Chrysler Dodge Coronet 1969 Series Service Manual Download Page 599

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Summary of Contents for Dodge Coronet 1969 Series

Page 3: ...er T Taxi 43 4 Door Hardtop S Special 4 5 6 Pass Sta Wgn W u p e r Stock 46 9 Pass Sta Wgn X Fast TOD l o O I 5th Digit 6th Digit 7th Digit Engine Ident Year Displacement 1969 Assembly Plant A 170 Cu In H 383 Cu In H P Lynch Road EL225 Cu In 5 426 Cu In HemiB Hamtramck C Spec 6cyl K 440 Cu In Std C Jefferson 0 273 Cu In Std L 440 Cu In H P D Belvidere F 318 Cu In Std M Spec 8 cyl E Los Angeles G 3...

Page 4: ...ich the car is subjected it is necessary to prescribe lubrication and Page HYDRAULIC BRAKE SYSTEM 9 LUBRICATION AND MAINTENANCE SCHEDULE 4 Normal Service 4 Trailer Towing and Severe Service 5 LUBRICATIONAND MAINTENANCECHART Dart and Coronet 6 Cylinder Models Dart Coronet and Charger 2 8 Cylinder Models 3 MANIFOLD HEAT CONTROL VALVES 17 MATERIALS ADDED TO ENGINE OILS 13 PARKING BRAKE MECHANISM 10 P...

Page 5: ...t seals for leakage Relubricate Clutch Torque Shaft Bearings MPG 2 EP or MML Remove and lubricate Refer to procedure Clutch Drive Lugs Bearing and Pivot MML lubricate contact surfaces Refer to procedure Floor Mounted Transmission Gearshift Controls EO II IIIv Apply ljght engine oil to contacl mechanism as required CAPACITIES See Capacities Chart FREQUENCY SYMBOLS 2 Months 3 Months or 4 000 Miles 6...

Page 6: ... MML Remove and lubricate Refer to procedure Clutch Drive Lugs Bearing Sleeve Fork and Pivot MML Lubricate contact surfaces as required Refer to procedure Automatic Transmission AA Check fluid level Front Brake Assemblies and Wheel Bearings MPG 2 EP or MML Manual Transmission AA or MP Check fluid level Rear Axles GL HL or MP SGL Check fluid level Floor Mounted Transmission Gearshift Controls EO Ap...

Page 7: ...tControlValve ITEM 12 X 16 X Carburetor Air Filter Paper Engine Oil Filter Tire Rotation Carburetor Air F i l t e r a i l Bath Carburetor Air Filter Paper Crankcase Ventilation System Carburetor Choke Shaft Every Second Oil Change 17 X 13 X 23 X 18 X 17 X 14 X X 19 X X Power Steering Fluid 121 I I x I I I Floor Mounted Gear shift Controls Parking Brake Mechanism Speedometer Cable PointsThat Should...

Page 8: ...ronet Charger Police2 or 4 BBL383 Cu in Engine Coronet Charger 440 Cu In HP Engine Automatic Transmission Manual Transmission Coronet Charger 426 Cu In Engine 7 114 Axle 8 314 Axle 9 314 Axle 170 225 273 318 340 and 383 4 BBL Cu In Engines 383 2 BBL and 440 Cu In Engines 426 Cu In Engine All Police and Taxi 3 Speed Model A 903 6 Cyl 4 Speed Model A 833 Dart Coronet and Charger when filter is repla...

Page 9: ...e housing Floor Jack A regular floor jack may be used under the rear axle housing or under the front suspension lower control arms however a floor iack must never be used on any partsof the underbody CAUTION Do not attempt to raise one entire side of the vehicle by placing a jack midway between the front and rear wheels This practice may result in permanentdamage to the body Bumper Jack The bumper...

Page 10: ...N Group 2 miles whichever occurs first SPECIFICATIONS SHOWN IN FRONT SUSPEN Relubrication is requiredevery 36 monthsor 36 000 t P r NR77 Fig Upper andLower BallJoints Dart Models PAD POSITION WITHIN THESE LIMITS SATISFACTORY NN192B WHEELS When lubricating control arm ball joints use only the special longlife chassis greases such as Multi Mileage Lubricant Part Number 2525035 intended for this purp...

Page 11: ...arly scheduled changes of the lubricant are not recom mended in vehicles where operation is classified as normal passenger car service The only exceptions however would be where the lubricant has become contaminated with water or in the case of the standard rear axle to provide the correct viscosity grade for the anticipated tem perature range as indicated by the accompanying table I FITTINGS NK55...

Page 12: ...ly axle failure BRAKES The brakes on all models equipped with drum brakes except police cars taxicabs vehicles equipped with high performance engines and trailer towing package are equipped with a self adjusting mech anism which makes it unnecessary to perform major brake adjustments Inspect brake linings for wear every 12 months or 12 000miles whichever occurs first Replace linings if necessary A...

Page 13: ...y a film of smooth white body hardware lubricant conform ing to NLGI grade 1 Lubriplate Part Number 1064768 is a type of lubricant recommended for this purpose When the hand lever can be pulled to more than four inches or the foot pedal depressed more than four and one half inches the brake cable should be adjusted For adjusting procedure refer to Parking Brakes Group 5 Fig 13 Wand Operated Parkin...

Page 14: ...ality permanent type anti freeze in suf ficient quantity to provide full protection for the low est anticipated temperature but never less than 40 percent of the cooling system capacity to ensure ade quate protection against corrosion If it becomes necessary to add coolant during the cold weather season be sure the system contains sufficient anti freeze to provide protection at least to 20 degrees...

Page 15: ...ion protection of all engines for all types of operation only those lubricants should be selected which a Conform to the requirements of the API classi fication FOR SERVICEMS b Have the proper SAE grade number for the ex pected temperature range Oils used in our engines labeled For Service MS should equal or exceed the Engine O i l Perform ance Rating Sequence T e s t s for varnish sludge and rust...

Page 16: ...l of the proper viscosity and API classification every three 3 months or 4 000 miles whichever occurs first When draining the old oil it is recommended that the engine be at normal operating temperature as the warmed oil will drain more readily and carry with it such foreign matter which might otherwise cling to the sides of the crankcase and the various moving parts A greater degree of contaminat...

Page 17: ...vacuum through another Fig 20 Engine Oil Filter 3 18 Cu In Engine buretor throttle valve body into the combustion chamber and dispelled with the exhaust gases Servicing Frequencies Proper maintenance of the crankcase ventilation system is required to keep the system clean and main tain good engine performance and durability Periodic servicing is required to remove combustion products from the vent...

Page 18: ...ventilator valve from cylinder head cover If valve is not plugged a hissing noise will be heard as air passes through valve and a strong vacuum should be felt when a finger is placed over valve inlet Fig 27 If vacuum is not felt at valve inlet remove valve hose at base of carburetor A distinct vacuum should be felt at end of fitting in carburetor Fig 28 If it is not felt the carburetor must be rem...

Page 19: ...er Cap Disconnect the air cleaner hose at the filler cap Fig 23 Remove filler cap and wash it thoroughly in kerosene or other suitable solvents Shake out sur I I Fig 26 Checking Vacuum at Oil Filler Tube Fig 27 Checking Vacuum at Ventilator Valve Inkt Fig 28 Checking Vacuum at Carburetor Throttle Body plus solvent Lubricate the filter element in the cap by inverting and filling the cap with SAE 30...

Page 20: ...ity Clean and tighten terminals apply grease to posts and termi nals Check circuit voltages as described in Electri cal Group 8 Starting Motor Test cranking ability as de scribed in Electrical Group 8 Valve Lash where applicable Should an en gine continue to be noisy and the idle rough after a tune up adjust valve lash to specifications Refer to Engine Group 9 for lash values and instructions Fig ...

Page 21: ...mbed foreign matter in the element paper Examine element for punctures Discard an ele ment that has small pin point punctures Examine soft plastic sealing rings on both sides of element for smoothness and uniformity Replace element if not satisfactory At this time also service the Carburetor Choke Shaft as outlined Oil Bath Type Extra Equipment The sediment level in the air cleaner Fig 40 THERMOST...

Page 22: ...l on carburetor Every six months apply Carburetor Cleaner Part c r 4 FILTER ELEMENT HOSE F TTING H0USlt w NR91 Fig 40 Carburetor Air Cleaner Oil Bath type Number 2933500 or equivalent to both ends of choke shaft where it passes through the air horn Fig 41 At same time move choke shaft back and forth until deposits are flushed out Run engine at idle to clean out excess cleaner from carburetor and i...

Page 23: ...ileage Lu bricant Part Number 2525035 Severe Service Requirements When the vehicle is operated under conditions classified as severe service as outlined below the uni versal joints should be inspected for leakage at seals Lr I I 1 1 I b Fig 44 Fuel Filter 383 426 440 Cu In Engines I Fig 45 Front Universal Joint every 3 months or 4 000 miles whichever occurs first a Continuous operation at higher t...

Page 24: ...rt from dropping into reservoir To restore level if necessary replenish with hy draulic fluid specially formulated for minimum effect on rubber hoses Such a fluid is available under Part Number 2084329 Power Steering Fluid 0 21 113 I J Fig 48 Power Steering Pump Reservoir I 06 Pump TRANSMISSION Manual Three Speed The lubricant installed in the transmission at the time of assembly is a high quality...

Page 25: ...on lubricant level should be checked every 3 months or 4 000 miles whichever The transmission should be drained and refilled with the specified lubricant initially after 36 months or 36 000 miles whichever occurs first and every 12 months or 12 000 miles thereafter whichever occurs first occurs first Column Mounted Transmission Gearshift Controls If operation of gearshift controls becomes noisy or...

Page 26: ...3314 Ex ception to this is a sealer which introduces a small amount of swelling of the seals to reduce fluid leakage resulting from hardening or shrinking of the seals in high mileage vehicles Such a product is available under Part Number 2298923 Transmission Sealer Trailer Towing Service and Severe Usage All models except 426 Hemi engine When the vehicle is equipped for trailer towing service or ...

Page 27: ...ner insists on a four tire switch only the tires SPARE 2 KP23A Fig 56 tire RotationDiagram 5 Tins should be rotated according to diagram Fig 57 Tires should be examined for unusual wear pat terns foreign material and proper inflation pressures Unusual wear conditions may reflect a need for a change in driving habits or indicate that mechanical corrections may be necessary A decal showing the recom...

Page 28: ...needed This is necessary to maintain ease of operation and to provide protection against rust and wear Prior to applying any lubricants wipe the parts clean to remove dust and grit After lubricating parts remove excess oil or lubricant Relubricate mechanisms as outlined in the follow ing paragraphs Where Lubriplate is specified use a smooth white body hardwarelubricant conformingto NLGI grade 1 A ...

Page 29: ...Coronetand Charger Models Apply light engine oil sparingly to outside and inside rotor beaMg surfaces Fig 65 Wipe off ex cess o i l Fig 64 Door Lock Ratchet and Striker Bolt Dart Models Door LocksandLockingControlLinkage All Models If necessary to inspect operation of and relubri cate these parts remove door t r i m panel Apply a film of Lubriplate to all pivot and sliding contact areas Door Remot...

Page 30: ... bar sup port bearing areas and interior surface of torsion Apply Lubriplate sparingly to all pivot and sliding CONTACT AR EXCEPT CONVERTIBLE CONTACT CONTACT AREA TORSION BAR SLIDE SURFACES NPl77B Fig 6 7 4 k lid Hinge fDaHModels BAR R E NP178 Fig 68 Deck Lid Hinge Coronet Models bar slide Fig 67 Also apply Lubriplate sparingly to contact surface of hinge cam and slide Deck Lid Hinge Except Dart A...

Page 31: ...ig 70 Also apply a film of the same lubricant to the accelerator pedal pivot pin where it turns in the end of the accelera tor shaft On models with automatic transmission also apply a film of the same lubricant to the engine mounted bellcrank pin In the passenger compartment apply a thin film of the prescribed lubricant to the acelerator pedal pivot pin Dart Models and cable ball end in the pocket...

Page 32: ... where it turns in the bracket Fig 74 On models with automatic transmission also apply a film of the same lubricant to the pivot points of both upper and lower transmission linkage bellcranks In the passenger compartment apply a thin film of the prescribed lubricant to the accelerator cable anchor end and in the pocket in the accelerator shaft lever Fig 74 Be sure plug is in place in lever PARTS R...

Page 33: ...ENANCE 0 Fig 72 Throttle Linkage Dart 383 Cu In Engine NR236A B E L L C R A N K PlVbT POINT LOWER AUTOMATIC TRANSMISSION ONLY NP413A f 77 I i A 1 Fig 74 Throttle Linkage Coronet and Charger 383 426 440 Cu In Engines MyMopar com ...

Page 34: ...bricated All Rubber Bushings Alternator Bearings Automatic Transmission Controls and Linkage Carburetor Air Cleaner Paper Element Type Clutch Pedal Push Rod Ends Clutch Release Bearing Drive Belts Fan Belt Idler Pulley Rear Springs Rear Wheel Bearings Starting Motor Bushings Throttle Linkage Ball Joints Upper and Lower Control Water Pump Bearings Arm Bushings NP403A MyMopar com ...

Page 35: ...1 Remove clock reset knob from front of instru ment panel 2 From under the instrument panel remove the wiring connector from clock terminal the three screws mounting the clock to the cluster and remove the clock Installation Coronet Models install mounting screws and clock wiring connector and check operation of clock 1 From under the instrument panel position clock 2 Install clock reset at front ...

Page 36: ...IS Condition Possible Cause Correction RADIO INOPERATIVE a Blown fuse a Replace fuse check for short or open in wiring harness b Test with an auxiliary antenna with lead in plugged into the receiver set and test antenna held outside of car If radio plays with test antenna use original antenna and check antenna mostly for shorts to ground while rocking antenna slightly Unplug an tenna lead from rad...

Page 37: ...or servicing Install an auxiliary speaker and com pare Replace if improved Replacethe speaker Send radio to authorized radio service station for repair Clean or replace speaker Test with a substitute antenna and re place if necessary Send radio to authorized radio service station for repair SERVICE PROCEDURES Antenna Trimming All radios are trimmed at the factory and should require no further trim...

Page 38: ...an 3 Remove capnut Figs 8 and 9 4 Remove antenna fender adapter and gasket 5 From under fender remove the lower adapter tenna body Fig 7 mounting collar and antenna lead Installation All Models removed insert through mounting hole in fender 1 Assemble mounting collar to antenna body if 2 Enter anenna body from underneath fender and 3 Install gasket adapter and capnut Tighten cap VOLTAGE LIMITER NR...

Page 39: ...tall upper center left air and lower center ducts on cars equipped with air conditioning 5 Install radio finishplate fourscrews Removal Coronet 1 Disconnectbattery ground cable 2 Remove radio upper trim panel 3 Remove radio finish plate 4 Remove radio rear mounting nut from mount 5 Disconnect electrical wiring and antenna lead 6 Remove two mounting screws from front of in 7 Remove radio from under...

Page 40: ...ich is used to deactivate the system when the brakes are applied The system may also be deactivated by turn ing the ignition key OFF The push button actuator momentary contact switch located at the end of the turn signal lever operates in three modes asfollows 1 When the push button is fully depressed and released current speed is locked in 2 When engaged holding the Speed Set button fully depress...

Page 41: ...a See Cut in speed Adjustment b Faulty electrical circuit adjustment b See Eelectrical Test a Faulty electrical circuit a See Electrical Tests b Vacuum hoses reversed at speed con b Install hoses properly trol servo SERVICE PROCEDURES Test und Adjustments A Servo Adjustments There are three adjustment set screws in the servo housing Figs 2 3 and 4 The adjustments of these set screws have been fact...

Page 42: ...mile per hour If cut in speed is too low turn the set screw counterclockwise If too high turn the set screw clockwise make ad justments in 1 8 turn increments CAUTION Total adjustment must not exceed two turns 3 System Cut out Adjustment Fig 4 affects the road speed at which the system is deactivated during deceleration Turning the screw clockwise increases road speed at which the speed control sy...

Page 43: ...djustment I I Fig Brake Switch Adjustment core length so that both cable drive ends are properly engaged in servo shaft keywayswithout binding Also insure that cable ferrule nuts are properly positioned on servo pilot diameters and nuts properly tightened D Electrical Test 1 Check fuse for continuity 2 Low speed inhibit switch test Disconnect harness plug at servo and using 12 volt signal light co...

Page 44: ...et studs and install attaching nuts Tighten 75 to 115 inch pounds 2 Install vacuum hoses and clamp insuring that the vacuum supply hose leading from brake booster or intake manifold is connected to the front servo INTAKE MA MODELS WITH MANUAL J BRAKE AND LA 318 ENGINE ONLY BRACKET H NR480A Fig 8 Speed Control Servo Installution Fig 9 Removing or Installing Cable Cover nipple Fig 10 Make sure hose ...

Page 45: ...g screw 5 Remove steering column cover plate and sup port steering column while clamp is removed to p r a vent column from sagging 6 Remove wire harness trough to facilitate reach ing the lower end of speed control switch lead wires Fig 11 and cut wires at terminal clips 7 Turn direction indicator lever sideways and pull lever up and wires out through opening between column and tube Installation 1...

Page 46: ...with glass in lower position by an elec tric driven pump supplying nozzle assemblies located inside the upper part of the tail gate SERVICE DIAGNOSIS Condition Possible Cause Correction INTERMIITENT a OPERATION OF WASHER b C PUMP INOPERATIVE a MOTOR RUNS b C PUMP ASSEMBLY a b C d e WIPER BLADES WILL a1 NOT GO ONTO GLASS b WIPER BLADES WILL NOT a COME OFF OF GLASS b UNWIPED STRIP IN a CENTER OF GLA...

Page 47: ...gh 7 under Wiper Blade Replacement and remove wiper mounting arm and wiper blades 2 Remove wiper actuator arm 3 Removewiper washer mounting bracket 4 Remove two nuts washers and screws and re 5 Install new intermediate wiper blade with move intermediate wiper blade assembly Fig 2 mounting screws Do not get lubricant on wiper blades 6 Install wiper washer mounting bracket assem bly 7 Install wiper ...

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Page 49: ...he blower motor or fan the assembly must be removed from the shelf panel from inside the luggage compartment After disconnecting the outlet hose and wire con nector remove the mounting screws from the mount ing clips and remove the assembly from the vehicle for service Disassembly 1 Remove the blower motor adapter plate to hous ing mounting screws and withdraw motor and fan as sembly from housing ...

Page 50: ...e lubrication fitting After lubrica tion knock off that portion of the fitting over which the lubrication gun was installed A ball check is in stalled in the remaining portion of the fitting to pre vent foreign materialsfrom passingthrough The tie rod ends are serviced separately and should be inspected for damage at all oil change periods Caster and camber adjustments are controlled by cams on th...

Page 51: ...eplace idler arm Worn or loose front wheel bearings Incorrect steeringgear adjustment Loose steering gear to frame mount ing bo1ts Worn tie rod ends Worn steeringgear parts Worn upper control arm ball joints Worn lower control arm ball joints Worn idler arm bushing a Adjust or replace wheel bearings as b Adjust steering gear c Tighten steeringgear to frame bolts necessary d Replacetie rodsas neces...

Page 52: ...bending All adjustments should be made in the following sequence a Front suspension height b Caster and Camber c Toe in d Steering Axis Inclination e Toe outon Turns Caster is the number of degrees of forward or backward tilt of the spindle support arm at the top Forward tilt of the spindle support arm at the top is negative caster Backward tilt of the spindle support arm at the top from true vert...

Page 53: ... to specifications to hold tire wear to a minimum and to maintain steering ease and handling of vehicle The equipment manufacturers recommended pro cedure should always be followed Any parts of the front suspension system should be replaced if they are found to be bent Do not attempt to straighten any Height Front suspension heights must be held to specifica tions for a satisfactory ride correct a...

Page 54: ...pension is in full rebound under no load If vehicle is to be raised on jacks placed under center of crossmember it will be necessary that a support first be placed between the crossmemberand the jack 3 Release all load from torsion bar Fig 4 by turning anchor adjusting bolt Fig 5 counterclock wise 4 Remove lock ring from torsion bar rear an chor Fig 4 5 Using Tool 3 3728 remove torsion bar Fig 5 f...

Page 55: ...ough to place upper stud under a load then strike steering knuckle sharply with a hammer to loosen stud Do not attempt to force stud out of steering knuckle with tool alone 7 Remove two upper bolts attaching steering knuckle to brake support 8 Remove two lower bolts attaching steering arm to steering knuckle and remove steering knuckle Support the brake assembly during this operation to adjusting ...

Page 56: ...kle arms Fig 8 Use care not to damage seals 2 Remove inner tie rod ends from center link 3 Remove idler arm stud from center link 4 Removeidler arm bolt from crossmember 5 Remove steering gear arm stud from center link Fig 7 Steering Linkage Coronet Charger e F KNUCKLE KNUCKLE ARM TIE ROD END Fig 7 Steering Linkage Coronet Charger 6 Removesteering gear arm lnstullution Replace all tie rod and stee...

Page 57: ... insulator and retaicer concave side toward rubber insulator and nut Tighten nut to 100 inch pounds 2 Position sway bar assembly in vehicle and in stall attaching bolts and nuts and tighten to 200 inch pounds 3 Install retainer on link followed by rubber insulator and sway bar Using a screwdriver or pinch bar between strut and sway bar if necessary apply pressure and install upper rubber insulator...

Page 58: ...Bushings Coronet Charger ing seats on shoulder of shaft 2 Press shaft and bushing assembly into lower control arm using Tool 2 3848 and an arbor press In some instances it may be necessary to reduce the diameter of shaft shoulder to facilitate use of tool 3 Install torsion bar adjusting bolt and swivel 4 Position strut in lower control arm and tighten nut 100 foot pounds lnstallation 1 On Dart mod...

Page 59: ...tion 1 Raise the front of vehicle and install safety floor stands under both lower control arms as far outboard as possible The upper control arms must not contact the rubber rebound bumpers 2 With the weight of vehicle on the control arm install dial indicator and clamp assembly to lower control arm Fig 15 3 Position dial indicator plunger tip against ball joint housing assemblyand zero dial indi...

Page 60: ...h of flat washers over lower ball joint stud to allow the use of Tool C 3711 without damaging threads on lower ball joint stud Place Tool 2 3711 over stud Turn threaded portion of tool locking it securely against the upper stud Fig 18 To use Tool C 3711as outlined it may be necessary to modify the tool Fig 19 4 Spread tool enough to place upper stud under a CAM ASSEMBLC JOINT SEAL 54D CAM A S S E ...

Page 61: ...ntil seated 125 foot pounds minimum The ball joint will cut threads into a new arm during tightening operations 3 Install a new ball joint seal using a 2 socket making sure it is seated fully on ball joint housing On Dart Modelsinstall seal using Tool C 4039 installation 1 Slide control arm into position and install cam bolts cams washers and nuts Figs 16 and 17 Tighten nuts in preparation for fin...

Page 62: ...rt tighten ball joint until it bottoms on housing Tighten to a minimum of 125foot pounds If ball joint cannot be torqued to 125 foot pounds inspect threads on ball joint and also in control arm and replace as necessary 3 Position a new seal over ball joint stud and in stall using a 2 socket making sure it is seated fully on ball joint housing On Dart Models install seal using Tool C 4039 4 Positio...

Page 63: ...ing Bracket 65 Shock Absorber N u F r o n t Lower 50 Upper 25 Steering Gear Mounting Bolts 80 Steering Knuckle Bolt Nuts Lower Coronet 1 2 0 REFERENCE Foot Inch Pounds Dart 100 Disc Brakes 115 Upper 55 Coronet Charger 50 Rear 100 Frame Bracket Bolt Nut Dart Link Insulator Retainer Bolt Nut Link to Frame Bracket Nut Sleeve Clamp Bolt Nut Stud Nuts 40 Except Dart 65 Strut Nuts Front Dart 40 Sway Eli...

Page 64: ...tan taneous fusing of the mating surfaces Scored gears should be replaced Fill rear axle to required capacity with proper lubricant See Specification section b Replace scored gears Inspect all gears and bearings for possible drm age Clean out and refill axle to re quired capacity with proper lubricant See Lubrication section c Excessivespinning of one wheel c Replace scored gears Inspect all gears...

Page 65: ...s 3 Differential 5 Drive Gear and Pinion Backlash 9 Drive Pinion Depth of Mesh 8 Pinion Bearing Cup Installation 7 GENERAL INFORMATION The 7 1 4 Rear Axle Assembly shown i n Fig 1 1 i s a semi floating type which incorporates a unitized rear axle housing assembly The drive pinion and the dserential case with drive gear are mounted directly into the center section of the rear axle housing as sembly...

Page 66: ... nuts 4 Attach axle shaft remover tool C 3725to axle shaft flange and remove axle shaft Remove brake assembly Fig 2 5 Remove axle shaft oil seal from housing CAUTION Under no circumstances should axle shaft collars or bearings be removed using a torch The use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because heat is fed into the axle shaft bearing journa...

Page 67: ...of Multi purpose Lubricant NK365 Fig 5 Tool C 3725 Installed on Axle Shaft C 3725 3926 NK366 Fig 6 Installing Rear Axle Shaft Bearing NLGI grade 2 EP on outside diameter of bearing to prevent rust and corrosion 4 Install a foam gasket on studs of axle housing and position brakes support plate assembly on axle housing studs 5 Carefully slide axle shaft assembly through oil seal and engage splinesin...

Page 68: ...ngles to back face of drive gear Fig 8 5 Measure drive gear runout by turning drive gear several complete revolutions and reading dial indicator Mark drive gear and differential case at point of maximum runout The marking of differential case will be very useful later in checking differential case runout Total indicator reading should be no more than 005inch If runout exceeds 005inch the NY 1038 F...

Page 69: ...ol and remove mount dial indicator in contact with drive gear flange face to take runout Fig 12 Spreading Rear Axle Housing Fig I 3 loosening Differential Assembly readings as in steps 3 4 and 5 Total allowable run out should not exceed 003inch It is often possible to reduce high runout by positioning drive gear 180 from point of maximum runout when reassembling ring gear on differential case 18 W...

Page 70: ...washer surface areas in side the differential case should be polished and with no surface imperfections The pinion shaft bore in differential case should be round and smooth The differential pinion shaft should be round and without excessive wear in areas of contact with either differ ential case or differential pinions 9 The ring gear and drive pinion teeth should have a uniform contact pattern w...

Page 71: ... thicker for installation Treat other pinion markings in a similar manner Spacers are available in one thousandths of an inch incre ments from 084to lo0inch 4 Remove tool arbor and tool from axle housing PINION INSTALLATION AND BEARING PRELOAD Pinion bearing mounting shims are chamfered on one side and must be installed on the pinion stem COMPRESSION SLEEVE REAR SPACER NY1028 Fig 17 Pinion Setting...

Page 72: ...LASH 1 With drive pinion and bearings installed and bearing preload set install differential case and ring gear assembly and cups Insert a 254 inch preload adjusting spacer on ring gear side Fig 22 of axle TOOL NY1024 Fig 2I Installing Companion Flange 2 Install a preload spacer on right side of housing that will fit snugly but still leave a slight amount of end play 3 To measure move dserential t...

Page 73: ...h I reading is not within this tolerance it will be necessary to refer to chart and Install Differential Spacers and re check backlash to bring within proper specifications 17 Apply a thin film of red or white lead on both the drive and coast side of the drive gear teeth Ro tate drive gear one complete revolution in both direc tions while pryhg with a round bar or screwdriver between the casting a...

Page 74: ...VE NR201 t SIDE CONVEX Fig 28 Incorrect Tooth Contact Pa ern Decrease Spacer Thickness toward the heel If the tooth contact pattern resembles that in Fig 28 the drive pinion is too close to the ring gear the pattern will appear low on the toe on drive side and l o w heel contact on the coast side To correct this type tooth contact pattern decrease the thickness of the rear pinion bearing mounting ...

Page 75: ...yfrom the vehicle Gear ratio identification numbers will be stamped on a metal tag and attached by means of the rear axle housing to carrier bolt Some 8 3 4 large stem differential and carrier as semblies have incorporated a new collapsible spacer which bears against the inner races of the front and rear bearing This collapsible spacer is used to estab lish preload on the pinion bearings Adjustmen...

Page 76: ...To prevent the possibility of damaging axle shaft seal surface slide protective sleeve SP 5041 over the seal surface next to bearingcollar ADJUSTER FLANGE I BEARING NK59A Fig 2 Axle Shaft Disassembled CAUTION Under no circumstances should axle shaft collars or bearings be removed using a torch The use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because hea...

Page 77: ...ers Fig 9 4 P u l l bearing roller retainer down as far as pos sible and cut with a pair of side cutters and remove fIg 7 Removing Roller Retainer Fig 8 Flange Ground Off Inner Cone 5 Remove roller bearing cup and protective sleeve SP 5041from axle shaft CAUTION Sleeve SP 5041 should not be u d as a protector for the seal journal when pressing o f f the bearing cone as it was not designed for this...

Page 78: ...eal Journal Protection Fig 12 Removing Bearing Cone with Tool C 397 I gasket on axle housing studs followed by brake sup port plate assembly on leftside of axle housing 2 Apply a thin coating of Multi Purpose Grease NLGI grade 2 E P to the outside diameter of the bearing cup prior to installing in the bearing bore This operation is necessary as a corrosion preventive 3 Install foam gasket on the s...

Page 79: ...ure in an upright position to prevent damage to front universal joint 7 Remove shock absorber from spring plate studs and loosen rear spring U bolt nuts and remove U bolts 8 Remove the assemblyfrom vehicle installation 1 With body of vehicle supported at front of rear springs position the rear axle assembly spring seats over the springcenter bolts 2 Install spring U bolts and tighten nuts to 45 fo...

Page 80: ...6 Removing Companion Flange drop from carrier 7 Apply identifying punch marks on differential bearing pedestals of carrier differential bearing caps and bearing adjusters for reassembly purposes Fig 17 8 Remove both differential bearing adjuster lock screws and locks 9 With a 3 4 inch socket loosen bearing cap bolts one on each side and back off bearing adjusters slightly using spanner wrench Tool...

Page 81: ...ten possible to reduce the runout by positioning the drive gear 1800 from point of maxi mum runout when reassembling drive gear on dif ferential case THRUS W A S U F KP7A Fig 194hecking Drive Gear Mounting Flange Runout 8 With a flat nose drift and hammer remove dif ferential pinion shaft lock pin from back side of drive gear flange he hole is reamed only part way through making it necessary to re...

Page 82: ...ferential pinion shaft for excessive wear in contact area of differential pinions Shaft should be smooth and round with no scoring or metal SH AFT pickup 5 Inspect differential side gears and pinions they should have smooth teeth with a uniform contact pat tern without excessive wear or broken surfaces The differential side gear and pinion thrust washers should be smooth and free from any scoring ...

