAY BAK BUSHING Z Z NR TTAINER BRACKET SCREW AND WASH...

Page 46: ...y from vehicle The sway bar bushings are not serv iced separately If replacement is necessary in stall a new sway bar assembly Remove lower cencave retainer 3 Remove sway bar link insulating bushings...

Page 47: ...1 STRUT KNUCKLE ARM Fig 17 10wer Control Arm barracuda Sate1l te IFRT C MEMBER NUT z i zyxwvu 6 WASHER SPRING PIN SLEEVE RETAINER NP89B B O L T NUT A R M 9 BALL Fig 19 lower Control Arm Imperial NN47...

Page 48: ...with a twisting motion Water may be used as a lubricant to aid in installation 1 Place strut bushing inner retainer on strut and DRIFT Fig 23 Removing Pivot Shoff install lower control arm shaft and...

Page 49: ...using Tool C 4034 install seal To facilitate in stallation of seal the ball joint stud should be perpendicular to ball joint body Lubricate ball joint see Lubrication section Group 0 Installation Impe...

Page 50: ...lower ball joints steering arm assemblies on all models except Imperial should not be replaced for looseness if the axial end play Up and Down movement is under 070 inch looseness of this nature is n...

Page 51: ...d Connect tie rod end to steering knuckle ing bolt clockwise 7 Install wheel tire and drum assembly and ad just front wheel bearing Group 22 8 Lower vehicle to floor and install upper con trol arm reb...

Page 52: ...31 Removing Or Installing Upper Ball Joint up and away from support Disassembty 7 Remove ball joint Fig 31 using Tool 2 3560 Tool C 3714 Valiant The seal will come off as ball joint is removed 8 Asse...

Page 53: ...r vehicle to floor 5 Adjust suspension height and wheel alignment as necessary Rem0Val Imperial 1 Place a jack under lower control arm as close to wheel as possible and raise vehicle until front wheel...

Page 54: ...pper control arm Fig 31 The seal will come off as ball joint is being removed lnsiollation When installing a ball joint make certain the ball joint threads engage those of the control arm squarely if...

Page 55: ...sembly by four bushing 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 re...

Page 56: ...Bars Length Inches Diameter Inches 6 Cyl Std With A C 318 C I Engine With A C 340 C I Engine 400C I Engine 2V 400 C I Engine 4V With A C Police 440 C I Engines 440 C I Engine With A C Heavy Duty Suspe...

Page 57: ...olator to Cross Member Isolator to Frame Rear Isolator Bracket Sleeve Ass y to Frame Isolator Assembly Nut Front Sway Bar Link Nut Sway Bar to Frame Sway Bar to Strut Sway Bar Plate to Cross Member Id...

Page 58: ...heel nuts Check rear wheel bearings If spalled or worn replace Defective or brinelled bearings must be replaced Check rear axle shaft end play Readjust axle shaft end play Replace bent or sprung axle...

Page 59: ...icant See procedure in Sure Grip section of Group 3 removing filler plug and allow lubricant to level at lower edge of filler plug hole b Replace worn oil seals with new ones Prepare new seals before...

Page 60: ...nditions Repeat while en gaging and disengaging clutch transmission in neutral to determine if noise can only be isolated by removing propeller shaft and operating transmis sion in high TIRE NOISE Tir...

Page 61: ...pinion bearing noise is usually most pronounced on coast whereby rear pinion bearing is loudest on drive Pinion bear ings are rotating at a higher rate of speed than the differential side bearings or...

Page 62: ...alignment to determine if a complaint of abnormal rear tire wear is the result of a bent rear axle housing 1 Raise both rear wheels off ground using a frame contact hoist 2 Place a one inch long piece...

Page 63: ...ose used in the 8 3 4 in axle Refer to the Sure Grip Differential Section of the Axle Group for the Servicing procedure A hooded breather is attached to the left leg of the axle housing approximately...

Page 64: ...rotective sleeve SP 5142 over bear ing race 5 Remove axle shaft oil seal from housing NK391A Fig 4 Removing Axle Shaft Bearing NY1023 TOOL Fig 6 Installing Axle Shaft Oil Seal Assembly and Installatio...

Page 65: ...g Companion Flange NY1037 Fig 70 Bearing Cap ldenfificafion DIFFERENTIAL Removal and Disassembly Side play and runout checks taken during disas sembly will be very useful in reassembly 1 Remove drain...

Page 66: ...ial and ring gear assembly from axle housing A light prying action must be used to unseat the differential assembly from the housing Fig 12 Differential bearing cups and preload adjusting spacers must...

Page 67: ...er cages must not be distorted or cracked 7 Differential side gears and pinions should have Fig 15 Installing Differential Bearing Cone smooth teeth with a uniform contact pattern with out excessive w...

Page 68: ...lling drive pinion bearing cups loosen tool nut and re tighten to produce 15 25 inch pounds of turning torque Attach gauge block to main tool us ing allen screw 2 Position cross bore arbor in axle hou...

Page 69: ...Gauges Measuring Thickness Belleville washer convex side up and pinion nut Hold companion flange with holding Tool C 3281 Maintain feel of diminishing end play while ro tating nut When no end play can...

Page 70: ...hten tool screw only finger tight at this time 9 Install pilot stud Tool C 3288 on left side of axle housing Attach dial indicator and load indica tor stem slightly against opposite side of axle hous...

Page 71: ...PACER NEEDED HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE1 NRX1 Fig 27 Incorrect Tooth Contoct Pattern Decrease Spacer Thickness teeth Rotate drive gear one complete revolution in both direc...

Page 72: ...inch pound torque wrench C 685 A measure pinion bearing preload by rotating pinion with handle of wrench floating read torque while wrench is moving through several complete revolu tions and record Th...

Page 73: ...FAILURE RESULTING FROM CON REAR AXLE ASSEMBLY 8 1 4 IN RING GEAR Page Axle Shaft and Bearings 17 Differential 19 Differential Case 21 Differential Bearing Preload And Drive Gear And Pinion Backlash 2...

Page 74: ...position by the axle shaft seal The axle shaft slides into position through the seal and bearing Both the seal and bearing rollers ride directly on a common ground journal surface on the axle shaft Th...

Page 75: ...CAUTION Inspect housing bearing shoulder for burrs and remove any if present otherwise bear ing could be cocked during installation Fig 4 Removal or Installation of Axle Shaft C Washer Locks SEAL NU9...

Page 76: ...at wheel cyl inders and cap fittings to prevent loss of brake fluid 5 Disconnect parking brake cables To maintain proper drive line balance when reassembling make scribe marks on the propeller shaft u...

Page 77: ...for case runout will be described later 8 Using an inch pound torque wrench measure pinion bearing preload and record Remove drive pinion nut and washer Using Tool C 452 and hold ing Tool C 3281 remov...

Page 78: ...with the exception of bearings dry with compressed air To clean axle housing tubes insert a stiff wire into tube attach a clean cloth to wire at center section and withdraw from center outward 2 All...

Page 79: ...th lu bricant as specified in lubrication Group O 1 Install thrust washers on differential side gears and position gears in counterbores of differential case 2 Position thrust washers on both differen...

Page 80: ...pan ion 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 installing cups Pinion dept...

Page 81: ...d install the pinion front bearing cone on the pinion from the front of the casting Install companion flange using Tool C 3718 and holding Tool C 3281 This is necessary in order to properly install fr...

Page 82: ...E DESIRED PRELOAD IS EXCEEDED A NEW COLLAPSIBLE SPACER MUST BE INSTALLED AND NUT RETIGHTENED UNTIL PROPER PRELOAD IS OBTAINED NU990 Fig 24 Measuring Drive Pinion Bearing Preload TOOL NU992 Fig 26 Meas...

Page 83: ...te lead on both the drive and coast side of the drive gear teeth Ro tate drive gear one complete revolution in both di HEEL END DRIVE SIDE CONVEX HEEL ENDTOAST SIDE CONCAVE NR1w Fig 28 Incorrect Tooth...

Page 84: ...1 Raise vehicle on hoist and make scribe marks on propeller shaft shaft universal joint drive pinion flange and end of pinion stem 2 Disconnect propeller shaft at pinion flange and secure in an uprig...

Page 85: ...r Installation 43 Differential Case 34 Drive Gear and Pinion Backlash 41 Gear Tooth Contact Pattern 4 2 Lubrication 43 Pinion Bearing Cup Installation 37 GENERAL INFORMATION CAUTION Anytime rear axle...

Page 86: ...he bearing cavity and to seal the bearing grease from leaking out and in general will not seal the axle oil from leaking when the inner seal has failed Therefore it is not necessary to replace this se...

Page 87: ...y be required to axle shaft flange and remove axle shaft Remove brake assem bly and gaskets 4 Remove axle shaft oil seal from axle housing using Tool C 637 Fig 4 5 Wipe axle housing seal bore clean an...

Page 88: ...ove Fig 10 5 Remove roller bearing cup and protective sleeve SP 5041 from axle shaft CAUTION Sleeve SP 5041 should not be used as a protector for the seal journal when pressing off the bearing cone as...

Page 89: ...ial indicator mounted on the left brake support Fig 14 TURN THE ADJUSTER CLOCKWISE UNTIL BOTH WHEEL BEARINGS ARE SEATED AND THERE IS ZERO END PLAY IN THE AXLE SHAFTS BACK OFF THE ADJUSTER COUN TERCLOC...

Page 90: ...universal joint 3 Remove the rear axle lubricant 4 Loosen and remove the carrier to housing atta ching nuts and lift the carrier assembly from axle housing Disassembly Side play and runout check taken...

Page 91: ...g cups must be kept with respective bearing cones 11 Remove drive pinion and rear bearing assem bly from carrier THRUST WASHER I SHAFT KP7A Fig 19 Checking Drive Gear Mounting Flange Runout Rear Pinio...

Page 92: ...Remove both differential side gears and thrust washers Cleaning and Inspection Figs 20 and 21 1 Clean all parts in a fast evaporating mineral Fig 22 Removing Differential Bearings spirits or a dry cl...

Page 93: ...lines If replacement is necessary replace both the drive pinion and drive gear as they are available in matched sets only 12 Inspect companion flange for cracks worn splines pitted rough or corroded o...

Page 94: ...Housing PINION BEARING CUP INSTALLATION 1 Position pinion bearing cups squarely in bores of carrier Assemble Tool C 758 D5 Fig 24 by placing spacer SP 2919 followed by rear pinion bearing cone over m...

Page 95: ...bearing Bearing preload should be uniform during complete revolution A reading that varies considerably during rotation of pinion indicates a binding condition which requires correction Use a thinner...

Page 96: ...ll parts in fast evaporating mineral spirits or a dry cleaning solvent and with the exception of bearing cones dry with compressed air Front Pinion Bear ing Cone and Cup Must Never Be Reused Under Any...

Page 97: ...and measure pinion bearing preload by rotating pinion using an inch pound torque wrench The correct preload specifications are 20 35 inch pounds for new bearings or 10 inch pounds over the original if...

Page 98: ...cation marks on caps correspond with those on carrier Install cap bolts and tighten bolts of each cap by hand 3 Install differential bearing adjusters on respec tive sides making certain that identifi...

Page 99: ...ith a round bar or screwdriver between the carrier casting and differential case flange This action will leave a dis v HEEL END DRIVE HEEL E N D O A S T SIDE CONVEX SIDE CONCAVE NRIPP Fig 33 Incorrect...

Page 100: ...to assure that the proper bearing preload is maintained in the axle assembly If this procedure is not followed it could result in a premature failure of the axle 1 Raise vehicle on hoist and make scr...

Page 101: ...ear 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 differential in...

Page 102: ...arrier casting NLGI grade 2 E P or equivalent Oil seals are Drive pinion bearing preload is maintained by us pressed into the outer ends of the housing tubes to ing different thicknesses of shim packs...

Page 103: ...ar wheels free to turn at ap proximately 40 MPH for ten 10 minutes This thoroughly circulates the lubricant and brings it to operating temperature 5 Stop vehicle and remove drain plug and drain as muc...

Page 104: ...ions the seal the proper dimen sion from the axle shaft bearing shoulder in the axle housing in order that seal will definitely contact the machined sealing surface of the axle shaft Disassembly CAUTI...

Page 105: ...ig 11 Removing 361 Bearing Cone with Tool C 3971 n Fig 13 Measuring Axle Shaft End Play 4 Inspect axle shaft seal journal for scratches and polish with No 600 crocus cloth if necessary Installation 1...

Page 106: ...ar wheels PB286 Fig 15 Bearing Cap Identification 4 Disconnect hydraulic brake lines at wheel cyl inders and cap fittings to prevent loss of brake fluid 5 Disconnect parking brake cables To maintain p...

Page 107: ...R CASTING 1 1 Remove dial indicator and remove differential case and ring gear assembly from axle housing A light prying action with a screwdriver or pinch bar will loosen assembly for easy removal Pr...

Page 108: ...aws of a vise and alternately tighten each cap screw to 100 120 foot pounds 4 Position each differential bearing cone on hub I Fig 20 Determining Shims To Obtain 0 End Clearance of differential case w...

Page 109: ...n the pinion The or figure indicates the varia tion from the nominal distance between the front of the pinion and the center line of the carrier For example if a pinion marked 2 was originally in stal...

Page 110: ...sition can be assumed to be correct If the setting is outside these limits it should be corrected by adding or removing the proper thickness shim behind the rear pinion bear ing cup 12 Remove the driv...

Page 111: ...nction with tool Fig 22 15 Install drive pinion and bearing assembly in carrier and install the original front pinion bearing NN1030 Fig 28 Checking Pinion Bearing Preload shim pack followed by the be...

Page 112: ...4 Remove differential bearing cones Install the correct thickness shim pack as determined in step 2 between bearing cone and differential case hub shoulder using Tool C 4025 Add an additional 015 inch...

Page 113: ...to be rather small Under the ac tual operating load however the contact area increases 3 If after observing the contact pattern you find Fig 33 Incorrect Tooth Contact Pattern Decrease Shim Pack Thick...

Page 114: ...re Grip Differential Noise 5 8 GENERAL INFORMATION CAUTION Anytime rear axle servicing is necessary or axle is being rotated through use of the engine or other means ELEVATE BOTH REAR WHEELS The Sure...

Page 115: ...ear wheels cle is equipped with a Sure Grip Differential An During torque application to the axle the initial other means of identification is by removing the fil spring loading of the cones is supple...

Page 116: ...ly turn either wheel the differential is not per forming properly and should be removed and replaced The Sure Grip Differential and internal parts are serviced as a complete assembly only Under no cir...

Page 117: ...Before lowering the rear wheels of the vehicle adjust brakes LUBRICATION Every six months check the fluid level in the axle through the filler plug hole When checking the level be sure the vehicle is...

Page 118: ...L BEARINGS LUBRICATION Capacity 4 4 PTS 3 1 2 Imperial Type 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...

Page 119: ...ct Shims Pinion and Ring Gear Backlash 004 009 at point of minimum backlash Runout differential case and ring gear backface 006 maximum Type Taper Roller Adjustment Threaded Adjusting Nut End Play 008...

Page 120: ...ng Bolt Nuts Axle Shaft Retainer Nuts PropellerShaft Bolts Rear Spring Clip U Bolt Nuts Wheel Stud Nuts Shock Absorber Stud Nuts Lower Differential BearingCap Bolts Differential Case Half Retaining Bo...

Page 121: ...ake lever is fully released then back off parking brake cable adjustment so there is slack in cable 4 Insert adjusting tool C 3784 into star wheel of adjusting screw Move handle of tool upward until a...

Page 122: ...ing with the right rear wheel clean all dirt from the bleeder valve Place bleeder hose C 4029 on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean...

Page 123: ...tools and to avoid routing the tubes against sharp edges moving components or in hot areas All tubes should be properly attached with recommended re taining clips Steel tubing is used to conduct hydr...

Page 124: ...n tubing 10 Remove tubing from flaring tool and inspect seat 11 Clean seat and tube of any lubricant before connecting to hydraulic system SCREW AND WASHER ASSEMBLY TORQUE TO 95 INCH POUNDS DO NOT PUL...

Page 125: ...essively worn brake lining Air in hydraulic system Improper brake fluid low boiling point Excessively worn or cracked brake drums Broken pedal pivot bushing Contaminated lining Front end out of alignm...

Page 126: ...80 to 40 MPH a Bent or out of round rear brake drum a Bent or out of round front brake drum SHOE KNOCK a Machine grooves in contact a Cam grind or replace brake b Replace saturated lining c Replace r...

Page 127: ...f the various serv ice procedures will not always show any one specif ic brake BRAKE DRUM REMOVAL Removing Front Brake Drums adjusting wheel To aid in brake drum removal loosen brake star 1 Remove rea...

Page 128: ...en Inch Brake Assemblies OVE LOAD SPRING LEFT REAR PBSUI ANCHOR PLATE SECONDARY PFTl I R N CABLE L K GUIDE SHOE RETAINERS AND SPRING NAIL ASSEMBLIES SHOE RETAINERS BRAKE LEVER LEVER SPRING OVE LOAD SP...

Page 129: ...y from notches of adjusting screw 3 Insert Tool C 3784 into brake adjusting hole and engage notches of brake adjusting screw Re lease brake by prying down with adjusting tool 4 Remove rear wheel and c...

Page 130: ...ring by slid ing forward to clear pivot then working out from under spring Remove spring from pivot Remove automatic adjuster spring from secondary shoe web and disengage from primary shoe web Remove...

Page 131: ...ary and secondary shoes with a star wheel PRIMARY AND 1 IARY SHOE i ADJUSTING WHEEL Fig I1 Installing Brake Shoes Left Front next to secondary shoe Fig 1 The left star wheel adjusting stud end is stam...

Page 132: ...using Tool C 3785 Be sure cable guide remains flat against shoe web and that sec ondary spring overlaps primary Fig 1 Using pliers squeeze ends of spring loops around anchor until parallel Fig 13 Inst...

Page 133: ...CYLINDER To disassemble the master cycinder Fig 1 clean outside of master cylinder thoroughly 1 Press bail to one side remove cover and gasket Empty brake fluid from reservoirs 2 Remove secondary pis...

Page 134: ...o GASKET RETAINER PISTON b MASTER CYLINDER BODY i E R Y C m 1 iECONDARY CUP PRIMARY CUP SECONDARY SYSTEM COMPONENTS REAR BRAKES 0 RING SEAL PISTON RETURN CUP RETAINER SPR NG I PRIMARY C U P THIN WASHE...

Page 135: ...iston cup retainer piston and cups into bore of master cylinder Fig 5 Be sure the lip of cups enter bore evenly in or der not to damage sealing qualities of cups Keep well lubricated with brake fluid...

Page 136: ...um Brakes 17 Testing Brake Warning Switch Unit 18 Combination Brake Warning Proportioning 17 Brake Warning Switch Unit 17 Proportioning Valve Unit 18 Testing Proportioning Valve Unit 18 Combination Br...

Page 137: ...ignition key ON and apply the parking brake If the light fails to light inspect for a burned out bulb disconnected socket a broken or discon nected wire at the switch To test the service brake warnin...

Page 138: ...fch Proportioning Valve Assembly Sectional sembly is identical to that used for the drum brake warning switch PROPORTIONING VALVE UNIT The proportioning valve unit of the brake warning switch proporti...

Page 139: ...ERING VALVE 1 A slight bump can be felt by the foot as the brake pedal is stroked This bump will occur after the pedal has been stroked about 1 inch 2 A visual check will show that the valve stem exte...

Page 140: ...e PROPORTIONING VALVE UNIT The proportioning valve unit operates by restricting at a given ratio hydraulic pressure to TESTING PROPORTIONING VALVE UNIT When a premature rear wheel slide is obtained on...

Page 141: ...ng is not affected by the metering valve as fluid pressures are in excess of 135 psi Follow normal procedure of pumping pedal and opening bleeder screws Do not pump master cylinder dry BLEEDING SATELL...

Page 142: ...oughly and blow dry with compressed air Inspect cylinder bore and piston for scoring and pitting Do not use a rag as lint from the rag will adhere to bore surfaces Wheel cylinder bores and pistons tha...

Page 143: ...ylinder or rear axle housing tee The hose should then be attached to the hose bracket in a manner to give minimum twist 15 degree twist is the maximum recommended Excessive twist can re sult in hose i...

Page 144: ...cket in a manner to give minimum twist 15 degree twist is the maximum recommended Excessive twist can re sult in hose interference problems with possible hydraulic system failure 4 Connect brake line...

Page 145: ...ring Replace the broken retainer spring Replace the grease seal or recondition the wheel cylinders and replace both brake shoes Adjust stop light switch Replace cable Replace the broken rear spring St...

Page 146: ...nt Hook RIGHT REAR CABLE CONNECTOR PARK BRAKE CABLE ADJUSTER RETAINER I BLE ASSEMBLY VIEW IN DIRECTION OF ARROW B PB529A Satellite Models Only ONT CABLE SSEMBLY D I M SWITCH L I LEFT REAR CABLEzyxwvut...

Page 147: ...ING 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 housing and attaching clip out...

Page 148: ...cket then remove vacuum valve To install vacuum valve unit Fig 9 proceed as follows 1 Move actuating arm on valve against spring to extreme position or until locating holes line up In stall a number 4...

Page 149: ...brake unit SERVICE DIAGNOSIS Condition Possible Cause Correction DRAGGING BRAKES ALL a Brake shoes improperly a Adjust brakes WHEELS adjusted b Brake pedal linkage binding c Excessive hydraulic seal f...

Page 150: ...valent coat the bearing surface of bolt that connects power brake pedal link with brake pedal linkage Install bolt and nut Tighten to 30 foot pounds 4 Connect vacuum hose to unit 5 Attach brace and su...

Page 151: ...GINES 2 Install master cylinder on power brake Tight en mounting nuts to 150 inch pounds With power brake attached to dash panel and vacuum supplied to unit the master cylinder should compensate force...

Page 152: ...ubriplate coat the bearing surface of bolt that connects power brake pedal link with brake pedal Install bolt and nut Tighten to 30 foot pounds Install lower pivot bolt if so equipped tighten to 29 fo...

Page 153: ...at connects power brake pedal link with brake pedal linkage Install bolt and nut Tighten to 30 foot pounds 3 Attach vacuum hose to check valve 4 Install master cylinder on power brake Tight en mountin...

Page 154: ...nstalling Splash Shield 44 Proportioning Valve 36 Removing Braking Disc and Hub 43 Removing Caliper 40 Removing Splash Shield 44 Routine Maintenance 36 Service Diagnosis 37 tween parallel machined abu...

Page 155: ...aulic pressure Fig 4 When the pressure is released the seals re CALIPER HOUSING DUST BOOT NN427B Fig 4 Piston Seal Function for Automatic Adiusfment lax or retract pulling the pistons back from the sh...

Page 156: ...It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged If the caliper is cracked or fluid leakage through the casting is evident it must be...

Page 157: ...or chassis interference Always use factory recommended hose to insure quality correct length and superior fatigue life Care should be taken to make sure that the tube and hose mating surfaces are cle...

Page 158: ...tons c Shoe and lining worn below d Brake fluid oil or grease on e Incorrect lining a Replace b Disassemble caliper and free up pistons Clean parts c Install new shoe and linings d Install new shoe li...

Page 159: ...nkage Power brake malfunction e Replace Corroded bore a Hone bore and replace boots and cups Damaged or worn caliper piston b Disassemble caliper and install seal new seal Scores or corrosion on surfa...

Page 160: ...nd remove a quantity of fluid from the reservoir before hand 2 Slide new shoe and lining into caliper with ears of shoe resting on bridges of caliper Fig 7 1 Fig 7 Installing Brake Shoes and Lining Be...

Page 161: ...ned to correct torque Separate assemblies 5 Peel dust boot out and away from caliper housing retainer and out of piston groove Fig 10 Remove remaining dust boots in same manner 6 Using Tool C 3999 rem...

Page 162: ...iff non metallic rotary brush Use extreme care in cleaning the caliper after honing Remove all dust and grit by flushing the FIBRE STICK PISTON CALIPER ASSEMBLY SEAL NN434B Fia zyxwv I 2 Removina Pist...

Page 163: ...all air bub bles have escaped bleeding caliper Replenish brake fluid in master cylinder 5 Pump brake pedal several times to actuate piston seals and position shoe and lining assemblies 6 After assembl...

Page 164: ...brake hydraulic system can be bled preferably with pressure bleeding equipment On disc brake equipped vehicles the brake pedal will require more pumping and frequent checking of the fluid level in th...

Page 165: ...side Fig 3 Four machined abut ments on the adaptor position and align the caliper fore and aft Two positioners installed over the guide pins control the movement of the caliper along with the piston...

Page 166: ...re metering valve or combination pressure metering proportioning valve see Hydraulic System Control Valves this Group the use of the valves is to better match the front disc brakes with the rear drum...

Page 167: ...DISC BRAKE FLOATING CALIPER 5 47 A Fig 4 Disc Brake Assembly Sectional NU4A MyMopar com...

Page 168: ...f after a short period of usage If rust is severe enough roughness will not clear up and the disc must be resurfaced or replaced BRAKE HOSE AND TUBING Installation of Brake Hose The flexible hydraulic...

Page 169: ...tapered shoe and lining assembly c Excessive disc runout d Rear brake adjustment required e Loose wheel bearing f Damaged caliper piston seal 9 Improper brake fluid boil h Power brake malfunction adj...

Page 170: ...ight switch improperly c Sticking pedal linkage d Frozen or seized piston e Residual pressure valve in e Remove valve f Power brake malfunction f Replace a Damaged or worn caliper piston a Disassembly...

Page 171: ...E SHOE INSTAllATION When installing new shoe and lining assemblies Fig 8 Removing or Installing Brake Shoes and 1ining it will be necessary to also install new POSITIONERS INNER BUSHINGS AND OUTER BUS...

Page 172: ...ave been necessary to remove fluid to put in new linings as fluid is pushed back 4 NU58 into master cylinder covers 9 Install wheel and tire assemblies and wheel 10 Remove jackstands or lower hoist RE...