Page 83: ...h the side gears having pinions exactly 180degrees opposite each other 3 Rotate side gears 90 degrees to align pinions and thrust washers with differential pinion shaft holes in case 4 From pinion shaft lock pin hole side of case insert slotted end of pinion shaft through case and the conical thrust washer and just through one of the pinion gears 5 Install thrust block through side gear hub so tha...

Page 84: ...h adjust ment first The large stem pinion using a collapsible spacer for bearing preload requires the depth of mesh setting first also GAUGE BLOCK SP 528 OR SP 3250 83 4 AXLE SP 5260 9 4 AND 93 4 AXLE SLEEVE sp 2920 CROSSBORE ARBOR PINION COMPRESSION LOCATING c NUT sp 533 NU418 SPACER FPACER SP 2919 CP 539 Fig 25 Rear Axle Setting Gauge Tool C 758 D4 KP13B Fig 26 Seating Bearing Cups in Carrier Ho...

Page 85: ...d be facing differential bearing pedestals Fig 28 Tighten screw with Allen wrench 2 Position arbor SP 561 part of Tool C 758 D4 in differential bearing pedestals of carrier Fig 29 Center the arbor so that an approximate equal dis tance is maintained at both ends Position differential bearing caps and attaching bolts on carrier pedestals and insert a piece of 002 inch shim stock between Fig 28 Inst...

Page 86: ...y cleaning solvent and with the exception of bearing cones dry with com pressed air 1 Assemble spacer SP 2921 to main section of tool followed by spacer SP 1730 Install rear pinion bearing cone over spacer SP 1730 and against spacer SP 2921 Fig 31 2 Insert assembly into carrier and install front pinion bearing cone over tool shaft and in its proper position in bearing cup Install tool spacer tool ...

Page 87: ...should be corrected Use a thin ner shim pack to increase preload and a thicker shim pack to decreate preload Preload shims are available in two thousandths of an inch increments from 014 026inch 20 Loosen and remove drive pinion nut washer and flange after proper bearing preload has been established 21 Apply a light coat of sealer in seal bore of carrier and install drive pinion oil seal into carr...

Page 88: ...ol to rotate as nut is being tightened in order not to brinnel bearing cone or cups Make sure bearing cup is prop erly seated against mounting shim and carrier casting 16 Loosen compression nut and support lower por tion of tool in carrier with one hand remove tool nut 1 Position rear pinion bearing cone on pinion stem small side away from pinion head Make certain that the pinion head contact surf...

Page 89: ...n depth of mesh has been established and correct bearing preload obtained remove the drive pinion flange Apply a light coat of sealer to drive pinion oil seal and carrier casting bore and install drive pinion oil seal with Tool C 3980 synthetic rubber seal or Tool C 3656 leather seal Install the pinion flange washer and nut and tighten nut to 240 foot pounds Pinion Bearing Preload Large Stem Pinio...

Page 90: ...der Light Load Fig 33 in a notch at a time notch referred to is the adjuster lock holes until backlash between drive gear and pinion is a minimum of 006 to 008 inch This will preload differential bearings and establish cor rect backlash 2 Tighten the remaining two differential bearing cap bolts to 85 90foot pounds 3 Install remaining adjuster lock lockwasher and attaching screw Tighten to 15 20foo...

Page 91: ...Fig 37 Incorrect Tooth Contact Pattern Decrease Spacer Thickness toe contact on drive side to raise and move toward the heel low heel contact on coast side will raise and move toward the toe DIFFERENTIAL AND CARRIER installation 1 Thoroughly clean the gasket surfaces of the car rier and rear axle housing 2 Using a new gasket install the carrier assembly into the axle housing Tighten the carrier to...

Page 92: ...nd holding Tool C 3281 13 Remove tool and install Belleville washer con vex side of washer up and pinion nut 14 Hold universal joint flange with holding Tool C 3281and tighten pinion nut to 100 foot pounds Ro tate pinion several complete revolutions to assure that bearing rollers are properly seated Using an inch pound torque wrench 2 685measure pinion bear ing preload Continue tighteningpinion nu...

Page 93: ... the centerline of the drive pinion is mounted below the centerline of the ring gear The rear axle housing is an iron casting with tubu lar legs pressed into and welded to the carrier to form a carrier and tube assembly A removable stamped steel cover is bolted to the rear of the carrier to permit visual inspection of the differential without removing the complete rear axle from the vehicle A smal...

Page 94: ...with special Sure GripLubri cant Part Number 2585318 or equivalent Reinstall fill plug and tighten 4 Start engine of vehicle and engage in gear and run on hoist with rear wheels free to turn 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 much of the old lubricant as possib...

Page 95: ... 3 Bearing Cap IdentMccrtion tial case at point of maximum runout The marking of differential case will be very helpful later in check ing differential case runout Total indicator readings in excess of 006 inch might indicate possible loose drive gear or damaged differential case A test for differential case runout will be described later 6 Check the clearance between the differential bearing cap ...

Page 96: ... Remove drive pinion nut and washer Using Tool C 452 and holding Tool C 3281 remove drive pinion flange 15 Using Tool C 748 remove drive pinion oil seal Remove slinger gasket front pinion bearing cone Fig 5 Removing Differential and Drko Gear Assembly NNlrnl Fig 6 Mwsuring Differential Case Drive O w r Mounting Flange Face Runov and preload shim pack Record the thickness of the shimsin case they s...

Page 97: ...er section Both ends of each shaft have two flat surfaces or ramps which mate with identical ramps in the differential case There is additional clearance in the case to permit a slight peripheral movement of the ends of the pinion shafts within the case Disassembly 1 Remove axle drive gear Measure runout of the drive gear mounting flange Replace both case halves if runout exceeds 003 inch 2 Before...

Page 98: ...ential Case Cap BEL1 KR720B l__l_l Fig 13 Removing or Installing Clutch Plates Cap Side SIDE GEAR RETAINER Fig 14 Removing or Installing Side Gear Retainer Cap Side GEAR R721A HAFl SPPrCER K R722 Fig 15 Removing or Installing Side Gear Cap Side AXLE THRU Fig 16 Removing or Installing Pinion Shafts and Gears MyMopar com ...

Page 99: ...ches or corrosion To remove any imperfections polish the area with 600 crocus cloth without reducing diameter of axle shaft oil sealjournal 6 Differential bearings and front and rear pinion bearing cone and cup assemblies should have a smooth appearance with no broken or dented surfaces on rol lers or roller contact surfaces The bearing roller retainer cages must not be distorted or cracked When r...

Page 100: ...ly on drive gear half matching scribe marks 6 Make sure markings on each differential case half coincide Install the differential case bolts and turn in a few threads 7 With shafts installed center the cross shafts be tween the two ramp surfaces in differential case Tighten differential case bolts evenly by alternately turning opposite bolts until all are tightened to 45 foot pounds To keep spline...

Page 101: ...inch and the new pinion is marked 1 the shim pack should be increased 003inch to bring the new pinion to its correct position and the new shim pack would be 038 inch This will give an approximate setting of the pinion A pinion depth gauge should be used for final setting of the pinion see steps 6 through 14 Shims are available in 003 005 and 010inch thickness 2 Install front pinion bearing cup in ...

Page 102: ...be assumed to be cor rect If the setting is outside these limits it should be corrected by adding or removing the proper thick ness shim behind the rear pinion bearing cup 12 Remove the drive pinion depth gauge and drive pinion 13 If shim adjustment is necessary remove drive pinion rear bearing cup and add or remove shims as determined in preceding Step 9 Measure each shim separately with a microm...

Page 103: ...thru 5 When cup is properly seated remove tool and pinion bearing cones c NP414 Fig 29 Determining Shim Puck Thickness for DrivePinion Deptho f Mesh 14 Lubricate rear drive pinion bearing cone with Sure GripLubricant Part Number 2585318or equiva lent and install bearing cone on pinion stem using Tool DD 955 An arbor press may be used in conjunc tion with tool Fig 2 4 15 Install drive pinion and be...

Page 104: ...resents the thickness of shim pack necessary to take up the clearance between the bear ing cup and the case on the ring gear side of the dif ferential assembly Subtract this reading from the previously recorded total reading to obtain the amount of shims necessary to take up the clearance between the bearing cup and the case at the pinion side of the differential 3 Remove differential and ring gea...

Page 105: ...ing gear the contact pattern will appear high on the heel on drive THICKER SPACER NEEDED v HEEL END DRIVE SIDE CONVEX HEEL END COAST SIDE CONCAVE NRm Fig 34 Effect on Tooth Contact Pattern a s Shim Pack Thickness is Increased side and high on toe on coast side To correct this type tooth contact pattern increase the thickness of shim pack located behind the rear pinion bearing cup Fig 34 which will...

Page 106: ...d as a special equipment option in the 7 1 4 and 8 3 4 rear axles will appear in the 1969 vehicle models Fig 1 The Sure Grip differential design is basic and sim ple and consists of a two piece case construction and is completely interchangeable with the conventional differential and also the previous type Sure Grip dif ferential Fig 2 A conventional differential allows the driving wheels to rotat...

Page 107: ...d to one wheel SURE GRIP DIFFERENTIAL IDENTIFICATION Identification of sure grip differential asse mbly can easily be made by lifting both rear wheels off the ground and turning them If both rear wheels turn in the same direction simultaneously the vehicle is equipped with a Sure Giip Differential Another means of identification is by removing the filler plug and using a flashlight to look through...

Page 108: ...the vehicle 1 Position vehicle on a hoist with engine off and the transmission selector lever in park if automatic or in low gear if manual 2 Attempt to rotate wheel by applying turning force with hands gripping tire tread area Fig 3 3 If you find it extremely difficult if not impos sible to manually turn either wheel you can consider the sure grip differential to be performing satisfac torily If ...

Page 109: ...As low as 30 F SAE 80 Below 30 F SAE 75 Temperature Range 7 Follow procedure outlined in conventional axle assemblyfor setting drive pinion depth of mesh drive gear backlash adjustment and bearing preload adjust ment INSTALLING SURE GRIP DIFFERENTIAL AND CARRIER ASSEMBLY 1 Using a new gasket install carrier assembly in axle housing Tighten mounting nuts to 45 foot pounds 2 Refer to Installation of...

Page 110: ...s such a lubricant is available under Part No 2933565 Hypoid Gear Lubricant 9 3 4 Axle TYPE Ring Gear Diameter PINION BEARINGS Type Number Used Adjustment Pinion bearing drag Torque seal removed DIFFERENTIAL Bearings Type Number Used Pre Load Adjustment RING GEAR AND PINION Serviced in Pinion depth of mesh adjustment Pinion and Ring Gear Backlash Runout differential case and ring gear backface Typ...

Page 111: ...arge Stem Tapered Pinions Carrier to Axle Housing Bolt Nuts Axle Shaft Retainer Nuts Propeller Shaft Bolts Rear Spring Clip U Bolt Nuts Wheel Stud Nuts Shock Absorber Stud Nuts Lower Differential Bearing Cap Bolts Differential Case Half Retaining Bolts Ring Gear To Differential Case Bolts Drive Pinion Flange Nut Carrier Cover Bolts Axle Shaft Retainer Nuts Propeller Shaft Bolts Rear Spring Clip U ...

Page 112: ...worn master cylinder f Recondition or replace master cyl inder and bleed hydraulic system g Excessivelyworn brake lining a Air in hydraulic system a Fill master cylinder and bleed hy b Improper brake fluid low boiling b Drain flush and refill with brake fluid c Excessively worn or cracked brake c Replace all faulty brake drums d Broken pedal pivot bushing g Reline and adjust brakes draulic system ...

Page 113: ...ncorrect lining a Replace lining b Distorted or out of round brake b Grind or replace drums c Overheated brake drums c Inspect for dragging brakes d Incorrect brake fluid low boiling d Drain flush refill and bleed hydraulic e Saturated brake lining e Reline both front or rear or all four a Bent or out of round brake drum a Grind or replace brake drums a Out of round brake drum a Grind or replace b...

Page 114: ...er star wheel Then to exlude the possibility of maximum adjustment that is the adjuster refuses to operate because the closest possible adjustment has been reached the star wheel should be backed off approximately 30 notches It will be necessary to hold the adjuster lever away from the star wheel to allow backing off of the adjustment Spin the wheel and brake drum in the reverse direction and appl...

Page 115: ...the hose bracket in a manner to give minimum twist Exces sive twist can result in hose interferewe problems with possible hydraulic system failure Inspection of brake hose and tubing should be included in all brake service operations The hoses should be checked for 1 Correct length severe surface cracking pulling scuffing or worn spots Should the cotton fabric casing of the hose be exposed to weat...

Page 116: ...and heavy duty vehicles Fig 3 are equipped with manual adjusters The service procedures covering these brakes are identical to the passenger car with exception of reference to application adjusters Illustrations of the various service procedures will not always show any one specific brake BRAKE DRUM REMOVAL Removing Front Brake Drums To aid in brake drum removal loosen brake star adjusting wheel 1...

Page 117: ...justing screw 3 Insert Tool C 3784 into brake adjusting hole and engage notches of brake adjusting screw Release brake by prying down with adjusting tool 4 Remove rear wheel and clips from wheel studs 5 Inspect brake lining for wear shoe alignment or that holds drum on axle Remove drum contamination from grease or brake fluid BRAKE SHOE REMOVAL Removing Front Brake Shoes 1 Using Tool C 3785 remove...

Page 118: ...m adjusting lever Remove cable SECONDARY PRIMARY SHOE AND LINING RETAINER Fig 5 Removing or Installing Shoe Retainers Springs and Nails Right Front Fig 6 Removing or Installing Shoe Return Springs Left Rear overload spring cable guide and anchor plate 4 Disengage adjusting lever from spring by slid ing forward to clear pivot then working out from under spring Remove spring from pivot Remove automa...

Page 119: ...ace more than 060 inch over the standard drum diameter BRAKE SHOE INSTALLATION lnstalling Front Brake Shoes Lubricate shoe tab contact area 6 places on sup port plate with Chrysler support plate lubricant Part number 2932524or equivalent Fig 11 1 Match a primary with a secondary brake shoe and place them in their relative position on a work bench 2 Install adjusting star wheel assembly between pri...

Page 120: ...hoe return spring in web of shoe and install free end over anchor using Tool C 3785 Fig 6 6 Install cable guide in secondary shoe web Hold SHOE CONTACT AREA 6 Fig I I Shoe Contact Area on Support ing in position engage secondary shoe return spring through guide and into web Install other end over anchor using Tool C 3785 Be sure cable guide re mains flat against shoe web and that secondary spring ...

Page 121: ... the disc brake section of the brake group SERVICE PROCEDURES 1 Disconnect front and rear brake tubes from master cylinder residual pressure valves will keep cylinder from draining 2 Remove nuts that attach master cylinder to cowl panel and or power brake unit if so equipped 3 Disconnect pedal push rod manual brakes from brake pedal 4 Slide master cylinder straight out from cowl panel and or power...

Page 122: ...linder in stalled If master cylinder pistons are badly scored or corroded replace them with new ones he piston cups and seals should be replaced when recondition ing a master cylinder When overhauling a master cylinder use all parts furnished in repair kit Discard all used rubber parts REASSEMBLING MASTER CYLINDER FrontPiston Before assembling the master cylinder dip all component parts in clean b...

Page 123: ...rake equipped vehicles or depress push rod slowly and allow the pistons to return under pressure of springs must be bled on the bench as follows bleeding tubes Tool C 4029 Fig 7 NT PISTON REAR PISTON SPRING I I RETAINING S C R E W REAR PISTON AND GASKET A S S E M B L Y NP22A Fig 6 Installing Rear Piston Assembly Fig 7 Bleeding Master Cylinder Do this several times until all air bubbles are ex pell...

Page 124: ...onnected Fig 8 If a malfunction occurs within the switch dis connect tubes from body assembly and install a new assembly The component parts of the switch body are not serviced However the terminal unit can be removed if a malfunction occurs and a new termi nal unit installed If a new body is installed bleed the brake system WHEEL CYLINDERS Page Page AssemblingWheel Cylinders 15 Installing Wheel C...

Page 125: ...y boots away from cylin ders and remove Remove push rods ifso equipped 2 Press in on one piston and force out piston cup suitable solvent cle thoroughly and dry w i t h air Inspect cylinder bore and piston for SCOrhg O r Pit ting DO not use a rag as Lint fromthe rag will adhere Wheel cylinder bores and pistons that are badly scored or pitted should be replaced Cylinder walls that have light scratc...

Page 126: ...to front wheel cylinder using a new gasket Tighten to 25foot pounds before attaching brake hose to frame bracket Should hose be connected to wheel cylinder last tightening of the hose into wheel cylinder will twist Fig 4 Wheel Cylinder Piston Stops hose and can result in suspension or tire interference REMOVING BRAKE SUPPORT Front bracket four support attaching nuts and washers spindle Rear suppor...

Page 127: ...r rusted cable equalizer a Properly adjust the service brakes then adjust the parking brake cable b Replace any broken return spring c Replace the broken retainer spring d Replace the grease seal or recondi tion the wheel cylinders and replace both brake shoes e Replace cable f Replace the broken rear spring g Straighten or replace and lubricate the equalizer Broken or rusted brake cable Improperl...

Page 128: ...om brake cable brack NUT I I S F R o N T CABLE ASSEMBLY NN559 Fig 3 Parking Brake Pedal Coronet et 4 Remove brake drum from rear axle 5 Remove brake shoe return springs 6 Remove brake shoe retaining springs 7 Remove brake shoe strut and spring from brake support and disconnect brake cable from operating arm 8 Compress retainers on end of brake cable hous ing and remove cable from support Fig 3 Ser...

Page 129: ... parking brake is in off posi tion REMOVING FRONT PARKING BRAKE CABLE 1 Disengage front parking brake cable from 2 Disengage cable from guideclip 3 Using a screw driver force cable housing and attaching clip out of body crossmember 4 Fold back left front edge of floor mat and re equalizer bar Refer to Figs 1or 2 MIDLAND ROSS POWER BRAKE Tandem Diaphragm INDEX Page Installing Power Brake 19 Removin...

Page 130: ...supplied to unit the master cylinder should compensate forcejet of fluid up through front chamber compensation port 6 Check stop light operation MIDLAND ROSS POWER BRAKE Single Diaphragm Page Page General Information 19 Removing Power Brake 20 Installing Power Brake 20 Service Diagnosis 19 GENERAL INFORMATION The Midland Ross power brake Fig 1 is located on the engine side of the dash panel The fr...

Page 131: ...ttings Leakingvacuum chamber d Replace unit Diaphragm assembly out of place in e Replace unit housing Vacuum leak in forward vacuum f Replace unit housing as required SERVICE PROCEDURES 1 Remove nuts attaching master cylinder to brake 2 Disconnect vacuum hose from power brake 3 From under instrument panel remove nut and attaching bolt from power brake input push rod and brake pedal blade Remove lo...

Page 132: ... Tighten to 30 foot 100 IN LBS PUSH ROD NP94A pounds 5 Check stop light operation Fig P Push Rod Measurement POWER BRAKE BENDIX Single Diaphragm GENERAL INFORMATION The single diaphragm type power brake Fig 1 engine intake manifold vacuum and atmospheric pressure for its power This type of units does not require a vacuum reservoir is a self contained vacuum hydraulic power braking unit It is of th...

Page 133: ...h vacuum hose to check valve 4 Install master cylinder on power brake Tighten mounting nuts to 100 inch pounds Be sure power brake output push rod is set to correct length With power brake attached to dash panel and vacuum sup plied to unit the master cylinder should compensate force jet of fluid up through front chamber compen sation port CAUTION Do not attempt to disassemble brake booster as thi...

Page 134: ...3 CHECK VALVE POWER BRAKES Fig 1 Power Brake Assembly Bendix Disc Brakes NR162 NUT AND WASHER TANDEM MASTER CYLINDER NP293 DRUM BRAKE Fig 2 Power Brake Assembly Bendix Drum and Disc Brakes 424 Hem Only MyMopar com ...

Page 135: ...two cylinder bores of 1 5 8 inch diameter Each cylinder contains a seal piston and externally attached molded rubber dust boot to seal the cylinder more from contamination The pis tons are sealed by rectangular section rubber piston seals positioned in grooves machined in the cylinder bores which provide hydraulic sealing between the pistons Fig 2 and the cylinder bores The cylinders are connected...

Page 136: ...ve between the master cylinder and the rear wheel cylinders which provides balanced braking ac tion between the front and rear brakes under a wide range of braking conditions The valve regulates the hydraulic pressure applied to the rear wheel cyl inders thus limiting rear braking action when high pressures are required at the front brakes In this manner premature rear wheel skid is prevented An a...

Page 137: ...nspection does not adequately deter mine the condition of the lining a physical check will be necessary To check the amount of lining wear remove the wheel and tire assembly the spring clips and the shoe and lining assemblies see Brake ShoeRemoval paragraph Three 3 thickness measurements with a micrometer should be taken across the middle sec tion of the shoe and lining one reading at each side an...

Page 138: ...tionof the test to prevent bear ing failure After tightening the adjusting nut be sure that the braking disc can still be rotated Dial indicator C 3339 should be clamped to the steering knuckle so that the stylus contacts the brak ing disc at a point approximately one 1 inch from the outer edge Fig 15 Rotate the disc and check the indicator reading The maximum total indicator reading on the gauge ...

Page 139: ...red e Remove lining and install correct lin tons Clean parts ing a Loose calipers b Frozenor seized pistons c Rear brake pistons sticking d Front end out of alignment e Broken rear spring f Out of round rear drums g Incorrect tire pressure h Brake fluid oil or grease on linings i Restricted hose or line j Rear brakesout of adjustment k Unmatched linings I Distorted brake shoes a Tighten caliper mo...

Page 140: ...lightly into bores Pistons can be forced back into bores by forcing shoe back with a water pump pliers placed on corner of the shoe and caliper housing Fig 6 Check the caliper for seal leaks evident by fluid moisture around the cavity and for any damage to the piston dust boot Wipe the cavity clean between the inner and outer caliper housings with a shop towel Check the piston dust boot for proper...

Page 141: ... steering knuckle Should it become necessary to in stall a new flexible brake hose on a disc brake equipped vehicle scribe a mark on hose bracket on side where hose enters and position of hose retaining clip underneath Fig 4 Be sure at reassembly that open end of retaining clip is facing out and away from caliper 5 Slowly slide caliper assembly up and away from brake disc Fig 8 and remove to bench...

Page 142: ...s cloth However bores that have deep scratches or scoring may be honed using Tool C 3993 providing the diameter of the bore is not increased more than 002 inch If the bore does not clean up within this specification a new caliper housing should be installed Blackstains on the bore walls are caused 1 8 CALIPER ASSY NN64B by the piston seals and will do no harm When using hone C 3993 Fig 13 be sure ...

Page 143: ... from 70 to 80 foot pounds Under no condition should these bolts be substituted or replaced by an inferior bolt The use of bolts other than those specified for this purpose could cause a caliper failure resulting in an accident Fig 13 Honing Piston Bores Fig 14 nstulling Pirtons in Culiper 7 Install transfer tube and tighten securely Be 8 Install bleeder screw but do not tighten sure tube is under...

Page 144: ...ok or loop to avoid strain on hose and damage to transfer tube 3 Remove grease cup cotter pin nut lock nut thrust washer and outer wheel bearing 4 Pull disc and hub off wheel spindle INSTALLING BRAKING DISC AND HUB 1 Slide brake disc and hub assembly on spindle 2 Install outer bearing thrust washer and nut 3 Tighten wheel bearing adjusting nut to 90 4 Position lock nut on nut with one pair of slot...

Page 145: ...ing the brakes proceed as follows 1 Install wheel and tire assemblies tightening to the right rear and left rear in order I I PRESSUR 1 AND REAR BRAKES Fig 17 Checking Proportioning Valve wheel stud nuts to 55 foot pounds 2 Install wheel covers 3 Removejackstands or lower hoist TEST1NG PROPORTIONING VALVE When a premature rear wheel slide is obtained on brake application it usually is an indicatio...

Page 146: ...d in position by parallel machined abutments within the caliper Fig 17 Operation As the brake pedal is depressed the hydraulic pressure exerted in the system loads the pistons clamping the disc between the brake shoe pads with equal and opposite force When the brake pedal is released the hydraulic pressure is reduced and the pistons relax The compressed piston return spring positions the brake sho...

Page 147: ...5 36 F BEAR NNW Fig 2 Disr Brake Assembly Sectional MyMopar com ...

Page 148: ...the casting is evident it must be replaced as a unit Shoe and Lining Wear If a visual inspection does not adequately deter mine the condition of the lining a physical check will be necessary To check the amount of lining wear remove the wheel and tire assembly the caliper assembly from knuckle then remove the shoe and lining assemblies see Brake Shoe Removal paragraph Three 3 thickness measurement...

Page 149: ...nsufficient fluid in sys tem or caliper Excessive disc runout Improper brake fluid boil Rear brake adjustment required Warped or excessively tapered shoe and liningassembly Loose wheeI bearing adjustment Damagedcaliper piston seal Power brake maIfuncton a Check system for leaks b Check disc for runout wth dial indi c Drain and install correct fluid d Check and adjust rear brakes e Install new shoe...

Page 150: ...sted under Pull and the caliper blies length disc run out specifications brakes ton inder inders seal der Bore Install new seal a Check and correct power unit b Corrections listed under Pull cylinder bore a Pistons pushed back in cylinder bores a Reposition brake shoe and lining as during servicing of caliper shoe and semblies Depress pedal a second lining not properly positioned time and if condi...

Page 151: ...ds mum drag covers CAUTION Road test vehicle and make several stops to wear off any foreign material on brakesand to seat linings The vehicle may pull to one side or other if this is not done REMOVING CALIPER 3 Install caliper mounting bolts and tighten 75 4 Make sure disc rotates freely and with mini r 5 Install wheel and tire assemblies and wheel 6 Remove jackstands or lower hoist Should it beco...

Page 152: ... be installed at reassembly Inspect piston bores in both housings for scoring or pitting Bores that show light scratches or corrosion can usually be cleaned with crocus cloth However bores that have deep scratches or scoring may be honed using Tool C 3993 providing the diameter of the bore is not increased more than 002inch If the bore does not clean up within this specification a new caliper 4 Re...

Page 153: ... new piston seal with 55 Dow Corning Pneumatic Silicone Grease or equivaient and work over piston land and down into position in groove using fingers only Fig 11 3 Install dust boot on piston with lip of seat to ward piston Fig 10 4 Using tapered sleeve Tool C 4031 install pis SPECIAL TOOL SPECIAL TOOL NP63 Fig 13 Piston and Sed lnstulling Tool ton seal and boot into sleeve with lip of seal to war...

Page 154: ...ackstands or lower hoist CAUTION Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat linings The vehicle may pull to one side or the other if this is not done REMOVING BRAKING DISC AND HUB Should it become necessary to remove braking disc for installation of a wheel stud proceed as fol lows SEAL NOTE SMOOTH SURFACE OF BOOT IN GROOVE PISTON NP66 F...

Page 155: ...ing a hoist or jackstands 2 Bleed brakes in usual manner starting with right rear then proceeding to left rear right front and left front in order After bleeding the brakes proceed as follows 1 Remove jackstands or lower hoist 2 Test drive vehicle to be sure brakes are oper ating correctly and that pedal is solid TESTING PROPORTIONING VALVE When a premature rear wheel slide is obtained on brake ap...

Page 156: ...han the disc brake master cylinder and is covered in the service brake section of this group SERVICE PROCEDURES MASTER CYLINDER REMOVAL Should it become necessary to service the master cylinder remove from the vehicle as follows 1 Disconnect front and rear brake tubes from master cylinder and install a plug in rear outlet The residual pressure valve in front outlet will keep cylinder from draining...

Page 157: ...he diameter of the bore is not increased more than 002 inch If master cylinder bore does not clean up at 002inch when honed the master cylinder should be discarded and a new mas ter cylinder installed If master cylinder pistons are badly scored or cor roded replace them with new ones The piston cups and seals should be replaced when recondition ing a master cylinder When overhauling a master cylin...

Page 158: ...from cylinder and i n s t a l l plug in rear outlet Astubes are removed fluid re maining in tubes willsyphon out 5 Place cover and gasket over reservoirs and secure with bail must be bled on the bench as follows bleeding tubes Tool C 4029 Fig 7 NOTE FLUTES ON PRIMARY _ _ c PISTON RETAINING i A SCREW A N D GASKET REAR PISTON Fia S lnstulllna Front Piston and Sarin NP32 n BRAKES 5 47 w w _ _ Fig 6 I...

Page 159: ...aulic System Safety Switch Exploded View sembly The component parts of the switch body a n not serviced However the switch unit can be re moved if a malfunction occurs and a new switch unit installed If a new safety switch or body assembly is installed be sure and bleed the brake system TESTING HYDRAULIC SYSTEM SAFETY SWITCH The brake warning light flashes only when the parking brake is applied wi...

Page 160: ...18 3116 114 1 118 15116 1 1 13116 wide Molded Asbestos 2 112 wide 8 l 2fflong 2 112 wide 1 1 long 1 314 wide 1 314 wide 3116 114 4 per car 1 1 8ff 15116 1 V 8 H D Sub Duo Servo Single Anchor 1W 1 1 8 2 112 2 1 p 3 2 112 Moulded Asbestos 1 1 8112 1 1 a 112ff 9 114 9114 3116 114 12 118 12 118 1 118 i51i6 1 KELSEY HAYES DISC BRAKE Type of Brake FixedCaliper Disc Location Front Wheels Only Master Cyli...

Page 161: ...s Caliper Mounting Bolts 50 80 70 80 Disc Splash Shield Bolts Caliper Bleeder Screw Brake Tube Fitting Nuts to Proportioning Valve Wheel Assembly to Front Wheel Hub and Disc Assembly Nuts Caliper Assembly Bridge Bolts Shoe Clips Retainers 7 9 55 BENDIX DISC BRAKE DISC BRAKE Type Location Master Cylinder Reservoir Proportioning Valve Location Brake Adjustment Residual Valve Location CALIPER ASSEMBL...

Page 162: ...25 DISC SPLASH SHIELD Type Non Vented Mounting 3 Bolt PROPORTI0NING VALVE Type PressureControl Cut In Pressure 300 P S I WHEELS Type Drop Center Diameter 14 x 51 2 JK Special Mounting Stud Circle Rear Wheel Shoe and Lining Cycleweld Molded Bonded Size 10x 2 1 2 inch Cylinder Bore Diameter 15 16 Rear line pressure proportioned at 2 3 l ratio 4 1 2 5 bolt REAR BRAKES TIGHTENING REFERENCE Foot Pounds...