Page 173: ...bushings from caliper by press ing out of bore Fig 12 using a suitable tool Dis card bushings 9 Remove inner bushing and discard Remove bleeder screw Fig 1 2 Removing Outer Bushings CLEANING AND INSPE...

Page 174: ...efore installing caliper assembly on vehicle in spect braking disc Conditions as described in PISTON D BOOT Fig zyxwv I 5 Installing Piston Dust Boot OUTER BUSHING PISTON INSTALLED d DUST BOOT OUTER 7...

Page 175: ...graph 8 Pump brake pedal several times until a firm pedal has been obtained 9 After bleeding caliper check for fluid tightness under maximum pedal pressures Recheck master cylinder reservoir level 10...

Page 176: ...oved before in stallation of new lining pads Lining deposit on the disc may cause erratic fric tion characteristics if new lining is installed without resurfacing or cleaning the disc and worn ridges...

Page 177: ...ns in resurfacing machines may cause the newly finished surface to be out of paral lel with the opposite unfinished side resulting in a thickness variation beyond acceptable limits Disc brakes are ver...

Page 178: ...e speed sensors consist of a stationary permanent magnet and coil in a case and a tone wheel attached to a mounting bracket A part of the mounting bracket forms a spring to hold the shaft of the tone...

Page 179: ...rnesses and the other leads that make up the wiring system Engine Running Vehicle Not in Motion The wheel sensors do not generate any signals for transmission to the LC when the vehicle is not in moti...

Page 180: ...far enough to open the hydrau lic shut off valve If this happens the driver may notice a slight drop in the brake pedal The cycle described above is repeated during a hard brake application until the...

Page 181: ...SURE BRAKE 5 61 t t MyMopar com...

Page 182: ...t the malfunc tion is in the Sure Brake System Perform Test No 3 Electrical Circuit Checks TEST NO 2 BASIC BRAKE TEST Step A Disconnect L C Connectors located behind right side lining in luggage compa...

Page 183: ...EED FROM STARTER RELAY TO REAR BYPASI SWITCH GAUGE FUSE AND SWITCH BODY HARNEg BRAKE WARNING LIGHT LR SPEED SENSOR K 4 h h K 3 B NOTE DO NOT USE A FUSE WITH A RATING a RR SPEED SENSOR MALE zyxwvutsrqp...

Page 184: ...ased Released Released Released Released ReIeased Released Released Released Released Released Released Released Released Applied Applied Applied Applied Applied AppIied Applied Released IEADINGSHOULC...

Page 185: ...round Figure 8 If the reading is still incorrect the appropriate modulator is faulty and must be replaced If the reading is correct 3 0 5 0 ohms at the modulator connector the engine compartment or bo...

Page 186: ...5 66 SURE BRAKE m MyMopar com...

Page 187: ...O BODY HARNESS LEFT REAR SPEED S E N S O R CONNECTORS PD385 T O LOGIC CONTROLLER MALE BLADE CONNECTOR A T O BODY HARNESS TO LOGIC K1 K6 CONTROLLER BLADE TO ENGINE HARNESS COMPARTMENT E CONNECTOR B T O...

Page 188: ...BODY T HARNESS K4 K5 MODULATOR SWITCH CONNECTOR ALL MODULATORS iEFT R E A R SPEED S E N S O R CONNECTOR RIGHT R E A R S P E E D S E N S O R CONNECTOR PD387 Fig 8 Electrical Connectors TO DASHBOARD T...

Page 189: ...y and must be replaced Step F Right Front Speed Sensor Circuit NOTE After finding an apparent circuit failure re connect all connectors except Connectors A B and C at the logic controller and repeat t...

Page 190: ...r rent line located in the engine compartment Figure 5 Replace the fusible link if necessary If the fusible link is good and battery voltage is present at the high current feed on the starter relay di...

Page 191: ...go to Test 7 Step G If lack of rear brakes is suspected disconnect both front sensor connectors Fig 5 red rubber in en gine compartment Restart car and make hard stop on slippery sur face from 45 mph...

Page 192: ...tep D below If the reading is 2 volts or more perform the bal ance of this step Rotate the right front wheel by hand at the rate of one revolution per second With all connectors connected measure the...

Page 193: ...onnector K 2 and K 8 close to the modulator connect a jumper lead capa ble of reaching the battery from the modulator K 2 K 8 connector Raise rear wheels clear of ground start engine en gage drive App...

Page 194: ...does not touch the tone wheel Inspect tone wheel teeth for low tooth 010 020 will cause trouble Step B Remove the rear wheel and drum and check that the sensor mounting bracket holds the sensor knurle...

Page 195: ...ire and wheel 3 Remove the speed sensor lead from the clamp holding it to the front wheel suspension system 4 Dismount the caliper Do not disconnect hy draulic lines Be careful to support the caliper...

Page 196: ...ing on the axle flange Press the speed sensor toward the axle while posi tioning the drive ring 4 Assemble the sensor lead in the clamp on the spring and in the frame rail clip and route the lead thro...

Page 197: ...lator plugs to the engine wiring harness plug 7 Connect the hydraulic lines to the modulator Be sure that each line is connected to the same port from which it was disconnected 8 Connect the vacuum ho...

Page 198: ...ort from which it was disconnected 6 Connect the vacuum hose to the modulator by bottom bracket to the radiator yoke with two nuts pass valve 7 Connect the modulator electrical plugs to the et to the...

Page 199: ...icks in the retracted P D W I CONNECT I I Fig 21 Re route Rear Brake Line position the hydraulic cut off valve in the modula tor remains closed Thus hydraulic pressure is cut off from the brake both b...

Page 200: ...Primary Rear Secondary Thickness Primary Secondary WHEEL CYLINDER Front Wheel Cylinder Bore Rear Wheel Cylinder Bore MASTER CYLINDER BORE 6 Cy1 Duo ServoSingleAnchor 9 8 Extruded and Molded Asbestos...

Page 201: ...CYLINDER CHRYSLER IMPERIAL MODELS Chrysler TYPE DRUM DIAMETER Heavy Duty NUMBER OF BRAKE SHOES WIDTH Front Rear Heavy Duty IncludingStation Wagon Front Rear BRAKE LINING LENGTH Rear Prirnary Rear Sec...

Page 202: ...Housing3 8 Short Overhead 1 5 8 BRAKING DISC Type Ventilated Cast Iron Diameter Outside 11 04 Disc Runout Maximum Allowable T I R 0025 Disc Surface Finish 15 to 80 Micro Inches Disc Thickness 810 Dis...

Page 203: ...ype LiningThickness Wide Long Braking Area MaximumMrear Minimum Thickness Allowed Diameter Inside MASTER CYLINDER Piston Bore Diameter Maximum Bore Diameter Allowable After Honing Residual Valve DISC...

Page 204: ...ke 110 Wheel Cylinder to Support Plate 10 and 11 Brake 220 BRAKE SUPPORT PLATE Front To Steering Knuckle Except Valiant Top attaching bolts 55 Bottom attachingbolts I20 Bottom attaching bolts 100 All...

Page 205: ...Power Only Metering Assembly SATELLlTE SUBURBAN ALL 11x3 11x2 1 2 BrakeWarning Switch Manual Only Optional Disc 11x2 1 2 BrakeWarning Metering Power Only Assembly FURY Except Suburban All 318 360 400...

Page 206: ...t end of this section The Semi centrifugal type clutch combines the feature of low pedal effort with that of a clutch ca Page SERVICE DIAGNOSIS 3 SERVICE PROCEDURES 4 SPECIFICATIONS 10 STEAM CLEANING...

Page 207: ...AL BRACKET PLAIN WASHER OVER CENTER SPRING HOOK RELEASE F O R K FRAME SIDE RAIL BOOT Fig 2 Cluich Pedal and linkage Carline Kl I NP131B PEDAL STOP SNAP RING I PLAIN WASHER PIN pY NR180A Fig 3 Clutch P...

Page 208: ...Drv clutch linkaae a Replace disc assembly b Replace disc assembly and c Replace cover assembly d Replace or tighten mounts e Align clutch housing a Replace disc assembly and b Adjust release fork rod...

Page 209: ...ransmissions only CLUTCH HOUSING LUTCH HOUSING SPRING WASHER ADJUSTING NUT Fig 6 Torque Shaft and linkage Carline VJ Gearsbifi lnierlock A 903 Transmission Only 1 Disconnect clutch rod swivel from int...

Page 210: ...eed as follows sembly from clutch release fork Fig 8 then re move release fork and boot from clutch housing Removal 7 Mark clutch cover and flywheel Fig 9 to 1 Remove transmission See a u a lmaintain...

Page 211: ...e plate with a suitable solvent 8 Using a straight edge check pressure plate for flatness The pressure plate friction area should be flat within 015 inch and free from discoloration burned areas crack...

Page 212: ...allation 1 Soak new bushing in oil before installing 2 Place handle SP 3549 on head SP 3551 and use this tool to drive new bushing into crankshaft flush to end 3 Place one half teaspoon of grease in c...

Page 213: ...curing pedal rod to torque shaft lever pin Figs 6 or 7 and remove pedal rod from pin 2 On 6 cylinder models equipped with A 903 transmission remove clip and plain washer securing gearshift interlock r...

Page 214: ...rrected by install ing correct size offset dowels Fig 1 4 These dow els are available in three offset sizes and they must REAR FACE OF ENGINE B L O C K NY 1601A Fig zyxwv I 4 Offset Dowel Diagram be i...

Page 215: ...rb moisture and the force exerted by the pressure plate will bond the facings to flywheel and or pressure plate if car is allowed to stand for some time before use If this condition occurs it will nec...

Page 216: ...Part Numberssubject to change during model year TIGHTENING REFERENCE Item Torque item Torque Clutch Cover to Flywheel Bolts 5 16 11 200 in Ibs Clutch Cover to Flywheel Bolts 3 8 30 ft Ibs Clutch Fork...

Page 217: ...maximum cooling system consisting of a larg er radiator and on some models radiator shrouds and or hood to yoke and bumper to yoke seals are used to provide protection against overheating for unusuall...

Page 218: ...lve compartment d Cracked valve port e Crack in block into push rod compartment 4Cracked cylinder wall 9 Leaking oil cooler a Low coolant level b Collapsed radiator hose A bottom hose with faulty spri...

Page 219: ...lace the sending unit n Faulty vacuum By Pass valve n Replace valve a Overfilling a Adjust coolant to the correct level b Coolant foaming due to insufficient corrosion inhibitor c Blown head gasket c...

Page 220: ...Removal There are no repairs to be made to the fan If the 1 Remove shroud attaching screws separate shroud from radiator position shroud rearward on engine Fan attaching screws can now be removed 2 On...

Page 221: ...olts and re move water pump Discard gasket With Air Conditioning and or Air Pump 1 Remove battery and drain the cooling system Remove fan shroud if so equipped and set back on engine 2 Disconnect radi...

Page 222: ...ct transmis sion oil cooler lines install shroud if so equipped 11 Fill the cooling system to 1 1 4 inch below filler neck seat with sufficient permanent anti freeze for 20 degrees F protection to ins...

Page 223: ...all joint leaks 6 Close the valve Gauge reading will then drop if cooler is leaking Repairing Oil Cooler The transmission auxiliary oil cooler being all alu minum can be repaired by a local reliable r...

Page 224: ...ermostat level 2 Remove upper radiator hose from thermostat NUMBER 2 1 D PIPE PMlO Fig 6 Temperature Operated Vacuum By Pass Valve 3 Remove thermostat housing bolts and remove thermostat and housing T...

Page 225: ...bar valve is defective and should be replaced 10 Idle engine radiator uncovered until temper ature is normal reconnect distributor solenoid wire at carburetor and re adjust idle rpm RADIATOR HOSES The...

Page 226: ...Ibs 4 Remove the wires from the spark plugs on one bank and operate the engine on the opposite bank If the needle continues to fluctuate it indicates a leak on the bank still in operation If the need...

Page 227: ...specified torque to the power steering bracket from the rear as shown in Figure 13 See Specifications A 1 2 inch square hole is provided in the bracket for this purpose GAUGE I Fig 11 Belt Tension Ga...

Page 228: ...IONS rn SPECIFICATIONS VALIANT iu v iuiuiu b d m zyxwvut co I n m x p ihk A I m rn iu hl b P b 1 i C 0 en C 0 0 0 E z 2 H U C m en C C 0 U C 0 0 44 L a 5 P i n a c Q Y P 0 44 C I v I Y f z U 0 0 i n 8...

Page 229: ...Standard 1 07 1 High Capacity 1 07 1 Air Conditioning Spacer Air Conditioning Ratio Fanto Crankshaft Air Conditioning 16 19 17 5 26 3574631 19 3574631 1 9 3574627 26 3574624 26 None 10 12 15 22 16 5...

Page 230: ...m zyxw Q Q b b 2 Q Q b b m m Q Q b b m m M 10 8 VI In M I I I I 0 Y 0 T3 J I c c c I v M M rnrnrnoiviv I Q Q Q m m m I o p 9 I a m k b OPQ b o 22 OPQ b o 22 Q Q Ob m m I Q l 1 F i l 32 3 I I 2 c r j...

Page 231: ...SPECIFICATIONS 7 15 iubb N N N zyxwvut Q m o 2 gbb I I I G I P m MyMopar com...

Page 232: ...Fan to Crankshaft WATER PUMP IMPELLER Diameter Number Blades Standard Air Conditioning 15 5 22 16 26 17 26 MC 3574621 22 3574618 26 3574617 26 lo 10 12 Yes Yes Yes Yes 2 00 Thermal 1 40 95 1 1 3 1 95...

Page 233: ...A C 35 With A C Imperial 50 120 100 120 45 35 zyxwv 70 35 30 65 65 55 USED BELT 318 198 340 400 225 360 440 50 35 20 10 70 10 25 15 20 25 20 90 80 30 40 20 40 40 30 A belt is considered Used after 15...

Page 234: ...battery case and cover for cracks 9 Install battery 10 Tighten battery hold down screw nuts to 3 foot pounds Observe polarity of battery terminals to be sure the battery is not reversed 11 Connect ca...

Page 235: ...pecific gravity points for every 10 degrees under 80 degrees F All read ings must be corrected at 80 degrees Fahrenheit Refer to Figure 1 and examples one and two as follows NP165 Q e Fig 2 Testing Ba...

Page 236: ...aced B If all cells vary LESS than five scale divi sions on the TOP scale and all are in the GREEN section of the Bottom Scale The battery is in good condition and a safe state of charge C If all cell...

Page 237: ...ery negative ter NY838B Fig 5 Three Minute Charge Test minal Fig 4 Voltmeter clips must contact bat tery posts or cable clamps and not ammeter lead clips zyxwv 4 Turn control knob clockwise until amme...

Page 238: ...occur where the live cir cuit is broken Keep all open flames away from the battery Slow Charging of Batteries Many discharged batteries can be brought back to good condition by slow charging especial...

Page 239: ...a 3 5 to 1 reduction gear set built into the Starter assembly which is housed in an Page Insulated Circuit Test 8 Installing the Starter 16 Removing the Starter 9 Resistance Test 9 Service Diagnosis 7...

Page 240: ...avity 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...

Page 241: ...ive voltmeter lead Red to Positive battery terminal Connect Negative voltmeter lead Black to Negative battery terminal DISCONNECT ignition primary lead from ignition ballast resistor coil to prevent C...

Page 242: ...caused from loose circuit connections a faulty cable burned starter relay or burned solenoid switch contacts A current that is high and is combined with slow cranking speed in dicates starter should...

Page 243: ...ne set of brushes are connected to this terminal The other pair of brushes is attached to the series field coils by means of a terminal screw Carefully pull frame and field assembly up just enough to...

Page 244: ...Shaft MOVING SHIFTING Fig 10 Removing or Installing Moving Core CAUTION Retainer is under tension and a cloth should be placed over the retainer to prevent it from springing away after removal 16 Rele...

Page 245: ...d just above it while slowly rotating armature in growler A shorted ar mature will cause blade to vibrate and be attracted to the core Replace armature if shorted Testing Armature for Ground Contact a...

Page 246: ...15 The shifter fork consists of two spring steel plates assembled with two rivets There should be approximately 1 16 inch side movement as shown in Figure 16 to insure proper pinion gear engagement l...

Page 247: ...Fig I 8 Assembling Solenoid to Brush Holder Plate SHIFTER FORK PIN CLUTCH ASSEMBLY MOVING CORE PD68 Fig I 7 Shifter Fork and Clutch Armngement Inspect condition of starter solenoid switch con tacting...

Page 248: ...sin flux 14 Install brush holder to solenoid attaching NU436 Fig 20 Installing Solenoid and Brush Holder Into Gear Housing Fig 22 Installing Starter Armature screws 15 Carefully enter solenoid coil an...

Page 249: ...ry Starter Tester CONTROL KNOB to OFF POSITION Turn voltmeter Selector Switch to 16 Volt position Connect Positive ammeter lead Red to Positive battery terminal Connect heavy Negative ammeter lead Bla...

Page 250: ...onnector 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 cla...

Page 251: ...stat in series with battery positive post and starter terminal 3 Connect voltmeter 15 volt scale across starter 4 Rotate carbon pile to full resistance position Fig 3 Field Coil Leads Disconnected fro...

Page 252: ...mmutator end head and brush plate 2 Disengage brushes from brush holders and re v NK512A ASSY Fig 7 Brush Replacement move brush plate 3 Disconnect series coil and shunt field coil ter minal at soleno...

Page 253: ...mature in a pair of zyx V blocks and check runout with a dial indicator Check both shaft and commutator A bent shaft requires replacement of armature When commutator runout exceeds 003 inch com mutato...

Page 254: ...re support bushings for wear by placing them on shafts and checking for side play Replace commutator end frame and bushing assembly if bushing is worn Replace drive end bushing if worn The bushing sho...

Page 255: ...r bottoms 3 Measure clearance between end of pinion and pin stop with plunger seated and pinion pushed to ward the commutator end Clearance should be 1 8 inch Adjust for proper clearance by loosening...

Page 256: ...ngs 9 Open rectifiers h LOW UNSTEADY CHARGING RATE engine ground lead a High resistance in body to b Alternator drive belt loose Adjust drive belt to specifications Connect regulator to a good ground...

Page 257: ...eads 9 Open or shorted winding in stator EXCESSIVE AMMETER FLUCTUATION a Properly install and tighten alternator mounting b Install a new drive belt and adjust to specifications c Remove and disassemb...

Page 258: ...ff rapidly is during low engine speed operation when high electrical loads are present and require that the alternator field be in the on state continuously One other important feature of the electron...

Page 259: ...circuit Observe the voltmeter reading The voltmeter reading should not exceed 7 volts If a higher voltage drop is indicated inspect clean and tighten all connections in the charging circuit A voltage...

Page 260: ...18 Remove jumper between alternator field and ground Connect the field wire to the alternator field terminal VOLTAGE REGULATOR TEST When Tester 19 Connect the battery ground cable ISOLATED FIELD ALTE...

Page 261: ...oltage regulator Fig 6 Voltage Regulator Test Depressing Test Button and Black Button A 7 If the voltage is more than one half 1 2 a volt above limits shown in chart change the voltage regulator and r...

Page 262: ...tor assembly or DRIVE SHIELD Fig 9 Separating Drive End Shield From Stator field brush is not grounded lamp will not light 2 If lamp lights remove field brush assemblies noting how the parts are assem...

Page 263: ...fiers are good and one is shorted reading taken at the good rectifiers will be low and reading at shorted rectifier will be zero Disconnect rectifiers with test probe CAUTION Do not break the plastic...

Page 264: ...time If the lamp lights the lead stator is grounded d Press probe firmly on one phase terminal lead and contact firmly each of the other two stator leads Test lamp should light when prod contacts eac...

Page 265: ...r end frame needle bearing protect end shield by support ing shield with Tool C 3925 when pressing bearing out with Tool C 3770A Fig 18 Make sure notch es in tool clear raised section of heat sink The...

Page 266: ...y placing one test prod on the positive and the other test prod on the ground slip ring Light should go on showing the field circuit is completed n If rotor is not grounded and field circuit is contin...

Page 267: ...14 Rotate pulley slowly by hand to be sure rotor fan blades do not hit stator connections 15 Install alternator and adjust drive belt to specifications 16 Connect output BAT and two field FLD leads 1...

Page 268: ...rk plug covers should be in good condition Nipples should fit tightly on the coil cap towers and spark plug cover should fit tight around spark plug insulators Cable connec tions that are loose will c...

Page 269: ...connection at the tower or for a faulty coil Inspect coil tower for cracks carbon tracking or oil leaks I ri I Fig 2 Installing Secondary Cable and Nipple at Coil Tower DISTRIBUTOR RESISTANCE TEST Th...

Page 270: ...ngine speed to 1500 RPM then slowly reduce to idle speed while observing Dwell Meter reading If dwell reading varies more than 2 degrees from initial reading between idle speed and 1500 RPM probable w...

Page 271: ...r from the engine shaft will rotate slightly as the distributor gear is disengaged from the camshaft gear SHAFT AND BUSHING WEAR TEST 1 Remove distributor rotor 2 Disconnect primary lead wire at distr...

Page 272: ...sembly as follows a Remove distributor drive gear retaining pin and slide gear off end of shaft If gear is worn or damaged see Assembling Distributor step 5 CAUTION Support hub of gear in a manner tha...

Page 273: ...scale MTU 36 on contact arm and pull in a straight line at a right angle to the contact surfaces Fig 7 Take a reading as contacts start to separate under slow and steady pull of the scale Spring tens...

Page 274: ...gn the contacts if necessary by bending the stationary contact bracket only Never bend the movable contact arm to obtain alignment 6 After aligning the contacts adjust contact clearance to Specificati...

Page 275: ...edge of crankshaft pulley should be in line with the 0 TDC mark on timing chain case cover b Rotate rotor to a position just ahead of the number one distributor cap terminal c Lower the distributor i...

Page 276: ...condenser vehicle frame and primary wiring make up the low voltage prima The ignition system consists of two separate ry circuit The secondary high voltage circuit in cludes the coil secondary winding...

Page 277: ...le and Nipple at Distributor Cap Tower a Engine not Replace and adjust contacts Replace coil Inspect condition of the distributor contacts Replace the coil Replace the coil running connect one end of...

Page 278: ...ibrator until Dwell Meter reads on the set line test leads separated 2 Leave Selector Switch in CALIBRATE position connect Tach Dwell red lead to distributor terminal of coil and black lead to a good...

Page 279: ...d to 1500 RPM then slowly reduce to idle speed while observing dwell meter reading If dwell reading varies more than 2 degrees from initial reading between idle speed and 1500 RPM probable wear in the...

Page 280: ...timing test will indicate the timing of the spark at No 1 cylinder at specified curb idle OnlY Test procedures are as follows 1 Disconnect vacuum hose at distributor 2 Connect secondary lead of Power...

Page 281: ...r end of wire loop and pull on a line with the plun ger of indicator guage Be sure wire loop on shaft end is down on the shaft to insure a straight pull and also that wire loop does not interfere with...

Page 282: ...ers contact gap with 1 drop of light engine oil and install rotor CONTACT ARM SPRING TENSION 1 Hook a spring scale Tool MTU 36 on the breaker arm and pull in a straight line at a right angle to the co...

Page 283: ...s Pitting of Contacts Contact pitting results from the transfer of materi al from one contact to the other so that a tip builds up on one contact while a pit forms in the other A small amount of pitti...

Page 284: ...If leakage is indicated replace vacuum unit assembly Vacuum Advance Curve Connect tester vacuum pump hose to the distribu tor vacuum advance unit and perform operations 1 through 4 under Centrifugal...

Page 285: ...rimary wire from the distributor the Dual Ballast Resistor mounted on the firewall and AUXILIARY RESISTOR ELECTRONIC IGNITION ONLY DUbL BALYST B A E R Y T o AMMETER IGNITION 1 TO VOLTAGE REGULATOR AND...

Page 286: ...d by the electronic circuitry in the control unit This determines dwell Dwell is not adjustable Even though it may be read with a dwell meter there is no means provided to change it because changes ar...

Page 287: ...auge held between pickup core and an aligned reluctor blade After resetting gap run distributor on test stand and apply vacuum advance making sure that the pickup core does not strike the reluctor bla...

Page 288: ...hicle must have a good battery 12 volts minimum for the tester to accurately analyze the system 1 With the ignition switch off remove the screw from the harness lead on the Electronic Con trol Unit an...

Page 289: ...off check wiring Re place control unit The circuit breaker will protect the tester against damage due to testing a shorted control unit Wait 30 seconds before attempting to reset a popped cir cuit br...

Page 290: ...uge to check spark plug gap Reset gaps to 035 inch Before setting spark plug gap file center electrode flat make adjustment by bending ground side electrode never bend the center electrode When instal...

Page 291: ...also optional on other models TEMPERATURE AND OIL INDICATING SYSTEM The operation of the temperature and oil pressure indicating system are identical in operation with the Printed Circuit Board ReDlac...

Page 292: ...od grounded ground NOTE Testing the system with the tank sending unit positioned for both empty and full is usually sufficient to determine the calibration in the range between these positions d Remov...

Page 293: ...FUEL WARNING RE1AY Test 1 Disconnect wire at the fuel tank unit Connect one lead of tester C 3826 to wire terminal and other lead to a good ground 2 Turn ignition key on turn tester knob to zy H posi...

Page 294: ...e tester in the zyxwvu H position and the gauge should advance to the H position of the dial Should the gauge respond to the above tests but not operate when the terminal is attached to the sending un...

Page 295: ...onic tachometer It is connected to the ignition coil on the negative distributor post Through this connec tion the tachometer senses ignition firings and counts their number This is shown by a pointer...

Page 296: ...ced without instrument cluster removal For proper replacement bulb numbers see Bulb Chart in Specifications LAMP PANEL FURY Removal 1 Disconnect battery 2 Remove mounting screws from lamp panel 3 Lowe...