Page 163: ...2 combines the feature of low pedal effort with that of a clutch capable of transmitting the full torque of the engine Page GENERAL INFORMATION 1 SERVICE DIAGNOSIS 2 SERVICE PROCEDURES 3 SPECIFICATIONS 11 11 STEAM CLEANING PRECAUTIONS 12 TIGHTENING REFERENCE TORQUE SHAFT AND BEARINGS 9 Six centrifugal rollers are assembled between the pressure plate and cover These rollers are provided to increase...

Page 164: ... tion SERVICE DIAGNOSIS Condition Possible Cause Correction CLUTCH CHATTER a Worn or damaged disc assembly b Grease or oil on disc facings c Improperly adjusted cover assembly a Replace disc assembly b Replace disc assembly c Replace clutch assembly CLUTCH SLIPPING a Burned worn or oil soaked facings a Replace disc assembly E M B L Y FRAME SIDE RAIL PEDAL STOP LOCK RING PLAIN WASHER BOOT NP131B Fi...

Page 165: ...URES CLUTCH PEDAL FREE PLAY The only adjustment required for the clutch is the pedal linkage adjustment to provide the prescribed clutch pedal free play The adjustment is necessary to restore pedal free play reduced by normal clutch wear Adjusting Clutch Pedal Free Play 1 Inspect condition of clutch pedal rubber stop Figs 3 4or 5 If stop is damaged install a new one 2 On models with 3 speed transm...

Page 166: ... Remove clutch release bearing and sleeve as sembly from clutch release fork Fig 10 then remove release fork and boot from clutch housing 7 Mark clutch cover and flywheel Fig 11 to maintain their same relative positions when reinstall ing clutch assembly 8 Loosen and back off clutch cover attaching bolts one or two turns at a time in succession to avoid bending cover flange 9 Remove clutch assembl...

Page 167: ... one portion 1 Use compressed air to clean dust out of clutch of wear circle and a very light contact 180 degrees housing Inspect for oil leakage through engine rear from that portion flywheel may be improperly main bearing oil seal and transmission drive pinion mounted or sprung In either case a dial indicator seal If leakage is noted it should be corrected at mounted on clutch housing with plung...

Page 168: ...etailed under Crankshaft to Transmission Drive Pinion Pilot Bushing 5 The end of transmission main drive pinion should be smooth and bright without grooves and ridges I RETURN SPRlN RELEASE F O R K RETURN SPRING BEARING AND SLEEVE TYPICAL MOUNTING d PIVOT S PRIYGS RETAINING SPRING CLUTCH HOUSING NN95A Fig IO Clutch Release Fork Bearing and Sleeve U ENGINE ONLY 6 The disc assembly should be handled...

Page 169: ...not tighten them 5 To avoid distortion of the clutch cover bolts should be tightened a few turns at a time alternately until they are all tight Tighten 5 16 inch bolts to 200 inch pounds 3 8 inch bolts to 30 foot pounds Re move 2 360Arbor or drive pinion if used 6 Fill cavity of bearing sleeve with Multi Mileage Lubricant Part No 2525035 or Automotive Multi Purpose Grease NLGI grade 2 EP Also appl...

Page 170: ...taining spring and contact areas of fork fingers 3 Install clutch release fork in housing being careful to engage flat retaining spring in hole in pivot and under retaining springs of bearing sleeve 4 Install dust seal over release fork and engage groove of seal in clutch housing Fig 10 5 Insert fork rod assembly in hole in release fork Install eye end of fork rod on torque shaft lever pin and sec...

Page 171: ...lvent Remove all grease from inside torque shaft 2 The two ball studs should be bright and free from scratches ridges or other surface imperfections 3 The inner surfaces of bearings should also be smooth and free from surface scratches or embedded foreign material The wear pattern should be uniform over entire surface 4 Replace worn or cracked rubber seals Installation 1 Install new seals on ball ...

Page 172: ... under consideration installation of two 007 inch dowels will bring runout within the allowable limits of 004inch or 010inch minus 007 inch dowels which equals 003inch runout 7 The amount of eccentricity of the dowel will produce a total indicator reading change of double the dowel eccentricity therefore select a pair of dowels with the nearest to one half of total indicator runout of bore For run...

Page 173: ...from steam vapors tend to accumu late on the internal clutch mechanism when the vehicle is steam cleaned The facings of the disc will absorb moisture and the force exerted by the pres sure 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 neces sitate replacement of disc assembly flywheel and or clutch...

Page 174: ...16 9 1 2ft 2 2401120 9 112 x 6 112 6 Enclosed 15116 10 3 2200051 10 x 6 314 5 Black 5 Red 15116 15116 10 112 4 2266232 10 1 2 x 6 112 5 Green 5 Tan 1 1 5 2409683 11 x 6 112 6 Blue 15116 11 6 2800861 11 x 6 1 2n 5 Green 5 Tan 15116 1 1 7 2768162 11 x 7 5 Plain 1 1 16 Part Numberssubject to change during model year TIGHTENING POUNDS FOOT INCH 200 200 200 Clutch Cover to Flywheel Bolts 5116 Clutch Co...

Page 175: ...oke seals are used to provide protection against overheating for unusually severe operation re quirements The trailer towing package is a combination of the maximum cooling package and the high capacity fan as necessary to provide protection against overheat ing when towing trailers For internal cooling system protection each cooling system is factory equipped with sufficient permanent type anti f...

Page 176: ...system replace the cylinder block g Repair or replace the oil cooler POOR CIRCULATION a Low coolant level a Fill radiator to correct level b Collapsed radiator hose A bottom b Replacethe hose and spring hose with faulty spring may collapse only at medium or high engine speeds c Fan belt lose glazed or oil soaked d Air leakthrough bottom hose e Faulty thermostat f Water pump impeller broken or loos...

Page 177: ...lts nhibitor stat 3ture gauge unit be D as specified Belt to loose a Adjust belt tension Dirt and paint imbedded in belt b Replace belt Non uniform belt c Replace belt Misaligned pulleys d Align accessories file brackets or use Non uniform groove or eccentric pul e Replace pulley ley spacers as required _ VER IN a Brokencord in belt b Belts not matched A C F a Belt too loose b Belts not matched A ...

Page 178: ... Higher Axle Ratio WATER PUMP Note The water pumpis servicedonly as an assembly When replacingthe water pumpdo not install a stand ard water pumpon any air conditionedvehicle or vice versa See specificationsfor proper pump Removal 1 Drain the cooling system Remove upper half of fan shroud if so equipped or set one piece shroud back on engine 2 Loosen power steering pump idler pulley and alternator...

Page 179: ...xiliary oil cooler air cooled mounted ahead of the radiator and is connected in series with the standard transmission oil cooler Fig 4 In case of a leak engine coolant may become mixed with transmission fluid also transmission fluid may enter cooling system Both cooling system and trans mission should be inspected in event cooler is leaking TestingOil Cooler for Leaks 1 Disconnectboth oil cooler l...

Page 180: ...orrect as necessary Reverse Flushing Radiator engine 1 Drain cooling system and remove hoses from 2 Install Tool 2 3514 or other suitable flushing 3 Fill radiator and turn on air in short blasts gun in radiator lower outlet CAUTION Internal radiator pressure must not ex ceed 20 psi as damageto radiator may result 4 Continue this procedure until water runs clean It is a good policy to reverse flush...

Page 181: ...t If outside of this range replace thermostat 4 Continue heating water to approximately 210 F for a 190 thermostat and 220 temperature for a 200 thermostat The thermostat valve should be fully open at this temperature If it is not replace thermostat lnstalluiion 1 Using a new gasket position thermostat so VENT ET NH186A Fig Radiator Pressure Cap pellet end is toward engine and attach with bolts th...

Page 182: ...lection Method If the specified tensions are not maintained belt slippage may cause engine overheating lack of power steering assist loss in air conditioning capacity reduced belt life To avoid any such adverse effects the following service procedure should be followed Adjust all belts to the specified used belt tension at new vehicle preparation Any belt that has operated for a mini mum for a hal...

Page 183: ...y when it i s not possible to use the torque method To adjust belts by the deflection method loosen all mounting bolts and use a bar to apply tensions to the belts being careful not to damage the accessory A 1 2 inch square drive hinge handle can be used if the acces sory has a square hole Tighten the mounting bolts and test the deflection See Specifications It may be necessary to repeat this proc...

Page 184: ...w 9 3 9 9 h cy eta cnl iz mm 5 5 Q a a oo o K sa K Z Z Z Z S e 3 I E a i n Q m m L J 2 m r c n Y c 0 U E O 3 w a MyMopar com ...

Page 185: ... E W a U a 4 t z 0 0 0 a p l n l n l n l n a m m m c n z I z 0 0 V 0 m U c m l n E c 5 s ln W a l n c a 0 0 V m X 3 L L P P L a a e C m r MyMopar com ...

Page 186: ...0 POWER STEERING 5 32 5 32 5 32 5 32 5 3 2 3 32 FAN BELT IDLER A C IDLER 118 1 8 3 16 3 16 ALTERNATOR Without A C 9 32 9 32 3 16 3 16 3 16 With A C 9 32 3 116 3 116 9 32 New Bolt 383 318426 Hemi 170 225 273 340 440 3 32 3 32 3 32 3 32 3 32 1 16 3 32 3 32 118 1 8 3 16 3 16 118 1 8 3 32 3 16 3 16 118 118 3 16 t Any belt that has operated for a minimum of a half hour is consideredto be used CONVERSIO...

Page 187: ...ctions with light min eral grease or petrolatum after tightening 12 If electrolyte level is low fill to recommended level with mineral free water SPECIFIC GRAVITY TEST indication of how much unused sulphuric acid re mains in the solution A hydrometer should be graduated to read from 1 160 to 1 320 in graduations of 005 specific gravity Graduated markings should be not less than 1 16 inch apart and...

Page 188: ...at tery should be recharged Make a high rate discharge test for capacity If battery cells test O K recharge and adjust gravity of all cells uniformly Test voltage regulator setting Thoroughly test the electrical sys tem for short circuits loose connections and corroded terminals b Cells show more than 25 points LO25 Specific Gravity VariationChort circuit low cell Loss of electrolyte by leakage or...

Page 189: ...READINGS A GREEN BAND RED AND GREEN BAND 0 oo C balance of the readings are within the first four scale divisions the battery is too low to make an accurate condition test Recharge battery and retest CAUTION Be certain to remove surface charge after rechargeand before retesting See Step 2 ADJUSTMENT OF ACID GRAVITY Hydrometer floats usually are not calibrated below 1 160 specific gravity and canno...

Page 190: ...lt the battery should be test charged to determine whether the battery can be satisfactorily charged Charging the Battery Three Minute Charge Ted Fig 5 This test should not be used if battery temperaturn is below 60 degree F 1 Connect Battery Charger positive lead to battery positive terminal and negative lead to battery negative terminal IMPORTANT Be sure of correct polarity when charg ing batter...

Page 191: ...e ampere per positive plate per cell Proper slow charging rate would be 3 amperes for a 38 am pere hour battery 4 amperes for a 48 ampere hour NY839A Fig 6 Fast Chargingthe Battery battery 5 amperes for a 59 ampere hour battery and 6 amperes for a 70 ampere hour battery The average length of time necessary to charge a battery by the slow charge method at normal rates is from 12 to 16 hours however...

Page 192: ...a light film of pet rolatum to terminals after tightening Internal ground inwindings Grounded starter fields Armature rubbing on pole shoes c Test and repair starter d Test and repair starter e Test and repair starter Starter clutch slipping Broken clutch housing Pinion shaft rusted dirty or dry due c Clean test and lubricate to lack of lubrication Engine basic timing wrong Brokenteeth on engine r...

Page 193: ... contact switch plunger wipe clean of all dirt apply a film of SAE 10oil on plunger wipe off excess Test and repair Test and replace relay if necessary SERVICE PROCEDURES AMPERAGE DRAW TEST with Starter Tester Check battery electrolyte gravity with a reliable hydrometer Gravity should be not less than 1 220 temperature corrected Or see that battery passes the High Rate Discharge Test shown in the ...

Page 194: ...ast part eliminated in test is at fault Maximum allowablevoltage loss is as follows Battery insulated cable 2 volt Solenoid switch 1 volt Each connection o volt Replace faulty cables Clean and tighten all con nections RESISTANCE TEST 1 Test battery electrolyte specific gravity Spe cificgravity should be 1 220or above 2 Disconnect positive battery lead from battery terminal post Connect an 0 to 300...

Page 195: ...ected 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 expose terminal screw and wire wrap connection of shunt field at brushterminal Placetwo wood blocksbetweenstarter frame and starter gear housing to facilitate removal ASSEMBLY 1 ND198 i Fig 2 Removing or Installing Terminal Sc...

Page 196: ...ft Fig 8 Do not spread retainer ring any greater than outside diameter of pinion shaft otherwise lock ring can be damaged 19 Push pinion shaft towards rear of housing Fig 9 and remove retainer ring and thrust washers clutch and pinion assembly with the two shifter fork nylon actuators as an assembly Fig 10 20 Remove driven gear and friction washer 21 Pull shifting fork forward and remove solenoid ...

Page 197: ... be replaced 2 When resoldering the shunt field and solenoid lead make a strong low resistance connection using a high temperature solder and resin flux Do not use acid or acid core solder Do not break the shunt field TestingArmature for Short Circuit Place armature in growler and hold a thin steel blade parallel to the core and just above it while slowly rotating armature in growler A shorted m a...

Page 198: ...INO Fig 14 Removhg and installing Pinion Housing Drive Shaft Bushing FIELD COILS REPLACEMENT A pole shoe impact screwdriver Tool C 3475 should be used to remove and install field coils to prevent damage to pole shoe screws and for proper tightening Pole shoes that are loose and not properly seated may cause armature core to rub on pole shoes Make sure area between the leads and starter frame is cl...

Page 199: ...hould rotate smoothly in one direction not necessarily easily but should not rotate in opposite direction If starter required to fit pre sized bushings The C 3944Tool and its adaptors are designed to service all of the gear reduction motor bushings with the exception of the end head bushing End head bushing and end head are serviced as an assembly Remove and install bushings Figs 13 14 and 15 The ...

Page 200: ...r proper entry of terminal stud into brush holder with the double wires curved around the contactor CAUTION The contactor must not touch the double SHIFTING FORK LUTCH ASSEMBLY MOVING CORE fig 18 Shifter Fork ond Clutch Arrongement 5132 3 16 NK77 Fig 194hecking Height of Solenoid Coil Retoinor Tangs wires when solenoid is energized after assembly is completed Fig 5 Make sure contact spring is posi...

Page 201: ...to the exact position on c ND523A Fig 22 Installing Solenoid and Brush Holder into Gear Housing TERMINAL POST e SHUNT FIELD COIL LEAD I Fig 23 Soldering Shunt Coil Lead Wire gear housing and enter armature into field frame and starter gear housing Fig 24 carefully engaging splines of shaft with reduction gear by rotating arma ture slightly to engage the splines 21 Install thrust washer fiber and w...

Page 202: ... 87 Starter Ground Circuit Test 17 Starter Resistance Test 17 Starter Circuit Tests Insulated Circuit Test 17 Starter Ground Circuit Test 17 Testing Armature Testing Armature for Short Circuit 20 Testing Armature for Ground 20 Testing Commutator Runout 20 Testing Field Coils for Ground 20 Testing Starting Motor Bench Test 17 SERVICE PROCEDURES CHECK AMPERAGE DRAW TEST with Starter Tester Check bat...

Page 203: ...ter relay and cable clamp at battery b A small change will occur each time a normal portion of the circuit is removed from the test A definite change in voltmeter reading indicates that the last part eliminated in the test is at fault Maximum allowablevoltage loss is as follows Battery insulated cable 2 volt Solenoidswitch 1volt Each connection o volt Replace faulty cables Clean and tighten all co...

Page 204: ...der springs and remove brushes commutator end head from field frame l from brush holders 4 Removebrush plate Fig 2 5 Disconnect field coil leads at solenoid connector 6 Remove solenoid attaching screws and remove 7 Drive out overrunning clutch shift fork pivot 8 Remove drive end pinion housing and spacer washer Replace the pinion housing assembly if the rubber seal Fig 1 is damaged unitssoequipped...

Page 205: ...at the factory and sol vent will wash lubrication from clutch 3 The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth BRUSHES AND SPRINGS REPLACEMENT 1 Brushes that are worn more than 1 2the length of new brush or are oil soaked should be replaced Brushes and springs can be replaced after removing commutator end head and brush plate 2 Disengage brush...

Page 206: ...amp lights it indicates a grounded armature Replace grounded armature Testing Commutator Runout Refacing Place armature in a pair of 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 003inch com mutator should be refaced Remove only a sufficient amount of metal to provide a smooth even surfac...

Page 207: ...e oil before it is installed New pre sized bushings should be pressed into the housing until bushing is flush with inner side of housing to provide proper clearance Use Tool C 3944 to remove and install bushing SERVICING THE DRWE UNIT Place drive unit on armature shaft and while hold ing armature rotate the pinion Drive pinion should rotate smoothly in one direction not necessarily easily but shou...

Page 208: ...unger cage Fig 14 NOT THE FORK LEVER until plunger bottoms 3 Measure clearance between end of pinion and pin stop with plunger seated and pinion pushed toward the commutator end Clearance should be 1 8 inch Adjust for proper clearance by loosening sole noid attaching screws and move solenoid fore and aft as required 4 Test starter operation under a Free Running Test NBl8B INSTALLING THE STARTER 1 ...

Page 209: ...ecessary e Open field circuit e Test all the field circuit connections and correct as required f Open charging circuit f Inspect all connections in charging circuit and correct as required g Open circuit in stator windings g Remove alternator and disassemble Test stator windings Install new stator if necessary h Open rectifiers h Remove alternator and disassemble Test the rectifiers Install new re...

Page 210: ...Circuit Resistance lest Fig 3 1 Disconnect the ignition wire at the coil side of the ballast resistor and connect the positive lead of a test D C voltmeter to the battery positive post and connect the test voltmeter negative lead to the voltage regulator FLD field terminal no other lights or accessories on 2 Turn the ignition switch on and turn the volt meter selector switch to the low voltage sca...

Page 211: ... carbon pile to the battery terminals 6 Start and operate the engine at a speed to ob tain 10 amperes flowing in the circuit Observe the Fig 2 Alternator Assembly ND240D voltmeter reading The voltmeter reading should not exceed 3 volt If a higher voltage drop is indicated inspect clean and tighten all the connections in the charging circuit A voltage drop test may be per formed at each connection ...

Page 212: ... engine speed should not be large enough to allow voltage to go above 16 volts 11 Observe the reading on the test ammeter The current output should be within the limits shown in Specifications If the output is slightly less 5to 7 amperes than that specified above it may be an indication of pos sible open rectifier or other alternator internal prob lem If the output is considerably lower than that ...

Page 213: ...test If upper contact voltage setting is not within specification remove regulator cover and adjust voltage setting as outlined in Regulator Adjustments step number 1 Lower Contact Test 1 Increase engine speed to 2200 R P M 2 Turn off all lights and or accessories or vary the carbon pile to decrease the current load to 7 am peres output as registered on the test ammeter The voltage should increase...

Page 214: ...netic force of the coil tends to attract the regu lator armature When battery line voltage is relatively low current flow through the voltage coil will be low The mag netic force or pull of the voltage coil will not be great enough to overcome the regulator armature spring tension which is holding the armature contact against the upper stationary contact Fig 8 Battery line voltage applied to the I...

Page 215: ...called for in the voltage regulator chart indicate a tolerance of one volt from the low setting to high setting at temperatures indicated for the upper contact setting To maintain battery in a full state of charge the voltage regulator should be adjusted to provide proper voltage limiting setting according to custom er s driving and load requirement habits as follows a Check entire charging system...

Page 216: ...wer stationary contact bracket making sure con tacts are in alignment If lower contact gap is correct and voltage regulator setting is still outside the 2 to 7 volt increase adjust air gap as follows IN GAUGE NK111 Fig 12 Testing the Air Gap a Connect a small dry cell and test lamp in series with the IGN and FLD terminal of voltage regu lator b Insert an 048 inch wire gauge between regu lator arma...

Page 217: ... shields by removing the three through bolts 3 Again test by placing one of the test prods to a slip ring and remaining test prod to end shield If lamp lights rotor assembly is grounded and requires replacement If lamp does not light after removing the insulated brush and separating the end shields the cause of the ground at the first ground test was a grounded insulated brush 4 Examine plastic in...

Page 218: ... The read ing of the good rectifiers will now be within satisfac tory range When one rectifier is open it will read approximate ly one ampere and two good rectifiers will read with in satisfactoryrange Negative Case Rectifier Fig 17 a Connect test lead clip to rectifier end housing b Touch exposed connection of each of the nega tive case rectifiers with test prod Test specifications are the same a...

Page 219: ...d contacts each of the three leads If lamp does not light stator winding is open Fig 21 T O 110 VOLT WOOD f Fig 20 resting Stator for Ground h Install a new stator if stator tested is ground ed or open If the rectifiers must be replaced un solder the rectifier wire from the stator lead wire at the soldered joint Three rectifiers are pressed into the heat sink and three in end shield When removing ...

Page 220: ...d ball bearing is an interference fit with the rotor shaft Remove bearing with Puller Tool C 4068 Fig 25 10 Remove output terminal nuts and washers and remove terminal screw and inside capacitor The heat sink is also held in place by the terminal screw 11 Remove insulator Fig 26 12 The needle roller bearing in rectifier end BEARING RETAINER 16 16 Fig 24 Disengaging BearingRetainer from End Shield ...

Page 221: ...S26A Fig 29 Cutting Old Slip Rings c Use a chisel to cut through the copper of both slip rings at opposite points 180 apart Fig 29 d Break the plastic insulator and remove the old slip ring e Clean away dirt and particles of old slip ring from rotor f Scrape ends of field coil wires clean for good electrical contact g Position field coil wires so as to clear path for new slip ring h Position new s...

Page 222: ...ound slip ring Light shouldgo On showing the staller adapter of Tool C 3928 With the installing field circuit is completed adapter positioned on the rectifier carefully apply circuit is con pressure with tool pressure screw until the installer tinuous lightly clean SUP rings surface with 00 sand tool rectifier rectifier end shield or heat sink are in paper alignment and after determining that rect...

Page 223: ... damaged by the soldering or pressing operations PRESS TOOL CAPACITOR STATOR LEARING OOL PRESS NF728A Fig 36 lnstalling RectifierEndShieldBearing PRESSING TOOL ROTOR ND116 Fig 37 lndalling Drive EndShieldBearing 6 Support end shield on Tool C 3925 so that notches in the support tool will clear the raised sec tion of the heat sink and press the bearing into posi tion with Tool SP 3381 Fig 36 until ...

Page 224: ... Distributor Advance Testing 45 Distributor Contact Dwell 40 Distributor Contacts 44 Distributor Disassembly 42 Distributor Installation 45 Distributor Lubrication 45 Distributor Removal 41 Distributor Resistance Test 40 Dwell Variation 40 General Information 38 Page Idle R P M Test 40 Ignition Coil 46 Ignition Timing 41 Installing and Aligning Contacts 45 Lubrication Distributor 45 Secondary Circ...

Page 225: ...ws Inspect conditions and correctly con nect the coil Test condenser and replace if neces sary Replace and adjust contacts Replace ignition switch Replace housing Replace and adjust contacts Replace coil Inspect condition of the distributor contacts Replace the coil Replace the coil probe to a good ground other end free for probing b Disconnect cable at spark plug end Insulate cable end from groun...

Page 226: ...al of coil and connect to the followingpoints a Distributor primary terminal outside b Distributor primary terminal inside c Contact terminal bracket insulated bracket d Ground side of contacts e Distributor housing 5 Repeat test at each connection until a notice able change occurs in meter reading If a poor con nection or faulty lead is indicated clean tighten or replace as necessary and repeat t...

Page 227: ...using in direction of rotor rotation If flash occurs when the vibration damper timing mark is located past the specified degree mark in the direction of engine rotation timing is retarded To adjust turn distributor housing against direction of rotor rotation Refer to Specifications Moving the distributor housing counterclockwise advances igni tion timing and clockwiseretards timing 6 Tighten distr...

Page 228: ... Remove wire and grommet as an assembly Push grommet towards inside of distributor to remove Do not pull the wire 4 Remove two screws and lockwashers attaching contact plate to the housing and lift out contact plate contacts and condenser as an assembly Distributor cap clamp springs are held in place by p n e d metal around the openingsand should not be removed 5 If the side play exceeds 006 inch ...

Page 229: ...is in line with centerline of rotor electrode Fig 6 drill a 124 129 inch hole and in CAUTION Support hub of gear when installing roll pin so that gear teeth will not be damaged 6 Install contact plate assembly align the con denser lead movable contact spring primary lead and install attaching screws 7 Attach vacuum advance unit arm to the con tact plate 8 Install vacuum unit attaching screws and w...

Page 230: ... but the ignition system and engine must be checked to determine the cause of the trouble so it can be eliminated Unless the condition causing contact burning or excessive pitting is cor rected new contacts will provide no better service than the old contacts Burning of Contacts Contact burning will result from high primary voltage presence of oil or other foreign material de fective condenser and...

Page 231: ...distributor cam when engine is running If this grease strikes the contacts arcing and burning of contacts will result DISTRIBUTOR ADVANCE TESTING Centrifugal Advance Curve Carefully mount distributor assembly less cap and A IGNITION SYSTEM ELECTRICAL 845 rotor in a reliable stroboscope type distributor tester so that gear is not damaged and proceed with tests as follows 1 Turn the Tach Dwellswitch...

Page 232: ...istributor IGNITION COIL The ignition coil is designed to operate with an external ballast resistor When testing the coil for output include resistor in tests Inspect the coil for external leaks and arcing Test coil according to coil tester Manufacturer s in structions Test coil primary resistance Test ballast resistor resistance Test coil secondary resistance Re place any coil or ballast resistor...

Page 233: ...istributor SERVICE PROCEDURES Secondary Circuit lnspection Check high tension cable connections for good con tact at the coil and distributor cap towers and at the spark plugs Terminals should be fully seated The nipples and spark plug covers should be in good con dition Nipples should fit tightly on the coil cap tow ers and spark plug covers should fit tight around spark plug insulators Cable con...

Page 234: ...at cap tower and check the cable resistance If resistance is more than 30 000 ohms replace cable assembly Test all spark plug cables in same manner To test coil to distributor cap high tension cable re move distributor cap with the cable intact Do not remove cable from the coil or cap Connect the ohm meter between center contact in the cap and either primary terminal at coil If the combined resist...

Page 235: ...t Tach Dwell red lead to distributor terminal of coil and black lead to a good ground 3 Turn Selector Switch to 8 LOBE position 4 Start engine and operate engine at idle speed 5 Observe dwell meter reading If the dwell read ing is within Specifications the contact gap cam rubbing block and contact arm are all in satisfactory condition If dwell reading is not within specifications incor rect contac...

Page 236: ...be rotated with a slight drag then turn distributor in the normal rotation until test lamp lights 4 Turn distributor against normal distributor ro tation until test lamp goes out If test lamp lights immediatelywhen connected turn distributor against normaldistributor rotation until lightgoes out 5 Tighten distributor clamp bolt securely and re move test lamp If the operation is performed proper ly...

Page 237: ...rom bottom of housing using Driver Tool C 3041 Fig 7 f Soak new bushings in light engine oil for ap proximately 15minutes g Position new upper bushing with hole in bush ing up and in line with oil hole in housing then press bushing into distributor housing with Tool C 3041and tool adapter until adapter bottoms on housing The bushing will measure 094 inch below the top of the housing bore Fig 8 Pla...

Page 238: ...LEAD CONDENSER XREW WASHER CONTACT SET SCREW BREAKER PLATE WASHER SCREW FELT SNAP RING LEAD c m SPRING SET WEIGHT WASHER CLAMP LOCKWASHER BEARING HOUSING C M P WASHER XREW OILER BUSHING COLLAR Fig S Dl riburor Disussornblod V i m k Chryskr Built fig 6 DisWbutor fDlsassombledViow Prosrolbo MyMopar com ...

Page 239: ...top of distributor cam with 1drop 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 contact surfaces Fig 11 Take a reading as the contacts start to separate under the slow and steady pull of the scale Spring tension should be as shown in specifications If the reading is outside t...

Page 240: ...or vapors up into the distributor Over oiling of the distributor will also cause burning of the contacts If the contact opening is too small cam angle too large arcing will occur between the contacts result ing in low secondary voltage and engine miss High series resistance in the condenser circuit will prevent normal condenser action so the contacts will burn rapidly This resistance may be caused...

Page 241: ...tions re place with a new distributor shaft with correct Cali bration shaft cam yoke governor weights and springs as an assembly or with a new distributor as sembly less cap and rotor For Prestolite distributors corrections can be at tempted by bending the prigary and secondary spring tabs on the cam yoke to increase or decrease spring tension DO NOT attempt calibration of Chryrler built dis tribu...

Page 242: ...ow speed opera tion when the primary circuit current flow is high ballast resistor temperature rises increasing resist ance This reduces current flow thereby prolonging ignition contact life At high speed operation when primary current flow is low the ballast resistance cools off allowing more current flow which is re quired for high speed operation During starter oper ation the ballast resistor i...

Page 243: ...with a num eral 1 molded in the glass The bulbs cannot be installed wrong as the mount ing lugs for the number one 1 and number two 2 bulbs are offset at different angles On high beam the number 1 bulbs provide the high intensity reach down the highway and the o f f focus filament in the number 2 bulbs provide the body light which illuminates the side of the road ditches etc On low beam only the n...

Page 244: ... Fig 1 Place split image target in like position at right rear wheel 2 Adjust range screw on transit until target split image coincides or merges into one unbroken line Make sure that the line of sight is perpendicular from the eye to the viewing port of the transit and that the target image is centered in viewing port of transit 3 Turn dial on side of transit until bubble in spirit level is cente...

Page 245: ...RING HEADLIGHT AIM Horizontal Test Turn the RIGHT LEFTscale knob until the split image is in alignment If the RIGHT or LEFT por tion of scale exceeds the following values the lights should be aimed Values given represent inchesat 25 feet Left Right No 1 Unit 4 4 No 2 Unit 0 4 Vertical Test Turn DOWN UP scale knob until the spirit level is centered If Down or Up portion of the scale exceeds the fol...

Page 246: ...red on screen or wall Fig 6 a A horizontal line at the level of centers of head b A center vertical line which must be lined up c A vertical line on left of screen or wall in line lights line number 3 with center of hood line number 5 with center line of left headlight line number 4 I NF689C 1 Fig 6 Low Beam Adlustmen Pattern d A vertical line on right of screen or wall in line with center line of...