Page 297: ...to allow hand clearance the bulb INSTRUMENT CLUSTER Valiant Fig 3 Standard Cluster Removal 1 Disconnect battery ground cable 2 From under instrument panel disconnect spee dometer cable and printed cir...

Page 298: ...nnect all wiring harnesses and remove lnstallation 1 Rest cluster in opening and connect wiring harnesses Replace the cluster to panel mounting screws 2 Position cluster bezel and connect stereo con t...

Page 299: ...tion INSTRUMENT PANEL Fig 8 Instrument Cluster Removd and lnrtcr oton Chrysler 6 Reach under panel and insert left spot cooler 7 Install A C center transition 8 Install column cover 9 Install lamp pan...

Page 300: ...e to the trim pad as the cluster is removed INSTRUMENT REPLACEMENT Valiant Barracuda Satellite To service the instruments of any cluster it is necessary to remove the cluster first See Instrument Clus...

Page 301: ...snap pin and screw holding the volt 4 Remove the voltage limiter Noise Suppression Choke 1 Remove the steering column cover the gear shift indicator pointer and lower the steering column 2 Working thr...

Page 302: ...ne Upon completion of the instru ment cluster installation test all instruments TESTS OUT OF VEHICLE Printed Circuit Board A visual inspection of the conductors should be made for cracks or damaged ci...

Page 303: ...ty is printed on the front face of the fuse block Refer to Specifications CIRCUIT BREAKERS Use only identical type and amperage value circuit breakers as replacements for service See Specification for...

Page 304: ...leads zyxwv 4 Remove mounting screws from back side of switch 5 Remove switch through back side of panel duct on air conditioned cars lnstallation 1 Place switch in panel 2 Secure switch with mounting...

Page 305: ...nd 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 rig...

Page 306: ...is not necessary to disconnect wiring harness 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...

Page 307: ...it to lower reinforcement housing to the instrument cluster panel iter Spot Cooler Imperial Removal center only 1 Remove air conditioner distribution duct 2 Remove center outlet bezel mounting screws...

Page 308: ...ary to remove the bezel assembly only roll it far enough to gain access to clock wiring and mounting screws 3 Disconnect clock wiring Removal 1 Remove the center A C connector 2 Disconnect the power l...

Page 309: ...trim pad mounting nuts 9 Disconnect map lamp wiring 10 Remove trim pad from panel 11 Remove center and right spot cooler 12 Remove map lamp bezel assembly assembly if so equipped Installation 1 Insta...

Page 310: ...pad on lower instrument panel sheet metal 2 Working through glove box opening replace 5 upper trim pad to lower panel mounting nuts Working from cluster opening of instrument panel replace 2 upper pa...

Page 311: ...ration 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 door is open Under these cond...

Page 312: ...ushbutton Radio Fig 1 To operate the radio the ignition switch must be in the ON or Accessory position Operation is by two rotary controls and five push buttons Left Center Knob On Off and Volume Page...

Page 313: ...FM radio will pick up noise The noise cancelling features of an FM radio require a certain signal strength before they can perform their function An FM radio oper ated in the fringe area where signal...

Page 314: ...is is particularly true of passing cars that do not use TVRS suppression spark plug wires As the station signal strength in creases the FM circuit rejects the noise and it disappears Noise will not be...

Page 315: ...holder down to engage the motor The tonal quality bass or treble and the speaker balance are adjusted by the radio controls When revolving these controls a slight detent can be felt that indicates th...

Page 316: ...rtial rotation of the control blends the volume of the speakers Foot Switch For Search Tuning The foot switch for search tuning is located on the left forward end of the floor panel By depressing the...

Page 317: ...or servicing RADIO RECEPTION DISTORTED a Speaker voice coil leads rubbing a Install an auxiliary speaker and on speaker cone compare Replace if improved b Torn speaker cone b Replace the speaker c Fau...

Page 318: ...allation 1 Operate radio for 5 minutes 2 Extend antenna to the usually maintained height 3 Manually tune radio to a weak signal between 1400 and 1600 KHZ on AM 4 Increase radio volume to full volume a...

Page 319: ...sembly the mast assem bly and the support tube assembly The antenna is MOTOR FEED WIRES ANTENNA LEAD NP103 COLLAR SCREWS 3 MOTOR FEED WIRES Fig 13 Power Antenna serviced as a mast assembly motor and t...

Page 320: ...ping 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...

Page 321: ...be tween mast and support tube or inner conductor from pin and pad 3 Remove clip lead from connector pin and clip on outer shell of connector Connect other clip lead to antenna support tube assembly T...

Page 322: ...d Barracuda 1 Disconnect battery ground cable at battery 2 Remove knobs 3 Remove the two radio mounting bolts at lower 4 Disconnect electrical leads and antenna lead at 5 While holding radio in positi...

Page 323: ...8 90 RADIO AND ANTENNA ELECTRICAL RIGHT ROOF RAIL RIGHT R E A R BODY PB173 Fig 19 Rear Speaker Siaiion Wagon Saiellite PB172 Fig 20 Rear Speaker Station Wagon Fury Chrysler MyMopar com...

Page 324: ...ut top of box door 2 Disconnect wiring 3 Remove two mounting screws 4 Remove crossover REAR SEAT SPEAKER Removal 1 Working through trunk compartment discon nect speaker leads 2 Remove the four sheet m...

Page 325: ...e faulty Replace or adjust horns If the test light fails to light reconnect the con nector to the horn terminal and connect one lead of test light to the horn relay B terminal and the other test light...

Page 326: ...ter counterclockwise until there is no vibration sound 4 Turn tone adjuster clockwise approximately 1 4 turn at a time until tone has a clear mellow sound Do not turn tone adjuster while horn is sound...

Page 327: ...SPEED SET button may increase speed setting incrementally To decrease speed tap brake pedal lightly disengag ing system When desired speed has been obtained depress and release SPEED SET button Decrea...

Page 328: ...See Electrical Tests a Repair or replace cable b Adjust speed control throttle cable See Tests and Adj ustments c Repair or replace linkage SPEEDOMETER NOISE EXCESSIVE NEEDLE WAIVER damaged bends or...

Page 329: ...his screw should never be adiurted indiscriminately Need for adjustment can be deter mined only after accurate diagnosis of the Speed Control System operation After the steps a b and c have been consi...

Page 330: ...ume position f Reconnect speed control lever harness connec tor to harness connector 3 Stop lamp and speed control switch tes a Disconnect the double connector at the switch pigtail and connect a twel...

Page 331: ...8 98 SPEED CONTROL SYSTEM ELECTRICAL 8 MyMopar com...

Page 332: ...nnect speedometer and transmission drive 4 With choke in full open position align throttle STOP LAMP AND SPEED BRAKE SWITCH Fig Removing or Installing Servo Hose 5 Install cable cover on servo studs a...

Page 333: ...h the opening in column Make guide wire long enough so that it can be reached at bottom of column before harness is attached to the upper hook When harness has been pulled through in Removal 1 Disconn...

Page 334: ...to the driver that the system is operating Hazard Warning The hazard warning system is actuated by a switch knob on the right side of the steering col umn just below the steering wheel On standard col...

Page 335: ...flasher and the hazard warning flasher are two separate plug in type units located in two different places under the instrument panel of each car a The turn signal flasher is mounted to the side of t...

Page 336: ...a depressed position Motor operation in the wipe direction returns the cam to run position to restore the normal link and wipe pattern All three speed wiper systems have the depressed parking feature...

Page 337: ...switch c Brush sticking in holder Two Speed d No brush spring Two Speed e Broken brush holder Two Speed f Low speed torque limiting resistor open Two Speed 9 Replace motor housing or Gear Housing Bru...

Page 338: ...Looseness of the motor crank or other drive parts c Park switch cover locator tab not in proper position a Twisted arm holds blade at wrong angle to glass b Bent or damaged blades c Foreign substances...

Page 339: ...torv Brown Red Green Battery z a Voltages less than 8 volts at the blue lead may in LOW 12 12 0 8 t o 1 0 12 dicate excessive current draw voltage cycling to 0 Medium 12 6 0 8 t o 1 0 12 volts indicat...

Page 340: ...park switch may have been damaged so the contacts do not open or the panel switch may be defective To isolate the defect unsolder the blue lead from the park switch If both the blue lead and brown lea...

Page 341: ...h the ignition switch in the accessory position for a half hour to warm the motor to observe inter mittent conditions or to cause the motor to run faster and possibly coast through park Switching the...

Page 342: ...peed brush or the spring off the low speed brush L 0 volts and H 12 volts at high speed switch position and the motor does not run on high speed Investigate for a stuck high speed brush or the spring...

Page 343: ...djacent commutator riser bars with a pair of test lamp probes The lamp should light on each bar If the lamp fails to light the wire to bar junction is open Replace open armature PANEL SWITCH TESTS Two...

Page 344: ...d jumper from motor terminal L to ground Connect a third jumper from the motor ground strap to ground The motor should run in reverse rotation for at least a half revolution and park Three Speed Motor...

Page 345: ...r arm and blade assemblies see Fig 2 3 Remove cowl screen 4 Hold the motor crank with a wrench while removing the crank arm nut to prevent overloading the gears to remove the crank arm from the motor...

Page 346: ...he as terisk only as shown in Fig 7 9 Lubricate intermediate gear shaft install the wave washer convex side of washer must face gear and the intermediate gear on the shaft 10 Install the park cam the...

Page 347: ...d wipers 7 Install cover using screws lock washers and nuts furnished Be sure the two cover locating pins are aligned with their hole in the gear housing 8 Bench test motor for proper operation 9 Inst...

Page 348: ...he outer cam Remove the park switch plate to run motor and relieve jammed condition 13 Install motor END PLA Y ADJUSTMENT Three Speed Motor To adjust the armature shaft end play turn the adjustment sc...

Page 349: ...ER under any circumstances push or bend the spring clip in the base of the arm in an attempt to release the arm LINKAGE AND PIVOT REMOVAL With Non Concealed Wipers 1 Disconnect battery ground cable 2...

Page 350: ...e gaskets to prevent water leakage 1 Install bushing on motor crank arm pin pos ition drive link on bushing so large side of pivot bushing faces away from drive crank arm Large side of pivot bushing w...

Page 351: ...8 118 WINDSHIELD WIPER AND WASHER ELECTRICAL rn MyMopar com...

Page 352: ...e Multi Purpose Lubricant NLG 12 LINKAGE AND PIVOT INSTALLATION With Concealed Wipers If servicing of the mechanism on the 2 speed mo tor crank is required be certain that during reassembly the link i...

Page 353: ...zzle jet under air intake b Replace switch assembly MOTOR RUNS DOES NOT a Clean nozzle jets b Replace hose assembly d Adjust nozzles PUMP FLUID grille PUMP ASSEMBLY INOPERATIVE LOW OUTPUT a Poor groun...

Page 354: ...IC PUMP ONLY FOOT PUMP ONLY OF WINDSHIELD 14 PY062A REFERENCE ONLY UPPER MOLDING Fig 1 Washer Aiming Diagram WINDSHIELD WASHER AIMING SPECIFICATIONSzyxwv 7 MODELS VALIANT DUSTER BARRACUDA CUDA 14 16 U...

Page 355: ...neck re move pump mounting nut and plastic washer from the reservoir Remove the ground wire IT MAY BE NECESSARY IN SOME PUMPS TO USE A THE EXPANSION OF THE NYLON FILTER NUT 4 Remove pump from bottom o...

Page 356: ...WINDSHIELD WIPER AND WASHER ELECTRICAL 8 123 MyMopar com...

Page 357: ...t and road splash tend to harden rubber wiper blades thus destroying their efficiency When blades smear or in general do not satisfactorily clean the windshield they should be replaced Wiping Element...

Page 358: ...e 12 Volts with NegativeGround Terminal REDUCTION GEAR STARTING MOTOR Starting Motor Model Make Voltage Number of Fields Number of Poles Brushes Spring Tension Drive End Play Cranking Amperage Draw Fr...

Page 359: ...ty and or Air Conditioning V L R WModels 60 Amp Spec Equip Fleet or P D C Ywith Air Conditioning 1889100 Chrysler 12 4 3 Series 1 Shunt 4 4 32 to 36 Ounces Solenoid Shift Overrunning Clutch zy 005 Min...

Page 360: ...mp Front Turn Signal Turn Signal Indicators Cigar Lighter Dome Light Dome Lamp Trunk Lamp Stop Lamps Map Lamp Glove Box Lamp Ignition Lamp Relay Ignition Lamp Cigar Lighter Hazard Flasher Includes Sto...

Page 361: ...s Cigar Lighter Parking Lamps Ignition Lamp Time Delay Instrument Lamps Switch Title Lamp Clock 5 Amps Instrument Lamps Cluster Lamps Gear Selector Lamp Ash Receiver Lamp Radio Lamp Heater or A C Cont...

Page 362: ...Instrument Lamps Side Marker Lamps Ignition Lamp Time Delay Relay Glove Box Lamp 20 Amps Gear Selector Lamp Ash Receiver Lamp Accessory Switch Lamps Accessory Rear Defogger Air Conditioning Clutch Tac...

Page 363: ...Lamps Ash Receiver Lamp Gear Selector Lamp Tail Gate Lock Switch Lamp Accessory Headlamp Delay Relay Rear Defogger Rear Air Conditioning Motor Air Conditioning Clutch Speed Control Cornering Lamp 20...

Page 364: ...ory 20 Amps Speed Control Rear Defogger Blower Motor Rear Air Conditioning Blower Motor Rear Heater Blower Motor Air Conditioning Clutch Cornering Lamps Low Fuel Relay Low Fuel Relay Lamp Heat A C Hea...

Page 365: ...r Lamps Accessory 20 Amps Speed Control Air ConditioningClutch ETR Valve Cornering Lamps 20 Amps Heat A C 20 Amps Heater Blower Motor Air Conditioning BlowerMotor 20Amps 20 Amps Radio Back up Lamps 20...

Page 366: ...816 53 6012 1443 194 4 Stereo Indicator Switch Courtesy Switch Lighting Tachometer Tail Stop and Turn Signal Trunk and or Under Hood Lamp Turn Signal Indicator Panel 1157 2 1004 158 2 or 1004 1892 330...

Page 367: ...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 LIGHT BULBS Include...

Page 368: ...SPECIFICATIONS 8 135 z 0 d v zyxwvu CD Lo CD m r 0 0 0 0 o o o m OCO ln 0 a Q MyMopar com...

Page 369: ...E Y a m O b zyxwvut 0 o OLD 0 0 0 g no 0 0 O m a kcn b Lo N g 0 O o 0 h l o O m 0 ki 0 0 003 0 0 OLD 0 u E S h E O G cv 9 o 0 L o 0 0 cv 0 O o O m i w c a o 0 Q g g 2 3 E b gj n E E w 2 E O c 3 v En c...

Page 370: ...S 8 1 z 37 z Gf O 0 0 M o o O h C I W 0 0 0 g 3 I cv a a 2 c c 0 0 o 0 2 n Z Z O I 0 0 03 C I W 0 0 u E Lc 0 I a 0 0 0 a 0 0 F 0 0 w c 0 0 o o d 0 Q F tn c r w C a o a E L o m n g E Y U0I F g a I I z...

Page 371: ...IFICATIONS 8 h zyxwvu 0 0 c l c l 0 0 b s a o 0 CI m Q 0 E L s z E ij n E E a L E O en c W V I I c 3 v K k F 0 z P m 2 1 g al Q m s 2 0 m I zyx x g c n c r b b i 7 j W U f a L n 3 0 3 L a 1 0 A N m m...

Page 372: ...Lo D m h l r N W I n W m co r N D Lo 0 z 5 p 8 E n 3 L v 2 za 5 c s g a O o m TI 0 0 0 0 0 0 o 0 0 0 O m a a c c 0 0 Z Z a a c c 0 0 Z Z c 0 m a _ ha z a e v n 3 I r n o E a a l a u a E z a a 1 3 r r...

Page 373: ...O N a O o Lo E g O O N Lorn zyxwvutsr 0 0 0 L o o o m 0 3 h a a LL I H za z acrg o o Zrn O o d O O N 0 0 0 L o 0 0 0 O O N 0 3 r 0 o o N 03 3 0s 0 z a o n w c w o 0 5 2 fn Q L g o w n E Y a 2 E O c 3...

Page 374: ...a SPECIFICATIONS 8 141 E W zyxwvutsrq c v v I c I zy co R Lo R CI c 9 0 z h zyx x a a rn MyMopar com...

Page 375: ...b m Q al c c 0 0 z z E 0 0 e 0 0 a w 0 0 0 0 s s 2 0 o CI c 3 c n E ccg 3 a a l a 5 ale z a Q 2 y g m m c c Q Q a Z O G G h a a m Y 3 Q a F C C k v u u ru ru P 3 I u a l a 3 L U U a zyx rr v Lv v CI c...

Page 376: ...u In 3 2 Barrel Manual or Automatic Electronic 3656353 0 to 3 5 650 RPM 8 to 10 5 1000 RPM 8 to 10 5 2150 RPM 1 to 4 10 5 8 to 10 5 15 5 None None None None Counterclockwise 2 5 BTC zyx k2 5 J11Y 14MM...

Page 377: ...gine Compartment Wiring Air MALE FEMALE MALE FEMALE INSULATORS VIEWED FROM TERMINAL SIDE Engine Compartment Wiring with ATC Instrument Panel Accessories Wiring Instrument Panel Accessory Wiring Instru...

Page 378: ...WIRING DIAGRAMS 8 145 Fig 2 Bulkhead Disconnect Valiant zyxw I zyxw P8357 Fig 3 Bulkhead Disconnect Barracuda Satellite PI3358 Fig 4 Bulkhead Disconnect Fury Chrysler Imperial MyMopar com...

Page 379: ...N FOR 400 AND 440 CUBIC INCH ENGINES FIRING ORDER 1 8 4 3 6 5 7 2 PD541 Fig 5 Distrirbutor Secondary Wiring I J E 16DBr J2E l8DBL Y A J3 L J2G 16DBL l4BR PD 542 CONTROL Fig 6 Electronic Ignition Wirin...

Page 380: ...rn WIRING DIAGRAMS 8 147 z 3 e zyxwvut 5 L w 20 MyMopar com...

Page 381: ...t 1 TO INSTRUMENT PANEL MAIN HARNESS ACCESSOR CONNECTOR LAMPS E2 200 TO INSTRUMENT PANEL MAIN HARNESS CIGAR LIGHTER CONNECTOR TO FUSE BLOCK INSTRUMENT LAMPS TERMINAL B R I ACC uBATT INST FEED FEED FEE...

Page 382: ...ACCESSORY TERMINAL PART OF INSTRUMEN1 PANEL MAIh HARNESS M6E 18Y JA6D 1 AcE gRy CONNECTOR M2D 20Y HEADLAMP ON REMINDER BUZZER RELAY WIRING SEND yT11 20GY 4 7 1 MOLDED I TO TACHOMETER T13 20DBL FEED T...

Page 383: ...M1M O B K M16B ZOBK 1 I X1 16R I 1 8 D B L 8W STOP LAMP B R RIGHT REAR DGN LEFT REAR HAZARD FLAS RIGHT FRONT N LEFT FRONT BK HORN M2f 3Y ACCESSORY LAMPS AND TIME DELAY CONNECTOR rM2C 2OY I IIIllX12 18...

Page 384: ...I I L G 4 1 8 D B L FUEL SENDING UNIT rE2A 1 zyxwvutsrqponm O I r D 3 2 1 8 1 HAZARD FLASHER D31 18P zy 7 F D 3 1 8 P l 17 18BR 18 18DGN 4 18W D4 18W 32 18P c12 18R STOP LAMP SWITCH 1 16R I I I 2A 14B...

Page 385: ...i G5A B P 010 2ODBL ZODBL I 1 I I LOW OIL PRESSURC 010 2ODBL r J1 12R Gl 2OBK C4 14LGN TURN SIGNAL FLASHER D1 18BK GLOVE BOX BATTERY GLOVE BOX rleP LAMP BATTERY I T T SEAT BELT RELAY I G5B G5C 0 TO PA...

Page 386: ...DLAMP SWITCH Ll lZBK PANEL LAMP DIMMER SWITCH zyx 1 PARKING LAMP SWITCH FOR MANUAL TRANS SEE INSEI BRAKE STARTER 6 IGNITION SWITCH HAZARD c I P2 2OBK D3 18P I E I 52 12Y DGN R 18 18P 5 1BDBL I 18BR 4...

Page 387: ...8 154 WIRING DIAGRAMS E O 4 U P z t v zyx p n 1 I I I I w a c 4 I I I I I I I I I I I I J I MyMopar com...

Page 388: ...8 WIRING DIAGRAMS 8 155 z u u u P I k 3 v i d m a zyxwv 5 c I I EE I I I I I k 3 v J Y U 9 i m UJ v I I I 1 I MyMopar com...

Page 389: ...X54A 20R X53A 20DBL IREAR SPEAKER 7 7 X 5 1 2 0 V 2 CONNECTOR CONTROL SWITCH 18V I I INSTRUMENT PANEL AND REAR COMPARTMENT STEREO SPEAKERS WIRING 1 LEFT CHANNEL OUTPUT AUDIO GROUND 4 RIGHT CHANNEL OUT...

Page 390: ...6 R j OY UPART OF INSTRUMENT PANEL MAIN HARNESS XlA 16R I MAPICOURTESY IGNITION SWITCH AND SWITCH TITLE LAMPS WIRING FRONT SPEAKER 1 F21 18DGN F21 18DGN K F23 1BDGN I DGN RADIO WITHOUT FADER SWITCH R...

Page 391: ...RING TO IGNITION SWITCH LAMP TIME DELAY RELAY WIRING M6 20Y M6A 20Y M16A 20BK M16B 20BK TO HEADLAMP ON WARNING BUZZER WIRING INSTRUMENT FEED ACCESSORY FEED GLOVE BOX LAMP CLOCK RIGHT TURN SIGN 3 o G Y...

Page 392: ...BK E2E 18 0 EZB 18 0 M6A 20Y8 M16A 20BK M16B 20BK Gll 20GY M16 20BK 1IIIIIII STOP LAMP SWITCH D3 18P 1 I I i l l I 12V FEED VOLTAGE LIMITER BRAKE SYSTEM OIL PRESSURE rE2F 18 0 E2F 18 0 EZE 18 0 ACCESS...

Page 393: ...NG TO IGNITION SWITCH LAMP TlME DELAY RELAY WIRING III TO HEADLAMP ON WARNING BUZZER WIRING YELLOW MOLD I 4 167 ACCESSORY 1 20BK 8 FEED HAZARD FLASHER D31 18BK PD561 I I I1 I1 SEAT BELT RELAY M16A ZOB...

Page 394: ...0Y 1 CONDIT10NING OR HEATER CONTROL LAMPS C4 16LGN STARTER AND IGNITION SWITCH HEATER BLOWER SWITCH S2 12Y 12Y STARTER 1ZBK ACCESSORY lZDBL IGNITION 1 12BR IGNITION 2 12R BATTERY E2B 18 0 0180 GEAR SE...

Page 395: ...8 162 WIRING DIAGRAMS CONSOLE GEAR SELECTOR LAMP WIRING WME LlGHlSWllCH WIRING W A R WORl I os r m I OF 4 IAIL GAlE AND POWER WINDOW WIRING Fig f 8 Instrument Panel Accessories Satellite MyMopar com...

Page 396: ...OL WI1ING N ONLYl I AIR CONDlllONER CONTROL WIRING REAR WINDOW DEFOGGLRWIRING w TO OD WIWNO Dl COWL WINDOW LlFl SAFLW RELAY WIRING I n IGNITION SWITCH LAMP TIME DELAY RELAY WIRING W Fig 18 Instrument...

Page 397: ...IGHT SIDE COWL CONSOLE GEAR SELECTOR LAMP WIRING 1 4 B K 14BKI PART OF INSTRUMENT PANEL WIRING LEFT SIDE COWL CONNECTION IN TRUNK AREA LEFT DECK LID RELEASE SOLENOID CONNECTION IN DECK LID 14BK ELECTR...

Page 398: ...14P 1 4 G Y 7 PART OF INSTRUMENT PANEL WIRING LEFT SIDE COWL 1 2 T 2 T 1 2 T GROUND LEFT SIDE COWL Y r L 1 2 B K 14DGN 14V _ I WINDOW LIFT SWITCH l4DGN 14 4R 1 4 G RIGHT FRONT DOOR WINDOW LIFT MOTOR F...

Page 399: ...8 166 WIRING DIAGRAMS rn r d m h r I c 0 W Z t nE Eoz MyMopar com...

Page 400: ...NES ONLY BJ3A 14BR IGNITION COIL R6D 6BK I zyxwv 0 FUSIBLE R6 16DBL PD 54 TEMPERATURE SEE ENGINE COMPARTMENT GAUGE GROUND G6 20GY TERMINAL BLOCK AIA IODGN J AI R Fig 21 65 Amp Alternator Fury FUSIBLE...

Page 401: ...ORY FEED YELLOW DQ4 161 WITHOUT TILT WHEEL L r DOOR SWITCH Fig 2 P5 2OBK1 k I y GROUND el LOOSE TERMINAL AND SCR 1 1 I I I E l i LIMITER LEFT TURN SIONAL INDICATOR LAMP G6 2OGY D9 201 4 5 2 O D B L CO...

Page 402: ...HEADLAMP REMINDER Ml6A 2OBK M16B 208K L7A l8BK Y zyxwvu e BUZZER WIRING L7B l8BK Y TIME DELAY YELL0 R 6 1 0 B K x M K JI 12R RELAY WIRING I I HANDBRAI SWITCH 8 Y HEADLAMP DELAY RELAY FEED I I I 4 I M...

Page 403: ...STRUMENT PANEL MAIN HARNESS 1 c4 18B R TILT WHEEL FEED JUMPER HEATER WIRING WITH UPPER VENTILATION IOTE PULL OUT EXISTIN CIR G6 AT BULKHE AND REPLACE WITH CIR G6A CAVITY 15 F v 1 6 D Y CAVITY 29 h J 2...