Page 247: ...osition lamp and spacer on bumper and install 2 Connect lamp connector to harness connector FRONT PARK AND TURN SIGNAL LAMPS Charger Models Fig 10 Removal 1 From underneath radiator grille air shield dis connect lamp socket connectors at harness connector 2 Remove the three screws attaching lamp to shield and remove lamp Bulb can be replaced by re moving lens attaching screws lnstallation shield t...

Page 248: ...NCE SOCKET AND CABLE 0 NU601 Fig 12 rurn Signal Indicator le ender Mounted All Models Except Dart k SOCK TAND CABLE NU602 Fig I3 Turn Signal Indicator Lamps Hood Mounted 2 Remove two screws attaching lamp to bumper and remove lamp lnstallation screws nector 1 Position lamp on bumper and install attaching 2 Connect lamp socket connector to harness con QUARTER PANEL TAIL STOP AND TURN SIGNAL LAMPS C...

Page 249: ...g Install nut assemblies QUARTER PANEL TAIL STOP TURN SIGNAL AND BACK UP LAMPS Dart Models Fig 17 Removal 1 From under fender remove four attaching nuts pull lamp out snap out lamp sockets and remove lamps lnstallation 1 Determine that sealing gasket has not been damaged then snap in lamp bulb and sockets into lamp housing 2 Position lamp on quarter panel extension and install attaching nuts 2 Sna...

Page 250: ... to the straight ahead position a lobe mounted to the under side of the steering wheel contacts one of two cancel ing cams in the turn signal switch mounted in the steering column upper housing Contact of the lobe with the canceling cam returns the switch to the off Page Service Diagnosis 64 Switch 65 position When the system is activated one of two indicator lights mounted in the instrument clust...

Page 251: ... switch 4 Remove three screws attaching horn ring and switch to steering wheel Remove horn ring and switch 5 Loosen steering wheel nut several turns and in stall Steering Wheel Puller Tool C 3428 Loosen steer ing wheel first Then remove steering wheel nut and LEFT PARK r F E N D E R INDICATOR AND TURN RIGHT PARK TURN AND RIGHT PAGEL I INDICATORS steering wheel 6 Disconnect switch wiring multiple c...

Page 252: ...in heavy duty type and is not to be confused with the turn signal flasher HORNS GENERAL INFORMATION The horn circuit consists of a horn switch located in the steering wheel hub and a horn relay mounted in the engine compartment for Coronet and Charger models On Dart models the relay is mounted in the passenger compartment under the instrument panel at left kick pad Battery current from the B ter m...

Page 253: ...re connector green wire and the other lead to a good body ground If test light illuminates there is a short in the horn wiring Repair or replace wire If the test light does not illuminate connect the positive lead back on the B terminal of the horn relay and repeat above test If the light now illumi nates then the relay contacts are sticking Replace horn relay Adjusting mine which horn is not oper...

Page 254: ...e gauge OilPressure Warning Light The oil pressure warning switch mounted on the engine is controlled by the engine o i lpressure When the engine oil pressure is high normal oper ating condition of the engine the switch is held in the OFF or OPEN position allowing no current to flow to the oil pressure warning lamp on the instru ment panel When the engine oil pressure is low the switch is in the O...

Page 255: ...ity has been established the gauge should be replaced Should the panel unit perform properly and the ground strap at the tank suction tube is properly in stalled the tank unit should be removed for testing See Tests Out Of The Vehicle Temperature Gauge Disconnect the terminal from the temperature sending unit on the engine Connect one test lead of Tester C 3826 to the terminal and the other test l...

Page 256: ... speedometer illumination bulbs it will be necessary to drop the steering column for accessibility Light Bulb Replacement Coronet Models The bulbs are all accessible from under the instru ment panel As an aid in reaching the right turn sig nal or oil pressure light bulb first loosen the wire harness from the retaining clip On air conditioning equipped models disconnect the left spot cooler hose Li...

Page 257: ...d reposition floor covering 6 Connect battery ground cable and test opera tion of all instruments Removal Coronet Models Fig 2 1 Disconnect battery ground cable 2 Tape steering column to keep from damaging 3 Removesteering column cover fourscrews finishwhen removing cluster 4 Roll carpeting down and remove steering col umn cover plate 4bolts 5 Remove column clamp at instrument panel two nuts 6 Rem...

Page 258: ... steering column lower support plate 5 Remove steering column upper clamp two 6 Disconnect speedometer cable at speedometer 7 Remove five screws mounting cluster to panel 8 Release wire harness from three retaining clips and rock cluster out of panel far enough to disconnect wiring at ammeter switches tachometer clock light bulbs and printed circuit board connectors then com plete cluster roll out...

Page 259: ...ng 5 Position new gauge studs through back of hous ing and install attaching nuts Do not overtighten 6 Carefully position cluster housing on bezel and install eight retaining screws 7 Install instrument cluster See Instrument Clus ter Installation SPEEDOMETER Replacement All Models 1 Remove instrument cluster See Instrument Cluster Removal 2 With cluster face down on padded work bench remove eight...

Page 260: ...re to positive post of a 12volt test battery 2 Connect a jumper wire from negative post of battery to instrument cluster base ground 3 Connect one lead from Tester 3 3826 to gauge sending terminal being tested 4 Connect remaining tester lead to instrument cluster base mound being tested should read on the low side of dial With gauge tester on M the gauge should read in the center of the dial scale...

Page 261: ...her switch is serviced in the same manner 1 Remove lower center air conditioning duct so 2 Remove left air conditioning duct so equipped 3 Remove steering column cover for visual assist 4 Remove ignition switch spanner with Tool C 5 Disconnectwiring connector and remove switch 6 For the ignition switch light remove bulb 3824 socket from bracket and remove bulb Ignition Switch Coronet and Dart Mode...

Page 262: ...f air conditioning equipped sambly with wo me al c r s lnstallation 1 Position the control assembly in the instru ment panel opening connect the control cables and The blower switch is attached to tho control as lnstallation the blower switch multiple connector or the vacuum connector if air conditioning equipped Adjust the Heaters Group 1 panel flange with the two mounting screws 1 From a positio...

Page 263: ...S TO OPERATE WIPER BLADES NOT PARKING PROPERLY BLADES SLAP AGAINST WINDSHlELD MOULDINGS BLADES CHAlTER MOTOR WILL NOT MENT PANEL SWITCH IS TURNED OFF MOTOR STOPS IN ANY STRUMENT PANEL SWITCH IS TURNED 0FF NO SPEED CONTROL STOP WHEN INSTRU POSITIONWHEN IN a Binding Linkage b Faulty instrument panel switch b Test Switch See Panel Switch c Linkage disconnected d Faulty motor e Open or grounded wiring...

Page 264: ...er that will allow it to come off the pivot shaft in the future regardless of how carefully it is reinstalled NEVER under any circumstances push or bend the spring clip in the base of the arm in an attempt to release the arm This clip is self releasing Models Right left Models Right left n Fig 2 End Play Adjustment END PLAY ADJUSTMENT Variable or Three Speed To adjust the armature shaft end play t...

Page 265: ...R530 Fig Two Speed Motor The ground circuit is completed through the car body Remove jumper 2 Connect jumper from battery positive terminal to resistor terminal Connect second jumper from terminal L to the second resistor terminal The motor should run at low speed Remove jumpers 3 Connect jumper from battery positive terminal to motor terminal Pl Connect a second jumper from motor terminal P2 to t...

Page 266: ...oval All 1 Disconnectbattery ground cable 2 If air conditioning equipped remove the duct supplying left spot cooler to provide easier access to the left wiper pivot Insert a wide blade screwdriver between plastic link bushing and the pivot crank arm Gently twist the screwdriver to force the bushing and link from the pivot pin SeeFig 5 Remove three motor mounting nuts pull motor away from bulkhead ...

Page 267: ...odels are equipped with push button electric washers as stand ard equipment Foot pump equipped models have a unique reser voir mounted in the engine compartment Check SEALING WASHER LEFT PIVOT CRANK ARM d I ARM C0N MTING LINK BUSHING BUSHING NP74A Fig 6 Pivot Arm and Link Assemblies PIVOT REPLACEMENT 1 Removebattery ground cable 2 Using Tool C 3982 remove wiper arm assembly Fig 1 3 From under inst...

Page 268: ...lace switch assembly a Nozzle jets plugged b Broken or loose hose c Faulty pump d Nozzle jet under air intake grille PUMP ASSEMBLY a Poor ground INOPERATIVE en mounting screw b Loose wiring terminals c Corroded terminals d Broken wires e Faulty switch f Faulty motor f Replace motor and pump assembly LOW OUTPUT a Low aimed nozzles b Poor electrical connections c Pinched or leaky hoses d Defective m...

Page 269: ...nnector and rubber hose to pump Fill reservoir inspect for leaks and test operation of washer system making sure the nozzles are adjusted properly FOOT PUMP Removal CAUTION Before removing foot pump clamp the hose at the reservoir to prevent the siphoning of washer fluid intothe passenger compartment 1 Remove the two screws which mount the pump to the floor pan 2 Disconnect hoses lnstallation 1 At...

Page 270: ...x hous ing to the entire inside diameter of seal marked A and the outside diameter of the gear and pinion assembly marked B where the seal contacts the rubber coupling If there is no lubricant in the gear box fill to top of gear with Mopar 2525035 Multi Mileage Lubricant or Mopar 1064768Lubri plate STATION WAGON TAIL GATE WINDOW LIFT Electrical Tests A tail gate glass may not move due to a binding...

Page 271: ...ht either time and wire continu ity has been established replace the circuit breaker Pump Motor Should the test bulb light on one Wire but not the other inspect wire harness for a broken wire If the bulb lights in both tests place one Wire of the test light to the black wire terminal ground on the motor and the other wire to a good body ground Position the switch in either UP or DOWN posi tion If ...

Page 272: ...0 12 12 Voltage Number of Plates Per Cell 13 13 Ground Terminal Negative Negative VoItage 12 12 12 Number of Plates Per Cell 1 1 1 1 1 1 24 MB 59 24 MB 59 24 HB 70R Cu In Engines Standard 440 Cu In Engines Equipment Special Equipment Model Identification Number 27 M8 70 27 MB 70R GEAR REDUCTION STARTING MOTOR Starting Motor Model 2098500 Make Chrysler Voltage 12 No of Fields No of Poles 4 Brushes ...

Page 273: ... Starting Motor Model Make Voltage No of Fields No of Poles Brushes Spring Tension Drive End Play Cranking Amper Free RunningTE Voltage Amperage Dra Minimum Spe Locked Resistan Voltage Amperage Dra Solenoid Pull In Coil age Draw Test St w ed RPM ce Test IW Hold In Coil i 0 Volts at 77 F 5 0 Volts at 77OF 1889100 Chrvsler Built s 1Shunt 2 to 36 Ounces Solenoid Shift Overrunning Clutch 005 Minim um ...

Page 274: ...lerance is provided to allow for temperature variation Current output is meas ured at 1250engine RPM and 15volts at the alternator If measured at the battery current output will be ap proximately 5 amperes lower than above values This is a test point and not the maximum output Voltage is controlled by variable load carbon pile across the battery Limited by Voltage Regulator 50Microfarad plus or mi...

Page 275: ...3 003Nto 017 Clockwise TDC N14Y Championor P 6 6P Mopar 14MM 3 4 Reach 035 1 to 4 7 5 1 5I3 6 2 4 Chrysler Presto1ite or Chrysler Essex 1 65 to 1 70 Ohms 9400 to 11700Ohms 2444242 2444241 2095501 0 5 to 0 6 Ohms 1 41 to 1 55 Ohms 9200to 10600Ohms 3 0 amperes 1 9 amperes Service wear tolerance should not exceed 006 inch Set at idle speed See Idle SpeedAdjustment Fuel System IGNITION SYSTEM WITH CLE...

Page 276: ...ance CentrifugaI Distributor Degreesat Distributor RPM Advance Vacuum Distributor Contact Gap Dwell Angle Degrees at Inches of Mercury Contact Arm Spring Tension Condenser Capacity Shaft Side Play New or Rebuilt Timing Spark Plug Type Size Gap Firing Order Coil Identification Number Primary Resistance 7O0 8O0F Secondary Resistance 7O0 8O0F Resistance 7O0 8O0F in circuit Engine Stopped Shaft End Pl...

Page 277: ... to 21 5 02 25 to 285 mfd OOo to 003 003 to 017 Clockwise TDC N9Y Champion 14MM 3 4 Reach 035 ____ 1 843 6 57 2 1 8 4 3 6 5 7 2 Chrysler Essex or ChrysIer Prestolite 2444241 2444242 1 41 to 1 55 Ohms 9200 to 10600 Ohms 1 65 to 1 79 Ohms 9400 to 11700 Ohms 2095501 0 5 to 0 6 Ohms 20 to 5 50 at 7 to 10 10 5 014 to 019 30 to 35 17 to 20 02 25 to 2a5 mfd OOO to 003 003 to 017 CIockwise 5 BTC N9Y ChamD...

Page 278: ...t Arm Spring Tension Condenser Capacity Shaft Side Play New or Rebuilt Shaft End Play After Assembly Rotation Timing Spark Plug Type Size Gap Firing Order CoiI Identification Number Primary Resistance 70 800F Secondary Resistance 70 800F Resistance 70 800F BaIlast Resistor Current Draw Coil and ballast resistor 383 Cu In 2875742 383 Cu In 2875747 1 to 9 5 550 RPM 1 to 6 500 RPM 1 1 to 13 800 RPM 8...

Page 279: ... 8 9 to 12 15 014 to 019 30 to 35 17 to 20 02 25 to 285 mfd OOo to 003 003 to 017 Counterclockwise 5 BTC J 11Y Champion or P 3 4P Mopar 14MM 318 Reach 035 1 8 4 3 6 5 7 2 or Chrysler Essex 2444241 1 41 to 1 55 Ohms 9400 to 11700 Ohms 9200 to 10600 Ohms 2095501 0 5 to 0 6 Ohms 3 0 amDeres Engine Idling 1 9 amperes Service wear tolerance should not exceed 006 inch Set at idle speed See Idle Speed Ad...

Page 280: ...uretors Manual or Automatic Trans Engine Application Engine Displacement Distributor Part No Chrysler Built Prestolite BuiIt 426 Cu In 2875140 1 BS4014A Advance Centrifugal Distributor Degrees at Distributor RPM Advance Vacuum Distributor Degrees at Inches of Mercury Contact Gap Dwell Angle 2 5 to 9 5 650 RPM 10 to 12 850 RPM 14 to 16 1550 RPM 1 5 to 4 5 10 8 25 to 1 1 15 014 to 019 Individual Con...

Page 281: ...set points 37 to 42 17 to 21 5 oz 17to 20oz 25 to 285 mfd 25 to 285 mfd 000 to 003 OOo to 003 003 to 017 003 to 017 Counter Clockwise Counter Clockwise TDC 5 BTC JllY Championor JllY Championor P 3 4P Mopar P 3 4P Mopar 14MM3 8 Reach 14MM 318 Reach 035 035 1 8 4 3 6 57 2 1 8 4 3 6 57 2 Chrysler Essexd r C h rysler Presto1 ite 2444241 2444242 2095501 1 41 to 1 55 Ohms 9200to 10700Ohms 1 65 to 1 79 ...

Page 282: ...004 158 2 BK LGN W Coronet 158 4 67 90 158 BLACK LIGHT GREEN WHITE 1157 2 1816 1815 53 4001 4002 57 1157 2 1004 158 2 L e 8 s e e e ACC Charger 57 3 158 3 67 90 Gauge 1816 53 4001 4002 1157A 2 1157 4 1004 57 2 WIRING DIAGRAMS INDEX Page Front End Lighting Charger 100 Front End Lighting Coronet 100 Front End Lighting Dart 99 Instrument Panel Accessory Wiring Diagram Coronet 104 105 Instrument Panel...

Page 283: ...TCH M2 RIGHT TAIL STOP AND FEMALE TURN SIGNAL LAMP INSULATORS VIEWED 62 18V4 FROM TERMINAL SIDE RIGHT BACK UP LAMP TWO DOOR HARDTOP TWO DOOR CONVERTIBLE AND FOUR DOOR SEDANS ONLY D7 18BR b 7 L7 18BK 0 RIGHT TAIL STOP AND TURN SIGNAL LAMP 17 18BK Fig 3 Body Wiring Diagram Station Wagon Coronet MyMopar com ...

Page 284: ...18BK TO REAR C12 20W RESISTANCE CABLE REAR WINDOW DEFOGGER MOTOR WIRING WINDOW DEFOGGER SWITCH MOTOR REAR WINDOW DEFOGGER Mll 18BK RIGHT TAIL STOP AND TURN SIGNAL LAMP FRONT DOOR JAMB SWITCH TO FOLDING TOP T 2 1 2 B R w T 2 1 2 R L 7 1 8 8 K a LICENSE LAMP SWITCH c T 3 1 2 Y WIRING ON LEFT BACK UP LAMP TO TRUNK L A M P SWITCH FOLDING TOP MOTOR DOWN INSTRUMENT PANEL WIRING CONVERTIBLE TO INSTRUMENT...

Page 285: ...GROUND E2 18 0 LEGEND FEMALE INSULATORS VIEWED FROM TERMINAL SIDE CONSOLE WIRING AUTOMATIC TRANSMISSION WITHOUT TACHOMETER TO CONSOLE WIRING ON INSTRUMENT PANEL NU184 i 9 RIGHT PARK 18BK AND TURN Fig 6 Console Wiring Diagram Dart RIGHT FRONT FENDER TURN INDICATOR PP L LEFT HEADLAMP GROUND LEFT PARK AND TURN SIGNAL LAMP I L9A BULKHEAD DISCONNECT D A 18BK T L6 18BKIY I LAA LEFT FRONTFENDER I I J N R...

Page 286: ...NR113A Fig Front End lighting Wiring Diagram Coronet RIGHT HOOD D6A l8BK LGN SIGNAL LAMP NR116A Fig O Front End lighting Wiring Diagram Charger MyMopar com ...

Page 287: ...I I I I h 1 3 t jb 0 1 g J I MyMopar com ...

Page 288: ... HEATER BLOWER MOTOR SWITCH C5 16DGN s 4 7 K a 14DGN C4 16BR COLUMN STEERING SUPPORT BRACKET COLUMN H5 18BK HORN GROUND CABLE 4 RIGHT TURN SIGNAL LAMP INSTRUMENT LAMP HIGH BEAM INDICATOR LAMP DPA 18T4FEED IGNITION SWITCH R6 l2BK M2A 18Y L6 18Y P2 188K G2 18V I I I I I I I I I I I Xl2 18R W I C1 14BK HEATER BLOWER MyMopar com ...

Page 289: ...3 INSTRUMENT LAMP INSTRUMENT LAMP GROUND m h LEFT TURN SIGNAL LAMP VOLTAGE LIMITER FUEL GAUGE I TEMPERATURI GAUGE P5 188K p 4 1 8 8 3 t I WARNING BRAKE SYSTEM LAMP ACCESSORY CIRCUIT BREAKER AND TOP LIFT SWITCH D32 18R D9 181 EMERGENCY FLASHER SWITCH 11II I I 1 I 1 I I I I I I I I 1 I I BUZZER RELAY WIRING ORN H2 16DGN BODY WIRING NR154A 14 18V Fig I I lnstrument Panel Wiring Diagram Dart MyMopar c...

Page 290: ...16LGN QA 141 M5 1 8P 2 113 1BDBL 111 1BGY E2B 180 MS 18P I I I I I I C7Aj141 C4 I4BR C 4 1 6 B R d C1 148K I1 C7A 141 p C 1 1 4 8 K o C2 l8DBL C2A 18DBL C1A 1BLGN 18 0 SPEED CONTROL BRAKE SWITCH 4 DASH LINE c TO BODY WIRING 7 M 2 A 1 8 Y SPEED CONTROL SERVO X5OE 1881 RIGHT SPEAKER X58 18DGN0 L E F T S P E A K E R X 5 7 1 8 L G N 1 GROUND X50 1BBK CHANNEL B X52 18DGN CHANNEL A X51 18 4 CENTER SPEAK...

Page 291: ... VACUUM SWITCH E2A TURN SIGNAL LEVER AND SPEED CONTROL LEVER AIR CONDITIONER AND HEATER LAMP AND II SOCKET 18DGN C4A 168R CROSSOVER DGN t W2A 121 W28 12R W9 181 TlA 12R p J BREAKER LAMP ON REMINDER e BUZZER Q4A lBBK Q4A 18BKo M2 18Y M2C l8Y W9 181 W9 1BT M2 18Y 1 6 l B B f i C10 1 M1 18P X32 18BK 8LGN E2 1 C10 1BLGN REAR WINDOW DEFOGGER SWITCH c12 18W B L6 18BK LAMP ON REMINDER BUZZER FEED MAIN AS...

Page 292: ... RECEIVER LAMP FEED a I M2A 1BY TO RIGHT DOOR SWITCH I E2C 18 0 FOR A LAMP HEATER BLOWER MOTOR SWITCH 16DGN 16LGN 14BK 1 16R TEMPERATURE GAUGE RIGHT TURN SIGNAL LAMP c OIL WARNING LAMP RESISTANCE CABLE CIRCUIT V7 24BR0 NOTREQUIRED FOR STARTER AND IGNITION SWITCH 2 SPEED WIPER MOTOR WINDSHIELD J R CONDITIONER CLOCK LAMP I I 13 16 R 14 16V D3 18P 1 RECEIVER LAMP WIRING TACHOMETER LAMP AND ASH I I z ...

Page 293: ...FEED DlOA l8LGN HIGH BEAM LAMP FEED L R INSTRUMENT LAMPS FEED E2A 18 0 RIGHT TURN SIGNAL LAMP FEED DPA 18T _ TEMPERATURE GAUGE SENDER G2 18V OIL WARNING SENDER G6 18GY E WARNING LAMP TO LAMP ON REMINDER BUZZER SEE ACCESSORY WIRING DIAGRAM t 18y INSTRUMENT FEED 4 LAMP BODY Fig 13 Instrument Panel Wiring Diagram Coronet MyMopar com ...

Page 294: ... D32 18R E2F 18 0 P5A 18BK 2A 148K 3 Gt 1 BGY C1 148K 1 c D 1 1 8 B K G t L V 1 1 6 P 02A 14BK A1 12R V3 16BR Dl lOBK D2 18R I TURN SIGNAL FLASHER L6A 18y t EMERGENCY I I F I I I I I I I I I I I t I I 1 1 1 I I I I H3 18BK I I I I I I r SWITCH a J M2A RIGHT DOOR I I L B 1 1 8 w T rB2 18W I E2C 180 82 18W D31 18F V4 18R I I I I I I I I v 7 I I l l I I I I I I I I 18DBL I I 18DGN 18GY I 0 4 I I I 18...

Page 295: ...180 I 1 r BRAKE SYSTEM WARNING LAMP REMINDER BUZZER SEE ACCESSORY WIRING DIAGRAM I BRAKE SWITCH I WIRING BODY I I MI 18P 81 1 8W D31 18P i 7 i 1 82 1 8W D8 18DGN G4 18081 D8 18DGN D7 188R STOP LAMPSWITCH 4 1 8 M28 18Y rD3 18P INSULATORS VIEWED FROM TERMINAL SIDE L4 16V 03 18P Pig 14 Instrument Panel Wirlng Diagram Charger VIOLET WHITE YELLOW NR204A MyMopar com ...

Page 296: ...o L m Y m m 3 MyMopar com ...

Page 297: ... 4 D G n UP mWl4 14GY Wl4 14GYfrzj RIGHT REAR QUARTER WINDOW LIFT LEGEND MOTOR FEMALE INSULATORS VIEWED FROM TERMINAL SIDE NU111 Fig IbEIedric Window Lift Wiring Diagram LOCK IN SWITCH r X33 18R 1 l 8 R 4 1 TURN SIGNAL LEVER AND SPEED CONTROL SWITCH PUSH BUTTON ACTUATOR 20Y 20R SERVO FEED X32A lBBK e 8 B K l 18DBL I n rX30 18DBL SPEED CONTROL BRAKE SWITCH CONTROL COIL BULKHEAD LINE MOLDED GROMMET ...

Page 298: ...I 1 1 T12 18V LINE DASH IGNITION SWITCH WITHOUT AIR CONDITIONER co _ _ _ _ _ R R n W N U M2E 18Y CONSOLE LAMP FEED BODY WIRING M E q WITHOUT TACHOMETER PART O F INSTRUMENT PANEL MAIN HARNESS a M2F 18Y 1 t MA lEY e M 2 F 1 8 YI I E 2 B 1 8 0 LOR CODE ORANGE TAN L l l TO FUSE B L E K INSTRUMENTtr T T t L L U W lWITH TRACEK LAMP TERMINAL TO RIGHT FRONT DOOR AUTOMATIC SWITCH ACCESSORY LAMPS WIRING NU2...

Page 299: ...space in the engine com partment for the long intake manifold branches The engine has in line overhead valves and wedge shaped combustion chambers and a nominal compression ratio of 8 5 l for the 170 cu in engine and 8 4 l for the 225 cu in engine The lubrication system consists of an externally mounted rotor type pump on the lower right side of the cylinder block A full flow replaceable element t...

Page 300: ...ect ignition timing 0 Dirt or water in fuel line or car j buretor Carburetor flooded k Incorrect carburetor float setting 1 Test battery specific gravity R s charge or replace as necessary Clean and tighten battery connec tions Apply a coat of petrolatum to terminaIs Referto Starting Motor Wipe wires and cap clean and dry m Faulty fuel pump m Install newfuel pump Replace any cracked or shorted cab...

Page 301: ... and replace if necessary j Incorrect tappet lash j Adjust to specifications a Incorrect ignition timing b Worn or burned distributor rotor c Worn distributor shaft or cam d Dirty or incorrectly gapped spark e Dirt or water in fuel line carburetor e Clean lines carburetor and replace f Incorrect carburetor float setting f Adjust float level g Faulty fuel pump 9 Install new pump h Incorrect valve t...

Page 302: ... in tappets d Clean tappets e Bent push rods e Install new push rods f Worn rocker arms f Inspectoil supply to rockers g Worn tappets g Install new tappets h Worn valve guides h Ream and install new valves with O S i Excessive run out of valve seats or i Grind valve seats and valves j Incorrect tappet lash j Adjust to specifications a Insufficient oil supply a Check engine oil level b Low oil pres...

Page 303: ...See Starting Motor Cranking Voltage Electrical Group 8 3 Tighten intake and exhaust manifold bolts to 15 foot pounds 4 Perform cylinder compression test Compres sion should not vary more than 20pounds 5 Clean or replace spark plugs as necessary and adjust gap to 035inch Tighten to 30foot pounds 6 Test resistance of spark plug cables Refer to Ignition System Secondary Circuit Inspection Elec trical...

Page 304: ...ifting fixture Tool 2 3804 to cyl inder head and attach a chain hoist to fixture eyebolt 18 Remove engine support fixture 19 Remove front engine mount bolts Figs 6 and 20 Lift engine from engine compartment and in move oil cooler lines filler tube and shift cable rods way leg 2 3806 to support rear of engine Figs 4 and 5 ing 7 stall in engine repair stand lnstullation 1 Install engine lifting fixt...

Page 305: ...sket ing to engine der head cover air cleaner alignment ROCKER ARMS AND SHAFT ASSEMBLY Stamped steelrocker arms are arranged on a single rocker arm shaft Hardened steel spacers are used between the pairs of rocker arms The rocker shaft is held in place by bolts and stamped steel retainers attached to the seven brackets on the cylinder head Removal 1 Remove closed ventilation system 2 Remove cylind...

Page 306: ...4 head bolts and remove cylinder 14 Place cylinder head in holding fixture Tool C distributor out in line with the plug pass hose flange buretor as an assembly head cover respective slots in holder Tool C 3068 head 3626 and remove spark plugs and tubes installation 1 Clean all gasket surfaces of cylinder block and cylinder head and install sparkplugs 2 Inspect all surfaces with a straight edge if ...

Page 307: ...with the cylin der heads celerator linkage and spark plug cables distributor flange 19 Install closed ventilation system Removal 1 With cylinder head removed compress valve springs using Tool C 3422A Fig 11 2 Remove valve retaining locks valve spring re tainers valve stem cup seals and valve springs Remove any burrs from valve stem lock grooves to prevent damage to the valve guide when valves are ...

Page 308: ...ty of the valve seat LT 7 I 3 A SEAT WIDTH INTAKE 1 16 TO 3 32 INCH B FACE ANGLE INTAKE 45 EXHAUST 43 C SEAT ANGLE INTAKE 45 EXHAUST 45 EXHAUST 3 64 TO 1 16 INCH SURFACE Flt Fig 14 Valve Face and Seat Angle VALVE SPRING RETAINER LOCK GROOVES n EXHAUST VALVE KH330D Fig 15 Intake and Exhaust Valves using dial indicator No 13725 Total runout should not exceed 002 inch totalindicator reading 5 Inspect...

Page 309: ... stems with lubrication oil and insert KUSlC Fig 19 Indulling Vulves undCup Seals them in cylinder head 2 If valves or seats are reground test valve stem height with Tool C 3746 If valve is too long grind off the tip until length is within limits 3 Install new cup seals on all valve stems long seal on intake valve and short seal on exhaust valve and over valve guides Figs 18and 19 Install valve sp...

Page 310: ...the chain may be measured 2 Place a torque wrench and socket over the cam shaft sprocket lock bolt and apply torque in the direc Fig 2 I Measuring Choin Stretch Fig 22 Alignment of Timing Marks tion of crankshaft rotation to take up slack 30 foot pounds cylinder head installed or 15 foot pounds cylinder head removed With torque applied to the camshaft sprocket bolt crankshaft should not be permitt...

Page 311: ...mover screw with the plate through INSTALLING PLATE p TOOL 1 REMOVER SCREW TOOL I I f 1 NY162A Fig PS Poritioning Installer Plate ER SCREW TOO HAlN CASE COVER NY163A Fig 26 Installing New Seal the seal opening inside of chain case cover facing up 7 Place the seal in cover opening with neoprene down Place seal installing plate into the new seal with the protective recess toward lip of seal retainer...

Page 312: ...r a minimum of 500 miles Drain the oil mixture at the next normal oil change When replacing camshaft all of the tappet faces must be inspected for crown with a straight edge If Fig 28 Installing Vibration Damper Assembly CAMSHAFT SPROCKET LOCATING DOWEL FUEL PUMP ECCENTRIC INTEGRAL WITH CAMSHAFT OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT NU265 t L b Fig 29 Camshaft and Sprocket Ass...

Page 313: ...ed for out of round and taper with Tool C 119 If the cylinder bores show more than 005 out of round or a taper of more than 010 or if the cylinder walls are badly scuffed or scored the cylinder block should be rebored and honed and new oversize pistons and rings fitted Whatever type of boring equipment is used boring and honing operation should be closely coordinated with the fitting of pistons an...

Page 314: ... 90 3 Measure cylinder bores halfway down cylinder f Rings 1 Measure piston ring gap about two inches from the bottom of the cylinder bore in which it is to be fitted An inverted piston can be used to push rings down to insure positioning rings squarely in cylinder wall 2 Insert feeler stock in the gap Ring gap should be 010to 047 inch for compression rings and 015 to 062 inch for oil ring steel r...

Page 315: ...sition connecting rod over the pilot which ex tends through piston hole The oil hole in connecting rod must point toward the direction shown in Figure 38 Fig 37 and pilot in the anvil Fig 36 Removing Piston Pin SPRING TOOL MAIN SCREW GUIDE LARGE TOOL KR196B Fig SI TOOl Arrangement for Installing Piston Ptn 8 Install main screw and piston pin in piston Fig 39 9 Install nut on main screw to hold ass...

Page 316: ...inch undersize 3 Install bearings in pairs Do not use a new bear ing with an old bearing Do not file rods or bearing caps MEASURING CONNECTING ROD BEAR1NG CLEARANCE Shim Stock Method 1 Smooth the edges of a 1 2 x 3 4 inch piece of brass shim stock 001inch thickness 2 Oil and place between the bearing and connect ing rod journal 3 Install bearing cap and tighten to 45 foot pounds 4 Turn connecting ...

Page 317: ...n oiling and can be identified by a red marking on the edge of the bearing Upper main bearings are grooved and lower main bearings are plain and are not inter changeable The NO 3 upper and lower main bear ings are flanged to carry the crankshaft thrust loads and are not interchangeable with any other main bearings in the engine Bearings that are not badly worn scored or pitted should be reinstalle...

Page 318: ...INEF NY132 Fig 45 Trimming Rear Main BearingOil Seal 002 inch undersize bearing shell with one 001 inch undersize shell Always use the smaller diameter bearing half as the upper Never use an upper bear ing more than W1 inch smaller than the lower bear ing half and never use a new bearing half with a used bearing half REAR MAIN BEARING OIL SEAL Crankshaft Removed Upper Seal 1 Install a new oil seal...

Page 319: ...ngine crankshaft to clear counterweights and remove oil pan begins to tighten in the crankcase continue tighten ing until screen is positioned Fig 47 Hold a steel rule against flat surface inside the case and meas ure from edge of rule to edge of oil screen Measure ment should be 1 1 8inches with screen properly positioned Screen must be an interference with bottom of o i l pan Cleaning and inspec...

Page 320: ...ley or vibration damper Remove front engine mount bolts 3 Raise engine approximately 1 1 2 to 2 inches 4 Remove o i l filter oil pump attaching bolts and remove pump assembly lndallation tighten to 200 inch pounds front engine mount bolts fan shroud if so equipped 1 Using new 0 rings install oil pump and 2 Lower engine to its original position install 3 Connect upper and lower radiator hoses Insta...

Page 321: ... wet or dry paper 9 For 170 225cubic inch engines the relief valve spring has a free length of 2 9 32to 2 19 64 inch and should test 14 85 to 15 85 lbs when compressed to 1 19 32inch Discard spring that fails to meet speci fications 10 If oil pressure is low inspect for worn bear ings or look for other causes of possible loss of oil pressure Assembly body Tighten cover bolts to 95inch pounds ing b...

Page 322: ...4 Perform cylinder compression test Compres sion should not vary more than 20 pounds 5 Clean or replace spark plug as necessary and adjust gap to 035 inch Tighten to 30 foot pounds using new gaskets 6 Test resistance of spark plug cables Refer to Ignition System Secondary Circuit Inspection Elec trical Section 7 Inspect the breaker plate contacts primary wire and vacuum advance operation Test coil...

Page 323: ...s Dart 340 Cubic Inch Engine fnstallation 1 Install insulator to engine bracket and tighten to specified torque 2 Lower engine and install washers and prevail ing torque nuts to insulator studs tighten nuts to specified torque 3 Connect throttle at transmission and carbu retor REAR ENGINE MOUNTS Figs 5 6 and 7 Removal 1 Raise vehicle on hoist 2 Install transmission jack 3 Remove rear engine crossm...

Page 324: ...th front engine mounts in place 4 Install engine support fixture Tool C 3487 on chassis to support rear of engine Remove the crane or lifting tool 5 Raise vehicle on a hoist install the transmis sion engine rear support crossmember tighten front engine mounts remove the engine support fixture 6 Connect propeller shaft wires linkage speed ometer cable oil cooler lines at transmission connect exhaus...

Page 325: ...tallation 1 Clean all gasket surfaces of cylinder block and cylinder heads 2 Inspect all surfaces with a straightedge if there is any reason to suspect leakage 3 Coat new gaskets lightly with number 1057794 Sealer and install on cylinder block 4 Remove cylinder heads from holding fixtures Tool C 3626and place heads on engine 5 Install cylinder head bolts Starting at top cen ter tighten all cylinde...

Page 326: ...d removed compress valve springs using Tool C5422A as shown in Fig 11 2 Remove valve retaining locks valve spring re tainers valve stem cup seals and valve springs 3 Before removing valves removeany burrs from valve stem lock grooves to prevent damage to the valve guide Identify valves to insure installation in original location Valve inspection 1 Clean valves thoroughly and discard burned 01 CYLI...

Page 327: ...ricity of valve seat using dial indicator No 13725 Total runout should not ex ceed 002inch totalindicator reading 5 Check the valve seat with Prussian blue to de termine where the valve contacts the seat To do this coat valve seat lightly with Prussian blue then set valve in place Rotate the valve with light pressure E the blue is transferred to the center of valve face contact is satisfactory If ...

Page 328: ...1I Checking Valve Spring Squareness JM MINIMUM MEASUREMENTI Fig 18 Measuring Valve Stem Length inches install a 1 16 inch spacer in head counterbore to bring spring height back to normal 1 5 8 inches to 1 11 16 inches HYDRAULIC TAPPETS Preliminary to Checkingthe Hydraulic Tappets 1 Before disassembling any part of the engine to correct tappet noise read the oil pressure at the gauge Install a reli...

Page 329: ...oce dure Remove cylinder head covers 2 Remove rocker arms and shaft assembly 3 Remove push rods and identify to insure in stallation in original location 4 Slide a magnetic pickup tool through opening in cylinder head and seat tool firmly in the head of tap pet 5 Pull tappet out of bore with a twisting motion If all tappets are to be removed identify tappets to insureinstallationin original locati...

Page 330: ...G CHAIN COVER OIL SEAL AND CHAIN Cover Removal 1 Drain cooling system and remove radiator fan belt and water pump assembly 2 Remove pulley from vibration damper and bolt and washer securing vibration damper on crankshaft 3 Install Tool C 3688and pull vibration damper from end of crankshaft Fig 22 4 Remove fuel lines and fuel pump 5 Loosen oil pan bolts and remove the front bolt at each side 6 Remo...

Page 331: ...en bolt to 35 foot pounds Fig 24 Camshaft HoldingTool C 3509 Fig 25 Alignment of Timing Marks 13 Check camshaft for 002 to 006 inch end play with a new thrust plate and up to 010 inch end play with a used thrust plate If not within these limits install a new thrust plate 14 If within limits slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket Oil Seal Repla...

Page 332: ...hain case cover capscrews to 30 foot pounds first then tighten oil pan capscrews to 15foot pounds 3 Lubricate seal with lubriplate position damper hub slot on key in crankshaft and slide hub on crank shaft 4 Place installing tool part of Puller set Tool 2 3688 in position and press damper hub on crank shaft Fig 31 5 Slide pulley over the shaft and attach with bolts and lockwashers Tighten the bolt...

Page 333: ...nstalled one quart of engine supplement Chrysler Part Number 1879406or equivalent should be added to the engine oil to aid in break in The oil mixture should be left in the engine for a minimum of 500 miles Drain the oil mixture at the next normal oil change Whenever the camshaft is replaced all of the t a p pet faces must be inspectedfor crown with a straight edge If any negative crown dish is ob...

Page 334: ...ith vacuum chamber pointing toward right of engine 2 Turn rotor until it points forward and to ap proximate location of No 1tower terminal in distrib utor cap 3 Place distributor gasket in position 4 Lower the distributor and engage the shaft in the slot of distributor drive shaft gear m Fig 36 Installing Distributor Drive Shaft Bushing 5 Turn distributor clockwise until breaker con tacts are just...

Page 335: ...g 38 Cross Watch Pattern 3 Honing should be done by moving the hone up and down fast enough to get a cross hatch pattern When hone marks intersect at 60 the cross hatch angle is most satisfactory for proper seating of rings Fig 3 8 4 After honing it is necessary that the block be cleaned again to remove all traces of abrasives CAUTION Be sure all abrasives are removed from engine parts after honin...

Page 336: ...e fitted An inverted piston can be used to push the rings down to insure positioning rings squarely in the cyl inder wall before measuring 2 Insert feeler stock in the gap The ring gap should be between 010 to 020 inch for compression rings and 015 to 062 inch for oil ring steel rails in Jtandard size bores for new service rings Maximum gap in 005 inch O S bores should be 060 inch for compression ...

Page 337: ...cates clearance is satisfactory 273 and 318 Cubic Inch Engine correct clearance is from 0005 to 0015 inch 340 Cubic Inch Engine with tri metal bearings correct clearance is from 001 to 002 inch 4 Side play should be from 009 to 017 inch two rods INSTALLING PISTON AND CONNECTING ROD ASSEMBLY 1 Before installing pistons and connecting rod as semblies into the bore be sure that compression ring gaps ...

Page 338: ...i cations Removal 1 Remove oil pan and identify bearing caps before removal 2 Remove bearing caps one at a time Remove upper half of bearing by inserting Tool C 3059 Fig 46 into the oil hole of crankshaft 3 Slowly rotate crankshaft clockwise forcing out upper half of bearing shell nsfallation Only one main bearing should be selectively fitted while all other main bearing caps are properly torqued ...

Page 339: ... the portion ENGINE OILING SYSTEM Fig OIL PAN Removal 1 Disconnect negative ground cable from the battery and remove dipstick 2 Raise vehicle on a hoist drain the oil Remove engine to torque converter left housing strut 3 Remove steering and idle arm ball joints from steering linkage center link 4 Remove exhaust pipes from exhaust manifolds and leave hang without disconnecting from the muffler on ...

Page 340: ...P B v Ly W Y U MyMopar com ...

Page 341: ...edge discard cover and install a new one Fig 5 2 3 Measure diameter and thickness of outer rotor If outer rotor measures less than 825inch Fig 53 and the diameter is less than 2 469 inches install a new outer rotor 4 Measure thickness of inner rotor DRIVE SHAFl RELIEF VALVE NF930B Fig 51 011 Pump Assembly Disassembled View FEELER GAUGE Fig 52 Measuring Oil Pump Cover Flatness 5 If inner rotor meas...

Page 342: ...g cap Tighten bolts to 35 foot pounds Fig 57 Measuring Clearance Over Rotors Servicing the Oil Pressure Relief Valve It is necessary to remove the oil pan and remove oil pump from rear main bearing cap to service the pressure relief valve To remove the relief valve proceed as follows 1 Remove cotter pin drill a 1 8 inch hole in the relief valve cap and insert a self threading sheet metal screw int...

Page 343: ...to 30 foot pounds using new gaskets 6 Test resistance of spark plug cables Refer to Ignition System Secondary Circuit Inspection Elec trical Section 7 Inspect the breaker plate contacts primary wire and vacuum advance operation Test coil output volt age primary and secondary resistance Test Conden ser Replace parts as necessary Refer to Ignition Sys tem and make necessary adjustments 8 Reset the i...

Page 344: ...orque bolts to specified torque 1 Install rear engine mount to crossmember and 2 Install rear crossmember to frame and tighten gine mount assembly fnstallation 1 Install insulator to engine bracket and tighten to specifiedtorque 2 Lower the engine and i n s t a l l washers and pre vailing torque nuts to insulator studs tighten nuts to specified torque NR42A Fig Front Engine Mounts Coronet and Char...

Page 345: ... hoses oil cooler lines and connect all wires and link age 11 Remove engine lifting fixture from intake gine carefully until engine is positioned in vehicle adjust to support rear of engine manifold and install carburetor and fuel lines Con nect throttle linkage 12 Install hood using scribe marks for proper alignment 13 Close all drain cocks and fill cooling system 14 Fill engine crankcase and tra...

Page 346: ...Lubrication Holes 5 Disconnect distributor cap coil wires and heat 6 Disconnectheat indicator sending unit wire 7 Remove spark plugs 8 Remove intake manifold ignition coil and car 9 Remove tappet chamber cover 10 Remove cylinder head covers and gaskets 11 Remove exhaust manifolds 12 Remove rocker arm and shaft assemblies Re move push rods and identify to insure installation in original location 13...

Page 347: ...aust valves operate in guides that are cast integral with the heads Removal 1 With cylinder head removed compress valve springs using Tool C 3422A Fig 11 2 Remove valve retaining locks valve spring re tainers valve stem cup seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent damage to the valve guide Identify valves to insure installation in or...

Page 348: ...ce Rotate valve with light pressure If the blue is transferred to the center of the valve face the contact is satisfactory If the blue is transferred to the top edge of the valve face lower the valve seat with a 30 stone If the blue is transferred to the bottom edge of the valve face raise the valve seat with a 60 stone 3 When the seat is properly positioned the width of the intake seats should be...

Page 349: ...ations to obtain specified height and allowable tension Discard the springs KK 143D Fig Il lnspecting Valve Spring Squareness L a RETAINER KU51 Fig 18 Valve Assembly DisassembledView that do not meet specifications ends with a steel square and surface plate Fig 1 7 square install a new spring installation 1 Coat valve stems with lubricating oil and insert them in position in cylinder head 2 Instal...

Page 350: ...sumed the noise is in the tappet Inspect the rocker arm push rod sockets and push rod ends for wear 3 Valve tappet noise ranges from light noise to a heavy click A light noise is usually caused by exces sive leakdown around the unit plunger which will necessitate replacing the tappet or by the plunger partially sticking in the tappet body cylinder A heavy click is caused either by a tappet check v...

Page 351: ...l C 3 160 VALVE TIMING All Models 1 Turn crankshaft until NO 6 exhaust valve is closingand NO 6 intake valve is opening 2 Insert a 1 4 inch spacer between rocker arm pad and stem tip of NO 1 intake valve second valve on the left bank 3 Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as possible 4 Allow spring load to bleed tappet down giving in effect a s...

Page 352: ...ing timing chain use Tool C 3509 to prevent camshaft from contacting the welch plug in the rear of engine block Remove distributor and oil pumpdistributor drive gear Locate tool against rear side of cam gear and attach tool with distributor re tainer plate bolt Fig 24 7 Place camshaft sprocket and crankshaft sprock et on the bench with timing marks on exact imaginary center line through both camsh...

Page 353: ...cing up 7 Place seal in cover opening with neoprene down Place seal installing plate into the new seal with protective recess toward lip of seal retainer Fig 28 The lip of the neoprene seal must be toward source of oil 8 Install flat washer and nut on remover screw hold screw and tighten nut Fig 29 9 The seal is properly installed when the neo prene is tight against face of cover Try to insert a 0...

Page 354: ...x lug holding the upper arm on the tool and rotate arm 180 degrees 3 Install Tool C 3509in place of distributor drive gear and shaft as shown in Figure 24 CHAIN CASE COVER TIMING INDICATOR CYLINDER BLOCK TIMING MARK KR157A Fig 3I Installing Vibration Damper Assembly BOLT CAMSHAFT SPROCKET CAMSHAFT KR158 CATlNG DOWEL Fig 32 Camshaft and Sprocket Assembly Disussembled View 4 Hold tool in position wi...

Page 355: ...oved 1 Insert Tool C 3052 into the old bushing and 2 Hold remover screw and tighten nut until bush nstallation 1 Slide a new bushing over burnishing end of Tool C 3053and insert tool bushing into the bore 2 Drive bushing and tool into position using a hammer Fig 35 3 As the burnisher is pulled through the bushing by tightening remover nut the bushing is expanded tight in the block and burnished to...

Page 356: ... of boring equipment is used boring and honing operation should be closely coordinated with the fitting of pistons and rings in order that specified clearance may be maintained Honing Cylinder Bores Before honing stuff plenty of clean rags under the bores over the crankshaft to keep the abrasive mate rials from entering the crankcase area 1 Used carefully the cylinder bore resizing hone C 823equip...

Page 357: ...es F All service pistons include pins and are available in standard and the following oversizes 005 020 and 040 inch Fifting Rings 1 Measure piston ring gap about two inches from bottom of cylinder bore in which it is to be fitted An inverted piston can be used to push rings down to insure positioning rings squarely in cylinder wall before measuring 2 Insert feeler stock in the gap Ring gap should...

Page 358: ...OOL SPRING TOOL MAIN SCREW GUIDE LARGE TOOL KR196B Fig 43 Tool Arrangement for InstallingPistonPin 6 Position connecting rod over the pilot which ex tends through piston pin hole Assemble rods to pistons of the right cylinder bank 2 4 6 and 8 with indent on piston head opposite to the larger chamfer on the large bore end of connect ing rod Assemble rods to pistons of the left cylinder bank 1 3 5 a...

Page 359: ...plete Do not alternate from one bank to another because when rods are assembled to the pistons correctly they are not interchangeable from one bank to another Each bearing cap has a small V groove across parting face When installing the lower bearing shell make certain V groove in shell is in line with V groove in cap This allows lubrication of the cylinder wall The bearings should always be insta...

Page 360: ...engine and larger chamfer of connecting rod bore must be installed toward crank pin journal fillet 8 Install rod caps tighten nuts to 45 foot pounds Fig 48 Installing Connecting Rod CRANKSHAFT MAIN JOURNALS Crankshaft main bearing journals should be in spected for excessivewear taper and scoring Journal grinding should not exceed 012 inch under the standard journal diameter DO NOT grind the thrust...

Page 361: ... bearing is too small and should be replaced with the correct 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 permissable to use one 001 inch undersize bearing shell with one standard bearing shell or one 002 inch undersize bearing shell with one 001inch unde...

Page 362: ... to 30 foot pounds Failure to pre oil the seals will result in an oil leak ENGINE OILING SYSTEM Fig 53 OIL PAN Removal 5 Drain crankcase o i l 4 Remove clamp attaching exhaust pipe to exten sion and remove exhaustpipe 1 Disconnect battery cable and remove dipstick 2 Raise vehicle on a hoist and disconnect steering 3 Disconnect exhaust pipe branches from right 6 Remove converter dust shield 7 Remov...

Page 363: ...3 Remove the oil pressure relief valve plug and Inspection and Assembly 1 Clean all parts thoroughly The mating face of filter base oil pump cover should be smooth Replace filter base if it is scratched or grooved 2 Lay a straightedge across oil pump filter base surface Fig 55 If a 0015 inch feeler gauge can be inserted between the base and straightedge filter ND WASHERS PLUNGER INNER ROTOR KR173 ...

Page 364: ...is low inspect for worn bearings or look for other causes of possible loss of o i l pres sure When assembling the oil pump be sure to use new oil seal rings between filter base and pump body NN359 Fig 61 Removing 011Filter lnstallation 1 Install a new 0 ring seal on the pilot of oil pump before attaching oil pump to cylinder block 2 Install oil pump on engine using a new gasket on engine and tight...

Page 365: ...cted The ignition timing should be set to compensate for altitudes and or gasoline grades 9 Set carburetor idle mixture adjustment Adjust engine RPM to specifications Perform a combustion analysis 10 Test the fuel pump for pressure and vacuum Refer to Fuel System Group 14 Specifications 11 Inspect the manifold heat control valve in the right exhaust manifold for proper operation and apply Manifold...

Page 366: ... Install lifting straps to engine attach front strap to front of left cylinder head and rear strap to rear of right cylinder head Caution Do not use intake manifold to remove en gine assembly Removecarburetorsto prevent damage 9 Attach hydro crane lifting hooks to lifting straps remove engine assembly from chassis and in stall engine in a repair stand lnstdlation 1 Attach hydro crane lifting hooks...

Page 367: ...ker Arms and Shafts Removal 1 With cylinder head cover removed remove the five bolts 3 4inch hexagon that attach the rocker arm support brackets to the cylinder head and block Fig 4 2 Remove rocker arm assemblies 3 Remove push rods and identify to insure instal lation in original location Cylinder Head Removal 1 With cylinder head cover and rocker arm as SUPPORT BRACKET BOLTS CYLINDER HEAD OUTER B...

Page 368: ...their respective rocker arms 3 Starting at the center tighten all head bolts and stud nuts to 50 foot pounds in sequence shown in Figure 8 then repeat the procedure tightening to 75 foot poundsin the same sequence 4 Adjust tappets See Tappet Adjustment Pro cedure 5 Install exhaust headers with new gaskets and tighten to 35 foot pounds 6 Place new cylinder head cover gaskets in posi tion and instal...

Page 369: ...leaner 4 Measure valve stem guide clearance as follows a Install sleeve Tool 2 3973 over valve stem Fig 11 and install valve The special sleeve places the valve at the correct height for checking with a dial indicator b Attach dial indicator Tool C 3339 to cylinder Fig I I fnstalling Valve and Tool C 3973 head and set it at right angle to the valve stem being measured Fig 1 2 c Move valve to and f...

Page 370: ...of Tool 2 647 until surface is in line with the 1 1 2inch mark on the threaded stud and the zero mark to the front Place spring over stud on the table and lift compressing lever to set tone device Pull on torque wrench until ping is heard Take reading on torque wrench at this instant Multiply this reading by two This will give the spring load at test length Fraction al measurements are indicated o...

Page 371: ...wise normal running direction until valve has lifted lo9inch CAUTION Do not turn crankshaft any further clock wise as the valve spring might bottom and result in seriousdamage The timing of the crankshaft pulley should now read from 10 degrees before top dead center to 2 degrees after toD dead center Readjust lash n 426 CUBIC INCH ENGINE 9 73 Fig 1 Removing Vibration Damper Assembly 4 If reading i...

Page 372: ... shafts 12 Use a straight edge to measure alignment of timing marks Fig 19 13 Install camshaft sprocket bolts and tighten to 40 foot pounds Slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket Oil Seal Replacement Cover Removed 1 Position remover screw of Tool C 3506through ARM 1 Fig 18 Camshaft Holding Tool C 3509 case cover inside of case cover up Positio...

Page 373: ...all and tighten bolts 15 foot pounds 3 Lubricate seal with lubriplate place damper hub slot on key in crankshaft and slide vibration damper on crankshaft 4 Place installing tool part of Tool 2 3688 in position and press damper on the crankshaft Fig 25 5 Install damper retainer washer and bolt Tight en to 135 foot pounds 6 Slide belt pulley over shaft and attach with REMOVER SCREW T REMOVING A INST...

Page 374: ...for a minimum of 500 miles Drain the oil mixture at the next normal oil change Whenever camshaft is replaced all of tappet faces must be inspected for crown with a straight edge If any contact surface isdished or worn tappet must be replaced CAMSHAFT BEARINGS Engine Removed from Vehicle Removal 1 With engine completely disassembled drive out camshaft rear bearing welch plug 2 Install proper size a...

Page 375: ...under 0 on timing indi cator 3 Coat shaft and drive gear with engine oil In stall the shaft so that after gear spirals into place it will index with the oil pump shaft so slot in top of drive gear will be parallel with center line of crankshaft Fig 30 lnstallation of Distributor 1 Hold distributor over mounting pad on cylinder block with vacuum chamber pointing toward center of engine 2 Turn rotor...

Page 376: ...ns and rings fitted Whatever type of boring equipment is used boring and honing operation should be closely coordinated with the fit ting of pistons and rings in order that specified clear ance may be maintained Honing Cylinder Bores Before honing stuff plenty of clean rags under the bores over the crankshaft to keep the abrasive ma terials from entering the crankcase area 1 Use carefullv the cvli...

Page 377: ...n ring faces top of piston 6 For the two top rings use ring installer Tool 2 3673 Piston Pins 1 The piston pin should be a tight thumb press fit in connecting rod and piston at normal room temperature 70 F If proper fit cannot be obtained with standard pins hone or ream piston and connect ing rod and install oversize piston pin Piston pins are supplied in standard and the following oversizes 003an...

Page 378: ...oot pounds CRANKSHAFT MA1N JOURNALS Crankshaft main bearing journals should be inspect ed for excessive wear taper and scoring Journal grinding should not exceed 012 inch under the stand ard journal diameter DO NOT grind the thrust faces of the No 3 main bearing Do not nick crankpin or main bearing fillets After regrinding remove rough edges from crankshhft oil holes and clean out all oil passages...

Page 379: ...onsidered satis factory If however no drag is felt the bearing is too large or crankshaft cannot be rotated bearing is too small and should be replaced with the correct size 4 Measure crankshaft end play 002to 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 BRfDGE PART O F TOOL SIDE SEAL GROOVES Fig 35 nst...

Page 380: ... is lowered linkage from idler arm and steering arm and left manifolds sion and remove exhaust pipe lnstallation 1 Inspect alignment of oil strainer The bottom of the strainer must be on a horizontal plane with machined surface of cylinder block The bottom of the strainer must touch the bottom of oil pan 2 Install oil pan 3 Install converter dust shield 4 Connect exhaust pipe branches to the manif...

Page 381: ...inch replace inner and outer rotor ServicingOil PressureRelief Valve Inspect o i l pump relief valve plunger for scoring and free operation in its bore Small scores may be removed with 400 grit wet or dry paper providing extreme care is used not to round off the sharp edge portion of the valve The relief valve spring has a free length of 2 9 32 to 2 19 64 inch and should test 22 3 to 23 3 lbs when...

Page 382: ... If the ventilation valve is plugged fully closed ventilation system only fumes flow into the air cleaner and are burned in the combustion chamber prior to reaching the atmosphere to prevent atmospheric contamination AIR CLEAN R HOSE NN359 Fig 44 Removing Oil Fiber The valve and hose are subject to fouling with sludge and carbon formation due to the nature of the material carried by the ventilatio...

Page 383: ...ression Ratio 170 Cubic Inch 225 Cubic Inch Compression Pressure with Engine Warm Spark Plugs Removed Wide Open Throttle Maximum Variation Between Cylinders any one engine Firing Order Basic Timing 170 Cubic Inch Manual Transmission Automatic Transmission 225 Cubic Inch All Type Bearings Main Bearing Journal Diameter Connecting Rod Journal Diameter Maximum Out of Round Permissible Number Main Bear...

Page 384: ... 0012to 0025 go40to 9045 Clearance Between Valve Stem and Rocker Arm Pad Engine Hot 010 Intake 020 Exhaust TAPPETS Body Diameter Type MateriaI Land Clearance diametral Clearance at Top of Skirt Weight std through oQo oversize Piston Length overall 3 51 Ring Groove Depth No 1 179 No 2 179 No 3 181 Piston for Service PISTONS Aluminum Alloy Tin Coated HorizontaI Slot wI SteeI Struts 024to 031 OOO5 to...

Page 385: ...e Angle Adjustment Lift Number Free Length Load when Compressed to valve closed Load when Compressed to valve open Valve Springs I D Valve Spring Installed Height spring seat to retainer Use 1 16inch spacer to reduce spring height when over specifications Combustion Chamber Valve Seat Run Out maximum Intake Valve Seat Angle Seat Width finished Exhaust Valve Seat Angle Seat Width finished Cylinder ...

Page 386: ...er Rotor Length Clearance Over Rotors Outer Inner Outer Rotor Clearance Tip Clearance Between Rotors BO15 inch or more 649 inch o r more 2 469 inch or less 649inch or less 004 inch or more O M inch or more 012 inch 010inch o r more When Filter Element is Replaced Add 1US Quart or 3 4 Imperial Quart OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS Engine Displacement Condition Identification Locati...

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Page 392: ...NDER NUMBERING front to rear CYLINDER BLOCK PISTONS No 2 No 3 Pistons for Service 90 v 8 4 25 3 375 383 cu in 9 2 to 1 10 0 to 1 125155 mi 13CL165 psi 20 psi 25 psi 1 8 4 3 6 5 7 2 T D C T D C 7 1 2 B T C 1 3 5 7 246 8 4 2495 4 2515 005 Ol Y 001 04 Yf 905 y 9058 ooo5 004 Y 4865 4880 0007 0027 Autothermic W Steel Struts 021 OBff 0003 0013 770 gms 3 874 220 22V 208 Std 005 0 2 Y W Oversize 90 v 8 4 ...

Page 393: ...llowable Diametral Clearance Desired Diametral Clearance Allowed Finish at Rear Oil Seal Surface Diameter Maximum Allowable Out of Round and or Taper Bearings for Service Available in Standard and the following undersizes Diameter Maximum Allowable Out of Round and or Taper Drive Bearings Number Diametral Clearance Maximum Allowable before Reconditioning Thrust Taken By Diameter No 1 No 2 No 3 CRA...

Page 394: ...imum Allowable Face Angle Valve for Service Oversize Stem Diam Lift Zero Lash Head Diameter Length to center of valve face Stem Diameter Standard Stem to Guide Clearance Maximum Allowable Face Angle Valve for Service Oversize Stem Diam Lift Zero Lash Number 16 TAPPETS CYLINDER HEAD VALVE GUIDES VALVES INTAKE VALVES EXHAUST VALVE SPRINGS 50 50 75 HydrauIic 9040 9045 0005 0018 Std 001 008 030 060 21...

Page 395: ...Add 1 U S Quart or 3 4 Imperial Quart tWithout Power Pack ttWith Power Pack O I L PUMP INSPECTION LIMITS FOR REPLACEMENT 383 and 440 Cu In Engines Oil Pump Cover a15 inch or more Outer Rotor Length 943 inch or less Outer Rotor Diameter 2 469 inch or less Inner Rotor Length 942 inch or less Clearance Over Rotors Outer 004 inch or more Inner 004 inch or more Outer Rotor Clearance 012 inch or more Ti...

Page 396: ...eight Std through 040 oversize Piston Length overall Ring Groove Depth No 1 No 2 No 3 Pistons for Service CYLINDER NUMBERING front to rear CYLINDER BLOCK PISTONS Hemispherical 90 V 8 4 25 3 750 426 Cu In 10 25to 1 150 205psi 30 psi 1 8 4 3 6 5 7 2 T D C 1 3 57 2 4 6 8 4 24975 4 25025 4 25075 4 25125 4 25175 005 olvt 001 040 9050 9058 0015 0040 I nterference 4865 488V 0007 0027 Forged Aluminum Tin ...