Page 404: ...TER RELAY ENGINE COMPARTMENq CLUTCH PEDAL RELEASEC CLUTCH START SWITCH SWITCH CLOSED CLUTCH START SWITCH CABLE 1 I 1 1 MANUAL TRANSMISSION ONLY I CLUTCH PEDAL DEPRESSEI oRAIR c C1 12BK zyxw j PART OF...

Page 405: ...lOA 16LGN TO WIRING BODY BLOWER SWITCH L W REAR 0LOWER CONNECTOR C20 16BR TO ACCESSORY FEED REAR AIR CONDITIONING BLOWER SWITCH WIRING cell 1 0 B K 7 2 TO DEFOGGER SWITCH IO 18LGN BODY WIRING BATTERY...

Page 406: ...GN AIR CONDITIONING BLOWER RELAY C2D lIDBL C8 16BR YELLOW TO INSTRUMENT PANEL MAIN HARNESS IGNITION FEED tY FEED ml X42 14LGN SIDE POWER DOOR LOCK RELAY OR FRONT SEAT BACK LATCH WIRING TO FUSE 10 DECK...

Page 407: ...A 16 LGN QYELLOW ACCESSORY FEED L7A 1BBK Y X32 18 BK ACCESSORY P E L L O W FEED xl2 2oiR TEMPERATURE TEMPERATURE INDICATOR INDICATOR RIGHT TURN SIGNAL LAMP COLD LAMP HOT1 BELTS D9A GSB 20 1 2ODBL II C...

Page 408: ...OT DIMMER SWITCH V5 18 DGN2 I M16 20BK D32 18P ACCESSORY FEED El 181 X12 20 R I I I r A N t L LAMP CONSOLE LAMP E 2 C 1 8 0 1 W 9 2 0 T B WINDOW LIFT SAFETY RELAY FEED HORN RELAY BATTERY BATTERY A1B 1...

Page 409: ...18P D32 18P D31 188K C18 16V ClBA 16V HlD ZOBK E2 180 G4A 18DBL W10 208K HAZARD FLASHER I I Cll 16BK FEED C10516LGN C12 16W RECEIVER E25180 zyxw 1 TO WHEEL SLIP RAKECONTROL SYSTEM WIRING SEE ACCESSORY...

Page 410: ...TER C616DBL C17A 16R ATC IN CAR SENSOR ClC 12BK C9 16T HIGH DEFROSTER FEED C1 12BK k 1 2 Y S T A R T 12BK ACCESSORIES 1ZDBL IGNITION 1 r L PSA 208K XlB 2OR IGNITION SWITCH LAMP 1 8 Y U lt JS 20Y START...

Page 411: ...NING LAMP SEE ACCESSORY WIRING TURN SIGNAL FLASHER D29 181 D28 181GN WPA 181 X32A 20BK 52 12Y J2 12DBL J3 l2BR J1 12R eM16A 2OBK D8 18DGN D7 18BR Ml6 2OBK M6A 20Y H3 20BK C2 16Y E2 18 zyxwvutsrqponmlk...

Page 412: ...ASHER RELAY G11 20Y G7A 20GY D29 18T _ _ _ I Y I I L 3 1 1 6 D E L I Y J V206 18DGN RELAY FLASHER 18 18DGN I th L7A 12BK I 18 12P TO LEFT FRONT Doof AUTOMATIC SWITCH TO BODY Cl l 16 8 K z b C12 16W WI...

Page 413: ...ONLY1 zyxwvu 1 IBDGN TAIL LAMPS FUSE 16R BATTERY 20Y IGNlTlO 20V BACK UP LAMP 2OLGN POTS 20w POT SWlTC 18BR W TAIL LAMP 16LBLHEADIAMP SWI 2OBK PHOTOCELL 20GY PHOTOCEL t20v AMPLIFIER BULKHEAD DISCONNEC...

Page 414: ...SWITCH AND POWER ANTENNA WIRING CHRYSLER AND IMPERIAL1 ICHRYSLER ONLY1 n X 3 2 A 2 0 B K o D 2 7 1 B V 1 BULKHEAD DISCONNECT PART OF INSTRUMENT PANEL RIGHT LAMP D LGN LEFT LAMP 027 1BV FEED D29 18T M...

Page 415: ...NT PANEL MAIN HARNESS LOW FUEL SIGNAL RELAY WIRING CHRYSLER SHOWN IMPERIAL SEEINSTRUMENT PANEL MAIN DIAGRAM SI H5 18BK HORN GROUND CABLE CHRYSLERAND IMPERIAL BATTERY FEED 0 BULKHEAD XVITY 2B TO ACCESS...

Page 416: ...FUSE TO BODY WIRINt REAR WINDOW DEFOGGER SWITCH WIRING CHRYSLER ONLY I ETR SW AMBIENT SW GROUND ETR S W C3 C2C 2OY I CZE ZOY Cl3A ZOBK M WIPER MOTOR LOWER STUD Ll AMBIENT SWITCH ELECTRIC FUEL PUMP lM...

Page 417: ...a 1 J PART OF INSTRUMENT PANEL MAIN HARNESS HEATER FEED CLUTCH START SWITCH CABLE HEATER WIRING WITH UPPER VENTILATION CHRYSLER ONLY MANUAL TRANSMISSION CHRYSLER ONLY PART OF HEATER AND AIR CONDITIONI...

Page 418: ...IER CONNECTOR MOLDED GROMMET ENGINE COMPARTMENV FOOT DIMMER SWITCH 4UTOMATIC HEADLAMP DIMMER WIRING IMPERIAL MANDATORYWITH HEADLAMP SENTINEL HEATER BLOWER MOTOR RESISTOR HEATER BLOWER SWITCH DEFROSTER...

Page 419: ...m 8 186 WIRING DIAGRAMS MyMopar com...

Page 420: ...14 16DGN K17 16DGN W K17 16DGN W L K 1 6 1 6 D B CONTROL WIRING ON INSTRUMENT PANEL K2 18T i i i i J GROUND K A K4 t18 jwe GROUND 18V 18BK LGN h r L LEFT REAR WHEEL SENSOR Fig 29 Wheel Slip Brake Cont...

Page 421: ...A full flow screw on throw away type oil filter is mounted on the rear of the oil pump body Oil is forced by the oil pump to a series of oil passages in the engine Fig 4 8 The semi series flow cooling...

Page 422: ...9 2 ENGINE MyMopar com...

Page 423: ...Weak battery a Corroded or loose battery b connections Faulty starter C Moisture on ignition wires and distributor cap d Test battery specific gravity Recharge or replace as necessary Clean and tighte...

Page 424: ...r condenser system ENGINE MISSES ON ACCELERATION Dirty burned or incorrectIy gapped distributor contacts Dirty or gap too wide in spark Incorrect ignition timing Dirt in carburetor plugs e Replace any...

Page 425: ...l new tappets h Worn valve guides i Excessive run out of valve seats i Grind valve seats and valves or valve faces j Incorrect tappet lash j Adjust to specifications carburetor h Ream and install new...

Page 426: ...and Chain 13 Tun e 4p 6 Valves and Valve Springs 10 Valve Timing 1 z 3 SERVICE PROCEDURES TUNE UP To provide best vehicle performance and lowest vehicle emissions it is most important that the tune u...

Page 427: ...install a new factory recommended filter element or equivalent Service unit more frequently when driv ing under severe conditions such as in dusty areas Fig 4 Engine Rear Support Valiant 4 f B Fig 6 F...

Page 428: ...s and transmission filler move engine support fixture rods tube T ON ROCKER SHAFT ADJUSTING SCREW ROCKER ARM Fig 8 Rocker Shaft Assembly 13 Lower vehicle 14 Tighten front engine mount bolts to specifi...

Page 429: ...plugs are located at the wide edge of the combustion chambers and aluminum spark plug tubes serve as spark plug gaskets 15 Place cylinder head in holding fixture Tool C 3626 and remove spark plugs an...

Page 430: ...to ex haust manifoM lo 240 inch pounds SequeMw t w t e n inner bolt first then the outer two bok 9 Start at dnter and work outward Torque in take and exhaust manifold nuts to cylinder to 12G inch poun...

Page 431: ...indicator reading is excessive or if stems are scuffed or scored 5 Service valves with oversize stems are available in 005 015 and 030 inch oversize Reamers to ac commodate the oversize valve stem ar...

Page 432: ...ING KR145B Fig 17 Inspecting Valve Spring Squareness RETAINER SPRING VALVE Fig 19 Installing Valves and Cup Seals Testing Valve Springs Fig 16 1 Whenever valves have been removed for inspection recond...

Page 433: ...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...

Page 434: ...staller Plate the centerline of crankshaft and camshaft Fig 22 10 Tighten camshaft sprocket lock bolt to 35 foot pounds Slide the crankshaft oil slinger over the shaft and up against sprocket flange a...

Page 435: ...case cover over locating dowels and tighten bolts to 15 foot pounds Be sure all oil pan gaskets are in place and tighten oil pan bolts to 200 inch pounds 3 Place damper pulley assembly hub key in the...

Page 436: ...l C 3132A by sliding the new camshaft bearing shell over the proper adapter 2 Position bearing in tool Install horseshoe lock and drive the bearing shell into place Fig 31 The camshaft bearing oil hol...

Page 437: ...loth remains 024 TO 031 IN LESS r T H A N DIAMETER AT C l THE ELLIPTICAL SHAPE OF THE PISTON SKIRT SHOUCD BE 008TO 010 IN LESS AT DIAMETER A THAN ACROSS ETER 8 MEASUREMENT IS MADE 18 IN BELOW LOWER RI...

Page 438: ...ton boss Be sure spring is removed from anvil ANVIL TOOL SCREW TOOL CONNECTING ROD KR195 B GUIDE LARGE TOOL Fig 35 Tool Arrangement for Removing Piston Pin ANVIL TOOL SPRING TOOL MAIN SCREW GUIDE LARG...

Page 439: ...is satisfactory 14 Remove tool CRANKSHAFT IDENTIFICATION A Maltese Cross stamped on the engine number ing pad on right side of block on top boss directly behind the coil indicates that engine is equip...

Page 440: ...Bearing Identification squirt hole side of connecting rod Rotate crank shaft so that connecting rod journal is on the cen ter of cylinder bore 6 Insert rod and piston into cylinder bore and guide rod...

Page 441: ...f brass shim stock 001 inch thickness 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 tighten bolts...

Page 442: ...BEARING OIL SEAL Crankshaft Removed Upper Seal Seal 1 Install a new oil seal in the cylinder block so that both ends protrude 2 Tap seal down into position using Tool C 3743 with bridge removed until...

Page 443: ...ent and wipe dry with a clean cloth Scrape all gasket material from mounting sur face of pan and block Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary Inst...

Page 444: ...ot pounds and secure with cotter pins Install dust shield 3 Install exhaust pipe to manifold use a new gasket Tighten to 30 foot pounds 4 Lower vehicle install oil dipstick and fill crankcase to recom...

Page 445: ...than 004 inch can be inserted between the rotors and straightedge replace pump body 7 If clearance between inner rotor and outer ro tor Fig 56 is more than 010 inch replace inner and outer rotors fig...

Page 446: ...ltage Electrical Section of this manual 3 Tighten the intake manifold bolts to specifications 4 Perform cylinder compression test Compres zyxwv c zyxwvutsrqpon F A Fig I Cleaning Filter Element sion s...

Page 447: ...ty areas 13 Inspect crankcase ventilation system as out lined on page 73 14 Inspect and adjust accessory belt drives refer ring to Cooling System Group 7 for proper adjustments Fig 4 Front Engine Moun...

Page 448: ...transmission mounting bolts Installation 1 Attach engine lifting fixture to carburetor flange studs on intake manifold 2 Attach a crane or other suitable lifting tool to fixture eyebolt 3 Remove engi...

Page 449: ...connect accelerator linkage NU266 Fig 8 Cylinder Head lightening Sequence 4 Remove vacuum control hose between carbure 5 Remove distributor cap and wires 6 Disconnect coil wires heat indicator sending...

Page 450: ...ng Valve Spring four to 25 foot pounds and tighten remaining cap screws to 25 foot pounds in the tightening sequence shown in Figure 9 then retighten cap screws one through four to zyxw 40 foot pounds...

Page 451: ...C 3339 to cylinder head and set it at right angle of valve stem being measured Fig 12 c Move valve to and from the indicator The to tal dial indicator reading should not exceed 017 inch Ream the guide...

Page 452: ...r replacement valve springs should be tested As an example the com pression length of the spring to be tested is 1 5 16 INTAKE VALVE B I R Fig 18 Installing Valve Cup Seals Spring and Retainer inches...

Page 453: ...operated at fast idle for sufficient time to allow all of the air inside of the tappets to be bled out Tappet Noise Diagnosis 1 To determine source of tappet noise operate engine at idle with cylinder...

Page 454: ...ts 2 Install tappets and push rods in their original positions Fig 21 Removing Vibration Damper Assembly 318 Cubic Inch Shown Typical 3 Install rocker arm and shaft assembly zy 4 Start and operate eng...

Page 455: ...16 inch 5 If chain is satisfactory slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket 6 If chain is not satisfactory remove camshaft sprocket attaching cup...

Page 456: ...ve seal Fig 26 5 Insert remover screw through removing and installing plate so that the thin shoulder will be fac REMOVING AND INSTALLING PLATE TOOL REMOVER S C R E W TOOL CHAIN CASE COVER Fig 26 Remo...

Page 457: ...manifold bolt on left side of engine Fig 31 CAMSHAFT new gaskets Tighten bolts to 30 foot pounds drains Engine Removed from Vehicle The camshaft has an integral oil pump and dis tributor drive gear a...

Page 458: ...negative crown dish is observed tappet must be replaced I 3USHIr Fig 35 Removing Distributor Drive Shaft Bushing CAMSHAFT BEARINGS Engine Removed from Vehicle Removal 1 With engine completely disassem...

Page 459: ...rod cap Install connecting rod bolt guide set on connecting rod bolts Push each piston and rod assembly out of cylinder bore Be careful not to nick crankshaft journals 4 After removal install bearing...

Page 460: ...shape It is important that pistons be V 8 019 TO OnIN LESS THAN DIAMETER AT a 1 t aLtumam THE ELLIPTICAL SHAPE OF THE DIAMETER D SHOULD B E PISTON SKIRT SHOULD B E 010 OOOO TO 001 INCH r o On IN LESS...

Page 461: ...43 Removing Piston Pin Piston Pin Removal 360 Cubic Inch Only ton pin Fig 42 1 Arrange Tool C 4158 parts for removal of pis 2 Install pilot on main screw 3 Install main screw through piston pin 4 Inst...

Page 462: ...ring 2 Insert feeler stock in the gap The ring gap should be between 010 and 020 inch for compres sion rings and 015 to 062 inch for oil ring steel rails in standard size bores for new service rings M...

Page 463: ...lower bearing shell make certain that the V groove in the shell is in line with the V groove in the cap This pro vides lubrication of the cylinder wall in the opposite bank The bearing shells must be...

Page 464: ...F ADDITIVES IN STANDARD OR HIGH PERFORMANCE ENGINES CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for ex cessive wear taper and scoring Limits of taper or out of round on any cran...

Page 465: ...ch undersize shell Always use the smaller diameter bearing half as the upper Never use an upper SEAL Fig 53 Removing Upper Oil Seal with Tool C 4148 bearing half more than 001 inch smaller than the lo...

Page 466: ...oil pan lnsfallation 1 Inspect alignment of oil strainer Bottom of strainer must be parallel with the machined surface of the cylinder block Bottom of strainer must touch bottom of oil pan with 1 16...

Page 467: ...8 318 340 360 ENGINE 9 47 b 2 Y U m I Y 4 zyxwvut I v zyxwvutsrq a Lu Y U 8 MyMopar com...

Page 468: ...8 Relief Valve Spring and i STRAIGHT EDGE FEELER GAUGE Fig 60 Measuring Oil Pump Cover Flatness Fig 62 Measuring Inner Rotor Thickness be smooth If cover is excessively scratched or grooved it should...

Page 469: ...g a new retainer cap Spring seats inside retainer cap Press retainer in housing so that top of retainer cap is within the relief valve bore diameter as shown in Figure 66 Install cotter pin 12 If oil...

Page 470: ...bolts to 50 foot pounds 4 Perform cylinder compression test Compres sion should not be less than 100 pounds for 400 440 Cubic Inch Engines and not vary more than 40 pounds 110 pounds for 440 Cubic In...

Page 471: ...ith Heat Shield on Fender Apron 1 3 5 7 2 4 6 8 TOP Bottom Bottom Bottom Top or Bottom Top or Bottom Bottom Bottom Ratchet Box Wrench Box Wrench Box Wrench Ratchet Ratchet Ratchet Avoid heat riser val...

Page 472: ...radiator 5 Disconnect fuel lines and wires attached to en gine units Remove air cleaner and carburetor 6 Attach engine lifting fixture to carburetor flange studs on intake manifold 7 Raise vehicle on...

Page 473: ...bly making sure to install the long stamped steel retainers in the number two and four positions 2 Install rocker shafts so that 3 16 inch diameter rocker arm lubrication holes point downward into ROC...

Page 474: ...ent rods 6 Install push rods in the tappets maintaining alignment using rod Fig 7 7 Install rocker arm and shaft assembly starting CYLINDER HEAD INTAKE PUSH RODS INSTALLING ROD Fig 7 Push Rods Install...

Page 475: ...cylinder head removed compress valve springs using Tool C 3422A Fig 8 2 Remove valve retaining locks valve spring retainers valve stem cup seals and valve springs 3 Before removing valves remove any b...

Page 476: ...3 When the seat is properly positioned the width of the intake seats should be 1 16 to 3 32 inch The width of the exhaust seats should be 3 64 to 1 16 inch 4 Measure the concentricity of the valve se...

Page 477: ...the Hydraulic Tappets 1 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 p...

Page 478: ...5 Pull tappet out of bore with a twisting motion If all tappets are to be removed identify tappets to insure installation in original location A diamond shaped marking stamped on the en gine numbering...

Page 479: ...pect timing chain for wear and determine accuracy of the DC mark on timing indicator Turn crankshaft counterclock wise until valve is closed and remove the indicator and spacer CAUTION Do not turn cra...

Page 480: ...camshaft sprocket 10 Lift sprockets and chain keep sprockets tight against chain in position as described 1 1 Slide both sprockets evenly over their respec tive shafts 12 Use a straight edge to measu...

Page 481: ...6 Installing New Seal CHAIN CASE COVER TIMING INDICATOR CYLINDER BLOCK TIMING MARK VIBRATION DAMPER TOOL A KRl57A Fig 28 Installing Vibration Damper Assembly 9 The seal is properly installed when the...

Page 482: ...ed all of the tap pet faces must be inspected for crown with zyxwvu a straight edge If any contact surface is dished or worn tappet must be replaced Fig 31 Removing Distributor Drive Shaft Bushing CAM...

Page 483: ...rive gear will be parallel with center line of crank shaft Fig 34 Insfallation o f Disfribufor 1 Hold distributor over mounting pad on cylin der block with vacuum chamber pointing toward center of eng...

Page 484: ...LLIPTICAL SHAPE OF THE PISTON SKIRT SHOULD BE 010 TO 012 IN LESS AT DIAMETER A THAN ACROSS THE THRUST FACES AT DIAMETER 6 MEASURE MENT IS MADE IN BE LOW LOWER RING GROOVE NU258 DIAMETERS AT C AND D CA...

Page 485: ...Ring gap should be between 013 to 052 inch for the compression rings and 015 to 062 inch for the oil ring steel rails in standard size bores Maximum gap on 005 inch O S bores should be 060 inch for co...

Page 486: ...the con necting rod 7 Install main screw and piston pin in piston Fig 40 8 Install nut on puller screw to hold assembly together Place assembly on a press Fig 41 9 Press piston pin in until piston pin...

Page 487: ...e Do not 001 UNDERSIZE 1 4 LETTERS M 10 010 UNDERSIZE p m Fig 44 Showing Location of Internal Marking of Counterweight alternate from one bank to another because when rods are assembled to the pistons...

Page 488: ...EQUIVALENT SHOULD BE ADDED TO THE INITIAL ENGINE CRANKCASE OIL FILL REFER TO LUBRICATION GROUP 0 FOR 2 385 3 4 5 UPPER 4 THRUST BEARING Fig 46 Main Bearing Identification SUBSEQUENT USE OF ADDITIVES I...

Page 489: ...t size 4 Measure crankshaft end play 002 to 007 inch If end play is less than 002 inch or more than 007 inch install a new number 3 main bearing 5 Fit remaining bearings in same manner It is permissab...

Page 490: ...ing lower Oil Seal for 440 Cubic Inch Engines with bridge removed until tool is seated in bearing bore 3 Hold the tool in this position and cut off por tion of seal that extends above the block on bot...

Page 491: ...ttom of the strainer must touch the bottom of oil pan 2 Clean oil pan gasket surface Inspect pan rail for distortion and straighten if necessary 3 Install oil pan 4 Install converter dust shield 5 Con...

Page 492: ...ase surface Fig 53 If a 0015 inch feeler gauge can be inserted between the base and straightedge filter base should be replaced Fig 58 Measuring Clearance Between Rotors 3 If outer rotor length measur...

Page 493: ...nscrew the filter from the base on bottom side of engine and discard Fig 59 2 Wipe base clean Installation 1 Install the spin on oil filter by hand finger tight Do not use tool 2 To obtain an effectiv...

Page 494: ...See the Lubrication and Maintenance section Group 0 of this manual for proper service procedures REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads can be repaired by the use of Heli Coils Esse...

Page 495: ...ngeability of Bearings CRANKSHAFT MAIN BEARINGS service CONNECTING RODS AND BEARINGS All available in Standard and the following Undersizes Type Length Centerto Center Weight Less BearingShells Bearin...

Page 496: ...arance in Block Clearance BetweenValve Stem and Rocker Arm Pad Engine Hot 0013 to 0026 9040 to 9045 010 Intake 020r Exhaust Body Diameter PISTONS Type Material Land Clearance diametrical Clearance at...

Page 497: ...ne Stem Diameter Stem to Guide Clearance Maximum Allowable Before Reconditioning Valve Face Angle Adjustment Lift VALVES Exhaust Material Head Diameter Length togauge dim Line Stem Diameter Maximum Al...

Page 498: ...Oversize Cylinder Bore Distributor Lower Drive Shaft Bushing pressfit in block Ream to Tappet Bore Diameter Shaft to BushingClearance Wedge Type 002 45 070r to zyx 090 45 040 to zyx 060 022 3 4000 00...

Page 499: ...3 main bearing journal and or R 1 4etc indicating No 1 4 connecting rod iournals 010 U S Crankshaft Maltese Cross and X M 10 indicates 010 Crankshaft counterweight U S all main journals and or R 10 in...

Page 500: ...9 80 SPECIFICATIONS H x x x b zyx v zyxw o O b o s 0 cn e B bbic b W h l o w o s 8 1 9 inink o w 0 ic k 0 E a o 7 Z o C m a o c m m E 0 c c 0 m L m i i MyMopar com...

Page 501: ...8 SPECIFICATIONS 9 8 1 p zyxw a 1 E zyxwvu 3 E c cn I g E b L a v a U MyMopar com...

Page 502: ...9 82 SPECIFICATIONS I z c3 z zyxwvu t T d v a z Q 0 L m C a e S 3 3 s MyMopar com...

Page 503: ...8 SPECIFICATIONS 9 83 z 0 9 z P7 a 5 c 0 u c 1 0 g rr F v C 9 3 b v z z z z z 0 0 0 0 0 W n 5 a 0 a g _ 0 0 0 0 0 z z z z z m MyMopar com...

Page 504: ...9 84 SPECIFICATIONS 8 zy io zy c 2 8 cu a3 c f c b b I g v z c Q g n C e a k o E 2 m m a I E E u E Q J m Q J N a 1 2 o A I m 3 I X w I cn W a Y MyMopar com...

Page 505: ...8 SPECIFICATIONS 9 85 E zyxwvuts E cr E w v S E W w L W U zyxwvu C W L a 3 o I b r o w s w s L n w O L L V S O noo g E a a c 3 3 c w O o o r S g E G g a 3 L L MyMopar com...

Page 506: ...005 O S Valve Stems X Milled pad adjacent to two 3 8 tapped holes on each end of cylinder head ENGINE 400 440 Type Number of Cylinders Bore Stroke Piston Displacement Compression Ratio Minimum Compres...

Page 507: ...od Pins for Service Number of Rings per Piston Compression PISTON RINGS Oil Oil Ring Type Ring width Compression Oil Steel rails Compression Oil Steel rails Ring Gap 1 3 5 7 2 46 8 4 2495 4 25 15 005...

Page 508: ...ble Out of Roundand or Taper Drive Bearings Number DiametraIClearance Maximum Allowable before Reconditioning Thrust Taken By CAMSHAFT 0015 0030 zyxw OOOO 005 013 023 015 062 0015 004 OOOO 005 6 356 6...

Page 509: ...ween Valve Stem and Rocker TIMI NG CHAIN 50 TAPPETS Body Diameter Clearance in Block 9035 9040 0011I f 0024 Std 001 008 030 Arm Pad Dry Lash 060 210 002 45 060 085 45 040 zyxwv 060 CYLINDER HEAD Valve...

Page 510: ...earance Valve Springs ENGINE LUBRICATION Pump Type Capacity qts Pump Drive Minimum Pump Pressure Idle Operating Pressure at 2000 Engine RPM Pressure Drop Resulting from Clogged Filter Oil Filter Type...

Page 511: ...S Engine Displacement Condition Identification Location of Identification 400 cu in OOl I U S Crankshaft Maltese Cross Top of front pad Right 440 cu in side of block M 2 3etc indicating Crankshaft cou...

Page 512: ...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 Attac...

Page 513: ...nder Block Flywheel Housing Cover Intake Manifold Oil Pan Drain Plug Oil PanScrew Oil Pump Cover Bolt Oil Pump Attaching Bolt Rocker Arm Adjusting Screw Lock Nut Rocker Shaft Retainer Bolt Spark Plug...

Page 514: ...lt Alternator Adjusting Strap Bolt Alternator Adjusting Strap Mounting Bolt Intake Manifold Bolt Oil Pan Drain Plug Oil Pan Screw Oil Pump Cover Bolt Oil Pump Attaching Bolt Rocker Shaft Bracket Bolt...

Page 515: ...ss or chromized steel components The tail pipes on all models are made Page 318 340 360 CID 15 400 440 CID 16 6 Cylinder Engines 16 318 340 360 CID 17 400 440 CID 18 SERVICE DIAGNOSIS 11 SERVICE PROCE...

Page 516: ...11 2 EXHAUST SYSTEM AND INTAKE MANIFOLD U NUT PLATE Fig 2 Valiant Exhaust System 318 CID Fig 3 Duster Exhaust System 340 CID MyMopar com...

Page 517: ...m EXHAUST SYSTEM AND INTAKE MANIFOLD 11 3 NR335D Fig 4 Satellite Exhaust System 225 CIO MyMopar com...

Page 518: ...11 4 EXHAUST SYSTEM AND INTAKE MANIFOLD ASSEMBLY VIEW zyxwvutsrqp F VIEW G PB178 Fig 7 Satellite Dual Exhaust System 400 4V CID MyMopar com...

Page 519: ...LD 11 5 SIDE RAIL ASSEMBLY SIDE RAIL ASSEMBLY SUPPORT I I I TAIL PIPE 440 CU IN 6 BARREL ONLY 2 DOQR MODELS ONLY Fig 8 Satellite Exhaust Extensions PD487 INSULATOR ASSEMBLY BOLT 4IL PIPE Fig 9 Fury Ex...

Page 520: ...een the exhaust pipes and pipe extensions on Fury Chrysler and Imperial models with 400 and 440 cubic inch engines Fig 11 to facilitate installation and alignment of the system The single and dual exh...

Page 521: ...ght cylinder engines where exhaust gases are taken from the intake manifold exhaust crossover passage In six cylinder engines gases are taken from the ex haust manifold plenum chamber located at the h...

Page 522: ...11 8 EXHAUST SYSTEM AND INTAKE MANIFOLD VIEW J RIGHT O R LEFT SIDE TIGHTENING TORQUE LEFT FLANGE ONLY ASSEMBLY LEFT PY207B Fig 1 2 Fury Chrysler Dual Exhaust System 400 4e 440 4V C O MyMopar com...

Page 523: ...EXHAUST SYSTEM AND INTAKE MANIFOLD 11 9 MyMopar com...

Page 524: ...11 10 EXHAUST SYSTEM AND INTAKE MANIFOLD w U MyMopar com...

Page 525: ...Valve Installation Six Cylinder Engines SERVICE DIAGNOSIS Possible Cause Correction EXCESSIVE EXHAUST NOISE a Leaks at pipe joints a b Burned or blown out muffler b c Burned or rusted out exhaust c d...

Page 526: ...d gaskets and careful ly clean manifold flanges of any gasket particles 4 Remove muffler and extension pipe assembly 5 Raise rear end of vehicle to relieve body weight from rear springs and remove tai...

Page 527: ...racuda Install exhaust system as prescribed for other SYSTEM AND INTAKE MANIFOLD 11 13 NOTE CONNECTOR MUST BE SCREWED ON NUT AN 2 FULL TURNS TORQUE TIGHTENING PD441 Fig 18 Carburetor Air Heater 318 34...

Page 528: ...air heater replace if damaged Installation 1 Refer to Figure 19 install carburetor air heater with attaching screw and washer assemblies Torque to specifications and carburetor air heater INTAKE AND...

Page 529: ...NIFOLD 318 340 360 CU In Engines Remove intake manifold as outlined in Group 9 Engine Servicing 1 Clean manifold in solvent and blow dry with Fig 27 Installing Exhaust Manifold 378 440 CIDj compressed...

Page 530: ...ck and forth until it turns freely Installation CAUTION If studs came out with the nuts install new studs applying sealer on the coarse thread ends If this precaution is not taken water leaks may deve...

Page 531: ...Complete assembly and installation 318 340 AND 360 CID ENGINES Removal 1 Remove exhaust pipe from manifold 2 Remove exhaust manifold from engine VALVE STOP WITH VALVE PLATE SET TO CLOSED POSITION IND...

Page 532: ...ngs and seals 4 Mark one end of shaft with a suitable dye at 1 240 inches press counterweight on marked end of shaft until flush with end of shaft 5 Install thermostatic springs on counterweight with...

Page 533: ...ree move ment in the coil housing If unit binds a new unit should be installed The well type choke is serv iced as an assembly Do not attempt to repair or change the setting Changes of the choke setti...

Page 534: ...eaned in a suitable solvent then inspected for damage or wear 3 Use air pressure only to clean the various orif z 4 Replace questionable parts with NEW ONES ices or channels CLEANING CARBURETOR PARTS...

Page 535: ...n park position Off its readings and indicates a richer mixture as the carburetor is leaned out if carburetor is set too lean c When it has been established that the meter is indicating a lower readin...

Page 536: ...throttle body assembly d Replace idle mixture screws 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...

Page 537: ...ure If pressure is in excess of recommended pressure replace fuel pump assembly b Leaking float c High float level c Adjust float level as necessary d Excessive fuel pump pressure d Test fuel pump pre...

Page 538: ...t or dirty such that the system is not entirely free to move from the open to the closed position d Choke valve improperly seated e Air cleaner gasket interferes e Reinstall gasket properly with choke...

Page 539: ...cubic inch engine in the BOWL VENT VALVE OPERATING LEVER ECONOMIZER COVER CHOKE VALVE BOWL VENT VALVE PLUNGER STEM Page Idle Speed Adjustment 11 Disassembling Carburetor 8 General Information 7 Inspe...

Page 540: ...ial item Fig 1 As the vacuum diaphragm bracket is being removed the bowl vent valve rod and spring will fall out Fig 2 To01 C 3866 CHOKE VACUUM DIAPHRAGM TUBE FITTING PY1091A Fig 2 Removing or Install...

Page 541: ...all idle mixture screw and spring in body The tapered portion must be straight and smooth If tapered portion is grooved or ridged a new idle FLOAT SPRING r CARBURETOR INVERTED Rg 8 Adjusting Float Lev...

Page 542: ...g a finger 2 Engage choke link in slot in choke lever 3 Install vacuum diaphragm assembly be sure vent rod is in position Install diaphragm attaching screws and tighten securely 4 Inspect vacuum diaph...

Page 543: ...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 CAUTION DO NOT APPLY TWISTING OR BEND FAST I...

Page 544: ...am Position 17 18 Fast Idle Speed On Vehicle GENERAL INFORMATION Ball and Ball dual throat 1 1 4 inch carburetor models BBD 6149s and BBD 6150s are used on the 318 cu in engines when the vehicles are...

Page 545: ...lips and disengage fast idle connector rod from fast idle cam and choke lever 4 Remove vacuum hose between carburetor main body and choke vacuum diaphragm 5 Remove clip from choke operating link and d...

Page 546: ...screw as the same number of turns from MAIN METERING JET NN696B J MAIN METERING JET Fig 4 Removing or lnsialling Main Meiering Jeis ACCELERATOR PUMP INTAKE CHECK BALL DISCHARGE AT BOnOi CHECK BALL OF...

Page 547: ...install new check balls The fuel inlet check ball is located at bottom of the plunger well Remove fuel from bowl 5 Install new gaskets on venturi cluster then in stall in position in main body Fig 5...

Page 548: ...ll air horn Fig 2 Install attaching screws and tight en securely When installing air horn be sure leath er on plunger does not fold back Install dash pot if so equipped 3 Engage fast idle connector ro...

Page 549: ...valve opening has been obtained Fig 12 DRILL OR GAUGE zy CHOKE VALVE DIAPHRAGM STE RETRACTED BY VAC PB375 Fig 13 Adiusting Choke Vacuum Kick Vacuum Kick Adjustment This test can be made ON or OFF vehi...

Page 550: ...e Speed Adjustment Curb Idle Section Fast Idle Speed Adiustment On Vehicle Refer to General Information at Front of Fast idle engine speed is used to overcome cold I x FAST IDLE SPEED CHOKE VALVE FAST...

Page 551: ...VER PLATE I I CHOKE ACCELERATOR PUMPzyxwvutsrq S CONNECTOR LINK I Page Choke Unloader Adjustment Wide Open Kick 27 Secondary Throttle Lockout 28 Bowl Vent 28 Fast Idle Speed Adjustment On Vehicle 28 I...

Page 552: ...e vacuum kick diaphragm provides two separate functions It still provides for vacuum kick but it also controls the secondary air valve Because of the separate nature of the two functions two separate...

Page 553: ...catch intake check seat disc disc retainer spring light pump plun ger and plunger spring heavy 6 If inspection shows plunger can be used again place in a jar of clean gasoline or kerosene to pre vent...

Page 554: ...hrottle shaft with the valve number on the bottom flange Fig 6 Step up Actuating Lever Installation side and opposite the vacuum port 4 Install new screws but do not tighten Be sure idle speed adjusti...

Page 555: ...take check seat with flange down on a clean flat surface 4 Position accelerator pump bore over the assembly then apply firm hand pressure to bowl cover to seat intake check seat in pump bore Fig 5 Ins...

Page 556: ...er gasket to bottom side of float should be 1 00 inch To adjust bend lever Fig 9 Never allow lip of float be pressed against needle when adjusting 13 Install accelerator pump passage tube plastic 14 C...

Page 557: ...wide open position and invert the carburetor Slowly open the primary throttle valves until it is possible to meas ure 11 32 inch between the lower edge of the pri mary valve and the bore opposite idl...

Page 558: ...to provide correct choke thermostat loads and choke linkage operation Adjust as follows 1 Off vehicle place carburetor on flat object with surface flush against bottom of flange and ex tending out und...

Page 559: ...s a spring connecting the control lever to an adjustment lever This spring must be fully extended for proper measurement of vacuum kick adjustment 5 Adjustment will be necessary if slight drag is not...

Page 560: ...ool remove bowl vent valve checking hole plug in bowl cover 2 With throttle valve at curb idle insert a nar row ruler down through hole Allow ruler to rest lightly on top of valve The reading should b...

Page 561: ...ecifications 3 After specified rpm has been obtained and with engine still running with solenoid energized adjust slow curb idle speed screw until end of screw just touches stop Now back off one full...

Page 562: ...Remove nut and washer attaching accelerator pump rocker arm to accelerator pump shaft Re ACCELERATOR PUMP ROD 3198 Fig 2 Removing or Installing Accelerator Pump Rocker Arm move arm from flats on pump...

Page 563: ...ft air horn straight up and away from main body Long screw in center USE EXTREME CARE WHEN HANDLING AIR HORN SO AS NOT TO 111 PB380 Fig 5 Removing Bowl Vent Valve Operating fever E Clip ACCELERATOR AC...

Page 564: ...T REMOVE SERVICED IN AIR HORN CASTING ONLY VACUUM POWER PISTON I Fig 11 Removing Vacuum Power Piston blown dry with compressed air If carburetor parts are cleaned in a basket be sure other carburetor...

Page 565: ...ages in the castings should be free of restrictions Install new castings as required Refer to General Information Section at front of k SPECIAL TOOL Fig 73 Removing or Installing Power Valve zy 1 PY84...

Page 566: ...arge passage Fig 15 Air Horn 1 Test freeness of choke mechanism in air horn The choke shaft must float free to operate correctly If choke sticks in bearing bores or appears to be gummed from deposits...

Page 567: ...on bottom of vent valve Slide plas tic valve and seal into cover with valve recess mat Installing Air Horn ing with shoulder on underside of cover 1 Place a new gasket on air horn then check to 6 Inst...

Page 568: ...EED r ADJUSTING SCREW ON Fig 23 Fast Idle Cam Position Adjustment Speed Adjustment on Vehicle paragraph However the Fast Idle Cam Position Adjustment can be made on the bench This adjustment is import...

Page 569: ...llowing check With no vacuum ap plied to diaphragm the choke valve should move freely between open and closed positions If move ment is not free examine linkage for misalignment or interferences cause...

Page 570: ...eter and set the curb idle speed and mixture then pro ceed as follows 1 With the engine off and transmission in PARK or NEUTRAL position open throttle slightly 2 Close choke valve until fast idle scre...

Page 571: ...cally operated air bleed to relieve an overrich con dition at idle in case of abnormal temperature Since the service procedures are identical on all Holley four barrel carburetors the illustrations s...

Page 572: ...m CHOKE YALVE CHOKE LINK SKONDARY FUEL BOWL JUM SECONDARY THROTTLE CONNECTING LINK FAST CURB IDLE SOLENOID PB467A FAST CU RBSPEED ADJUSTING zyxwv SCREW Fig 2 Carburetor Assembly Holley Model 4160 Man...

Page 573: ...VALVE SECONDARY FUEL BOWL SECONDARY VACUUM DIAPHRAGM CARBURETOR CLEANER TUBE PRIMARY FUEL BOWL CHOKE VACUUM DIAPHRAGM ADVANCE TUBE CONNECTION CLOSE CRP VENT TUBE PB468A Fig 3 Carburetor Assembly Holle...

Page 574: ...f 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 strong enough to d...

Page 575: ...e The difference between the pressure in the ARGE NOZZLE POWER VALVE Fig 7 Power Enrichmeni Sysiem booster venturi and the normal air pressure in the float chamber causes fuel to flow through the main...

Page 576: ...mp diaphragm up As the diaphragm moves up the pressure forces the DIP CI PRIMARY DIAPHRAGM SECONDARY DIAPHRA M ROD THROTTLEPLATE NP604C Fig 9 Secondary Throttle Operation System pump inlet check ball...

Page 577: ...es are opened further the pressure differential causes the secondary main metering system to begin functioning CHOKE CONTROL LEVER VACUUM TUBE THERMOSTATIC IDLE COIL SPRING LEVER ASSEMBLY NP606B Fig 1...

Page 578: ...fully cleaned in a suit BOWL VENT PRIMARY METERING FUEL VALVE ASSEMBLY b TRANSFER BOWL VENT PRIMARY METERING FUEL FUEL PUMP LEVER ACCELERATING PUMP OPERATING LEVER PB463A Fig 12 Removing or Installing...

Page 579: ...t Fig 15 If so equipped 14 Remove curb idle speed screw and spring BAFFLE PLATE BBrEVENT FLOAT NEEDLE AND SEAT ASSEMBLY ACCELERATOR PUMP COVER AND LEVER FLOAT SPRING PB471 Fig 16 Primary Fuel BOW Asse...

Page 580: ...file 2 Slide damaged throttle valves out of bores It should be noted at this time that the secondary throttle valves are thicker than the primary valves Be sure to install throttle valves in same bore...

Page 581: ...th tabs against stop 2 Slide a new gasket over power valve and install using Tool C 3747 Tighten securely Fig 3 Install main metering jets Fig 18 using Tool 17 C 3748 Tighten securely PB474A Fig zyxwv...

Page 582: ...rottle body then low CURBzyxwvutsrqp IDLE PB476A fig 23 Main Body Identification Bottom View er main body Fig 23 down on throttle body aligning roll pin guides with openings in main body Be sure prima...

Page 583: ...ix does not correct the condition a new carburetor will have to be installed 12 Install pump discharge nozzle gasket nozzle and mounting screw and gasket Tighten screw securely Test nozzle operation P...

Page 584: ...t Fuel Level I t h THROTTLE VALVES IN PUMP VERRIDE rrpJl ADJUSTING SCREW PB479A Fig 27 Checking Accelerator Pump lever Cleamnce Checking Bowl Vent Valve Clearance To check the bowl vent valve clearanc...

Page 585: ...n the wide open position Insert the specified drill between the upper edge of the choke valve and the inner wall of the air horn see specifications 3 With a finger lightly pressing against the choke c...

Page 586: ...OKE VALVE RETRACTED ADJUST VCK w u n T CLOSlNG PRESSURE PD319 Fig 32 Vacuum Kick Adjustment choke valve within the air horn by use of linkage between the choke shaft and the diaphragm The diaphragm m...

Page 587: ...end of screw just touches stop on carburetor throttle lever Now back off one full turn to obtain slow curb idle speed setting Approximately 600 to 650 rpm with sole noid de energized Checking Wet Fue...

Page 588: ...ssembly the fuel bowl the metering body assembly and the throttle body Operation The carburetor uses the four basic systems re quired for efficient carburetion These four systems are The idle system w...

Page 589: ...4 57 DISTRIBUTOR I FAST U R B SOLENOID PLUNGER GROUND SWITCH LEAD IDLE SOLENOID CENTER FRONT VACUUM THROTTLE CONTROL VACUUM DIAPHRAGM Fig I Tri Carburefor lnsiallafion THROTTLE CONTROL VACUUM RIBUTOR...

Page 590: ...rating pump Fig 4 is located in the bottom of the fuel bowl The pump begins to func tion when the pump operating lever is actuated by throttle movement When the throttle is opened the pump linkage act...

Page 591: ...s function identically only one side will be considered in this explanation Fuel flows from the float chamber through the main metering jet and into the idle tube The fuel flows up the idle tube and i...

Page 592: ...nce The carburetor is teamed with the distributor to effect spark timing that will satisfy all engine speed and load conditions The spark must be advanced as the engine speed is increased since a defi...

Page 593: ...G SCREW OKE DIAPHRAGM CRANKCASE VENT BOWL VENT TUBE PLUG THROTTLE CHOKE CONTROL LEVER BODY BOWL VENT ER IG FUEL LEVEL ADJl ACCELERATING PUMP ADJUSTING SCREW FAST CURB IDLE ADJUSTING SCREW FUEL BOWL AT...

Page 594: ...DIAPHRAGM VACUUM NU1005 Fig I I Removing or Installing Fast Idle Cam lever ACCELERATOR PUMP DISCHARGE NOZZLE GASKET ATTACHING SCREWNU1OO Fig zyxwv IO Removing or Installing Metering Body Fig 1 2 Remov...

Page 595: ...EWS 2 VALVE SEAL PB489 Fig I 6 Removing or Installing Bowl Vent Valve FLOAT FLOAT SPRING LEVER I ET FLOA ATTACH IN SCREWS PB491A Fig I 8 Removing or Installing Float Assembly Disassembling Main Meteri...

Page 596: ...a rinse it INSTALLATION TIGHTEN TO 120 INCH POUND POWER VALVE Fig 20 Removing or Installing Power Valve NUlOldA IDLE MIXTURE SCREW 2 Fig 22 Removing Idle Mixture Screws and Gaskets should be HOT After...

Page 597: ...dle air mix ture ports then thread idle air mixture screws through gasket and into body using a small screwdriver Lightly seat screws then back off num ber of turns from seat counted at disassembly Be...

Page 598: ...ll new clamp over vacuum diaphragm hose with tee for outboard carburetors then slide hose over tube fitting Fig 26 Position clamps properly Choke Vacuum Diaphragm Inspect the diaphragm vacuum fitting...

Page 599: ...ter qualifi cation of the choke control lever 1 Open the throttle to mid position 2 Close the choke valve by slight pressure on 3 The top of choke rod hole in control lever choke control lever 1 k 1 L...

Page 600: ...etor and connect it to the hose from the vacuum supply with a small length of tube to act as a fitting Removal VACUUM DIAPHRAGM STEM RETRACTED Fig 32 Vacuum Kick Adiusfmenf of the hose from the diaphr...

Page 601: ...s with the center or control carburetor proceed as follows 1 Remove air cleaner if not previously done then remove outboard throttle connector rod clips and disengage front and rear rods from throttle...

Page 602: ...OL VACUUM DIAPHRAGM ADJUSTING NUT FUEL LEVEL SIGHT PLUG VACUUM TUBE FITTING LOCK SCREW FUEL VENT FUEL LEC ADJUSTING zyxwvutsrqpo N I FUEL BOWL Y THROTTLE CONTROL VACUUM DIAPHRAGM THROTTLE LEVER THROTT...

Page 603: ...ng Metering Body Plate and Gaskets 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 o...

Page 604: ...Installing Main Body FUEL PUMPS INDEX Page Page Service Diagnosis 74 Specifications 85 Testing Fuel Pump On Vehicle 75 Electric Fuel Pump 73 Fuel Vapor Separator 75 General Information 72 Fig 4 optio...

Page 605: ...iaphragm upwards against the fuel pump main spring creating a vacu um in the valve housing and opens the inlet valve and fuel is drawn into the valve housing chamber On the return stroke the main spri...

Page 606: ...FFICIENT OR NO FUEL DELIVERY Worn ruptured or torn a Install new pump diaphragm Loose diaphragm mounting b Install new pump plates Loose inlet or outlet line c Tighten line fittings fittings Cracked o...

Page 607: ...1 quart of fuel in 1 Inlet Volve Test on the inlet fitting while the line is disconnected To test the inlet valve connect a vacuum gauge 1 Start engine or turn over with starting motor 2 There should...

Page 608: ...ow forward to the charcoal canister Fig 1 Limiting valves are not required on Station Wag ons or Satellite model passenger cars due to the co nfiguration of the fuel tank The charcoal canister is a ne...

Page 609: ...I FUEL TANKS FUEL SYSTEM 14 77 Fig 1 Evaporation Confrol Sysfem VIEW IN DIRECTION OF ARROW C VIEW IN DIRECTION OF ARROW D Fig 2 Fuel Tank Assembly Valiant PD342 MyMopar com...

Page 610: ...TANK INSULATOR ASSEMBLY VENT TUBE VAPOR QUARTEP PANEL Fig 3 Fuel Tank Assembly Barracuda SHIELD PY954Bzy O F ARROW 2 CHARCOAL CANISTER VIEW I VIEW IN DIRECTION SCREW 4 SCREW 3 OF ARROW X N DIRECTION...

Page 611: ...el Tank Assembly Satellite Station Wagon Only BRACKET J BOLT 2 VIEW IN DIRECTIONzyxwvuts O F ARROW A BRACKET TO CHARCOAL P I WASHER WPCLAMP FLOOR PAN FILLER TUBE MEMBER INSULATOR PB503A Fig 6 Fuel Tan...

Page 612: ...re con nected to a vapor liquid separator by rubber hoses The vapor liquid separators are various containers which internally holds four vent lines from the tank and a vent line which leads to the cha...

Page 613: ...ith both hands twist tube and at the same time force upwards away from tank until end of tube clears quarter panel Remove gasket If tube is frozen in tank use a rubber lubri cant around joint and work...

Page 614: ...lamps securely 6 On models with dual exhaust install tail pipe 7 Install heat shield with attaching screws 8 Reconnect fuel supply line ground strap and 9 Refill tank and check for leaks wire lead to...

Page 615: ...all new clamps on vent tube then install tube on tank fitting Tighten clamps securely 4 Raise hoist far enough to engage spring hanger with frame 5 Position left rear spring hanger at frame and instal...

Page 616: ...14 84 FUEL TANKS FUEL SYSTEM BRACKET Fig 1 Throttle Linkage Adjustment 6 Cylinder Engines BRACKET ASSEMBLY NU454 Fig 2 Throttle Linkage Adjustment 8 Cylinder Engines MyMopar com...

Page 617: ...I m N N m h l N m N N L n N N m N N a3 z a3 2 a3 z CO z i 5 u z W 5 4 0 n E n Lu z 3 z w Q ml b b b m b m m m m o m m m m 0 4 C O m d d N e 0 m m m Q W h d b b Om03 m b d 0Q C O m b b OCTlO3 m d d 2 n...

Page 618: ...eed RPM After Approx 500 Miles if necessary CHOKE BBD 6149s BBD 6150s BBD 6151 BBD 6152 318 318 318 318 Automatic Manual Automatic Manual 1 7 16 1 711 6 1 711 6 1 7 16 1 31 16 1 3 16 1 3 16 1 3 16 120...

Page 619: ...4 87 z K W rn E 3 2 I W n zyxwvu a L a m a 0 5 0 3 a 0 8 d 8 d 0 0 U 0 d m 0 d 0 iu t zyxwvuts A a 5 m v Q 0 v U K m E 3 7 E 3 E 3 7 E 3 7 E 3 c b 9 Q 0 Y L 8 0 Q 8 9 L 0 JZ I 0 9 I Q 0 1 Y V E K a P...

Page 620: ...d RPM Fast Idle Speed Engine Hot and of float and float stop Screw on Second Highest Step of Cam RPM CHOKE R 6164A 360 Automatic 1 9 16 1 13 32 65 64 63 3 Slot 250 Travel 180 130 110 015 170 700 1900...

Page 621: ...v 9 a a s G s K Lo v K 9 3 m v K 9 a z 0 9 K a m w f t 2 a z z K 0 CT K 0 I I 0 I 0 co D hl Dco m 7 Dm 0 coco 0 coco 0 coca 0 Dm zyxwv 5 m I n 0 co 0 D E m m m I n Q I n Q m O b 0 77 O b yo Y O b 0 7...

Page 622: ...Steps Lean 5 000 10 000 Ft 1 ADJUSTMENTS Dry Float Setting Wet Fuel Level Vacuum Kick Fast Idle Cam Position 2nd HighestStep Choke Unloader Bowl Vent Valve At Curb Idle Curb Idle Speed RPM Fast Idle S...

Page 623: ...ce Carter or Airtex RD 4046 Diaphragm 2 Camshaft 3 1 2 to 5 MS 4588SA Carter or Airtex RD 4066 Diaphragm 2 Camshaft 5 t o 7 MS 4587SA Carter Carter Carter MS 6191 MS 6190 MS 4845s or Airtex RD 4076 Di...

Page 624: ...spline yoke are permanently lubricated The joints should be in spected every time the vehicle is serviced for exter nal seal leakage Figs 2 and 3 The joints need not be disassembled or relubricated u...

Page 625: ...omplete angle between the two joints Fig 4 The constant velocity universal joints and center ing ball and sockets are permanently lubricated and should not be disturbed unless external leak age is evi...