Page 397: ...ECTING ROD BUSHING CONNECTING ROD BEARINGS CRANKSHAFT MAIN BEARING JOURNALS CONNECTING ROD JOURNALS Diameter Maximum Allowable Out of Round Maximum Allowable Taper Drive Bearings Number Clearance Desired Maximum Allowable before reconditioning Thrust Taken By CAMSHAFT CAMSHAFT JOURNALS Diameter No 1 No 2 No 3 No 4 No 5 CAMSHAFT BEARINGS Diameter 013 023 015 062 001VI 003 0002 005t 6 859 6 863 770 ...

Page 398: ... to Guide Clearance Maximum Allowable Face Angle Valve for Service Lift Zero Lash Number Free Length Load when Compressedto valve closed less surge damper Load when Compressed to valve open less surge damper Valve Springs I D Maximum Allowable Out of Plumb Valve Spring Installed Height spring seat to retainer TIMING CHAIN TAPPETS CYLINDER HEAD VALVE GUIDES VALVES4ntake VALVES Exha ust VALVE SPRING...

Page 399: ... more Inner 005inch or more 0Uter Rotor Clearance 012 inch or more Tip Clearance Between Rotors 010inch or more FOR IDENTIFICATION ENGINES WILL BE STAMPED ON CYLINDER BLOCK BOSS AS SHOWN BELOW EXAMPLE HEMISPHERICAL SERIES INCH E H 426 8 3 32 ENGINE BUILT THIS DAY MONTH A L D A Y OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS Condition Identification Location of Identification 001 U S Crankshaft ...

Page 400: ...lug Oil Pan Bolt Oil Pump Cover Bolt Oil Pump Attaching Bolt Oil Filter Attaching Stud Oil Pressure Gauge Sending Unit Rocker Shaft Bracket Bolt Starter Mounting Bolt Temperature Gauge Sending Unit Water Pump to Housing Bolt 45 65 85 30 35 30 200 in lbs 30 40 30 30 30 40 in lbs 200 in lbs 85 45 35 10 30 20 20 200 in lbs 55 55 270 in lbs 50 7 30 30 200 in lbs 15 30 200 in lbs 50 in lbs 20 200 in lb...

Page 401: ...ng to Cylinder Block Bolt Flywheel Cover Bolt Fuel Pump Attaching Bolt Alternator Mounting Bolt Alternator Adjusting Strap Bolt Alternator Adjusting Strap Mounting Bolt Intake Manifold Bolt Manifold Heat Control Counterweight Bolt Oil Pan Drain Plug Oil Pan Bolt Oil Pump Cover Bolt Oil Pump Attaching Bolt Rocker Shaft Bracket Bolt Starter Mounting Bolt Vibration Damper Pulley Bolts Valve Tappet Co...

Page 402: ...ck Bolts Ft Lbr 30 40 7 1518 1518 75 135 30 70 75 70 75 40 In Lbs 200 In Lbs 35 15 70 30 200 In Lbs 30 50 Fuel Pump Attaching Bolt Intake Manifold See Figure 9 Main Bearing Cap Bolt 100 Main Bearing Cap Tie Bolt 45 Oil Pan Bolt 15 Oil Pan Drain Plug 20 Oil Pump Attaching Bolt 30 Oil Pump Cover Bolt 10 Rocker Shaft Bracket Bolt 30 Spark Plug 3 0 Starter Mounting Bolt 50 Torque Converter to Flex Pla...

Page 403: ...e a metal blade rubber block type support at the extensions Dart models equipped with the 340 or 383 cubic inch engine Coronet or Charger models with 440 cubic inch Power Pak engine or 426 Hemi engine Page INTAKE MANIFOLD 426 Hemi Engine 10 INTAKE MANIFOLD HEAT TUBES 426 Herni Engine 10 MANIFOLD HEAT CONTROL VALVE 6 Cylinder Engine 11 273 Cubic Inch Engine 12 318 Cubic Inch Engine 12 340 Cubic Inc...

Page 404: ...s as required Tighten stud nuts or bolts to specifications e Burned or rusted out heat tubes e Replace heat tubes as required a Tighten U bolt nuts at leaking joints to 150inch pounds kets ENGINE HARD TO WARM UP OR WILL position NOT RETURN TO trol solvent NORMAL IDLE NOISE IN MANIFOLD a Thermostat broken a Replace thermostat a Heat control valve frozen in the open a Free up manifold heat control v...

Page 405: ...0 EXHAUST SYSTEM 11 3 NR332A Fig 2 Exhaust System Dart 273 318 Cu In Engines MyMopar com ...

Page 406: ... 0 PLATE ASSEMBLY 2REQUlREDFOR DUAL PLAIN WASHER INSERT BOLT FROM BOTTOMFOR LEFT INSERT BOLT FROM BOlTOM FOR RIGHT REAR FL cF R HOLE RIGHT FLANGE i GASKET e NR334A Fig CExhaust System Coronet 225 Cu In Engines MyMopar com ...

Page 407: ...0 EXHAUST SYSTEM 11 5 Fig 6 Single Exharust System Coronet483 Cu In Engine MyMopar com ...

Page 408: ...tail pipe support attaching clamp screws to 95 inch pounds at same time maintaining proper clearance with adjacent parts 6 Tighten exhaust pipe ball joint connection bolt nuts to 24 foot pounds Alternate tightening nuts to insure parallelism of flanges hstallation Modelswith 426 Hemi Engine 1 Assemble exhaust pipes mufflers and tail pipes loosely to permit proper alignment Fig 8 2 Assemble exhaust...

Page 409: ...MyMopar com ...

Page 410: ...ot tighten at this time 2 Position manifold assembly on cylinder head using a new gasket Install triangular washers and nuts on upper studs and on the four lower studs oppo site numbers 2 and 5 cylinders The eight triangular washers should be positioned squarely on the ma chined surfaces of both intake and exhaust manifold retaining pads These washers must be installed with cup side against manifo...

Page 411: ...uds applying sealer on the coarse thread ends If this precaution is not taken water leaks may developat the studs 1 Position two outboard arms of manifolds on the two studs on cylinder heads using new gaskets In stall conical washers and nuts on studs Fig 11 2 Install two screws and conical washers at inner ends of outboard arms of manifold Install two screws Fig 1 I Installing Exhaust Manifold 27...

Page 412: ... tube remove two stud nuts and 2 Remove screws attaching upper end of inlet tube 3 Remove tube and gaskets and discard gaskets Outlet Tube 1 To remove outlet tube remove nut washer and bolt from tube clamp at exhaust pipe Fig 13 Remove clamp from tube 2 Remove two screws attaching heat shield and outlet tube to rear face of intake manifold and remove tube nstallation nlet Tube 1 Clean gasket surfa...

Page 413: ...t is observed shaft is binding due to accumulation of deposits or thermo stat is weak or broken The application of a suitable manifold heat control RETAINER NY1040E Fig I4 Manifold Heat Control Valve Disussernbkd 170 225 Cu In Engines valve solvent every o i l change to both ends of mani fold heat control valve shaft at bushings will keep valve working freely A suitable solvent is available under ...

Page 414: ...stall valve stop on counterweight so looped ends face away from thermostatic spring hook end 9 Holding thermostatic spring wrapped 140 de grees in a counterclockwise direction viewed from counterweight end install shaft assembly through outer bushing seal and valve plate with strap facing flange end of manifold attach hook end of thermo static spring to stop pin PIN THERMOSTAT NUS02 Fig 17 Propor ...

Page 415: ...facing flange end of manifold and attach hook end of ther mostatic spring on stop pin 10 With Counterweight end of shaft positioned 1 240 inches previously identified away from mani fold and valve plate closed arc weld valve plate to shaft Arc welding ground must be made at counter weight 11 Test for free operation 12 Position new gasket on studs install exhaust 13 Assemble exhaust pipe with a new...

Page 416: ...lve shaft The bumper should be located on the left hand side of the hub section of the counterweight and on the left hand side of the stop pin Fig 19 3 Tighten clamp bolt to 50 inch pounds with C 3380 Torque Wrench Test operation of valve for freedom of movement 426 HEMI ENGINE Removal shaft by loosening clamp bolt Fig 23 from valve shaft slot 1 Remove counterweight from outer end of valve 2 Unhoo...

Page 417: ... freely it will be necessary to hone bushings to shaft size 3 Pull shaft out far enough to position valve plate on shaft then slide shaft into position in both bushings 4 Align hole in valve plate with hole in shaft and insert a drift into both holes to maintain correct posi tioning of valve plate while it is being welded to shaft 5 Remove drift from valve plate and shaft 6 Install new thermostat ...

Page 418: ...r lower part of heat tube except drill to a depth of 1 4 inch below surface of manifold Y lnsfallation 1 Position taper end of heat tube in bottom side of manifold and press in heat tube 7 1 4 inches until only 1 2 inch is left outside of bottom of manifold Fig 27 Failure to install from bottom of manifold will destroy heat tube NU448 Fig 27 Manifold and neut Tuba Assembly TIGHTENING REFERENCE Wyl...

Page 419: ...n Lbr 50 383 440Cu In Engines Intake to Exhaust Manifold Screw Rear Muffler Support Bolt and Nut Rear Muffler Support to Underbody Bolt Support Clamp Screw 95 Tail Pipe Support to Underbody Bolt Tail Pipe U Bolt Nut 426 Hemi Engine 15 200 200 200 95 200 95 200 MyMopar com ...

Page 420: ...subsequent stalling a heat tube is installed in the exhaust manifold and hoses connected from air cleaner and carburetor base supplies preheated air on the throttle valves No serv ice procedures are required to maintain this device Only periodic inspection is required to maintain effi cient operation Fig 1 SERVICING THE CARBURETOR Often the carburetor is blamed for a great variety of trouble which...

Page 421: ... Electric Combustion Vacuum Unit Model 80 Ex haust Condenser Model EC and Hose 669 14 or equivalent The above analyzer is recommended however other reliable makes of analyzers in good condition may be used 1 Engine running at normal operating tempera ture and timing checked to the specifications shown in the Electrical Group 2 Air Cleaner installed 3 Six cylinder engines only turn headlights on 4 ...

Page 422: ...escribed in Step No 9 re place valve Fig 2 11 Replace vacuum valve cover Reset carbu retor dash pot if so equipped and check valve performance as outlined in Step No 9 If distributor vacuum does not fall below 6 inches of mercury within 4 seconds after throttle is released readjust or replace dash pot MANIFOLD IVACUUM h ACUUM UNIT I XKtW I COVER I l NN705 Fig 2 bistribv or Vacuum Control Valve Adj...

Page 423: ... g Clean and inspect needle valve and seat If found to be in questionable condition replace assembly Then test fuel pump pressure Refer to Specifications for correct fuel pump pressure a Accelerator pump piston or plunger a Disassemble carburetor Replace ac leather too hard worn or loose on celerator pump assembly if leather stem is hard cracked or worn Test follow up spring for compression b Faul...

Page 424: ...e Test fuel pump pressure If pressure is in excess of recommended pres sure refer to Specifications replace fuel pump Remove and clean air cleaner or re place element Disassemble carburetor Replace leaking float Test float level and cor rect as necessary to proper level Adjust float level as necessary to se cure proper level Test fuel pump pressure Refer to specifications for recommended pres sure...

Page 425: ...UNS LEAN AFTER HALF MILE ENGINE HEAT INSUFFICIENT b Heatvalve thermostat distorted b Replace thermostat a Heatvalve stuck open a Free with solvent c Heat valve failed within exhaust See c Replace heat valve d Water temperature sub normal d Check thermostat engine section for proper diagnosis INDEX Page 2 Accelerator Pump and Bowl Vent 1 1 Choke Vacuum Kick 12 Fast Idle Cam Position 1 1 Fast idle S...

Page 426: ...VALVE CHOKE OPERATING CHOKE VACUUM DIAPVRAGM CLOSED CRANKCASE VENT TUBE FITTING CHOKE LEVER ACCELERATOR PUN C R O C K E R ARM 4TOR D IDLE THROTTLE LEVER IDLE SPEED ADJUSTING SCREW plunger is to be installed place plunger in a jar of clean gasoline or kerosene to prevent leather from drying out 9 Remove fuel inlet needle valve seat and gasket from main body 10 Lift out float fulcrum pin retainer th...

Page 427: ...g or InstallingAir Horn If a new shaft should be installed in an old worn throttle body it would be very unlikely that the origi nal relationship of the ports to the valve would be obtained Changing the relationship of the valve to the ports would adversely affect normal car operation between the speeds of 15 and 30 miles per hour If a new shaft or valve is to be installed adhere to the followingi...

Page 428: ...ortion must be straight and smooth If tapered portion is grooved or ridged a new idle mix ture screw should be installed to insure having cor rect idle mixture control DO NOT USE A SCREW DRIVER Turn screw lightly against its seat with the fingers Back off number of turns counted at disas sembly Install new plastic cap blue with tab against stop Main Body 1 Install accelerator pump discharge and in...

Page 429: ...t affected by gasoline and is stable over a wide range of temperatures The tip is flexibleenough to make a good seal on the needle seat BRASS ROD PRESS DOWN NO FUEL TO B E WMTED FROM TO SEAT BALL PUMP DISCHARGE PASSAGE EMITTED FROM THE PUMP 1 APPROXIMATELY 1 2 INCH OF FUEL IN THE BOWL NH274B Fig IO Testing Acceferutor Pwmp Intake and Discharge Check Balls WIRE N K W A Fig 1I Step up Piston Wire Fr...

Page 430: ...for cracks before placing it on correct carburetor fitting Do not connect vacu um hose to diaphragm fitting until after vacuum kick adjustment has been made See Carburetor Adjust ments CARBURET0R ADJUSTMENTS It is very important that the following adjustments be made on a reconditioned carburetor and in the sequence listed Accelerator Pump and Bowl Vent When assembling the accelerator pump to the ...

Page 431: ... LIGHT CLOSING PRESSURE AGAINST HOKE LEVER N T NN77lA Apply a vacuum of 10or more inches of mercury 3 Insert specified drill refer to Specifications between choke valve and wall of air horn Fig 15 Apply sufficient closing pressure on lever to which choke rod attaches to provide a minimum choke valve opening without distortion of diaphragm link Note that the cylindrical stem of diaphragm will ex te...

Page 432: ...g 17 4 Start engine and determine stabilized speed Turn fast idle speed screw in or out to secure speci fied speed SeeSpecifications 5 Stopping engine between adjustments is not necessary However reposition fast idle speed screw on cam after each speed adjustment to provide cor rect throttle closing torque Before adjusting idle and or fast idle speeds and mixtures make sure that the basic timing a...

Page 433: ...lip bending operation as required CAUTION When bending the float lip do not allow the lip to push against the needle as the tip can k compressed rufflciently to cause a falu retting which will affect correct levelof the fuel in the bowl After being compressed the tip is very slow to recover its original shape It is very important that the float lip be perpen dicular to the needle or slanted not mo...

Page 434: ...so equipped 2 Remove vacuum hose between carburetor throt tle body fitting and vacuum diaphragm 3 Remove choke vacuum diaphragm link and bracket assembly Disengage link from slot in choke lever place to one side to be cleaned as a special item Figs 1 or 2 4 As the vacuum diaphragm bracket is being re moved the bowl vent valve rod and spring will fall out Fig 3 5 Using a 5 8 wrench remove fuel inle...

Page 435: ...fng or fnstaffing Fuel Bowl VENT ID Fig 6 Removing or fnstaffing Economizer Body PUMP DIAPHRAGM STEM NH296A Fig 7 Pump Diaphragm and Spring seat must be maintained at installation Remove screw and spring from throttle body Discard plastic cap 15 Remove fast idle and curb idle speed screws and spring from throttle lever The carburetor assembly now has been disassem bled as far as necessary for clea...

Page 436: ...n attaching screws securely and stake by squeezing with pliers 3 Test choke valve for binding by rotating lever through extent of its full travel 4 Install fast idle and curb idle speed screws and springs in throttle lever 5 Engage pump link hook with throttle lever then install in pump lever and secure with clip When installing link be sure link is in center hole of throt tle lever 6 Slide pump s...

Page 437: ... of Fuel System Group 3 If an adjustment is necessary bend fast idle link at lower angle using Tool T 109 213 until correct valve opening has been obtained Fig 10 When the correct fast idle position cam adjustment has been made the choke unloader wide open kick adjustment has also been obtained No further ad justment is required LIGHT PRESSURE ON J FAST IDLE SPEED ADJUSTING S C R E W ON CLOSING CA...

Page 438: ...hen proceed as follows CHOKE VALVE FAST IDLE SPEED ADJUSTING SCREW ON OPEN FAST IDLE CAM THE SECOND HIGHEST SPEED STEP OF THE Fig 12 Fast Idle Speed Adjustment On Vehicle Fig 13 Measuring Wet Fuel Level 1 With engine off and transmission in PARK or NEUTRALposition open throttle slightly 2 Close choke valve until fast idle screw can be positioned on second highest speed step of fast idle cam Fig 12...

Page 439: ...ly and an Anti Icing Device The U S Ball and Ball Carburetor models BBD 46058 with Dash pot and BBD 4606s are used on the 273 cu in engine when the vehicle is equipped with a manual or automatic transmission respectively Car buretors BBD 4607S with dash pot and BBD 4608S are used on the 318 cu in engine when the vehicle is Page Idle Speed Adjustment 27 Dashpot Adjustment 28 Cleaning Carburetor Par...

Page 440: ...ly 85D 46OSS 88D 4608S and 88D 46 IOS Canadian ACCELERATOR PUMP ROD IN OUTER HOLE O F ROCKER ARM VALVE ACCELERATOR PUMP ROCKER ARM FAST IDLE CONNECTOR ROD ACCELERATOR PUMP ROD CHOKE VACUUM VACUUM DIAPHRAGM CLOSED CRANKCASE VENT TUBE FllllNG DASH POT MANUAL TR4NSMISSION ONLY FAST IDLE CAM ELEVATING LEGS THROTTLE LEVER FAST IDLE SPEED CURB IDLE SPEED ADJUSTING SCREW NN693B ADJUSTING SCREW Fig 2 Carb...

Page 441: ...ering Jets 10 Lift out float fulcrum pin retainer then lift out floats and fulcrum pin 11 Remove step up piston retaining screw and slide step up piston and rods out of well Fig 4 Now lift out step up piston spring Remove step up piston gasket from the bottom of well 12 Remove main metering jets Fig 5 13 Remove venturi cluster screws then lift ven turi cluster and gaskets up and away from main bod...

Page 442: ...ARK ADVANCE ORT valves Tap valves with a screwdriver to seat in throttle bores Tighten screws lightly Hold up to a strong light to check for a proper position in bore They may have to be rotated slightly as the valves are eliptical When properly positioned tighten screws securely and stake using pliers 6 Install idle mixture screws and springs in body The tapered portion must be straight and smoot...

Page 443: ... when the carbu retor is being overhauled proceed as follows 1 Install floats with fulcrum pin and pin retainer in main body 2 Install needle seat and gasket in body and tighten securely 3 Invert main body catch pump intake check ball so that weight of floats only is forcing needle against seat Hold finger against retainer to fully seat fulcrum pin 4 Using Tool T 109 282or a T scale check the floa...

Page 444: ...owl vent can be placed in any one of the three positioning notches These notches correspond to the long medium and short pump stroke holes in the throttle lever Normally the bowl vent clip on the pump stem will be at the middle notch and the pump operating rod in the medium stroke hole The proper procedure is to adjust the amount of bowl vent opening instead of measuring and setting the height of ...

Page 445: ...MyMopar com ...

Page 446: ...MyMopar com ...

Page 447: ...s own throttle valve and main metering systems and are supplemented by the float accelerating idle and power systems Page Idle Speed Adjustment 34 Cleaning Carburetor Parts 1 Closed Crankcase Vent System 2 Disassembling Carburetor 28 Inspection and Reassembly 29 Specifications 67 These carburetors are equipped with two idle limiter and one off idle mixture control screws Fig 1 These adjustments ar...

Page 448: ...discharge check ball and intake check ball m e intake check ball is the largest Remove screws that attach throttle body to STEP UP PISTON STEP UP TEP UP PISTON PRING GASKET AT OTTOM O F WELL NR379 MAIN METERING JETS Fig 2 Removing or fnstalling Step up Piston main body Separate the bodies and discard gasket The carburetor now has been disassembled into three sub assemblies the air horn main body a...

Page 449: ...rong light to check for a proper position in bore They may have to be rotated slightly as the valves are eliptical When properly positioned tighten screws securely and stake using pliers 7 Turn idle mixture adjusting screws lightly against their seats with fingers Back off one full turn for approximate adjustment DO NOT USE A SCREWDRIVER This screw has a left hand thread Turn counterclockwise Rich...

Page 450: ...T MOVE FREELY NK617 GUIDE SIZE INTERMEDIATE POWER STAGED MIXTURE STEP Fig 7 Step up Rods Free Play bottom of the bowl and bend float lip toward or away from needle Recheck the 5 16 inch setting again and repeat the lip bending operation as required CAUTION When bending the float lip do not allow the lip to push against the needle as the synthetic rubber tip can be compressed sufficiently to cause ...

Page 451: ...ment The fast idle engine speed adjustment should be made on the vehicle as described in the Fast Idle Speed Adjustment On the Vehicle Paragraph How ever the Fast Idle Cam Position Adjustment can be made on the bench This adjustment is important to assure that the speeds of each step of the cam occur at the proper time during engine warm up 1 With fast idle speed adjusting screw contacting second ...

Page 452: ...ine linkage for misalignment or interferences caused by bending operation Re peat adjustment if necessary to provide proper link operation Choke Unloader Wide Open Kick The choke unloader is a mechanical device to par tially open the choke valve at wide open throttle It is used to eliminate choke enrichment during DRILL OR GAUGE AT WIDEST CHOKE OPENING NG PRESSURE HOSE TO VACUUM SUPPLY CHOKE DIAPH...

Page 453: ... needle or slanted not more than 10 degrees away from the needle when the float is set correctly 5 After float has been correctly set reassemble the air horn AVS SERIES FAST IDLE SPEED ADJUSTING SCREW ON SECOND HIGHEST STEP OF THE CAM CHOKE VALVE ADJUST SCREW TO OBTAIN FAST IDLE SPEED w S R E W NRW I I I Fig Fast Idle Speed Adiustment On Vahicla Fast Idle Speed Adjustment On Vehicle Fast idle engi...

Page 454: ...irements The AVS air valve secondary carburetor con tains many features some of which are the locations for the step up rods and pistons The step up rods pistons and springs are accessible for service without removing the air horn or the carburetor from the engine The primary venturi assemblies are replace able and contain many of the calibration points for both the high and low speed system One f...

Page 455: ...otect the floats then proceed to disassemble as fol lows 1 Using a suitable Tool remove float fulcrum pins left and right then lift float up and out of bosses on air horn It is suggested that the float on the pump side be marked so that floats can be reinstalled in their respective positions 2 Remove two needle valves from their respective seats after marking one on pump side for identifica tion U...

Page 456: ...MyMopar com ...

Page 457: ...ake check ball using 7 Install hot idle compensator and gasket if so To01T 109 59 equipped Tighten screws securely Accelerator Pump Test 1 Pour clean gasoline into carburetor bowl ap proximately 1 2 inch deep Remove accelerator pump plunger from jar of gasoline Flex leather several times then slide into pump cylinder 2 Install accelerator pump discharge check needle in discharge passage Raise pump...

Page 458: ...each float shell to determine if side of the float is parallel to outer cage of air horn casting Fig 8 2 If sides of float are not in alignment with edge of casting bend float lever by applying pressure to end of float shell with thumb To avoid damage to the float apply only enough pressure to bend the float lever 3 After aligning floats remove as much clearance as possible between arms of float l...

Page 459: ...over the vacuum fitting to seal the opening Release the diaphragm stem If the stem moves more than 1 16 inch in ten 10 seconds the leakage is excessive and the assembly must be replaced Install the diaphragm assembly on the car buretor as follows 1 Assemble to carburetor and tighten attaching screws securely 2 Install choke operating link in position between diaphragm plunger stem and choke lever ...

Page 460: ...agm link CAUTION DO NOT APPLY TWISTING OR BENDING FORCE TO DIAPHRAGM 5 Reinstall vacuum hose on correct carburetor fitting Return fast idle linkage to its original condi DRILL O R GAUGE OF 10 i OF PHRAGM STEM DIAPHRAGM WIRED TO VACUUM URCE TUBE c Fig 13 Checking Choke Vacuum Kick Swing tion if disturbed as suggested in step no 1 6 Make following check With no vacuum applied to diaphragm CHOKE VALV...

Page 461: ... and close the choke valve The tang on the secondary throttle lever should freelv engage in the notch of the NR524A FULLY CLOSED Fig 15 Checking Accelerator Pump Adjustment NOTCH OF TANG ON SECONDARY L NR5ZA Fig 1 Checking Secondary throttle Adjusrment lockout dog Fig 16 If an adjustment is necessary bend the tang on the secondary throttle lever until engagement has been made Use Tool T 109 22for ...

Page 462: ...he second highest speed step of fast idle cam Fig 20 3 Start engine and determine stabilized speed VALVES CLOSED NR528A NR527A Turn fast idle speed screw in or out to secure specified speed Refer to Specifications 4 Stopping engine between adjustments is not necessary However reposition fast idle speed screw on cam after each speed adjustment to provide cor rect throttle closing torque Before adju...

Page 463: ...city valves to position themselves according to engine require ments Page Secondary Throttle Lockout 51 Cleaning Carburetor Parts 1 Closed Crankcase Vent System Group Engine Disassembling Carburetor 45 General Information 44 Inspection and Reassembly 47 Specifications 69 Secondary Throttle Lever 51 The AFB aluminum four barrel carburetor con tains many features some of which are the locations for ...

Page 464: ... attaching step up piston and rod cover plates Hold cover down with a finger to prevent piston and rods from flying out Lift off plates and slide step up pistons and rods out of air horn Fig 2 Remove step up piston springs Step up rods are not interchangeable 5 Remove ten screws that attach air horn to main body 1 screw in hole in air horn Lift air horn straight up and away from main body When rem...

Page 465: ...e from discharge pas sage 2 Using Tool T 109 58 remove main metering jets primary side Fig 4 The primary and secondary main metering jets are not interchangeable It is very important that these jets be installed in their re spective locationsin the main body at reassembly 3 Again using Tool T 109 58 remove main meter ing jets secondary side Fig 4 4 Remove screws that attach primary venturi choke a...

Page 466: ...However if the throttle valves have become nicked burred or damaged new valves may be installed pro viding the following instructions are carefullv fol Fig 7 Removing or Installing Velocity Valves IDLE TRANSFER PORTS NR577 Fig 8 Parts in Relation t o Throttle Valves lowed The screws that attach the throttle valves are staked on the oppositeside and care should be used in removal so as not to break...

Page 467: ...d attaching screws Tighten screwssecurely 3 Press down on accelerator pump plunger shaft and as plunger is being depressed a clear straight stream should emit from each jet If streams are not identical if either one is diverted or restricted a new accelerator pump jet housing should be installed After test pour gasoline from carburetor bowl and remove pump plunger Assembling Air Horn 1 Slide fuel ...

Page 468: ...air horn without being damaged Be sure the fuel baffles on the air horn slide down in front bowl side of the float chamber baffles or the air horn will not index correctly with the main body and can cause the floats to hang up Be sure the leather on the plung er does not curl or wrinkle Accelerator pump opera tion will be affected if this precaution is not observed Installdashpot if so equipped 4 ...

Page 469: ...IGHT CLOSING P AGAINST CHOKE IU O R GAUGE FAST fM E WEED ADJUSTING SCREW NW32f O F HIGHEST STEP Fig I4 Far Idle Com Position Adjustment CHOKE PISTON INDEX AFB 4620S and AFB 46218 Rear CarburetorsOnly The choke piston should be indexed to provide proper fuel delivery during warm up proceed as fol lows 1 Remove choke housing retainer ring heat tube cap and choke coil housing baffle plate and gasket ...

Page 470: ...ry throttle lever adjustment block the choke valve in the wide open position and invert the carburetor Slowly open the primary throt tle valves until it is possible to measure 17 64 inch between the lower edge of the primary valve and the bore opposite idle port Fig 18 At this measure ment the secondary valves should just start to open If an adjustment is necessary bend the secondary throttle oper...

Page 471: ...stments is not necessary However reposition fast idle speed screw on cam after each speed adjustment to provide cor FUEL W FAST IDLE SPEED SCREW ON THE SECOND HIGHEST STEP OF THE CAM T NN707A Fig 20 Fast Idle Speed Adjustment On Vehicle rect throttle closing torque Before adjusting idle and or fast idle speeds and mixtures make sure that the basic timing and the distributor control valve are corre...

Page 472: ...o not attempt to clean SERVICE DIAGNOSIS Condition PossibleCause Correction FUEL PUMP LEAKS FUEL FUEL PUMP LEAKS OIL INSUFFICIENT FUEL DELIVERY FUEL PUMP NOISE a Worn ruptured or torn diaphragm a Install new pump b Loose diaphragm mounting plates b Install new pump c Loose inlet or outlet linefittings c Tighten line fittings a Cracked or deteriorated pull rod oil a Install new pump b Loose rocker ...

Page 473: ...e vacuum test should be made with the fuel line disconnected from the carburetor Thiswill allow the pump to operate at full capacity which it must do to prime a dry carburetor The minimum reading should NH414A Fig 2 Fuel Pump Assembly 273 318 and 340 Cu In Engine NH415A Fig 3 Fuel Pump Assembly 383 and 440 Cu In Engine be at least 10 inches of vacuum at 500 r p m with the fuel line disconnected at...

Page 474: ...n the end of the pull rod for deterioration Check the outlet air dome diaphragm for cracks or deterioration Check the rocker arm for scoring or galling on the cam shaft push rod bearing surface ASSEMBLING FUEL PUMP Fig 5 1 Place the air dome diaphragm in position on the valve body 2 Align the scribe marks on the cover and the valve body then install attaching screws Tighten securely 3 Slide the di...

Page 475: ...oration If unfit for further service install a new rocker arm housing Check the Fig 7 Fuef Vapor Separator Mounting 440 Cu In Engine HOSE NR45 Fig 8 Fuel Vapor Separator Mounting 426 Hemi Engine rocker arm for scoring or galling on the camshaft push rod bearing surface ASSEMBLING FUEL PUMP 1 Assemble rocker arm by sliding the pull arm into eccentric cam and install sleeve Be sure the hook on the a...

Page 476: ... clip and insert through re stricted orifice to clear If necessary use air pressure to clear return line to fuel tank after removing filler cap INDEX GENERAL INFORMATION TANK Page General Information 57 Installing Fuel Tank 58 Installing Fuel Tank Station Wagon 59 The fuel tank conventional models 111 wheel base is located at the rear of the body under the trunk compartment floor Figs 1or 2 The fi...

Page 477: ...ning tangs on gauge with those in tank Install lockring then tighten se curely using Tool C 3582 If tank insulator was torn or damaged during removal of tank be sure and in stall a new insulator at reassembly 2 Locate insulation pad on top of tank Slide tank under car and up in position Hold in position then raise retaining straps and thread onto J bolts Install nuts and tighten Not over 50 inch p...

Page 478: ...ts that hold ends of fuel tank hold down straps to frame Lower front end of tank far enough to disengage filler tube from rear panel and slide out from under vehicle 5 Remove tank gauge unit using spanner wrench Tool C 3582 Fig 4 Check rubber grommet around filler tube If cracked or grommet at reassembly TANK INSTALLATION deteriorated install a new 116 5 W B MODELS Station Wagons Fig 3 1 Install T...

Page 479: ...using Tool C 3582 If tank insulator was torn or damaged during removal of tank be sure and install a new insulator at reas sembly 2 Slide fuel tank under vehicle Raise tank far enough to engage filler spout with opening in rear panel and locator embossments on floorpan 3 Push tank toward rear to fully engage filler spout in opening 4 Hold fuel tank in this position and place hold down straps in po...

Page 480: ...y to 1 Disconnect rubber elbows from inner filler tube 2 Remove quarter panel to filler tube attaching 3 Remove floor pan to filler tube rubber end 4 Remove outer filler tube from underneath ve INSTALLING THE FILLER TUBE CLIP FUEL GAUGE TUBE FUEL LINE WIRING FUEL GAU CLIP FUEL GAUGE TUBE FUEL GAUGE TANK UNIT NRl1 Fig 6 Fuel tank Ground Strap avoid leaks 3 On station wagons outer mer tube and rubbe...

Page 481: ...arburetor lever 4 Back off ferrule 2 1 4 This provides 1 4 cable slack at idle Tighten cable clamp nut 1 to 5 Connect choke rod or remove blocking fixture 45 inch pounds n Manuul Transmission Fig 2 6 Cylinder Engines 1 Apply a thin film of m u l t i p u r p o s egrease on accelerator shaft where it turns in bracket anti rattle spring where it contacts shaft ball end and pocket at rear end of throt...

Page 482: ...0 THROlTLE LINKAGE FUEL SYSTEM 14 63 Fig 2 Throttle linkage Adjustment 6 Cylinder Engines NN974A Fig Throttle Linkage Adjustment 426 Hemi Engine MyMopar com ...

Page 483: ...en throttle adjust length of connector rod 4 so that front carburetor is also at wide open throttle To lengthen this rod 4 turn adjusting stud 17 clockwise as viewed from front of engine Tighten lock nut 18 6 Remove choke valve blocking fixture HOOD FRESH AIR INTAKE SYSTEM Fig 1 If so Equipped GENERAL INFORMAT10N Functional hood fresh air intake scoops allow fresh air to flow directly from the out...

Page 484: ...Well Thermostatic Coil Spring 2 Notches Rich Type Model Manual Trans Automatic Trans Engine Displacement Cu In Bore Venturi Main Metering Jet Standard One Step Lean Two Steps Lean Float Setting Float Level Height Wet Vacuum Kick Drill Size Cam Position Adjustment Drill Size Choke Unloader See Fast Idle Cam Pos Adj Bowl Vent Valve Idle Mixture Screw turns open Approx Fast Idle Speed EngineHot and S...

Page 485: ...0 650 Vacuum Kick Adjustment Fast Idle Cam Position Main Metering Jets ADJUSTMENTS Idle Mixture Screws turns open 2 2 1 1 Drill Size 20 41 20 2a Fast Idle Speed R P M 1500 1600 1300 1700 Drill Size 41 41 41 41 Well CHOKE Type Well Well Well Control Thermostatic Coil Spring Setting On Index On Index After Approx 500 Miles if necessary CANADIAN CARBURETORS BALL AND BALL 1 1 4 BBD CARBURETOR Type Bal...

Page 486: ... Screws Turns Open 1 112 1 112 Idle Speed RPM Curb Idle 700 600 Fast Idle Speed RPM 1600 1600 Type Well Well Control Thermostatic Coil Spring Thermostatic Coil Spring Setting 2 Notches Rich 2 Notches Rich 75 1818 ADJUSTMENTS 5116 1116 CHOKE After Approx 500 Miles If Necessary CARTER AVS SERIES CARBURETORS Type Model AVS 4611S Transmission Type Manual Automatic Manual Automatic Engine Displacement ...

Page 487: ...STMENTS Accelerator Pump top of plunger to air horn Fast Idle Cam Position drill site Choke Unloader Vacuum Kick drill size Bowl Vent Valve Setting Piston Index Fast Idle Speed r p m 1 Idle Speed r p m 1 Secondary Throttle Lockout Adj Float Drop Idle Mixture Screw turns open Air Valve Spring Tension from Vertical Turns Type Control Setting Secondary Throttle Lever Adj Float Setting CHOKE After App...

Page 488: ... Hemi 1 7116 1 7116 1 111 16 1 111 16 1 3116 1 9116 1 3116 1 9116 089 089 L 089 R 089 092 L 077 R 65 028 65 028 16 82X 16 543L 16 544R 750 17 64 02 Y 7 32 314 7116 50 1 I4 5 32 39 2000 750 17I64 020 7 32 314 1 2 AFB 4621S Automatic 426 Hemi 1 7116 1 11 16 1 3116 1 9116 089 L 089 R 092 L 077 R 65 031 16 543L 16544R 7116 50 11 4 5I32 39 2000 750 17164 02 Y 7132 314 1 2 Well Well Thermostatic Coil Sp...

Page 489: ...shafts are the same in all respects SERVICE DIAGNOSIS Condition Possible Cause Correction PROPELLER SHAFT a b C d e VIBRATION UNIVERSAL JOINT a NOISE b Undercoating or other foreign matter a Clean exterior shaft and wash with on shaft solvent Loose universal joint flange bolts b Tighten bolt nuts to specified torque Loose or bent universal joint flange c Install new flange Tighten to specifi or hi...

Page 490: ...eference position gauge SP 5060 squarely and firmly along underside of the propeller shaft Fig 6 Make sure Veeway is in alignment and that both adapter pins are contacting propeller shaft Be sure arrow on gauge is pointing toward the front of car 6 Observe position of bubble in spirit level and compare the position with that shown on Chart Fig 13 for front joint angle A normal joint angle w i l l ...

Page 491: ...ating pin in rear bolt hole GAUGE SP 5060 ADAPTER DIFFERENTIAL C 4050 NR295 Fig Propeller Sbcrt Angulurhy roo1C 3976 iING NF571B Fig 8 The arrow on gauge should point toward the front of car On models equippedwith 7 1 4 axleplace propeller shaft alignment gauge adapter SP 5038be tween the gauge and machined pads of the carrier Fig 9 On models equipped with 9 1 4 or 9 3 4 axle position adapter C 40...

Page 492: ...ure Ow On gauge is Fig 10 AdjuHing Gauge on Diffem lrl M els whl pointing toward the front of car 9 114 or 9314 Axle Rear Joint Angle Reference 4 Observe position of bubble in spirit level and compare the position with that shownon Chart Fig 13 for rear joint angle A normal joint angle will cause the bubble to Dosition itself within the acceDt able range 5 If bubble in Spirit level i s found outsi...

Page 493: ...lies on universal joint cross if so equipped CAUTION Do not allow propeller shaft to drop or hang loose from either joint during removal Wire up or otherwise support the loose end of shaft to prevent damage to joint Front Joint All Models 1 Slide propeller shaft with the front yoke from the transmission output shaft Fig 2 Be careful not to damage splines on output shaft or yoke Examine sliding yok...

Page 494: ...ARDTOP AND 4 SPEED MANUAL I DODGE 116 W B HARDTOP AND CHARGER EXCEPT 426 AND 440 C I ENG AND 4 SPEED MANUAL DODGE 116 W B HARDTOP AND CHARGER WITH 426 AND 440 C I ENG AND 4 SPEED MANUAL DODGE STATION WAGON 117 W B ACCEPTABLE REGION FRONT OF CAR ACCEPTABLE REGION ANGLE HIGH ANGLE LOW FINAL READING ON PROPELLER SHAFT ALL MODELS PLI FRONT OF CAR ADD SHIMS AT R E A R AXLE HOUSING iPRlNG SEATS 1 WEDGE ...

Page 495: ...Length Inches Type Tubular MANUAL TRANSMISSION 3 SPEED 170 225 273 C I Engine 7 1 4 Axle 54 36 318 C I Engine 8 3 4 Axle 52 27 273 318 340 383 C I Engine 8 314 Axle 51 53 170 225 273 318 C I Engine 7 1 4 Axle 54 36 318 C 1 Engine 8 3 4 Axle 52 27 340 383 C I Engine 8 3 4 Axle 47 81 MANUAL TRANSMISSION 4 SPEED AUTOMATIC TRANSMISSION 904 AUTOMATIC TRANSMISSI0N A 727 AXLE RATIO MANUAL TRANSMISSION 3 ...

Page 496: ...8 crj Y 8 8 6 6 8 8 m m n s Y Y 8 8 6 6 a 2 8 6 Y h Y 8 5 Y 0 m 9 m 2 M C 0 rD N k L e 2 c c 0 v h h I a s Q 3 c 0 L I 2 I t a x a w I J k g 0 a MyMopar com ...

Page 497: ...nch Pinion FlangeClamp Screw 7 1 3 3 4 Axle 170 Pinion Flange Clamp Screw 9 3 4 Axle 170 Rear Spring U Bolt Nut 7 1 4 Axle 40 Rear Sprin U Bolt Nut 3 4tt 4n Axle 45 Pinion Bumper Plate Screw Pinion Bumper Plate Screw 7 1 4 Axle 1 5 0 3 4 9 3 4 Axle 200 MyMopar com ...

Page 498: ... Their action does NOT change with use Slight fluid seepage during cold weather operation resulting in a damp appearance is normal and does not affect the perform ance or life of the shock absorber Replace a shock absorber only if it is broken or leaking badly not just damp or has lost resistance in one or both directions due to internal damage Resistance in the rebound direction is usually greate...

Page 499: ...shed with the lower bushing installed however bushings are furnished separately for service installation Test and expel air from shock absorber before installation Testingand Expelling Air 1 With shock absorber removed extend fully in an upright position 2 Inspect for evidence of fluid running from u p per end of reservoir Actual leakage will be a stream of fluid running down side and dripping off...

Page 500: ...g shock absorbers to spring plate mounting stud and remove shock absorber from stud 4 Loosen and remove nut and bolt from upper shock absorber mounting and remove shock absor ber Dart remove nut and washer and remove shock absorber ND69B Fig Rear Shock Absorber Dart A WASHER BRACKET ND68B Fig 5 Rear Shock Absorber ICoronet Chargor 5 Inspect appearance of shock absorber mount ing bushings and if th...

Page 501: ... and if necessary replace bushing see Pivot Bushing Re placement procedure 1 Assemble shackle and bushings in rear of spring and rear spring hanger Do not lubricate rub ber bushings Start shackle bolt nut Do not tighten 2 Assemble front spring hanger to front spring eye and install pivot bolt and nut Do not tighten 3 Position rear spring hanger to body bracket and install bolts and tighten bolts t...

Page 502: ...ylinder Dart and 125 foot pounds on all other models Tiphten shackle nuts 45 foot pounds Coronet Charger 30 foot pounds Dart 12 Reinstall shock absorber on spring plate stud and tighten to 50 foot pounds Fig 9 Zinc Interleuf NH171A Spring lnterliner Replacement Removal 1 Raise vehicle on hoist to a comfortable working position 2 Using floor stands under axle assembly raise axle assembly to relieve...

Page 503: ...Pivot Rubber Bushing Shackle Rubber Bushing Double Acting Rubber Bushing Models equipped with 426 Hemi or 440 C 1 engine use 6 full spring leaves on left side and 5 leaves PIUS two 112 leaves forward of axle on right side TIGHTENING REFERENCE Foot Pounds REAR SPRINGS Center Bolt Nut 10 Pivot Bolt or Nut Coronet Dart 8 Cyl 125 Shackle Nutdoronet 45 Dart 30 U Bolt Nut Coronet and Dart Front Hanger N...

Page 504: ...nsufficient lubricant in the steering b Lubricate as necessary gear housingor in steering linkage c Steering gear shaft adjusted too tight c Adjust according to instructions d Front wheels out of line d Align the wheels See Front Sus e Steering column misaligned e See Steering Column Manual PULL TO ONE SIDE a Incorrect tire pressure a Inflate tires to recommended pres Tendency of the Vehicle sures...

Page 505: ...PLINO CROSS SHAFT GEAR CLEARANCE ADJUSTING SCREW WORM SHAFT RECIRCULATING CROSS SHAFT ND 458 ItIrnIIM Fig 1 Steering Gear Cross Section Replace shock absorbers as neces sary Replace worn parts and adjust ac cording to instructions Replace worn parts See Front Wheel Alignment Adjustaccording to instructions Inspect for damage to the gear shaft and steering arm replace parts as necessary Tighten att...

Page 506: ...onnect shift linkage on all models equipped with column mounted transmission gear selectors 4 Loosen steering column to instrument panel clamp nuts far enough to disengage tab on clamp from slot in underside of column jacket Slide column as sembly up far enough to disengage coupling from wormshaft CAUTION Care is required to avoid scratching col umn jacket when sliding up and down in clamp 5 DartM...

Page 507: ...ll return guides Place ball nut and wormshaft assembly ina cleanplace 10 Remove cross shaft needle bearing by placing steering gear housing in an arbor press insert Tool 8 Slide worm shaft adjuster o f f shaft Fig 6 WORMSHAFT BEARING ADJUSTER Fig 5 Removing Worm Shaft Adjuster WORMSHAFT AND BALL NUT ASSEMBLY ND468 Fig Removing Worm Shaft andBallNut Assembly 2 3786 in lower end of housing Fig 7 and...

Page 508: ...Pressbearing into housing to 1 2inch below end PULLER Fig M e m o v i n g Lower Bearing Cup CROSS SHAFT BEARING TOOL RAM Fig 9 Installing Inner Bearing of bore to provide space for o i lseal 20 Install inner needle bearing by placing bearing on Tool C 3333 Fig 9 Press bearing into inside end of housing bore flush with inside end of bore surface 21 To install wormshaft bearing cups position cups in...

Page 509: ...tall adjusting screw lock nut but do not tighten at this time 37 Rotate wormshaft to centralize ball nut 38 Place new cover gasket on housing cover 39 Carefully install cross shaft and cover assem bly into steering gear housing Fig 4 The cross shaft and sector teeth should be coated with steering gear lubricant before installing cross shaft in housing 40 Make certain some lash exists between cross...

Page 510: ...ft Oil Seal 5 Install and adjust steering column as outlined in the column section of this manual CROSS SHAFT OIL SEAL REPLACEMENT The cross shaft oil seal may be replaced by the following procedure either on the bench or without removing steering gear from vehicle CAUTION When replacing oil seal in vehicle clean the exposed portion of cross shaft to help prolong oil seal life 1 Remove steering ge...

Page 511: ...r as follows 1 See Gear Shaft Adjustment 2 Repair as necessary 3 Inspect for leakage at the lower sector shaft oil seal the sector shaft cover 0 ring 4 Recondition steering gear a Inflate tires to recommended pres sures b Repair and lubricate as necessary c See Front Wheel Alignment Front Suspension Group 2 d Remove jacket tube and replace bear ally accompanied by pump noise 1 Gear shaft adjustmen...

Page 512: ...lined under Hard Steering condition and cor rection g a Noisy pump make pressure test and repair as necessary Damaged hydrau lic lines or interference of the hoses with components attached to the fen der shield Air in system work steer ing wheel from right to left until the air is expelled b Correct as follows 1 See Gear Shaft Adjustment 2 Recondition steering gear 3 Inspect worm shaft splines for...

Page 513: ... A Fig 2 Steering Gear Housing position and tighten lock nut to 50 foot pounds maintain this setting ValveBody Recondition 1 Disconnect high pressure and return hoses to at the valve body and tie the ends above the reservoir fluid level 2 Remove two screws attaching valve body to main gear housing 3 Lift valve body upward to disengage from valve lever Fig 8 4 Remove the two screws attaching contro...

Page 514: ...o 7 foot pounds to prohibit leakage during valve centering operation 17 Connect high pressure and return hoses to valve body 18 Start engine If unit is self steering tap valve up or down to correct When tapping valve down hit valve body on end plug When tapping valve up tap on head of screw attaching the valve body to main valve body Do not hit control valve body 19 Turn steering wheel from stop t...

Page 515: ... ground cable 2 Remove steering column coupling to wormshaft roll pin 3 Raise carpet and remove three bolts in lower steering column support plate at floor pan 4 Loosen steering column jacket clamp nuts suf ficiently to allow column to be pulled up about 2 inches In some models it is necessary to remove the steer ing column finishplate to expose the column clamp 5 Tap coupling assembly upward and ...

Page 516: ...holding Tool C 3323so sector shaft is in a horizontal position Place Tool C 3875on thread ed end of gear shaft and slide tool into housing until both tool and shaft are engaged with bearings 8 Turn wormshaft to full left turn position to compress power train parts Remove power train re taining nut with Tool 2 3634 Fig 1 1 Remove hous ing head tang washer 9 While holding power train firmly compress...

Page 517: ...Remove lower thrust bearing and lower thrust 20 Remove lower reaction ring and reaction 21 Remove cylinder head assembly 22 Remove two 0 rings in two outer grooves in cylinder head 23 Remove reaction 0 ring from groove in face of cylinder head with air pressure directed into oil hole located between two 0 ring grooves Fig 1 6 24 Remove snap ring sleeve and rectangular oil seal ring from cylinder h...

Page 518: ...MyMopar com ...

Page 519: ...ring race thin h Start wormshaft thrust bearing adjusting nut donot tighten 34 Turn wormshaft clockwise onehalf turn Hold wormshaft in this position with splined nut Tool C 3637 and socket wrench and hold in this position through items 35 and 36 then tighten nut to 50 foot pounds to prestretch wormshaft threads 35 Loosen adjusting nut Place several rounds of cord around center bearing race Fig 20 ...

Page 520: ... the center bearing race with the valve pivot lever hole in center bearing spacer assembly The small 0 ring for the ferrule groove should not be installed until after upper reaction spring and spacer have been installed 38 Install upper reaction ring on center race and spacer with flange down against spacer 39 Install upper reaction spring over reaction ring with cylinder head ferrule through hole...

Page 521: ...lign valve lever hole in center bearing race and spacer exactly with the valve lever hole in the gear housing Turn the housing head by tapping on a reinforcing rib with hammer and drift Use Tool C 3649 to maintain alignment Fig 23 The aligning tool should not be nmoved until tho spanner nut is securelytightened 54 Install housing head tang washer to index with groove in housing Install spanner nut...

Page 522: ...is evident Then retighten adjusting screw until backlash just disappears Continue to tighten for 3 8 to 1 2 turn from this position and tighten lock nut to 50 foot pounds to maintain setting L NH621A Fig 25 Adjusting Steering Gear Mesh d Starting from a point at least one full turn of the wormshaft either side of center torque at sector shaft required to turn unit through center at 2 rpm in each d...

Page 523: ...lumn as outlined in the steering col 4 1 NH630 Fig 27 lnrtalling Worm Shaft 011 Soul umn section of this manual Group 19 Hose nsiullutton When either hose is reinstalled or replaced it is essential that the sponge sleeve hose protector be installed as follows 1 Avoid sharp bends in large section of hose about 10inch diameter is recommended 2 Hose must remain at least 1inch away from all pulleys ba...

Page 524: ... valve permits a regulated amount of OVAL SHAPED FILLER TUBE KEY NN1002 Y Page Tightening References 43 oil to return to the intake side of the pump when ex cess output is generated during high speed operation This reduces the power requirements to drive the pump and minimizestemperature build up The 1 06pump incorporates a two stageflow control valve High pressure oil passes through two orifices ...

Page 525: ...us d Remove reservoir visually check inlet oil hole and service as necessary e Vanes improperly installed e Install properly or replace if neces sary 94 pump f Vanes sticking in rotor f Recondition pump and correct cause 94 pump g Faulty flow control valve g Replace flow control valve pump h Pressure plate thrust plate or rotor h Replace badly scored part or lap in if scored tightly scored 94 pump...

Page 526: ...f C 3309Bto the steering gear The valve must be installed on the outlet side of the gauge Fig 3 4 Insert thermometer in fluid reservoir start engine and warm up fluid to a temperature between 150 and 170degreesFahrenheit Turning the wheels from stop 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 engin...

Page 527: ...g to 160inch 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 properly positioned to prevent hose contact with other components in engine compartment 7 After hoses are installed check for leaks while system is being bled See Pump Installation MI TOP VIEW HIGH PRESS...

Page 528: ...ng for burrs nicks or score marks that would allow oil to bypass outer PLASTIC HAMMER DRIVE SHAFT SEAL Fig 9 Oil Seal Removal seal surface 13 If necessary to disassemble flow control valve for cleaning see Flow Control Valve Disassembly 14 After lifting pressure plate and cam ring from rotor remove ten vanes from slotsin rotor 15 Clamp drive shaft in soft jawed vise with rotor and thrust plate fac...

Page 529: ...force will distort the seal SEAL s SOCKET 1 NNlOlO Fig 12 0il Seal Installation I PORTED SIDE UP i NNlOll Fig 13 nstalling Thrust Plate 2 Lubricate seal with power steering fluid and clamp pump body in vise shaft end down 3 Install end cover and pressure plate 0 rings in grooves in pump cavity These rings are the same size Lubricate with power steering fluid 4 Lubricate large pump body to reservoi...

Page 530: ... groove in pressure plate and position end cover lip edge UP over spring 12 Press end cover down below retaining ring groove with thumb and install ring making sure it is seated in groove Fig 19 This operation can be performed in an arbor press if available Care should be exerted to prevent cock ing the end cover in the bore or distorting the as sembly 13 Using a punch tap retainer ring ends aroun...

Page 531: ...to spring out k RELIEF 3RIFICE I NN1018 Fig 20 Installing Pressure Hose Fitting of bore 3 Clamp land end of valve in a soft jawed vise and remove hex head plug and shim s Note number of shims on plug Same number of shims should be installed on assembly of valve 4 Remove valve from vise and remove pressure relief ball guide and spring Assembly 1 Insert spring guide and pressure relief ball in end o...

Page 532: ...e end of ring lines up with hole in pump body Insert punch in hole far enough to dis engage ring from groove in pump bore Remove ring from body Fig 26 8 Tap end cover with plastic hammer to jar it loose Spring under cover should push cover up 9 Remove pump body from vise place in inverted position on clean flat surface and tap end of drive shaft to loosen rotating group Lift pump body off rotating...

Page 533: ... 80 inch pounds shaft seal into bore with ToolC 4061 pump bore Lubricate with power steeringfluid 4 Lubricate new large pump body to reservoir 0 ring and install on pump body 5 Install brass seal plate to bottom of housing bore Align index notch in plate with dowel pin hole in housing Fig 27 6 Carefully install front plate in pump bore Chamfered edge first Align index notch in plate with dowel pin...

Page 534: ...l with pump shaft 10 To insure proper alignment of pressure plate to dowel pin insert the largest possible number drill into the large 3 16 inch diameter oil hole in the cam ring next to the cam notch Select from a number 13 through 16 drill clean thoroughly and bottom on housing floor Fig 31 11 Install new 0 ring on pressure plate lubri cate with power steering fluid and carefully position in pum...

Page 535: ...drive pulley placed on end of shaft securely thread installer Tool C 4063 without adapter into 3 8 inch threaded hole in end of shaft Fig 34 Pumps installed on eight cylinder engines have drive pulleys pressed flush with the end of the pump shaft With drive pulley placed on end of shaft se curely thread installer Tool C 4063 with adapter SP 5399 into 3 8 inch threaded hole in end of shaft Fig 35 1...

Page 536: ... fluid and carefully install into bore Install snap ring CAUTION Do not depress the bore plug more than 1 16 inch beyondsnap ringgroove COLUMN CONTENTS Page Page STEERING COLUMN AUTOMATIC STEERING COLUMN MANUAL TRANSMISS10N 33 TRANSMlSSlON 38 STEERING COLUMN AUTOMATIC TRANSMISSION INDEX Page Assembly 36 Disassembly 35 Inspection 36 GENERAL INFORMATION The steering column under head on collision co...

Page 537: ...driver side SERVICE PROCEDURES When the column is installed in a car it is no more susceptible to damage through ordinary usage than previous columns however when it is removed special care must be taken in handling this assembly When the column is removed from the car such actions as a sharp blow on the end of the steering shaft or shift levers leaning on the column assembly or dropping of the as...

Page 538: ... out gearshift lever pivot pin then remove lever and spring from housing 5 Remove snap ring from upper end of steering shaft Fig 2 Remove turn signal switch and upper bearing retainer screws Remove retainer and lift RETA1NER SCREWS 3 Fig 2 Removing or InstallingSteeringShaft Snap Ring FLOOR PLATE ASSEMBLY BEARING SUPPORT BOLTS 21 BEARING SUPPORT COUPLING BEARING NR427 Fig Steering Column Lower End...

Page 539: ...d install on lower hub of gearshift housing Position gearshift housing on the jacket 3 Install two bearing housing retaining bolts Fig 7 and start nuts about three turns 4 With turn signal wiring threaded through bear ing housing install the assembly while guiding wiring through gearshift housing Position bearing housing on end of jacket engaging the bolt heads in slots in jacket then tighten the ...

Page 540: ... switch retainer plate And dial lamp if so equipped and secure with the three screws 11 Guide gearshift pointer over dial then snap base of pointer on lug provided on gearshift hous 12 Install gearshift lever spring into gearshift ing Columnlnsfallation Fig I 1 Position bracket assembly on steering column Fig l install and securely tighten the four short retaining screws to 95 inch pounds Insert c...

Page 541: ... ing counterclockwise 6 Disconnect wire at horn switch Remove three screws attaching horn ring and switch to steering wheel then remove horn ring and switch 7 Remove steering wheel retaining nut and wash er Remove steering wheel with Tool C 3428A Do not bump or hammer on steering shaft to remove wheel Removeturn signal lever 8 Remove floor plate to floor pan attaching screws Remove finish plate fr...

Page 542: ... shift lever Inspect steering shaft upper bearing for smooth operation and lubricate with Multi Purpose Chassis Lubricant or similar lubricant If bearing has any signs of roughness or wear it should be replaced Replacement bearings are pre lubricated After cleaning inspect all parts for wear or damage Note condition of pins in two lower shift levers shift lever socket at top end of shift tube and ...

Page 543: ...ssembled SHIFT TUBE AND 7 LEVER ASSEMBLY SELECTOR SPRING NYLONBUISHING I NDBOB Fig 6 Removing ShW Tube Assembly sembly through jacket and into gearshift housing start the two bushing retaining screws through slots in jacket but do not tighten 7 Install spacer Fig 5 around selector lever so it rests against 2nd and direct shift lever Install low and reverse lever Then install support and bear ing a...

Page 544: ... straight ahead position and master splines on wormshaft and coupling aligned engage coupling with wormshaft and install the roll pin 3 Hold column assembly with bracket against the instrument panel support Install but do not tighten the two upper bracket nuts 4 Center steering shaft coupling at midpoint of its travel This is accomplished by moving column and bracket assembly fore and aft in the i...

Page 545: ...ift linkage refer to Transmission Group SPECIFICATIONS MANUAL STEERING Type Recirculating Ball Nut Ratio 24 to 1 Cross Shaft Bearings 3 Needle Bearings Dart 6 cyl Bronze Bushings Worm Shaft Bearings 2 Caged Ball Bearings Cross Shaft Adjusting Screw End Play OOO OO4 Inch Worm Bearing Pre Load 1to 4 in Ibs to KeepWheel Sector Mesh Adjustment Pre Load Torque Moving spot Includes worm bearing Pre Load...

Page 546: ...eel Nut 27 Gear Assembly to Frame Bolt 80 POWER STEERING GEAR Foot Inch Pounds Gear Housingto Frame Bolt Dart Coronet and Charger 55 Polara and Monaco 80 Gear Shaft Adjusting Screw Lock Nut 50 Gear Shaft Cover Nut 20 Pump Inlet Fitting 30 Foot Inch Pounds Steering Arm Nut 120 Steering Column Support Nut Steering Shaft Coupling Bolts Valve Body Attaching Bolts Valve Body End Plug Steering Wheel Nut...

Page 547: ...or A 745 When replacement of parts is required always refer to the Parts Catalog to make sure the correct part is being installed The three speed manual transmissions are of the synchromesh type with helical cut gears to provide silent operation The countershaft gear is in constant mesh and is supported by roller bearings at each end The mainshaft front end is piloted in roller bear ings in the en...

Page 548: ...eplace parts as neces sary Replace worn gears Replace worn bearing SERVICE PROCEDURES SERVICE IN VEHICLE 3 Adjust 2nd 3rd rod swivel so it will enter 2nd 3rd lever at transmission while the hand lever on steering column is held 10 above horizontal position Install washers and clip Tighten swivel nut to 70 1 Remove both shift rod swivels from transmis 4 Place screwdriver or suitable tool between cr...

Page 549: ... clip Tighten swivelbolt to 100inch pounds 6 Remove tool from cross over blade at steering column and shift through all gears to check adjust Fig 5 Holding Crossaver Blade in Neutral Posfih ment and cross oversmoothness zontal position Install washers and clip Tighten swi vel nut to 70 inch pounds 4 Place screwdriver or suitable tool between cross overblade and 2nd 3rd lever at steering column so ...

Page 550: ...olt to 100 inch pounds Clutch pedal has to be in full re turned position during this adjustment SPEEDOMETER PINION GEAR Removal and nstallation Rear axle gear ratio and tire size determines pinion gear size requirements Refer to Speedometer Pinion 1 Disconnect clutch rod swivel from interlock Chart in Specificationsfor pinion usage 4 Loosen swivel clamp bolt and slide swivel on 2ND 3RD LEVER 1ST R...

Page 551: ...ng in adapter then push them into adapter with Tool C 4004 until tool bottoms Fig 10 5 Note number of gear teeth and install speed ometer pinion gear into adapter Fig 9 CAUTION Before installing pinion and adapter as sembly make sure adapter flange and its mating area on extension housing are perfectly clean Dirt or sand will cause misalignment resulting in speedometer d SEAL I TOOL NP2 Fig IO Ins...