Page 626: ...S PROPELLER SHAFT ANGULARITY The increased empbasis on the need for a quiet smooth operating drive line in all cars require that the universal joint angles be maintained within ac ceptable torerances...

Page 627: ...ion with that shown on Chart SP 5060 I Fig IO Aa iusting Gauge on Differential Models with 7 1 4 in Axle Rear Joint Angle Reference Figs 18 or 19 for front joint angle A normal joint angle will cause...

Page 628: ...ng underside of propeller shaft Fig 1 2 Make the acceptable range 5 If bubble in spirit level is found outside the ac ceptable range indicated on Chart Figs 18 or 1 9 you will have to install a wedge...

Page 629: ...shaft being careful not to burr the splines Fig 2 Rear Joint Install rear universal joint of propeller shaft in the same position as removed by matching scribe marks 1 Install rear universal joint cr...

Page 630: ...be Fig 14 Rear Constant Velocity Universal Joint SHAFT AND UNIVERSAL JOINTS 16 7 UNIVERSAL JOINT MODELS marks 1 Before installing propeller shaft wipe sliding yoke clean and inspect machined surface f...

Page 631: ...s Rollers that have been operating in damaged races L L JOINTS m SHAFT YOKE Fig 17 Removing Centering Ball and Socket Assembly should not be reused Examine seals on cross assem blies for damage Seals...

Page 632: ...ALL MODELS CORRECTION PROCEDURE PY265A FRONT JOINT ANGLE ADJUST POSITION OF BUBBLE WITH GAUGE AT ENGINE OIL PAN FLANGE FRONT OF CAR ACCEPTABLE REGION FRONT OF CAR ADD SHIMS AT ENGINE REAR MOUNT FOR E...

Page 633: ...to bore and install snap ring 12 Install remaining bearing in center yoke In stall snap ring 13 Install slip spline yoke on the constant veloci ty joints with screws and lockwashers and tighten to 300...

Page 634: ...Pinion Flange Clamp Screw 9 3 4 Axle 170 Rear Spring U Bolt Nut 7 1 4 Axle 40 Rear Spring U Bolt Nut 8 1 4 8 3 4 9 3 4 Axles 45 Pinion Flange Clamp Screw 7 1 4 8 1 4 8 3 4 Axles Pinion Bumper Plate S...

Page 635: ...hers Zinc interleaves are used between the leaves of all springs to reduce corrosion and improve spring life The shock absorbers do not help support the load but are a means used to control ride motio...

Page 636: ...rm mounting bracket 3 Compress shock absorber completely by push ing upward and remove from vehicle by pulling down and out of upper shock absorber mounting bushing On Fury Chrysler and Imperial model...

Page 637: ...performance 3 Test for low fluid level or air trapped in cylinder by holding shock absorber in its normal vertical position and alternately extending and com pressing unit There should be no lost moti...

Page 638: ...stud 4 Loosen and remove nut and bolt from upper shock absorber mounting and remove shock absorber On Barracuda models it is necessary to remove rubber plug in luggage compartment to gain access to up...

Page 639: ...nds under axle assembly raise axle assembly to relieve weight on rear spring 3 Disconnect rear shock absorber at spring plate lower mounting stud Lower axle assembly permit ting rear springs to hang f...

Page 640: ...dy bracket Remove pi vot bolt and hanger from spring 5 Place new bushings on Tool C 3709 or Tool C 3729 Valiant models Fig 13 Arrange tool in spring eye then press out old bushing while press ing in n...

Page 641: ...1I2 7 7 Station Wagon Standard 4 1I2 7 7 Heavy Duty 5 112 zyxwv 6 1 2 Taxi 4 1I2 6 112 Police 7 1 2 5 1 2 6 112 LENGTH Inches 55 57 58 62 62 WIDTH Inches 2 112 2 1 2 2 1 2 2 1 2 2 1 2 MOUNTING 225CI E...

Page 642: ...earing 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 the cross shaft adju...

Page 643: ...heels 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 ab...

Page 644: ...out 1 4 turn away from I Fig 3 Removing Steering Gear Arm center of high spot position Then using torque wrench Tool 2 3380 at steering wheel nut measure torque required to rotate steering wheel throu...

Page 645: ...teeth Remove cross shaft seal as out lined in Cross Shaft Oil Seal Replacement 3 Position steering wormshaft in straightahead position 4 Remove bolts from cross shaft cover and slow ly remove cross sh...

Page 646: ...of tool Withdraw bearing cup by turning rem over 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 b...

Page 647: ...hrust bearing in lower cup in housing 26 Hold ball nut from turning Fig 6 and in sert wormshaft and ball nut assembly into housing with end of worm resting in thrust bearing 27 Place upper thrust bear...

Page 648: ...e shaft through high spot at center position The reading should be be tween 8 and l l inch pounds Readjust cross shaft adjusting screw as necessary to obtain proper torque reading Tighten lock nut to...

Page 649: ...Adjustments 20 Gear Reconditioning 15 Gear Installation 21 Gear Removal 15 Wormshaft Oil Seal Replace 14 Specifications 5 8 Tightening Reference 61 piston which is in constant mesh with the cross shaf...

Page 650: ...POWER STEERING 19 9 z t 5 zyxwv U MyMopar com...

Page 651: ...EADS TO EITHER SIDE b Improper wheel alignment c Valve body out of adjustment d Valve lever damaged Correction Inflate tires to recommended pressures See Fluid Level Power Steering Pump See Group 7 Co...

Page 652: ...hrust bearing d Coupling loose on the worm bracket stop when the engine is running adjustment loose adjustment b See Group 7 Cooling c Replace the belt and adjust d Lubricate and repair as necessary e...

Page 653: ...d View Valve Body Recondition 1 Disconnect high pressure and return hoses at the valve body and tie the ends above the reservoir fluid level 2 Remove two screws attaching valve body to main gear housi...

Page 654: ...l air from system Refill reservoir as required CAUTION Do not turn hard against ends of travel This will generate high pressure and may blow out the 0 rings since the valve body screws have not been f...

Page 655: ...r SP 5148 with short step of lip against seal Fig 7 Install tool nut on cross shaft and tighten until shoulder of tool adapter contacts gear Worm Shaff Oil Seal Replacemenf The worm shaft oil seal may...

Page 656: ...taining bolts or nuts Remove gear Gear Reconditioning Clean the gear assembly thoroughly in a suitable solvent and clamp in vise 1 Drain steering gear through the pressure and return connections by tu...

Page 657: ...19 16 POWER STEERING m zy t 3 Z DL Lu zyxwvutsrq Z v Q 4 a b o 8 3 z I 2 MyMopar com...

Page 658: ...g 12 Remove large 0 ring from groove in hous ing head 13 Remove reaction seal from groove in face of housing head with air pressure directed into ferrule chamber Fig 14 14 Inspect all grooves for burr...

Page 659: ...ring resting on land of tool Fig 18 b Press down on piston to seat ring in piston groove forcing open ends of ring out for ease of locking the ring 28 Place piston assembly in a vertical position worm...

Page 660: ...worm balancing ring without flange inside upper reaction ring 41 Lubricate ferrule zyxwvut 0 ring and install in groove on cylinder head ferrule 42 If oil seal was removed from housing head REACTION...

Page 661: ...n end of lever with wooden end of hammer handle or han dle of plastic screw driver to seat lower pivot point in center race 54 Center lever in hole in housing by turning housing head by tapping on a r...

Page 662: ...ht cross shaft adjustment 6 With unit under power but with no load tor que required to rotate wormshaft through an includ ed angle of 180 degrees 90 degrees either side of center at 6 rpm or one revol...

Page 663: ...am ring As the rotor begins to rotate centrifugal force throws the vanes against the inside surface of the cam ring to pick up residual OVAL SHAPED FILLER TUBE NN1002 Pump Removal pa8 Reconditioning 2...

Page 664: ...sure relief valve on both the 94 and 1 06 models High pressure lifts the relief valve ball from its seat and allows oil to flow through a trigger or ifice located in the outlet fitting of the 94 pump...

Page 665: ...d correct c Adjust belt See Cooling System Group 7 1 06 pump d Remove reservoir visually check inlet oil hole and service as necessary e Install properly or replace if necessary 94 pump f Recondition...

Page 666: ...to stop will aid in warming the fluid Do not hold wheels against stop for extended period as undue internal pump over heating will result 5 With engine idling at specified idling speed and gauge valv...

Page 667: ...o 160 inch pounds 5 Hoses must remain at least one inch away from all pulleys battery case and brake lines and two inches away from exhaust manifold 6 When used protective sponge sleeves must be prope...

Page 668: ...nd spring should slide out of bore also Fig7 and clean exterior of pump with solvent PLASTIC zy NN1007 Fig 7 Removing Drive Shaft Assembly Fig 9 Removing Full Diameter Lock Ring 10 Remove and discard...

Page 669: ...Light score or scuff marks can be removed by polishing with a small flat oil stone 6 Inspect end cover for nicks or burrs on surface contacting 0 ring and remove with a fine stone 7 Inspect pump body...

Page 670: ...g making sure it is seated in groove Fig 17 This operation can be performed in an arbor press zyxwv P Fig 16 Seating Pressure Plate I NN1018 Fig 18 Installing Pressure Hose Fitting if available Care s...

Page 671: ...e to spring Fig 20 Removing Drive Pulley 1 06 Pump out of bore 3 Clamp land end of valve in a soft jawed vise and remove hex head plug and shim Note num ber of shims on plug Same number of shims shoul...

Page 672: ...h shaft down use vise with soft protective jaws Dis card mounting bolt and reservoir zyx 0 rings 7 Using a punch tap end cover retaining ring around until one end of ring is near hole in pump body Ins...

Page 673: ...is recommended that all the interior parts be replaced 5 Inspect pump body drive shaft bushing for ex cessive wear Replace pump with pump partial as sembly if badly worn or scored Pump partial as sem...

Page 674: ...Before installing pressure plate rotate shaft by hand to make sure rollers are all seated parallel with pump shaft 10 To insure proper alignment of pressure plate to dowel pin insert the largest poss...

Page 675: ...eaded hole in end of shaft Fig 33 19 With installer shaft clamped securely in vise tighten drive nut against thrust bearing and press pulley onto shaft ADAPTER SP 5399 C 4063 NU278 Fig 3 3 Pulley Inst...

Page 676: ...astic inserts and shear pins 3 A two piece telescoping steering shaft with up per and lower sections connected by plastic friction collars and shear pins 4 A mounting bracket connecting steering colum...

Page 677: ...FT HOUSING AUTO TRANS SHIFT LEVER MANUAL TRANS SHIFT LEVER PY87OB NUT WASHER fig 1 Column Installation Fury Chrysler COLUMN BRACKET FORWARD MOUNTING POINT SHIM AS REQUIRED COLUMN BRACKET GROUND WIRE r...

Page 678: ...are covered in the fol lowing service procedures The Barracuda column Fig 3 has a telescoping steering shaft but all other components are conventional A corrugated cylinder is added be tween steering...

Page 679: ...n 11 Carefully pry lower coupling from steering gear wormshaft then remove column assembly out through passenger compartment being careful not to damage paint or trim Disassembly to column jacket 1 Re...

Page 680: ...tion Key Buzzer Switch LOCK CYLlN RELEASE H PYWA Fig 1 2 Removing lock Cylinder from shaft Fig 8 3 Remove bearing lower snap ring from shaft 4 Pry sleeve off steering shaft lock plate hub to expose pi...

Page 681: ...P SEAT BELT SWITCH LOCK HOUSING pD3n Fig zyxwvutsr I 5 Seat Belt Switch SHIFT HOUSING TO SHIFT TUBE SET SCREW 8 hex head retaining screws and remove housing from jacket Fig 14 8 If so equipped remove...

Page 682: ...Pull the tube and lever assembly out of jacket lower end Fig 20 and 21 Steering Shaft Coupling Rubber shaft Chrysler Imperial nuts and zyxwvuts 4 bolts 1 Remove roll pin and slide flange off steering...

Page 683: ...19 42 STEERING COLUMN STANDARD MyMopar com...

Page 684: ...y a thin coating to all friction surfaces 1 Install column holding tool C 4132 and clamp column in a vise with both ends of column accessible 2 Install the zyxwvuts 0 ring retainer 0 ring and floor pl...

Page 685: ...ift tube Fig 29 Install ShiH lever Manual MASTER SPLINE MARK STEERING SHAFT ROLL PIN HOLE PY21 RING STEERING SHAFT Fig 31 Assembling Steering ShoH Coupling and metal spacer over crossover blade so it...

Page 686: ...er shaft lock plate pin and against lock plate LEVER ADAPTER Fig 33 Shaft Centering Tool 4 Install the bearing lower snap ring on the pypo2 steering shaft Bearing Housing Assembly Fig 23 1 Install the...

Page 687: ...g bolts Slide zyx 0 ring down the jacket to floor plate position retaining plate over 0 ring and secure with the two bolts Do not pry to align plates and attaching bolts or column mi salignment will o...

Page 688: ...o remove column mounted shift indicator move tilt mechanism to full down tilt Remove spring clip from rear of indicator housing and remove indicator housing Withdraw pointer from shift housing Fig 4 R...

Page 689: ...19 48 STEERING COLUMN TILT WHEEL MyMopar com...

Page 690: ...th grooves in Fig 6 housing and remove spring and guide Fig 7 10 Remove three housing cover screws and re 12 Push upper steering shaft in sufficiently to re move housing cover Fig 5 move steering shaf...

Page 691: ...actuator rod assembly 16 Remove coupling from lower end of steering shaft Double coupling is retained to shaft with a roll pin Single coupling must be disassembled see procedure in Standard Columns 1...

Page 692: ...er can be used Repeat for other race Inspection 1 Inspect all bearings and race seats for brinneling nicks scratches and wear 2 Inspect centering sphere for nicks damage or wear If damage is found che...

Page 693: ...nob and pull knob out Install cancelling cam spring canceling cam and shaft lock Depress shaft lock and install retain ing ring with Tool number 2 4156 Fig 4 16 Install tilt release lever and signal s...

Page 694: ...lock shoes ring Remove tool lock plate carrier and spring Remove bearing housing assembly by pulling up 6 Remove three turn signal switch attaching ward to extend rack full down and moving housing scr...

Page 695: ...19 54 STEERING COLUMN TILT A SCOPE p I p MyMopar com...

Page 696: ...y Buzzer Switch I RETAINER DE PY942 Fig 6 lilt Spring Retainer and Guide SPECIAL TOOL zy C RING PY941 Fig 3 Removing or Installing Lock Plate C Ring LOCK RELEASE SLOT PY920 Fig 5 Removing Lock Cylinde...

Page 697: ...and bolt Remove rack and rack spring 4 Remove tilt release lever pin with punch and hammer Remove lever and release lever spring To relieve load on release lever hold shoes inward and wedge block bet...

Page 698: ...ing Assem ble bearing housing over steering shaft and engage rack over end of actuator rod 7 Install external tilt release lever and holding lock shoes in disengaged position assemble bearing housing...

Page 699: ...C 3428B Do not bump or hammer on steering shaft to remove wheel Installation 1 Install steering wheel with master serration in hub aligned with missing spline tooth on end of steering shaft Install an...

Page 700: ...rew 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 1I2 16 24OZS Type Constant Displacement...

Page 701: ...ear Assembly to Frame Bolt 100 POWER STEERING Foot Foot Pounds Pounds Gear Housing to Frame Bolt 100 Steering Arm Nut 175 Cross Shaft Adjusting Screw Lock Nut 28 Housing Head Spanner Nut 200 Valve Bod...

Page 702: ...vided on the right side of the transmission Fig 2 for identification numbers Page Assembling Transmission 9 Cleaning and Inspection 7 Disassembling Transmission 3 Extension Housing Bushing Replacement...

Page 703: ...er clutch sleeve damaged a Refer to Clutch Group for corrections b Perform linkage adjustment as outlined in Gearshift Linkage Adjustments c d e Causes noted can only be corrected by disassembling tra...

Page 704: ...ase Fig 4 3 If shaft seals need replacement or interlock le vers are cracked proceed as follows Pull shift forks out of shafts 4 Remove nuts attaching operating levers to the shafts Disengage levers f...

Page 705: ...21 4 zyxwvuts 3 MyMopar com...

Page 706: ...sion Housing Removed Fig 5 Tap Drive Pinion Forward for MainshaH Pilot Clearance MAINSHAFT BEARING RETAINERzy L AND KEY ARBOR FOR ROLLERS PY633 Fig 6 Position 2nd Gear and Shift Sleeves For Clearance...

Page 707: ...ove through HOLE FOR PINION BEARING RETAINER DRAIN rear of case Fig 8 Counfershaff Gear and Drive Pinion 1 Using a mallet and arbor tool C 4112 tap countershaft rearward and remove key Continue to dri...

Page 708: ...erse gear it can push the bearing off shaft as pressure is ap plied to shaft Fig 19 When bearing clears shaft don t let parts drop through 7 Remove from press and remove from end of shaft the mainshaf...

Page 709: ...ective shafts Needle Type Bearing Rollers and Spacers Inspect all bearing rollers for flat spots or brineling Inspect all bearing roller spacers for signs of wear of galling Inspect roller contact sur...

Page 710: ...rbor against gear with tangs forward 6 Coat rear thrust washer with heavy grease and RETAINING RING PY640 Fig 25 Installing Rollers in Drive Pinion Gear MAINSHAFT BEARING SNAP RETAINER TO RETAINER STO...

Page 711: ...mainshaft with thrust surface against flange Fig 16 12 Install properly indexed stop ring and 2nd 3rd synchronizer assembly against second gear Fig 15 21 Fig 29 2nd 3rd Synchronizer Disassembled 13 In...

Page 712: ...nd Housing Disassembled Drive Pinion Bearing Retainer 1 Install the outer snap ring on the drive pinion bearing and tap the assembly back until the snap ring contacts case 2 Using Tool C 3789 Fig 37 i...

Page 713: ...d external shift levers Tighten shift lever nuts to 18 foot pounds Tighten back up light switch to 15 foot pounds OCATING KEYWAY FOR BEARING RETAINER Fig 33 Extension Housing Front View TOOL INSTALLIN...

Page 714: ...d on out side of adapter representing number of teeth on REAR MOUNT TAlN MOUNT ZROSSMEMBER NU45A Fig 39 Center Crossmember and Rear Engine Mount Carline Kl TRANSMISSION EXTENSION HOUSING REAR MOUNT g...

Page 715: ...ing bolts Tighten to specifi cations Figs 39 or 40 6 Remove engine support fixture and disengage hooks from holes in the frame side rails Install ex tension housing to rear engine mount bolts and tigh...

Page 716: ...yxwvuts e I WASHER PLAIN WASHER QUE I I BUSHING IP STEERING COLUMN 2ND 3RD ROD FRO1 2ND Fig 44 Column Shifi linkage Carline V l T 2ND 3RD LEVER IST REVERSE LEVER 1ST REVERSE ROD IST REVERSE ROD DETAIL...

Page 717: ...osition Carefully pull shaft yoke out of transmis sion extension housing CAUTION Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installation of the shaft as...

Page 718: ...ON EXTENSION SPACER A S S E M B X 3 SCREW T gz 4 ASSEMBLY BOOT GROMMET 3 OD SECOND AND THIRD SWIVEL LEVER 518 o zyxwvu T 4 bit 2 318 1 16 LEVER ALIGNMENT TOOL SHEET METAL Fig 48 Floor Shift 3 Speed Ca...

Page 719: ...ft lever 5 Remove shift lever attaching screws and re move lever 6 Remove retaining clips washers and shift rods from shift mechanism levers under floor pan 7 Remove bolts securing shift mechanism to...

Page 720: ...ch end and the thrust is taken on thrust washers between the ends of the gear and the transmission case The alignment of the needle type roller bearings within the gear is maintained by a tubular spac...

Page 721: ...eth Rough or pitted bearing races d Replace worn bearing or balls SERVICE PROCEDURES IN VEHICLE FOUR SPEED GEARSHIFT RemovaJ Figs 4 5 and 6 1 Disconnect negative ground cable from battery 2 Remove con...

Page 722: ...SION REVERSE ROD PD 161 Fig 4 A 833 Floor Shift linkage Carline V l FIRST AND SECOND ROD BOOT ASSEMBLY O N E D WASHER 2 FIRST AND SECOND ROD ASSEMBLY GEAR SHIFT CONTROL MECHANISM THIRD AND FOURTH ROD...

Page 723: ...washers and clips 5 Remove aligning tool and test shifting action Fig 8 Speedometer Pinion and Adapter Installed SPEEDOMETER PINION GEAR Removal and Installation Rear axle gear ratio and tire size det...

Page 724: ...ch pounds 8 Fill transmission to level of fill plug Refer to Lubrication Group 0 EXTENSION HOUSING YOKE SEAL Replacement 1 Place drain pan under yoke seal 2 Disconnect propeller shaft at rear universa...

Page 725: ...tallation of the shaft assembly extension housing and on the mainshaft splines 3 Remove extension housing yoke seal Fig 11 Align marks made at removal and connect propeller with Tool C 3985 shaft to r...

Page 726: ...5 Woodruff Key 46 Countershaft 47 Thrustwasher Gear 1 Gearshift Housing and Mechanism 1 Remove reverse shift lever from shaft Remove bolts that attach gearshift housing to transmission case Fig 17 2 W...

Page 727: ...21 26 4 SPEED MANUAL TRANSMISSION rn Fig 16 A 833 Transmission Disassembled zyxw NH740F MyMopar com...

Page 728: ...n exten sion housing in a rearward direction Slide housing and mainshaft assembly out and away from the case Fig 18 s GASKET EXTENSION AOUSING k NH741 Fig 18 Removing or Installing Extension Housing a...

Page 729: ...ROOVE NH748 Fig 26 Mainshaft Bearing Sudaces bearing from extension housing 9 Remove snap ring that retains mainshaft bear ing on the shaft Fig 24 Remove bearing from mainshaft by inserting steel plat...

Page 730: ...C 3642 Pump Shaft Seal Remover Fig 30 4 Place tool in case with socket against end of shaft and other end of tool against the case Turn screw counterclockwise to press shaft out of the case Remove woo...

Page 731: ...etermined by slow ly turning outer race by hand Measure fit of bear ings on their respective shafts Needle Type Bearing Rollers and Spacers Inspect all bearing rollers for flat spots or brinelling Ins...

Page 732: ...BEARING MAIN DRIVE PINION TOWARD THE FRONT _ ROLLER BEARINGS 16 NH755A Fig 35 Main Drive Pinion and Bear Assembly front of case 9 Start countershaft in its bore at rear of case Raise countershaft gea...

Page 733: ...NG PY201 Fig 38 1st 2nd Synchronizer Disassembled for minimum end play 6 Install partially assembled mainshaft into ex tension housing far enough to engage bearing retain ing ring in slot in extension...

Page 734: ...to raise the interlock lever against it s spring 1 2 SHIFT LEVER 1 MARKED A MORE CLEARANCE MARKED 8 LESS Ah4 CLEARANCE REVERSE POSITION REVERSE DETENT REVERSE IDLER GEAR NN200B BALL SPRING Fig 41 Reve...

Page 735: ...cle install gearshift lever and console refer to Four Speed Gearshift 12 Road test vehicle to make sure transmission shifts smoothly and operates quietly MANUAL TRANSMISSION4 SPEED A 903 INDEX Page Ge...

Page 736: ...ON SLIPS OUT a b OF GEAR Synchronizer clutch sleeve C damaged Synchronizer spring improperly installed Broken or worn synchronizer stop rings Linkage interference a Gearshift rods out of b adjustment...

Page 737: ...ng SERVICE PROCEDURES 3 Move shift lever to line up locating slots in bottom of steering column shift housing and bearing housing Install suitable tool in slot and lock igni 4 Place screwdriver or sui...

Page 738: ...ds 7 Remove gearshift housing locating tool unlock 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 wil...

Page 739: ...o not pull clutch rod rearward to en zy d T TOOL SEAL NP2 Fig 10 Installing Speedometer Pinion Seal Gearshifi Interlock Fig 7 pawl clutch section 1 Disconnect clutch rod swivel from interlock 2 Adjust...

Page 740: ...sembly so that the number on the adapter corresponding to the number of teeth on the gear is TRANSMISSION EXTENSION HOUSING in the 6 o clock position as the assembly is installed Fig 8 8 Install retai...

Page 741: ...with Tool C 3995 Fig 15 Installation 1 Slide extension housing with a new gasket over mainshaft and down against the case Install and tighten attaching bolts to 50 foot pounds 2 Install center crossme...

Page 742: ...ine support fixture C 3487 A mounting hooks firmly into holes in the side frame members with support ends up against underside of oil pan flange Use Adapter Leg C 3806 on 6 cyl Fig I 8 Measuring Synch...

Page 743: ...able tool To avoid leakage around the new seal do not nick or scratch the bore in which the seal is pressed or the surface on which seal bottoms SYNCHRONIZER OUTER STOP RINGS A CLUTCH GEAR SLEEVE PY63...

Page 744: ...st reverse gear and shift forks from the case CLUTCH G E A R SPRING SLEEVE SNAP RING OUTER STOP RIN INNER STOP RINGS PY140 Fig 26 A 903 Synchronizer Disassembled BACK UP LIGYT SWITCH REVERSE IDLE GEAR...

Page 745: ...broken teeth and signs of ex cessive wear Small nicks or burrs must be stoned Off Inspect teeth on main drive pinion If excessivley worn broken or chipped a new pinion should be installed If the oil s...

Page 746: ...de interlock sleeve in its bore in case fol lowed by one of the interlock balls Install interlock spring and pin 4 Place remaining interlock ball on top of inter lock spring using Tool C 3765 Fig 29 A...

Page 747: ...so that the omitted clutch tooth area is next to countershaft gear for assembly clearance Fig 19 Guide drive pinion through front of case and engage inner stop ring with clutch teeth then seat pinion...

Page 748: ...on 8 Carefully guide front universal joint yoke into extension housing and onto mainshaft splines Con nect propeller shaft to rear axle pinion yoke align ing the marks made during removal Tighten clam...

Page 749: ...TROL SYSTEM The hydraulic control circuits on pages 51 through 67 show the position of the various valves with col or coded passages to indicate those under hydraulic pressure for all operations of th...

Page 750: ...TORQUEFLITE TRANSMISSION 21 49 z t v zyxwvutsrqpo t z P U I 3 U zyxwvutsr t U W z 2 m PI 2 W I I n Y 2 PI Q z 3 v n z 2 5 I v Y z U 2 9 5 P e w 5 t MyMopar com...

Page 751: ...21 50 TORQUEFLITE TRANSMISSION zyxwv t 9 2 v Y zy Z V w s Z w MyMopar com...

Page 752: ...ONT CLUTCH LUBRICATION PUMP SUCTION I CONVERTER 5 30 psi LUBRICATION 5 30 psi TO LUBRICATION u PUMP HIGH PRESSURE RELIEF VALVE w LINE 55psi SELECTOR LEVER IN NEUTRAL ENGINE RUNNING Park and Neutral 6...

Page 753: ...ERVO I TO LUBRICATION LIMIT VALVE LUBRICATION PUMP SUCTION CONVERTER 30 75 pai r HIGH PRESSURE RELIEF VALVE OIL FILTER I Drive Breakaway 8 Cylinder 5 30 pai 1 2 SHIFT CONTROL 25 35 pai L SELECTOR LEVE...

Page 754: ...rn TORQUEFLITE TRANSMISSION 21 53 F R O N T S E R V O REAR SERVO t PB3 Drive Second 8 Cylinder MyMopar com...

Page 755: ...21 54 TORQUEFLITE TRANSMISSION L REAR SERVO LIMIT VALVE PB4 MyMopar com...

Page 756: ...LVE 7 2545 psi 3 40psi 30 75 psi HIGH PRESSURE RELIEF VALVE qgPkW OIL FILTER Drive Part Throttle Kickdown 8 Cylinder E LyLUBRICATION 5 30 psi 1 2 SHIFT CONTROL 25 35 psi SELECTOR LEVER IN DRIVE PART T...

Page 757: ...REAR SERVO I LIMIT VALVE PUMP SUCTION TO LUBRICATION CONVERTER 30 75 psi RELIEF VALVE 1 2 SHIFT CONTROL 55 65 ps Drive Full Throttle Kickdown 8 Cylinder SELECTOR LEVER IN DRIVE lFULL THROTTLE KICKDOW...

Page 758: ...TORQUEFLITE TRANSMISSION 21 57 REAR CLUTCH T REAR SERVO LIMIT VALVE P07 Selector lever Two 8 Cylinder MyMopar com...

Page 759: ...m FRONT SERVO LIMIT VALVt 3 1 1 1 1 1 1 1 LUBRICATION PUMP SUCTION CONVERTER 30 55 c u 1 2 SHIFT CONTROL 45 55 psi SELECTOR LEVER IN CLOSED THROTTLE PUMP ONE MANUAL LOW OIL FILTER D m m PBB Selector l...

Page 760: ...TRANSMISSION 21 59 REAR SERVO LIMIT VALVE 230 260 psi PUMP SUCTION CONVERTER TO LUBRICATION HIGH PRESSURE RELIEF VALVE 0 30 75psi 5 30 psi 0 PUMP L I I Reverse 8 Cylinder SELECTOR LEVER IN REVERSE PB9...

Page 761: ...NSMISSION II REAR SERVO r 1 OIL PRESSURES PUMP SUCTION LUBRICATION GOVERNOR OZOP I CONVERTER 3075 F 1 LUBRICATION 5 30 P S l m l SELECTOR LEVER IN DRIVE BREAKAWAY HALF THROTTLE PB10 Drive Breakaway 6...

Page 762: ...ITE TRANSMISSION 21 61 ACCUMULATOR __ TO FRON OIL PRESSURES PUMP SUCTION LUBRICATION CONVERTER 30 75 PSI LUBRICATION 5 30 PSI SELECTOR LEVER IN DRIVE 2ND HALF THROTTLE Drive Second 6 Cylinder PB11 MyM...

Page 763: ...TE TRANSMISSION rn LUBRICATION OIL PRESSURES PUMP SUCTION LUBRICATION GOVERNOR 3 90P 5 I m ASSE12Ly CONVERTER 30 75 P51 E LUBRlCATlON 5 30 PSlm SELECTOR LEVER IN DRIVE IIRKT d I I Drive Direct 6 Cylin...

Page 764: ...FLITE TRANSMISSION 21 63 A OIL PRESSURES PUMP SUCTION LUBRICATION THROTTLE 4 75 P S I r LUBRICATION 5 30 P SELMOR LEVER IN DRIVE PART THROTTLE KICKDOWN Drive Part Throttle Kickdown 6 Cylinder 13 MyMop...

Page 765: ...SSION TORQUE A R COOLER P TO LUBRICATION OIL PRESSURES PUMP SUCTION GOVERNOR 3 75 P LUBRICATION 5 24 P SELECTOR LEVER IN DRIVE FULL THROTTLE KICKDOWN I ACCUMULATOR II F Drive Full Throffle Kickdown 6...

Page 766: ...21 65 rn TORQUEFLITE TRANSM REAR SERVO T O FRONT OIL PRESSURES PUMP SUCTION LUBRICATION GOVERNOR 3 55 P S I r SELKTOR LEVER IN TWO MANUAL 2ND CLOSED THROTTLE PBl5 Selector Lever Two 6 Cylinder MyMopa...

Page 767: ...21 66 TORQUEFLITE TRANSMISSION L REAR SERVO TORQUE 4 a ACCUMULATOR PUMP 0 TER I O DETENT I SLEEVE I SELECTOR LEVER IN ONE MANUAL LOW CLOSED THROllLE PB16 Selector fever One 6 cylinder MyMopar com...

Page 768: ...TORQUEFLITE TRANSMISSION 21 67 REAR SERVO II J 1 I I I I OIL PRESSURES m 2 6 0 PSI PUMP SUCTION LUBRICATION OIL FIL SELECTOR LEVER IN REVERSE PB17 Reverse 6 Cylinder MyMopar com...

Page 769: ...ne third of trav el to insure proper choke operation 3 Turn the ignition key all the way to the right to START position When the engine starts release the key and it will return to the ON position The...

Page 770: ...as required f Inspect servo for damaged seals binding linkage or faulty band lining Repair as required 9 Disassemble and inspect clutch Repair or replace as required a Refill to correct level with Dex...

Page 771: ...form pressure tests to leakage determine cause and correct as required Clutches or servos sticking or 9 Remove valve body assembly not operating and perform air pressure tests Repair as required Fault...

Page 772: ...se and correct as required 9 Remove valve body assembly and perform air pressure tests Repair as required h Inspect servo for sticking broken seal rings binding linkage or faulty band lining Repair as...

Page 773: ...d repair overrunning clutch as required k Inspect and replace seal rings as required also inspect respective bores for wear Replace parts as required specifications and readjust transmission throttle...

Page 774: ...or replace as required e Remove valve body assembly and perform air pressure tests Repair as required f Adjust idle speed to specifications and readjust transmission throttle rod 9 Inspect and replace...

Page 775: ...ken seal rings e Oil pump scored or binding f Front and or rear clutch faulty 9 Planetary gear sets broken or seized h Overrunning clutch worn broken or seized a Low fluid level a Kickdown band out of...

Page 776: ...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 attaching bolts to prop...

Page 777: ...ired by the use of Heli Coils Essentially this repair consists of drilling out the worn or damaged threads tapping the hole with a special Heli Coil Tap and installing a Heli Coil insert into the tapp...

Page 778: ...nds 7 Pour six quarts of DEXRON type Automat ic Transmission Fluid through the filler tube 8 Start engine and allow to idle for at least two minutes Then with parking brake on move selec tor lever mom...

Page 779: ...r 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 Fig 12 models only 2 At steering column upper e...

Page 780: ...s in place install shift knob as follows with gearshift lever in NEUTRAL thread button spring and knob assembly on the cable end until dimension from top of button to top of knob is 13 32 in Fig 9 Sec...

Page 781: ...ch 7 To test switch remove wiring connector from switch and test for continuity between the two out side pins 8 Continuity should exist only with transmission in Reverse position 9 No continuity shoul...

Page 782: ...t ing sure that no other force is exerted against the lower end of the rod It may be necessary to loosen the throttle lever move it downward and retighten to allow installation of the tool on the thro...

Page 783: ...TORQUEFLITE TRANSMISSION 8 Fig 18 Throttle Rod Adiustment 8 Cylinder Models with 3 Section Throttle Rod PY369 Fig 19 Throttle Rod Adjustment 8 Cylinder Models with Single Section Throttle Rod MyMopar...

Page 784: ...the adjustment is made 4 With a 3 16 in diameter rod 9 placed in the holes provided in the upper bellcrank 6 and lever adjust length of intermediate transmission rod 10 by means of threaded adjustment...

Page 785: ...rol Pressure Adjustments If front servo release pressures are less than pres sures specified and line pressures are within limits there is excessive leakage in the front clutch and or Fig 22 Pressure...

Page 786: ...rew Fig 23 This measurement must be 1 7 8 inches correct by loosening spring retainer screws and reposi tioning the spring retainer The regulator valve may cock and hang up in its bore if spring retai...

Page 787: ...e passages after the valve body assembly has been removed To make air pres sure tests proceed as follows CAUTION Compressed air supply must be free of all dirt or moisture Use a pressure of 30 to 100...

Page 788: ...acement 1 Mark parts for reassembly then disconnect propeller shaft at rear universal joint Carefully pull shaft yoke out of the transmission extension housing CAUTION Be careful not to scratch or nic...

Page 789: ...sing into place then release the snap SUPPORT 1 G GEAR RINGS SNAP RING GOVERNOR BODY rs 4 NN77 Fig 34 Governor Shaft and Weight Snap Rings ring Make sure snap ring is fully seated in bearing outer rac...

Page 790: ...and spring and se cure with snap ring inside of large governor weight Place weight assembly in governor body and install snap ring 4 Place governor valve on the valve shaft insert assembly into the bo...

Page 791: ...dy in the case install retaining bolts finger tight 5 With neutral starting switch installed place manual lever in the neutral position Shift valve body if necessary to center neutral finger over the...

Page 792: ...eld material at rear side of ring gear with a hack saw or grinding wheel Fig 40 Be careful not to cut or grind into front cover stamping 2 Scribe a heavy line on front cover next to front face of ring...

Page 793: ...motor to an input shaft to spin the turbine and includes a drawing for a simple wooden fixture to hold the converter This fixture will hold the converter upright for the spinning and draining operatio...

Page 794: ...ion assembly in repair stand 2 Unscrew oil pan bolts and remove oil pan and Valve Body Assembly gearshift levers from the transmission 1 Loosen clamp bolts and remove throttle and PB333 Fig 44 Transmi...

Page 795: ...While supporting output shaft and driving shell carefully slide assembly forward and out through the case CAUTION Be very careful not to damage ground surfaces on output shaft during removal w PB332 F...

Page 796: ...itally important to this type of valve Sharp edges prevent dirt and foreign matter from getting between the valve and body thus reducing possibility of sticking When it becomes necessary to reconditio...

Page 797: ...LUG SHUTTLE VALVE SHUTTLE VALVE SPRING GOVERNOR PLUG PB339 Fig 51 Shuiile Valve and Governor Plugs A 9041 3 Remove shuttle valve E clip and slide shut tle valve out of its bore Pressure Regulators and...

Page 798: ...out the kickdown detent kickdown valve throttle valve spring and the throt tle valve Shift Valves and Regulator Valve Pressure Sensing Plugs 1 Remove the line pressure regulator valve end plate Fig 5...

Page 799: ...converter and line pressure valves out of their bores 4 Remove E clip and washer from throttle lever shaft Fig 57 Remove any burrs from shaft then while holding manual lever detent ball and spring in...

Page 800: ...THROTTLE VALVE THROTTLE VALVE SPRING LINE PRESSURE MANUAL VALVE ADJUSTING SCREW KICKDOWN VALVE KICKDOWN DETENT SPRING RETAINER Fig 57 Pressure Regulators and Manual Control A 727 and A 904 LA 1 2 SHI...

Page 801: ...spect all valves and plugs for burrs nicks and scores Small nicks and scores may be re moved with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges...

Page 802: ...then fasten end plate to valve body Torque to 28 inch pounds Pressure Regulators and Manual Control Fig 57 1 Install throttle valve throttle valve spring kickdown valve kickdown detent and throttle l...

Page 803: ...mbly 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 seal ring from pu...

Page 804: ...at each stake slot location will suffice SP 5117 Fig 63 Staking Pump Bushing A 904 Fig 6 5 Assembling Pump and Reaction Shat 8 Using a narrow bladed knife or similar tool remove high points or burrs a...

Page 805: ...clamping tool intact Install support to pump body bolts and tighten to 160 inch pounds Remove clamping tool pilot studs and rotor align ment tool 5 Place a new oil seal in opening of pump hous ing li...

Page 806: ...tool bottoms in the pump cavity Be careful not to cock tool dur ing installation 7 Stake the bushing in place by using a blunt punch or similar tool Fig 68 A gentle tap at each stake slot location wil...

Page 807: ...d bump it on a wood block to remove the piston Remove seals from the piston and clutch retainer hub Inspection Inspect facing material on all driving discs Re place discs that are charred glazed or he...

Page 808: ...stalling head Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retainer before assem bly and installation PISTON S E A L INNER I PISTON ND2A Fig 73 Measuring Front Clutc...

Page 809: ...seals from piston and clutch retainer hub REMOVER HEAD SP 3629 REMOVAL TOOL HANDLE SP 3549 FRONT CLUTCH RETAIN ND35W Fig 76 Replacing Front Clutch Retainer lUrMy A 727 Inspection Inspect facing materi...

Page 810: ...nd start them in clutch retain er bore 4 Install handle Tool SP 3549 in the installer Fig 76 Drive bushing into clutch retainer until tool bottoms Fig 82 Front Clutch Spring Location 13 Springs 5 Thor...

Page 811: ...press input shaft from piston retainer Inspection Inspect facing material on all driving discs Re place discs that are charred glazed or heavily pitted Discs should also be replaced if they show evide...

Page 812: ...lutch for both six cylinder engines Three plates and four discs are used in the A 904 transmissions for eight cylinder engines 7 Measure rear clutch plate clearance by having NO3 Fig 85 Measuring Rear...

Page 813: ...turn freely in the grooves Do not remove rings unless conditions warrant Inspect bushing in input shaft for wear or scores Inspect rear clutch to front clutch thrust washer for wear Washer thickness s...

Page 814: ...es sun gear and driving shell before removing these parts from output shaft Stand assembly upright with forward end of output shaft on a wood block so that all parts will move forward against selectiv...

Page 815: ...t in rear opening of rear an nulus gear Carefully work shaft through annulus gear support and planetary gear assembly Make sure shaft splines are fully engaged in splines of an nulus gear support 4 In...

Page 816: ...ear carriers for wear scores or other damage replace as required Inspect planetary gear carrier for cracks and pinions ND28B C Fig 91 Overrunning Clutch Service Replacemenf Cam A 904 TORQUEFLITE TRANS...

Page 817: ...not to drill into the transmission Fig 95 Removing Overrunning Clutch Cam A 727 Fig 94 Installing Output Shaft Support A 904 case Chip off rivet heads with a small chisel then drive rivets and cam fr...

Page 818: ...n all burrs and chips from cam area in the case 4 Place spring retainer on the cam making sure retainer lugs snap firmly into notches on the cam 5 Position cam in the case with cam serrations aligned...

Page 819: ...washer and snap ring to complete the assembly LOW REVERSE SERVO AND BAND Disassembly piston plug and spring Fig 101 Inspection Inspect seal for deterioration wear and hardness Inspect piston and pist...

Page 820: ...pressor Tool C 3422 then in stall snap ring Planetary Gear Assemblies Sun Gear and Driving Shell 1 While supporting assembly in the case insert output shaft through rear support Carefully work assembl...

Page 821: ...all remaining bolts and snug down evenly Rotate input and output shafts to see if any bind ing exists then tighten bolts to 175 inch pounds Check shafts again for free rotation L I I REACTION SHAFT IN...

Page 822: ...ary to center neutral finger over the neutral switch plunger Snug bolts down evenly then tighten to 100 inch pounds 7 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in th...

Page 823: ...extension to the crossmember Tighten bolts as noted Fig 111 112 or 113 Tighten Imperial crossmember to 75 foot pounds 9 The engine support fixture Fig 39 may now be removed 10 Install oil filler tube...

Page 824: ...NSMISSION 21 123 TRANSMISSION EXTENSION 4 R E A R MOUNT Fig 112 Center Crossmember and Rear Engine Mount Carline B J R W R E A R MOUNT NU48A Fig I13 Center Crossmember and Rear Engine Mount Carline P...

Page 825: ...n also occur at the torque converter drain plug Torque the drain plug to 110 inch pounds After performing these two operations re check for leakage If a leak persists perform the following operation o...

Page 826: ...N SEAL THIS END AIR TIGHT 1 876 OUTSIDE OF OPEN END FOR THIS DISTANCE ON TUBE MATERIAL 1 7 8INCH O D THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC Fig 1 1 7 A 727 Converter Hub Seal Cup PY304 15 32...

Page 827: ...f fluid leakage has occurred in the bell housing area the torque converter can be leak checked as 13 32 DRILL 2 HOLES 3 3 41 RADIUS MATERIAL 3 16 STEEL STOCK P Y m Fig 121 A 904 Vent Plug Retainer 1 8...

Page 828: ...aft Gear End Play Clutch Housing Face Squareness Clutch Housing Bore Run Out Synchronizer Float 002 to 016 005 to 022 006 Max 008 Max 060 to I 17 3 SPEED TRANSMISSION A 230 ALL SYNCHRONIZED 198 225 34...

Page 829: ...ISSION APPLICATION AND STALL SPEED Transmission Engine Transmission Converter Stall Other Assembly No Cu In TYPe Diameter R P M Information 198 A 904 10 3 4 1625 1925 Standard 3515871 3515871 225 A 90...

Page 830: ...with Torque Converter 10 314 inches 11 314inches 10 314 inches U S Imperial U S Imperial Measure Measure Measure Measure 17 Pts 14 Pts 19 Pts 16 Pts 16 114Pts 13 1 2 Pts Water Heat Exchanger Pump Roto...

Page 831: ...5X14 G78X14 F70X14 G78X15 H78X15 H78X15 L84X15 198 318 340 360 400 2 400 4 440 225 440 Hi Perf Throttle Minimum 1 2Upshift 10 14 10 15 8 12 10 15 10 15 9 13 10 15 2 3 Upshift 14 19 17 23 14 19 17 23 1...

Page 832: ...28 29 29 28 28 27 26 28 27 26 24 25 26 32 31 31 30 30 29 28 29 28 28 27 27 31 30 30 28 30 30 29 31 30 30 29 29 28 29 28 28 25 26 27 32 31 31 30 30 29 28 29 28 28 27 27 31 30 30 28 30 30 29 31 30 30 2...

Page 833: ...LIED APPLlED RELEASED OVER RUNS 1 45 to 1 To Low RELEASED APPLlED RELEASED RELEASED HOLDS 2 45 to 1 2 SECOND 1 45 to 1 RELEASED APPLlED APPLl ED RELEASED OVER RUNS 1 LOW 2 45 to 1 RELEASED APPLlED REL...

Page 834: ...tor Mounting Bolt 40 Governor Body to Support Bolt Kickdown Lever Shaft Plug Kickdown Band Adjusting Screw Lock Nut 35 Inch 110 85 110 270 100 150 Foot Pounds Gearshift Operating Lever Nuts 18 Transmi...

Page 835: ...gned for the vehicle and provide the best overall Page Care of Tires Cleaning 2 Inflation of Tires 2 Radial Ply Tires 3 Rotation of Tires 2 Repairing Tire leaks 3 Tire Noise Complaints 4 Tire Wear Pat...

Page 836: ...A WIRE BRUSH After the car is in service ordinary road dirt that collects on white side wall tires may be cleaned with soap or a non abrasive cleaner and if necessary a soft bristle brush Under no cir...

Page 837: ...ity characteristics may require adjustment in driving habits when these tires are installed Should these tires be desired the maxi mum allowable size should be selected Radial ply tires must be used i...

Page 838: ...ferent speeds and note the effect of acceleration and deceleration on noise level Axle and exhaust noise change in intensity as speed varies while tire noise will usually remain constant If after road...

Page 839: ...h unbalance conditions Regardless of the cause of cupped wear on either front tire no alignment or balance job can prevent future exces sive wear of the spots Once a front tire acquires flat or cupped...

Page 840: ...oose 180 degrees from the valve stem hole first Continue prying toward the valve stem hole until covers are loose Do not remove the wheel cover at the valve stem hole The cov ers are structurally stro...

Page 841: ...and adjusting nut NUT Fig IO Front Wheel Bearing Adiustment Installation with Disc Brakes 1 If bearing cup was found defective and re placed during inspection install new cup by driving flush with hu...

Page 842: ...tion Placard Located on Vehicle Sedan Front Seat 2 passengers Second Seat 3 passengers Luggage 0 Total 750 Ibs Coupe Front Seat 2 passengers Rear Seat 1 passenger Luggage 0 Total 450 Ibs BARRACUDA Tir...

Page 843: ...sengers Second Seat 3 Passengers Luggage 0 Total 750 Ibs FURY Tire Size Wheel Size Restrictions F78 15 5J 5 1 2JJ G78 15 5 1 2JJ 6JJ H78 15 5 1 2JJ 6JJ J78 15 6JJ 6 1 2JJ Station Wagon has ample chain...

Page 844: ...e Sedans Hardtops Front Seat 2 Passengers Second Seat 3 Passengers Luggage 0 Total 750 Ibs Tire Snow chains are not recommended for use with some tire sizes as indicatedon the Tire Size Chart by the s...

Page 845: ...tute a safety hazard 4 Cargo loads particularly in station wagon models should be distributed as far forward as possible 5 Vehicles with luggage racks do not havea maximum vehicle capacity greater tha...

Page 846: ...outlets On Valiant models outside air ducts for warm weather use are located under each end of the in Page Service Procedure 13 Fury 10 Blower Motor Removal and Installation 13 Control Cable Adjustmen...

Page 847: ...essary to remove the con trol assembly from the instrument panel to make these adjustments See Heater Controls in Instrument Panels Group 8 The cable eyelets are placed over the control AIR SHUT OFF H...

Page 848: ...le and drain radiator PLENUM CHAMBER MOUNTING NUT 3 2 Disconnect heater hoses from heater and re move heater hoses at dash panel seal and retainer plate 3 Disconnect wires from blower motor resistor F...

Page 849: ...ng clips holding spacers and heat OUTLET HOSE er motor to heater housing 3 Remove fan from heater motor 4 Remove mounting support plate from heater 5 Remove heater motor resistor assembly from 6 Remov...

Page 850: ...the cable retaining replace as necessary screw in the elongated hole in the flag attached to 1 Position blower motor mounting plate on back the cable of housing and install six sheet metal screws and...

Page 851: ...TING STUD IN PLENUM PANEL 4 MOUNTING SCREWS LEFT OUTSIDE AIR VENT VIEW IN DIRECTION OF ARROW A TEMPERATURE ONTROL CABLE VIEW IN DIRECTION O F ARROW B REAR VIEW PY136B Fig I Heater Assembly Barracuda M...

Page 852: ...connect hoses Fig 2 10 Connect battery cables fill radiator bleed air from system inspect for leaks and test operation of heater BLOWER MOTOR Removal The entire heater assembly must be removed from th...

Page 853: ...V VIEW IN CIRCLE W Z HEAT DEFROST DOOR CABLE TEMPERATURE CONTROL DOOR CABLE TEMPERATURE CONTROL DOOR CABLE VIEW IN CIRCLE Y VIEW IN DIRECTION O F ARROW A VIEW IN CIRCLE X PB255A Fig 1 Healer Assembly...

Page 854: ...ousing 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 le...

Page 855: ...door of heater assembly while holding crank in extreme counter clockwise position 5 Connect air shut off cable right cable to air shut off door of heater assembly on the front sur face of the heater...

Page 856: ...S 24 1 1 DEFROSTERDUCT HEAT SHUT OFF DOOR CRANK TO DEFROSTER HEAT DEFROST DOOR CRANK DISTRIBUTION DUCT LOCATlNG SCREW PASSENGER SIDE HOUSING ENGINE SIDE HOUSING NU252A Fig 2 Heater Assembly Fury MyMop...

Page 857: ...er shield must be re moved from vehicle to service heater blower motor or engine side housing See Body Manual Unit 3 for detailed illustrations of fender shield removal 1 Drain radiator and disconnect...

Page 858: ...he green temperature indicator light goes out move the temperature control lever to the warm position Push the Heat button and move the fan switch to high The temperature condition inside the vehicle...

Page 859: ...FROSTER DUCT PASSENGER SIDE TEMPERATURE CONTROL DOOR ACTUATOR BLOWER MOTOR RESISTOR BLOCK DISTRIBUTION DUCT GROUND TO WIPER PASSENGER SIDE HOUSING 7 T xMOTORSTUD ENGINE SIDE HOUSING NU253A Fig 7 Heate...

Page 860: ...e the kick pad at the air vent 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 PY135 Fi...

Page 861: ...trunk lock hoses if so equipped 7 From engine compartment remove plugs from core tubes and connect hoses to heater Fig 3 8 Fill cooling system and connect battery nega tive cable 9 Start engine operat...

Page 862: ...Heater Removal and Installation Blower Motor Resistor Replacement 1 From under instrument panel disconnect wir ing at resistor heater and remove resistor in heater assembly and install the mounting s...

Page 863: ...r Motor Rear Unit removing heater from vehicle as follows The heater blower motor can be replaced without 1 Remove spare tire from luggage compartment 2 Disconnect motor feed wire and ground wire 3 Re...

Page 864: ...e temperature control lever in the Heat is in the Vent position no coolant is circulating position during ventilation through the heater core since the water valve is shut off at this time CHECK VALV...

Page 865: ...VE 14 BLEND AIR DOOR CABLE TURN BUCKLE ADJUSTER PUSH BUTTON CONTROL TOP VIEW I HEAT DEFROST DOOR ACTUATOR UPPER LEVEL VENT DOOR ACTUATOR VIEW IN DIRECTION OF ARROW A DEFROSTER DUCT UPPER LEVEL FRONT V...

Page 866: ...y push ing the A C button and adjusting the fan switch Page Satellite 5 9 Valiant 50 Gauge Set Manifold Installation 2 3 Operating Instructions for Owners 21 Service Procedures 40 Servicing the Compre...

Page 867: ...E SERVICE PORT ADAPTER COMPRESSOR 9 INLET SERVICE PORT TlON LINE Fig 1 Gauge Set Manifold Connections All Models except Valiant EVAPORATOR SUCTION GAUGE DISCHARGE PRESSURE GAUGE COMPRESSOR INLET GAUGE...

Page 868: ...essor inlet gauge is con nected to the compressor inlet service port by a spe cial service port adapter This gauge is used when checking the EPR Valve Not used on Valiant installations Fig 2 which do...

Page 869: ...act with an open flame Do not discharge large quantities of re frigerant in an area having an open flame A poi sonous gas is produced when using the flame type leak detector Avoid inhaling the fumes f...

Page 870: ...rge 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 the sight glass the...

Page 871: ...24 26 AIR CONDITIONING W MyMopar com...

Page 872: ...ressure of 475 to 550 psi therefore the fact that the valve vented refrigerant does not mean the valve is defective The valve is part of the receiver drier assembly and must not be removed nor otherwi...

Page 873: ...so that any refriger ant remaining in the container is sealed Remove sert the free end of this test hose into an exhaust system outlet Open the right hand gauge set mani fold valve a fraction of a tur...

Page 874: ...can on an accurate scale so the amount of refrigerant added can be weighed Open the refrigerant manifold valve 8 Purge all air from test hoses Air in the system will be trapped in the condenser causi...

Page 875: ...r or not the system is performing up to standard This test also provides valuable clues to the possible cause of trouble The preliminary inspections in TESTS 1 thru 4 outlined previously should be mad...

Page 876: ...he appropriate Performance Temperature Chart for vehicle and type installation being tested Figs 7 thru 14 determine the maximum allowable discharge air temperature for the prevailing Dry and Wet bulb...

Page 877: ...EN 75 AND 110 F NP655 Turn roof unit blower motor switch to high speed position Place motor driven psychrometer Tool C 3704 near roof unit air outlet grille and a ther mometer Tool C 3623 in right han...

Page 878: ...arge pressure on the gauge This test should be performed with the discharge pres sure from 190 to 210 psi The 190 to 210 pound pressure is for test purposes only These pressures change according to th...

Page 879: ...erate the system for at least five minutes in order to obtain partial stabilization and sufficient re heat to load the system Pressure at the discharge service port should reach 140 210 psi If the hea...

Page 880: ...in your hand for sever al minutes until the suction pressure stabilizes The evaporator suction pressure should read a minimum of 40 psi Any expansion valve which does not produce this reading is defec...

Page 881: ...1300 Valiant 6Cyl 1250 8 Cvl 1000 and fan switch on high 5 Allow the system to operate at full capacity for at least 15 minutes at the rpm shown in the chart This will cause most of the compressor oil...

Page 882: ...wires When installing a new receiver drier use new 0 rings Tighten the new unit to 40 foot pounds Do Not overtighten as this might damage the 0 rings Connect Low Pressure Cut Off Wires CAUTION Replace...

Page 883: ...VAC tl w LEFT SUCTION GAUGE VALVE CHARGING HOSE REFRIGERANT h MANIFOLD HOT 12 RIGHT DISCHARGE GAUGE VALVE SERVICE PORT rinu I INE NK1444A NK1445A Fig 3 Complete Charging of the System All Models Exce...

Page 884: ...ts can be replaced periodically This will insure a good seal without excessive tighten ing of the can or the manifold nuts 1 Attach center hose from gauge set manifold to refrigerant dispensing manifo...

Page 885: ...ines at least once a year to make sure they are in good condition and properly routed 0 rings and fittings must be in good condition The slightest burr or foreign material may cause a leak 0 rings and...

Page 886: ...the system Do not re use the old antifreeze The permanent type antifreeze does not lose its antifreeze qualities during the winter season operation but the chemi cal inhibitors for rust and corrosion...

Page 887: ...as push buttons are operated Start the test by pushing the HEAT button Vacuum tester gauge needle will drop until the ac Fig 6 Vacuum Actuator Test tuator has operated and then will return to 8 inche...

Page 888: ...nt COMPRESSOR Page Compressor 44 MAGNETIC CLUTCH The compressor is equipped with an electro mag netic clutch that is built in the drive pulley assembly Fig 1 An electro magnetic field coil is mounted...

Page 889: ...bly with pulley side facing down on Tool C 3807 3 Start drive hub into the inner bearing race and press hub into position with an arbor press 4 Install bearing snap ring and hub snap ring CAUTION The...

Page 890: ...y important The work area must be clean and free of air borne dust and dirt All parts must be thoroughly cleaned and blown dry before reassembly Do not use air to dry the crankshaft front main bearing...

Page 891: ...unit wire 4 Remove the caps or plugs and connect the suction line to the suction muffler and connect dis charge line to the muffler fitting CAUTION When replacing the compressor assembly the cranksha...

Page 892: ...der Head and Valve Plate Assembly Removal Remove the cylinder head bolts head and valve plate assembly If plate does not separate from head tap the removing lip on the valve plate lightly with a plast...

Page 893: ...ng spring misalignment then tighten 14 to 20 foot pounds 7 Refill with new refrigerant oil after the com pressor is installed on vehicle Do not re use the oil that was previously drained Crankshaft Be...

Page 894: ...hten belts Evacuate system and recharge Crankshaft and Ball Bearings Removal 1 Remove cylinder heads and valve plates 2 Remove pistons and connecting rods AIR CONDITIONING 24 49 a Fig 14 Measuring Cra...

Page 895: ...temperature control slide lever and a fan blower switch Push Buttons Control the source and route of circulating air Off turns off the entire system Max A C maximum air conditioning A C air conditioni...

Page 896: ...on in and the temperature control lever all the way to the right the outside air door is opened to the cowl ventilation inlet At the same time the outside air door actuator closes the recirculating do...

Page 897: ...ized only when the ig nition is on and any push button other than Off is depressed The fan switch is controlled by moving the control lever from left Low to right High Temperature Control Switch The t...

Page 898: ...ed Hi Med Blower Speed Off Low Low Low Low Compressor Clutch Off On On Off Off Fig 3 Expansion Valve Details If all the controls operate in the proper sequence but the action of the dampers and doors...

Page 899: ...will go approximately five inch depth 4 After expansion valve is installed it must be completely tested Then the system must be tested for leaks and recharged Recirculating Door Linkage To adjust the...

Page 900: ...FULL HEAT POSITlOb VIEW AT ARROW B Fig 6 Heater and Evaporator Assembly Passenger Side Typical EVAPORATOR MOUNTING STUDS EVAPORATOR TEMPERATURE CONTROL SWITCH I I BLOWER MOTOR GROUND WIRE NK1404 Fig...

Page 901: ...give about 10 inches of sponge at the instru ment panel control on each end of its travel with the temperature control door fully sealed in mini mum and maximum heat positions HEATER CORE The heater...

Page 902: ...circulating door Adjust if necessary With recircu lating door closed outside air door should be fully open 8 Install outside air recirculating actuator 9 Position heater assembly in the vehicle and pr...

Page 903: ...nuts and remove refrigerant lines evaporator from case Fig 12 Removol 1 Disconnect elbow assembly and suction lines from evaporator Use two wrenches to loosen each of these connections Cap all the ref...

Page 904: ...APORATOR HEATER ASSEMBLY INDEX Page Electrical Controls and Circuits 65 Evaporator Removal and Installation 68 Expansion Valve Removal and Installation 67 General Information 59 GENERAL INFORMATION Th...

Page 905: ...24 60 AIR CONDITIONING rn VIEW IN DIRECTION O F ARROW A Fig I Evaporator Heater Assembly Barracuda Installation PY182A MyMopar com...

Page 906: ...I AIR CONDITIONING 24 61 MyMopar com...

Page 907: ...perature by sliding the lever right or left Controls when operating either the heater or air conditioner Fan Switch Permits selection of low medium or In addition to the six position slide lever selec...

Page 908: ...BY PASS ACTUATOR SOLID LINE ENGINE VACUUM INDICATES OPEN CLOSED 1 1 1 SEALED t AIRKOND RECIRCULATING OUTSIDE AIR AIR CONDITIONING 24 63 VACUUM CONTROLS AND CIRCUITS When testing or adjusting the doors...

Page 909: ...CATES ENGINE WHITE 1 1 1 4 VACUUM ACTUATOR RECIRCULATING OUTSIDE AIR BY PASS ACTUATOR DEFROSTER A OPEN CLOSED t HEAT YELLOW CHECK VALVE SOLID LINE INDICATES ENGINE VACUUM RECIRCULATING OUTSIDE AIR A C...

Page 910: ...ts in the instrument panel HEAT The inlet air door pivots away from the outside air inlet and closes off the recirculating inlet supplying outside air to the blower which forces it through the evapora...

Page 911: ...on at the engine manifold Push each 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 posi...

Page 912: ...must be kept open to pre vent condensation from collecting in the bottom of the housing Restrictor A plastic restrictor is installed in the vacuum hose Fig 9 Blower Motor Removal leading to the A C d...

Page 913: ...ve blower motor cooling tube and blower motor tFig 9 7 Remove glove box 8 Remove appearance shield from lower edge of 9 Remove left spot cooler duct and air distrib instrument panel HEATER CORE BY PAS...

Page 914: ...5 Remove three screws from evaporator core ac cess plate remove plate this will provide access to two evaporator core mounting screws Fig 14 6 Remove four screws holding evaporator core to front cover...

Page 915: ...G TUBE EQUALIZER TUBE 318 AND 340 CUBIC INCH ENGINES CAPILLARY SENSING TUBE f SUCTION LINE 198 AND 225 CUBIC INCH ENGINES SAME AS 318 AND 440 EXCEPT AS SHOWN VIEW IN DIRECTION OF ARROW A ALL ENGINES H...

Page 916: ...el 9 Install glove box 10 Install blower motor and connect wiring 11 Connect blower motor cooling tube and in stall evaporator drain tube 12 Connect refrigerant lines to evaporator core tubes Examine...

Page 917: ...24 72 AIR CONDITIONING m ENGINE SIDE HOUSING NU344B Fig I Air Conditioner Heater Assembly Plymouth Chrysler and Imperial MyMopar com...

Page 918: ...unit only the front unit will be described in detail Trunk Unit Control Imperial The trunk unit evaporator is dependent upon the controls used to operate the front unit The evapo rator of a trunk uni...

Page 919: ...TING ACTUATOR AIRICOND 4 t A C SOLID LINE INDICATES ENGINEVACUUM SOLID LINE INDICATES ENGINE VACUUM CHECK VALVE SEALED SEALED CHECK VALVE ACTUATOR 1 1 DEFROSTER HEAT 3 WHITE ACTUATOR OUTSIDE AIR L L i...

Page 920: ...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 t...

Page 921: ...utton to test the over all operation of the electrical and vacuum controls The Push Button Control Chart summarizes the actions that should take place when each button is pushed See Chart Also refer t...

Page 922: ...0 c Y 6 0 U L m c a S 3 v 0 0 U 0 0 c a Q 0 c a Q 0 c a Q 0 L 0 0 CJ c S 0 c 1 3 S 0 0 n L a U 0 0 g L 0 0 n L a c cc1 a I c a Q 0 z v 0 0 U 0 a I u a 3 7 2 I I 3 0 4 X L L x 3 a Q c n L 0 m Y Y 0 Y 5...

Page 923: ...tect the linkage when the evaporator unit is being shipped and need not be replaced after linkage adjustment Adjusting gauges can be made as shown in Fig 7 The Heater door bleed gauge is made from a s...

Page 924: ...clip first Remove three screws from right FRONT REAR HOUSING HOUSING I w v EVAPORATOR COIL PD233 Fig 9 Heater and Evaporator Core Passenger Side side of housing On Auto Temp remove amplifier and mast...

Page 925: ...under the instrument panel 1 Disconnect negative battery cable drain cool ing system remove air cleaner and disconnect heat er hoses Plug both heater core tubes to prevent spilling coolant when unit...

Page 926: ...ng nut from housing end of support bracket and swing bracket up out of the way FRONT COVER NU383 Fig 13 Evaporator Removed From Front Cover 10 Carefully roll unit out from under instrument panel 11 Pl...

Page 927: ...or tube and place in clip 8 Connect vacuum hoses at push button switch recirculating housing and dash panel On ROOF UNIT Auto Temp carefully push the vacuum hoses through hole in dash panel and connec...

Page 928: ...is con nected to the left front bolt 2 Install the electrical connection and drains 3 Use new 0 rings with clean refrigerant oil on connections Install the suction and discharge lines using two wrench...

Page 929: ...d four available on the heat mode the maximum blower speed on air conditioning is higher than the maximum blower speed on heat Hi Auto Same as Lo Auto except the blower will operate at the higher blow...

Page 930: ...m AIR CONDITIONING 24 85 IN CAR TO ASPIRATOR CENTER OUTLETS ENGINE SIDE HOUSING PB140 Fig 2 Aufo Temp I Housing Assemblies MyMopar com...

Page 931: ...olenoid is energized the valve closes and stops the flow of re frigerant to the compressor Ambient Sensor The ambient sensor is located in the plenum panel behind the glove box Fig 3 This sensor sense...

Page 932: ...anel grommet Fig 5 Servo Assembly The servo assembly s internal components are posi tioned by a signal from the amplifier through a small electric motor and gear train assembly The electric servo moto...

Page 933: ...lant temperature is above 125 de grees F SERVICE DIAGNOSIS Condition Possible Cause SYSTEM OPERATES ONLY ON a A short circuit in the ambient MAXIMUM COOLING AND or in car sensor b A short circuit in t...

Page 934: ...ircuit f Resistor block burned out 9 Pinched vacuum line to master switch h Blower motor not grounded a Clutch wire disconnected b Vacuum operated compressor c Compressor ambient switch d Ambient is b...

Page 935: ...te to pot actuator vacuum hoses reversed side red to shaft side a Vacuum hoses to pot side of mode actuator and pot side of defrost actuator reversed a Route properly b Air conditioning and heat and b...

Page 936: ...switch c Pinched vacuum hose a Check valve 1 failed closed or installed backwards a Defective amplifier a No defect a Air conditioning heat and heat defroster mode actuator hoses interchanged and rev...

Page 937: ...ut in setting too high d ExDansion valve defective e Clutch not running pinched vacuum line to compressor switch wires not connected or high resistance compressor switch f Fresh air door stuck in 100...

Page 938: ...tank a Test and replace if necessary b Vacuum leak b Inspect all connections repair if possible replace if necessary c Check valve 1 reversed or c Check connections test and failed open replace if nec...

Page 939: ...repair or replace a Test and replace if necessary b Test and replace if necessary c Check and replace if necessary d Check and connect to fuse block battery terminal if disconnected e Check and conne...

Page 940: ...to Temp II Tester C 4144 is col ored blue and cannot be used to test any previ ous Auto Temp systems nor can any other tester be used to test this system Connect the tester in the following manner 1 D...

Page 941: ...24 96 AIR CONDITIONING s m a MyMopar com...

Page 942: ...n on pressed rotate voltmeter knob from off to the ambient sensor position Observe the voltmeter if the indicator is in the red area to the left the sensor is shorted if indicator is in the red area t...

Page 943: ...pen Bleed Lo 100 Open Closed Closed Lo to M1 100 Open CIosed Closed M1 to M2 100 Open Closed Closed M2 to M3 20 Open Closed Closed M3 to Hi AIC 20 Open Closed Closed Hi HI AUTO Blower Volts AIC 20 Ope...

Page 944: ...g This electrical voltage signal from the amplifier to the servo assembly is fed through the tester and read directly on the voltmeter when the voltmeter switch is at Servo Amp The driving voltage sho...

Page 945: ...SH LINE GROMMET CdllLGN c5 16T THUMBWHEEL POTENTIOMETER s IN CAR i i I C6B l6DBL 1 Tl SERVO DRIVE 2 DEFROST 3 SENSOR 4 GROUND 5 PARK Fig IO Wiring Diagram 6 BATTERY 7 T2 SERVO DRIVE 8 IGNITION BLOWER...

Page 946: ...rnal 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 check...

Page 947: ...ntial will show during switching ac tion of the ETR switch ETR SOLENOID VALVE The ETR valve is a precision part with extremely small operating clearances The presence of foreign material between the t...

Page 948: ...t 12 and check for refrigerant leaks Reconnect 12 volt lead from antifreeze switch to ETR valve at the terminal gasket Check system for proper operation NU51214 FIG 13 Thumbwheel Calibration TEMPERATU...

Page 949: ...approximately 650 ohms at 65 degrees F 550 ohms at 75 degrees F and 450 ohms at 85 degrees F If the resistance is constantly 1500 ohms the sensor is open and if the resistance values are consistently...

Page 950: ...With the Lo Auto button depressed place system on Heat mode by rotating tester Mode Knob to Heat 3 Allow vacuum at master switch gauge to build up to at least 18 inches and stabilize 4 Turn engine of...

Page 951: ...wYELLOW 1 WHITE VACUUM RESERVOIR GREEN1 GREEN c ENGINE COMPARTMENT 1 1 II DASH GROMMET VACUUM CONNECTOR TO ENGINE VACUUM FITTING 1 CHECK VALVE PUSH BUTTON 2 CHECK VALVE AIR COND HEATING TRANSFER SWITC...

Page 952: ...AIR CONDITIONING 24 107 td Z s 2 MyMopar com...

Page 953: ...24 108 AIR CONDITIONING m c3 e tri Z 8 E a MyMopar com...

Page 954: ...m AIR CONDITIONIN G 24 109 2J I1 4 MyMopar com...

Page 955: ...24 1 10 AIR CONDITIONING 100 300 m MyMopar com...

Page 956: ...is meter to prevent drying out and hardening 42 43 44 45 46 47 48 49 50 50 50 51 51 52 52 53 53 53 54 54 55 56 57 58 59 59 60 62 64 66 67 68 69 70 71 the wet sock Place thermometer Tool C 3623 fully i...

Page 957: ...s follows a Disconnect the inboard electrical insulator Sway at the servo assembly b Using the ohmmeter check the resistance across the 2 most inboard servo terminals numbers 1 and 2 see Wiring Diagra...

Page 958: ...ording to the specifications shown on a label under the hood These adjustments should be checked after the first 1 000 miles SYSTEMS 25 1 Page EVAPORATION CONTROL SYSTEM 14 EXHAUST EMISSIONS 1 EXHAUST...

Page 959: ...25 2 EMISSION CONTROL SYSTEMS 8 w MyMopar com...

Page 960: ...cu um diaphragm But should a burst of power be required and the throttle is opened wide the intake manifold vacuum drops and the heat control door drops to the floor of the snorkel closing off the hot...

Page 961: ...teps VACUUM HOSE NIPPLE I FRONT LOCK TAB OPERATING ROD PY94a Fig 6 Opening Front lock Tab 2 and 3 7 Should the vacuum diaphragm perform ade quately but proper temperature is not maintained replace the...

Page 962: ...emissions is achieved See Group 8 Electrical Section of this manual DISTRIBUTOR SOLENOID A start only solenoid is used this year on the dis tributors of models equipped with 400 and 440 CID engines to...

Page 963: ...ifornia to control nitrous oxide emissions This system has two separate and distinct configurations TRANSMISSION SOLENOID VACUUM VALVE PB405A Fig 1 NOx System Components Manual Transmission TO VOLTAGE...

Page 964: ...try the fol lowing check out procedures To test the solenoid vacuum valve first remove connector on valve to expose valve blade terminals Jumper from the piggy back connector on the bal last resistor...

Page 965: ...y check op eration of the NOx system See figures 6 7 and 8 for solenoid vacuum valve hose routing To functionally check the system warm the engine TO AIRCLEANE CONTROL UNIT ASSEMBLY VIEW IN DIRECTION...

Page 966: ...ATED VACUUM is corrected NUMBER 1 BY PASS VALVE On some models equipped with a 440 Cubic Inch Engine air conditioning and automatic transmission a temperature operated vacuum valve is used Fig 9 This...

Page 967: ...25 10 EMISSION CONTROL SYSTEMS rn DIVERTER VALVE VACUUM SUPPLY HOSE C C H E C K VALVE WITH AIR CONDITIONING UBE ASSEMBLY POWER STEERING PUMP Fig 3 Air Injection System Imperial Models MyMopar com...

Page 968: ...gs by clamps The only serviceable component of this pump is the centrifugal fan filter Do not assume the pump is defective if it squeaks when turned by hand Do not lubricate pump in any way NOTE If th...

Page 969: ...ENTRIFUGAL FAN FILTER GASKET PD178 Fig 5 Centrifugal Fan Filter Installation Locate source of leak and correct Reassemble and replace or tighten hose clamp Adjust hose position Replace valve Replace v...

Page 970: ...air escapes from the silencer at engine idle speed and entire valve assembly should be replaced Rem0V a l 1 Disconnect vacuum hose from diverter valve 2 Release clamp and remove air hose from fit tin...

Page 971: ...oth adjusting and pivot bolt to 30 foot pounds maximum cure with clamp 3 Connect air hose to check valve inlet and se lniecfion Tube Removal Imperial Only 1 Remove clamps and disconnect air hoses from...

Page 972: ...ve VENTILATOR CRANKCASE VALVE HOSE AIR CLEANER INLET AIR FUEL TANK A FILLER TUBE I k BZFFLE PD181 Fig 3 Pressure Vacuum Filler Cap hicle is parked and purging or cleaning the c harcoa1 bed occurs when...

Page 973: ...mrn irbntifv t h i c r n a n d CAUTION Remove filler cap prior to removing or repairing fuel lines CRANKCASE EMISSIONS The crankcase ventilation system is designed to el iminate emission of residual f...

Page 974: ...2 5 48 5 46 5 55 5 54 5 46 5 55 5 55 5 52 5 46 5 49 5 83 5 5 5 7 5 9 5 11 5 12 5 10 5 11 5 20 5 17 5 17 s I 7 Combination Brake Warning Metering Brake Warning Switch Unit Testing Brake Warning Switch...

Page 975: ...5 60 5 21 5 22 5 22 5 21 5 24 5 23 5 23 5 21 Page 6 7 6 3 6 10 6 10 6 11 6 8 6 4 COOLING SYSTEM INDEX Page Accessory Belt Drives 7 10 Conversion Chart 7 18 Engine Water Temperature Gauge 7 10 Fan 7 4...

Page 976: ...52 8 51 8 46 8 50 8 48 8 51 8 50 8 48 8 45 8 46 8 43 8 45 8 51 8 46 8 50 8 50 8 44 8 43 8 48 8 137 8 49 8 52 8 52 8 52 8 55 8 53 8 55 8 58 8 62 8 78 8 70 8 70 8 58 8 72 840 Instruments 8 67 Instrument...

Page 977: ...Carburetors and Chokes 25 1 Exhaust Port Air Injection 25 11 Crankcase Emissions 25 16 General Information 25 1 Distributor Solenoid 25 5 Heated Air System 25 1 Electronic Ignition System 25 5 Idle S...

Page 978: ...s Rear Main Bearing Oil Seals Rocker Arms and Shaft Assembly Spark Plug Replacement Specifications Timing Chain Cover Oil Seal and Chain Tune Up Valves and Valve Springs Cylinder Block Valve Timing Pa...

Page 979: ...14 76 Wagon 14 83 Removing Fuel Tank 14 82 Station Wagon 14 83 Fast Idle Speed On Vehicle Idle Speed Adjustment Disassembling Carburetor General Information Inspection and Reassembly Specifications H...

Page 980: ...4 80 24 76 24 71 24 79 24 24 24 18 24 76 24 75 24 50 24 59 24 52 24 58 24 53 24 50 24 56 24 24 24 52 24 50 24 43 24 44 24 43 24 40 24 41 24 41 24 40 24 41 24 41 Page Correcting Low Refrigerant Level 2...

Page 981: ...STEERING GEAR SUMMARY OF LUBRICATION AND MAINTENANCE SERVICES THROTTLE LINKAGE TIRES TOWING TRANSMI SSION AUTOMAT1C TRANSMISSION MANUAL WINDSHIELD WIPER BLADES PROPELLER SHAFT A N D UNIVERSAL JOINTS I...

Page 982: ...ng Tool C 758 D 5 Gear Tooth Contact Pattern Lubrication Pinion Bearing Preload Rear Axle Assembly Removal Rear Axle Assembly Installation REAR AXLE ASSEMBLY 7 1 4 IN RING GEAR Axle Shafts and Bearing...

Page 983: ...1 20 Speedometer Pinion Gear 21 22 Service Out of Vehicle 21 25 Assembling Transmission 21 30 Cleaning and Inspection 21 30 Disassembling Transmission 21 25 Installation 21 31 Transmission Removal 21...

Page 984: ...ain A 904 Planetary Gear Train A 727 Pump Oil Seal Rear Clutch A 904 Rear Clutch A 727 Recondition Sub Assemblies Removal Transmission and Converter Starter Ring Gear Torque Converter Flushing Valve B...

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Summary of Contents for CHRYSLER New Yorker 1972

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Chrysler CHRYSLER New Yorker 1972, Chassis Service Manual, Page: 638 / 984

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Summary of Contents for CHRYSLER New Yorker 1972

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