Page 552: ...olts to 50foot pounds 2 Install center crossmember and tighten retain ing bolts to 90 foot pounds Lower transmission in stall extension housing to rear engine mount bolts and tighten to 40 foot pounds 1 Drain transmission fluid 14 2 Disconnect propeller shaft at rear universal joint Carefully pull shaft yoke out of transmission extension housing CAUTION Be careful not to scratch or nick ground sur...

Page 553: ...ersal joint yoke into extension housing and on the mainshaft splines Con nect propeller shaft to rear axle pinion shaft yoke 6 Fill transmission to level of fill plug Refer to Lubrication Section SERVICE OUT OF VEHICLE TRANSMISSION REMOVAL Removal 1 Drain lubricant from the transmission 2 Disconnect propeller shaft at rear universal joint Carefully pull shaft yoke out of transmission extension hou...

Page 554: ...d be 060 to 117 inch when measured between synchronizer outer ring pin and opposite synchronizer outer ring Fig 18 This measurement must be made on two pins 180 de grees apart with equal gap on both ends for float determination 4 There should be a snug fit between pins and outer rings similar to that obtained when measuring with a micrometer Extension Housing 1 Remove bolt and retainer securing sp...

Page 555: ...hdrawn from the case 6 Remove selective snap ring and rear bearing from the mainshaft Fig 19 Removing Drive Pinion Assembly Mainshaft 1 With transmission in reverse remove mainshaft rear bearing outer selective snap ring then partially remove mainshaft CountershaftGear 2 Cock mainshaft then remove clutch sleeve outer synchronizer rings front inner ring and 2 3 shift fork Fig 21 or 22 3 Remove clut...

Page 556: ...s are leaking 1 Remove operating levers from their respective shafts 2 Drive out tapered retaining pin from either of the two lever shafts then withdraw lever shaft from inside transmission The detent balls are spring loaded as shaft is being withdrawn the ball will drop to bottom of the case 3 Remove interlock sleeve spring pin and both balls from the case Fig 27 or 28 Drive out remain ing tapere...

Page 557: ... stop ring assembly for being straight and attached securely Replace parts as required Mainshaft Inspect mainshaft gear and bearing mating sur faces If gear contact surfaces show signs of galling or are excessively worn a new mainshaft should be in stalled Inspect snap ring grooves for burred edges If rough or burred remove condition using a fine file or crocus cloth Inspect synchronizer clutch ge...

Page 558: ...ide 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 2 3765 Fig 29 A good method of installing second ball is to stick ball in the tool recess by means of lubricant then use tool to positionball on the detent spring 5 Install seal protector Tool 2 3767 on second and ...

Page 559: ...ing with clutch teeth then seat pinion bearing The pinion N U 4 Fig 3I Drive PinionSeal Replacement shaft bearing is fully seated when snap ring in in full contact with the case 6 Install a new seal in pinion bearing retainer using Tool C 3789 Fig 3 1 7 Using a new gasket install drive pinion and re tainer in the case Install attaching bolts and tighten to 30 foot pounds Extension Housing 1 Using ...

Page 560: ... roller bearings in the end of the main drive pinion and a ball bearing in the front of the extension housing The output end of the mainshaft is splined to the sliding universal joint yoke which is supported by a bushing in the extension housing The countershaft gear is supported by a double row SAMPLE NUMBER PP 833 1861 0250 Page Service Out of Vehicle 18 Assembling Transmission 25 Disassembling ...

Page 561: ...am nut and unscrew gearshift lever knob 3 Remove console and wiring if so equipped Fig 4 or Fig 5 4 Remove retaining screws from floor pan boot and slide up and off shift lever 5 Remove shift lever using a 010 feeler gauge as a tool to release the internal spring clip as shown i n Fig 6 6 Remove retaining clips washers and control rods from shift unit levers 7 Remove twp bolts and washers which se...

Page 562: ...o enter transmission levers Start with 1 2 shift rod it may be necessary to pull clip at shifter I CONSOLE LID FRONT FINISH PLATE SCREW AND WASHER 2 end to rotate this rod 4 Replace washers and clips as shown in Fig 3 5 Remove aligning tool and test shifting action SPEEDOMETER PINION GEAR Removal and fnstalldon Rear axle gear ratio and tiresize determines pinion gear size requirements Refer to Spe...

Page 563: ... sion housing Fig 8 7 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into ex tension housing and tighten retainer bolt to 100 ASSEMBLY Fig 7 Gearshift Linkage Adjustment Fig 8 Speedometer Pinion and Adapter fnstalled inch pounds Lubrication Section 8 Fill transmission to level of fill plug Refer to EXTENSION HOUSING YOKE SEAL Replacement 1 Place drain...

Page 564: ...spline yoke during removal and TOOL NN125 Pig I2 lnstalling Extension Housing Yoke Seal installationof the shaft assembly 4 Disconnect speedometer cable and back up light switch leads 5 Some models have exhaust systems which will have to be partially removed for clearance See Ex haust Systems Section 11 6 Install engine support fixture C 3487 engaging the hooks in holes in frame side member Be sur...

Page 565: ...on pull housing out and away from the case The first and second third and fourth shift fork may remain in engagement with synchronizer sleeves Work forks out of sleeves and remove from the case The following three steps need only be done ifoil 2 Remove nuts lockwashers and flatwashers that attach first and second third and fourth speed shift operating levers to the shafts Disengage levers from fla...

Page 566: ...21 20 TRANSMISSIONS4 SPEED 0 0 Fig 16 A 833 Transmission Disassembled NH740D MyMopar com ...

Page 567: ...48 Thrustwasher Needle Roller 68 Oil Seal Reverse Lever Shaft 92 Gasket Shift Control 70 Flatwasher LEGEND FOR FIG 16 housing allowingdetent balls to fall free 5 Remove snap ring Fig 20 that retains 3rd and 4th synchronizer clutch gear and sleeve slide and spring out of housing 3rd and 4th synchronizer assembly off end of main shaft Extension Housing and Mainshah 6 Slide 3rd speed gear and stop ri...

Page 568: ... EXTENSION HOUSING Fig 2I Removing or Installing Mainshaft Bearina Snaa Rina Front SNAP RING GROOVE MAINSHAFT NH745 EXTENSION HOUSING 4 Fig 22 Removing or Installing Mainshaft and clutch unless inspection reveals a replacement part is required Remove 2nd speed gear Figure 26 shows various mainshaft bearing surfaces of the gears Inspect these surfaces for signs of wear scoring or any condition that...

Page 569: ...lowing step need only be done if oil leakage is visible around reversegearshift lever shaft 3 Remove any burrs from shaft so as not to dam age the case bore then carefully push reverse gear shift lever shaft inward and remove it from case Fig 31 Lift out detent ball from bottom of case Remove shift fork from shaft and detent plate Drive Pinion und Countershaft Gear 1 Using countershaft arbor C 393...

Page 570: ...lvent dry with compressed air Inspect case for cracks stripped threads in various bolt holes and ma chined mating surfaces for burrs nicks or any condi tion that would render the case unfit for further serv ice The front mating surface should be smooth if any burrs are present dress them off with a fine mill file If threads are stripped install Helicoilinserts Ball Bearings Wash ball bearings usin...

Page 571: ...re of gear at each end then install roller bearing spacer Insert arbor Tool C 3938 into gear and through spacer Center spacer and arbor 2 Coat needle type roller bearings with heavy grease then at each end of gear install 19 rollers followed by a spacer ring and 19 more roller bearings and 1 spacer ring Fig 16 3 If countershaft gear end play exceeded 029 when measured during disassembly Fig 27 ins...

Page 572: ...OL INSTALLING REMOVING NU43 Fig 37 Replacing Bushing in Extension Housing with Tool C 3985 2 Drive the bushing out of housing Fig 37 with 3 Slide a new bushing on installing end of Tool C 3974 Align oil hole in bushing with oil slot in hous ing then drive bushing into place Fig 37 4 To install a new seal position seal in opening of extension housing and drive it into housing with Tool C 3972 Fig 1...

Page 573: ...aft with Multi purpose grease and start shaft into housing Place remaining detent ball OB the spring and com press ball and spring with a small screwdriver then push shaft in until seated Fill recess around shaft with Multi purpose grease then install operating lever flatwasher lockwasher and nut Tighten nut to 18 foot pounds 3 Position 1st 2nd and 3rd 4th clutch sleeve gears in neutral Install ge...

Page 574: ...lve Body and Accumulator Piston 61 Assembly Sub Assembly Installation 88 Disassembly S ub Assembly RemovaI 65 Installation Transmission Converterand Drive Plate 91 Service Out of Vehicle The TorqueFlite Transmission model identification marking shown in the following application chart is cast in raised letters about 3 8 inch high on the lower left side of the bell housing Transmission usage is de ...

Page 575: ...I Z 2 U t 8 U 1 1 L u I v B Z Q rn f B Y Y u t 9 6 v Y z Q Q a r 0 c t 0 H H E e H e c Q Y Q 3 c c L I m ci I Y w MyMopar com ...

Page 576: ...cw v QI 3 QI Q Z n L 4 w I 4 n W QI 2 n MyMopar com ...

Page 577: ...g The torque converter is attached to the crankshaft through a flexible driving plate Cooling of the con verter is accomplished by circulating the transmission fluid through an oil to water type cooler located in the radiator lower tank The torque converter assem bly is a sealed unit which cannot be disassembled The transmission fluid is filtered by an internal Dacron Type filter attached to the l...

Page 578: ... Park Hydraulic Circuits I Ill CONTROL SYSTEM IN PARK ENGINE RUNNING NN34C OIL P R E S S U R E S LINE 5sw m PUMP SUCllON COWElT t 3055 pu LU IUlIOW 5 30psi CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING NN35C Neutral Hydraulic Circuits MyMopar com ...

Page 579: ...NSMISSIONS 21 33 OIL PRESSURES PUMP SUCTION 6OVEINOI 0 15 psi C O N V E M E l 30 15 p LUIIICATION 5 30 pw CONTROL SYSTEM IN RELIEF VALVE DRIVE BREAKAWAY HALF THROTTLE NR733A Drive Breakaway Hydraulic Circuits MyMopar com ...

Page 580: ...ITE 0 I tllIID OIL PRESSURES LINE 15 psi PUMP SUCTION 40 psi THROllLE GOVtRNOR bl5pd CONVtRTER 30 15 psi LUBRICATION 5 30 psi I I I I CONTROL SYSTEM IN DRIVE SECOND HALF THROTTLE NR734A Drive Second Hydraulic Circuits MyMopar com ...

Page 581: ...SMISSIONS 21 35 OIL PRESSURES LINE 51 90 psi PUMP SUCTION THROTTLE 0 90 psi GOVERNOR 6 90 psi CONVERTER 31 75 psi LUBRICATION 5 30 nil CONTROL S Y S T E M IN DRIVE DIRECT NR735A Drive Direct Hydraulic Circuits MyMopar com ...

Page 582: ...21 36 TRANSMlSSlON TORQUEFLlTE 0 C TC Drive Kickdown Hydraulic Circuits MyMopar com ...

Page 583: ...UTCH LUB l Y T O LUB I I I I d OIL PRESSURES LINE PUMP SUCTION GOVfRNOI 655 Pi HIGH PRESS RELIEF VALVE h OIL FILTER PUMP 1 7 7 9 I CONVfllfl 30 75 psi LUBRICATION 5 30 ps CONTROL SYSTEM IN MANUAL SECOND CLOSED THROTTLE NR737A Selector lever Second Hydraulic Circuits MyMopar com ...

Page 584: ...21 38 TRANSMISSIONS TORQUEFLITE 0 PUMP 011 PRESSURES CONVtlTtR 3475 LUIICATIOW 1 30psi I CONTROL SYSTEM IN MANUAL LOW CLOSED THROTTLE NR738A Selector Lever Low Hydraulic Clrcuhs MyMopar com ...

Page 585: ...FLITE T RANSMISSI0NS 21 39 PUMP 1 OIL PRESSURES LlNt 230 260 psi PUMP SU 1ION CONVtRItR 30 75 psi LUBRI A1ION 5 30 psi I I CONTROL SYSTEM IN REVERSE OIL FILTER I I NR739A Reverse Hydraulic Circuits MyMopar com ...

Page 586: ...the kickdown servo and band when making direct to second kickdowns SHIFT PATTERN II I I NU371 THROTTLE PRESSURE Fig 3 Part Throttle Downshift Hydraulic Circuh Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are re leased by spring tension when hydraulic pressure is released ...

Page 587: ...uire heavy throttle for 1 2 mile or more This reduces possibility of overheating the transmission and converter under these conditions lowing Vehicle Transmission Inoperative Tow the vehicle with a rear end pickup or remove the propeller shaft Transmission Operating Properly The vehicle may be towed safely in N neutral with rear wheels on the ground at a speed not to exceed 30 mph If the vehicle i...

Page 588: ...rectthrottle linkageadjustment b Adjust throttle linkage c Hydraulic pressurestoo high or low c Perform hydraulic pressure tests and adjust to specifications d Kickdown band out of adjustment d Adjust kickdown band e Valve body malfunction or leakage e Perform pressure tests to determine cause and correct as required f Governor malfunction f Inspect governor and repair as re quired g Accumulator s...

Page 589: ...nding linkage or faulty band lining Repairas required i Overrunningclutch not holding i Disassemble transmission and repair overrunningclutch as required NO KICKDOWN OR NORMAL DOWNSHIFT justment SHIFTS ERRATIC a Low fluid level b Aerated fluid c Incorrect throttle linkage adjustment c Adjust throttle linkage d Incorrect gearshift control linkage d Adjust control linkage e Hydraulic pressurestoo hi...

Page 590: ... g Remove valve body assembly and per not operating form air pressure tests Repair as re quired Low reverse servo band or linkage h Inspect servo for damaged seals malfunction binding linkage or faulty band lining Repair as required Faulty oil pump i Perform hydraulic pressure tests ad just or repair as required Low fluid level a Refill to correct level with Automatic Transmission Fluid AQ ATF Suf...

Page 591: ... for damaged seals maIfunction binding linkage or faulty band lining Repair as required Worn or faulty front clutch g Disassemble and inspect clutch Re pair or replaceas required Incorrect gearshift control linkage ad a Adjust control linkage justment Valve body malfunction or leakage Rear clutch inoperative b Perform pressure tests to determine c Inspect clutch and repair as required cause and co...

Page 592: ...operation of switch with a test lamp Adjust or replace as required c Broken lead to neutral switch c Inspect lead and test with a test lamp Repair broken lead starting switch STALL TEST WARNING DURING TEST LET NO ONE STAND IN FRONT OF VEHICLE The stall test consists of determining the engine speed obtained at full throttle in D position This test checks the torque converter stator clutch operation...

Page 593: ... original thread size The chart lists the threaded hole sizes which are used in the aluminum case and valve body and the necessary tools and inserts for the repair of damaged or worn threads Heli Coiltools and inserts are readily available from most automotive parts jobbers NOTE Some thread drag may occur in screwing a bolt into the installed Heli Coil insert Therefore a toque reading should be ta...

Page 594: ...g a new gasket Tighten oil pan bolts to 150inch pounds 7 Pour six quarts of Automatic Transmission Fluid AQ ATF Suffix A or Dexron through the filler tube 8 Start engine and allow to idle for at least two minutes Then with parking brake on move selector lever momentarily to each position ending in the neutral position 9 Add sufficient fluid to bring level to the ADD ONE PINT mark Recheck fluid lev...

Page 595: ...arshift to floor bracket bolts and re move unit installation 1 Install gearshift unit in its bracket install and CABLE END SHIFT LEVER Fig O Cons le Oeurshift Unit Fig 9 Removing or Inrtullhg Console Coronet tighten retaining bolts securely Fig 11 Attach up per rod to the unit 2 Coronet and Charger Models Connect dial lamp wires and install upper finish plate Secure with the two screws If removed ...

Page 596: ...ved to Park and then to Neutral positions and inspect to see that the switch operating lever fingers are cen tered in switch opening in the case 4 Screw switch and new seal into transmission case and tighten to 24 foot pounds Retest switch with the test lamp 5 Add fluid to transmission to bring up to proper level 6 The Back up Light Switch Circuit is through the two outside terminals of the 3 term...

Page 597: ...0or 225 Cu In Eng Fig 14 1 Follow detailed instructions in Lubrication Sec tion for linkage lubrication of all models 2 Disconnect choke 4 at carburetor or block choke valve in full open position Open throttle slight ly to release fast idle cam then return carburetor to curb idle 3 Hold transmission lever 9 firmly fomard against its stop while performing the next two steps It is importantthat the ...

Page 598: ...21 52 TRANSMISSIONS TORQUEFLITE 0 Fig 15 Throttle Linkage Adjurtment Dart With 2 7 3 3 18 or 340 Cu In Eng NR343A Fig 16 Throttle Linkage Adjustment Dart With 383 Cu In Eng MyMopar com ...

Page 599: ...ocket 2 must line up with the ball end with a slight downward effort on rod 5 Assemble ball socket 2 to ball end and remove 3 16 rod 9 from upper bellcrank and lever 6 Disconnect clip washer and return spring E then adjust length of carburetor rod 12 by pushing rearward on rod with a slight effort and turning the threaded adjustment 1 The rear end of slot should contact carburetor lever pin withou...

Page 600: ...21 54 TRANSMISS10NS TORQU EFLlTE 0 Fig 18 Throttle Linkage Adjustment Coronet with 273 or 3I 8 Cu In Engfno NN974A Fig 19 Throttk linksge Adjustment With 426 Cu In hg MyMopar com ...

Page 601: ...throttle linkage travel 12 Attach carburetor rod assembly 4 between the carburetors with slotted rod end 16 attached to outboard side of inboard lever on rear carburetor With rear carburetor at wide open throttle adjust length of connector rod 4 so that front carburetor is also at wide open throttle To lengthen this rod 4 turn adjusting stud 17 clockwise as viewed from front of engine Tighten the ...

Page 602: ...ected if part throttle shift speeds are either very delayed or occur too early in relation to vehicle LUBRICATION COOLER R E T U I PRESSURE 1 Fig 2I Pressure Test Locations Rear End of Care GOVERNOR PRESSURE CHART Six Cylinder Engines VEHICLE SPEED TO AXLE RATIOS Pressure 1 7 0 Cu In Eng 225 Cu In Eng limits 2 7 6 l 3 2 3 l 2 7 6 l 2 9 3 l 3 2 3 l psi 18 20 15 17 18 20 17 20 16 19 15 44 57 37 48 3...

Page 603: ...de with spring fully compressed and valve bottomed in the 6 Remove tool and tighten stop screw lock nut securely AIR PRESSURE TESTS ThrottlePressure Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a malfunction is evident 1 Remove valve body assembly from transmission to perform adjustment 2 Loosen throttle lever stop screw lock nut and back off approx...

Page 604: ...gear ratio and tire size determines pinion gear size requirements Refer to Speedometer Pinion Chart in Specificationsfor pinion usage 1 Remove bolt and retainer securing speedometer pinion adapter in the extension housing Fig 26 2 With cable housing connected carefully work adapter and pinion out of the extension housing 3 If transmission fluid is found in cable housing replace seal in the adapter...

Page 605: ...positions parking lock control rod rearward so it can be disengaged or engaged with the parking lock sprag 5 Remove two screws plate and gasket from bot tom of extension housing mounting pad Spread large snap ring from output shaft bearing with Tool C 3301 Fig 31 With snap ring spread as far as possible carefully tap extension housing off the output shaft TOOL NN361 Fig 29 Removing Extension Housi...

Page 606: ...GEAR I RINGS PNAP GOVERNOR BODY 5 4 weight Figure 34 shows a disassembled view of the governor assembly 5 Remove snap ring from behind governor body then slide governor and support assembly off the out put shaft If necessary remove the four bolts and separate governor body from the support Cleaning and inspection The primary cause of governor operating failure is due to a sticking governor valve o...

Page 607: ...alve body in position while removing the bolts 7 While lowering valve body down out of trans mission case disconnect parking lock rod from the lever To remove parking lock rod pull it forward out of the case If necessary rotate propeller shaft to align parking gear and sprag to permit knob on end of control rod to pass the sprag A 727 8 3116 PLUG AND PIN CONTRO ROD NN78B Fig 35 Parking Lock Compon...

Page 608: ...nge bolt circle inner and outer circle of holes in drive plate and four tapped holes in front face of converter all have one hole offset so these parts will be installed in original posi tion This maintains the balance of engine and con verter 6 Rotate engine with remote control switch to lo cate two converter to drive plate bolts at 5 and 7 o clock positions Remove the two bolts rotate en gine wi...

Page 609: ...gear in a shallow con tainer add water and heat for approximately eight minutes after water has come to a boil Steam Place ring gear on a flat surface and direct a steam flow around gear for approximately two minutes Flame Place ring gear squarely on a flat surface Using a medium size tip direct a slow flane evenly around inner rim of the gear Do not apply flame to the gear teeth Place a few drops...

Page 610: ...smission Converter Housing Area a Replace torque converter hub seal inspect torque converter hub for roughness or damage b Check pump housing bolt torque and tight en to 175 inch pounds c Replace kickdown lever shaft plug and ap ply thread sealer Chrysler Parts Sealing Compound P N 1057794or equivalent TORQUE CONVERTER LEAK CHECK iual rom ar luid lo may lug re ing is recommended using the type e c...

Page 611: ...nd out put shaftson A 904 transmissions 1 Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Fig 43 Move input shaft in and out to obtain end play reading End play specifications are 030 to 089 inch for A 904 transmissions and 037 to 084 inch for A 727transmissions 2 Record indicator reading for reference when reassembling the transmission Oil P...

Page 612: ...earing 4 Using heavy duty snap ring pliers C 4020 re move output shaft bearing rear snap ring Remove bearing from shaft then remove front snap ring Governor and Support 1 Carefully pry snap ring from weight end of governor valve shaft Fig 33 Slide valve and shdt assembly out of the governor body 2 Remove snap ring from behind governor body then slide governor body and support assembly off the outp...

Page 613: ...ston rod from not to damage piston rod or guide 1 A O A a n t I I a La ND173 Fig 48 Compressing Kickdown Servo Spring Low and Reverse Servo 1 Compress low and reverse servo piston spring by using engine valve spring compressor Tool C 3422 then remove the snap ring 2 Remove spring retainer spring and servo pis ton and plug assembly from the case RECONDIT10N SUB ASSEMBLIES The following procedures c...

Page 614: ...screws from fluid filter and lift off the filter 2 While holding spring retainer firmly against the ZONTROL VALVE A LINE PRESSURE THROTTLE LEVER STOP SCREW Fig 50 Valve Body andControl Assembly spring force remove the three bracket retaining screws Fig 50 3 Remove spring retainer torque converter con trol valve spring and regulator valve spring with line pressure adjusting screw assembly Do not al...

Page 615: ... Fig 52 Steel Ball Location CLIP SHUlTLE VALVE COVER PLATE N82A Fig 53 Valve Body Controls Assembled View valve throttle pressure plug out of valve body Cleaning and inspection Allow all parts to soak a few minutes in a suitable clean solvent Wash thoroughly and blow dry with compressed air Make sure all passages are clean and free from obstructions Inspect manual and throttle valve operating leve...

Page 616: ...and springs Fig 55 Install shift valve end plate and tighten the three retaining screwsto 28inch pounds Six Cylinder Vehicles Install the 3 2downshift plug and cover tighten the three screws to 28 inch pounds 5 Install regulator valve throttle pressure plug sleeve and line pressure plug Fig 55 Install regu lator valve end plate and tighten the two retaining screws to 28inch pounds 6 Install thrott...

Page 617: ...parts as required EXTENSION HOUSING BUSHING AND OIL SEAL Replacement 29 with Tool C 3994 or C 3985 1 Remove the extension housing yoke seal Fig 2 A 904 Press or drive out bushing with Tool A 727 Remove bushing in the same manner with 3 A 904 Slide a new bushing on installing end of Tool 2 3996 Align oil hole in bushing with oil slot in the housing then press or drive bushing into place Fig 57 A 72...

Page 618: ...y 3 Drive out oil seal with a blunt punch inspection Inspect interlocking seal rings Fig 58 on reaction shaft support for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant Inspect front clutch piston retainer to reaction shaft support thrust washer for wear Washer thickness should be 043 to 045 inch replace if necessary Inspect machined su...

Page 619: ...ll bushing from reaction shaft Thoroughly clean reaction shaft to remove chips made by remover threads 5 Lightly grip bushing in a vise or with pliers and back tool out of the bushing Be careful not to damage threads on bushing remover 6 Slide a new bushing on installing head Tool SP 5325 and start them in the bore of reaction shaft Fig 61 7 Support reaction shaft upright on a clean smooth surface...

Page 620: ...oring or pitting With rotors cleaned and in stalled in pump body place a straight edge across face of rotors and pump body Use a feeler gauge to measure clearance between straight edge and face of rotors Clearance limits are from 0015 to 003 inch Also measure rotor tip clearance between inner and outer teeth Clearance limits are from 005 to 010 inch Clearance between outer rotor and its bore in oi...

Page 621: ...inst reaction shaft thread remover into bushing as far as possible by hand 3 Use a wrench to screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing 4 Turn hex nut down against the cup to pull bushing from reaction shaft Thoroughly clean reac tion shaft to remove chips made by removing threads 5 Lightly grip bushing in a vise or with pliers and back tool out of t...

Page 622: ...etainer for scores the contact surface should be protected from damage during disassembly and handling Note ball check in clutch retainer make sure ball moves freely Inspect piston seal ring surfaces in clutch retainer for nicks or deep scratches light scratches will not inter fere with sealing of neoprene rings Inspect clutch retainer inner bore surface for wear from reaction shaft support seal r...

Page 623: ...ates install one steel plate followed by a lined plate until all plates are installed Install pressure plate and selective snap ring Make sure snap ring is properly seated The A 904 transmission uses three plates and discs in front clutch for both six cylinder engines Four t I h 1 7 J ND2 Fig 70 Measuring Front Clutch Plate Clearance plates and discs are used in A 904 transmissions for eight cylin...

Page 624: ...h Retainer Snap Ring A 727 retainer for scores Note ball check in clutch re tainer make sure ball moves freely Inspect seal sur faces in clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of nee prene rings Inspect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal grooves ...

Page 625: ...g 75 Front Clutch Piston Return Spring Location 10 Springs I UP144 Fig 76 Front Clutch Piston Return Spring Location 8 Springs the springs Compress springs with Tool C 3863 Fig 72 and seat snap ring in hub groove Remove com pressor tool 4 Lubricate all clutch plates install one steel plate followed by a lined plate disc until the num ber given in the chart is installed Install pressure plate and s...

Page 626: ...tches light scratches will not interfere with sealing of the neoprene rings Inspect neoprene seal rings for deterioration wear and hardness Inspect piston spring wave spring and spacer for distortion or breakage Inspect interlocking seal rings Fig 78 on input shaft and piston retainer for wear or broken locks make sure they turn freely in the grooves Do not remove rings unless conditions warrant I...

Page 627: ...portant in obtaining proper clutch operation Clearance can be adjusted by the uw of various thickness outer snap rings Snap rings are available in 060 062 068 070 and 076 078 inch thickness REAR CLUTCH A 727 Disassembly Figure 81 shows a disassembled View of the rear clutch assembly 1 Remove large selective snap ring that secures pressure plate in clutch retainer Lift pressure plate clutch plates ...

Page 628: ... shaft 8 Stand input shaft upright on a clean smooth surface and install handle Tool SP 3549in the install ing head Fig 82 Drive bushing into shaft until tool bottoms 9 Thoroughtly clean input shaft and clutch piston retainer before assembly and installation Assembly 1 If removed press input shaft into clutch piston retainer and install snap ring 2 Lubricate and install inner and outer seal rings ...

Page 629: ... gear Inspection Inspect bearing surfaces on output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect speedometer drive gear for any nicks or burrs and remove with a sharp edged stone Make sure all oil passages in shaft are open and clean replace sun gear assembly if bushings are damaged Inspect all thrust was...

Page 630: ...e can beadjusted by the use of various thickness snap rings Snap rings are available in 040 044 048 OS2 and 059 065 inch thickness PLANETARY GEAR TRAIN A 727 Measure end play of planetary gear assemblies sun gear and driving shell before removing these parts from output shaft With assembly in an upright posi tion push rear annulus gear support downward on output shaft Insert a feeler gauge between...

Page 631: ...e tary gear set then slide assembly into front annulus gear 6 Carefully work front planetary and annulus gear assembly on output shaft meshing planetary pinions with the sun gear teeth 7 With all components properly positioned install selective snap ring on front end of output shaft Re measure end play of the assembly The clearance can be adjusted by the use of various thickness snap rings Snap ri...

Page 632: ...er in the followingmanner 1 Remove set screw from the case below clutch cam 2 Remove four bolts securing output shaft support to rear of transmission case Insert a punch through bolt holes and drive cam from the case Fig 90 Alternate punch from one bolt hole to another so cam will be driven evenly from the case IMPORTANT The output shaft support must be in the case to installthe overrunningclutch ...

Page 633: ...on bore in the case for scores or other damage Inspect fit of guide on piston rod Inspect piston spring for distortion Inspect band lining for wear and bond of lining to the band Inspect lining for black burn marks glaz ing non uniform wear pattern and flaking If lining is worn so grooves are not visible at ends or any portion of the bands replace the band Inspect band for dis tortion or cracked e...

Page 634: ...ol C 3422 then install snap ring 3 Position rear band in the case install short strut then connect long link and anchor to the band Fig 97 Screw in band adjuster just enough to hold strut in place Install low reverse drum A 727 Be sure long link and anchor assembly is installed as shown in Figure 96 to provide running clearance for the low and reverse drum Fig 96 Overrunning Clutch Low and Reverse...

Page 635: ...st washer Fig 84 and install washer on front end of the outtmt shaft If drive train end play was not before disassembly replace thrust washer with one of proper thickness The following selective washers are available for A 904 transmissions Thickness Color 052 054 inch Natural 068 070 inch Red 083 085inch Black A 727 Apply a coat of grease on the input to output shaft thrust washer Fig 85 and inst...

Page 636: ...nap ring in the front groove on output shaft Install bearing on shaft with its outer race ring groove toward front Fig 32 Press or tap bearing tight against front snap ring then install rear snap ring 2 Place a new extension housing gasket on the transmission case Position output shaft bearing re taining snap ring in the extension housing Spread snap ring as far as possible Fig 31 then carefully t...

Page 637: ...re also vertical and fully engage pump inner rotor lugs Test for full engagement by placing a straight edge on face of the case Fig 104 The surface of con verter front cover lug should be at least 1 2 inch to rear of straight edge when converter is pushed all way into the transmission 3 Attach a small C clamp to edge of bell hous ing to hold converter in place during transmission installation 4 In...

Page 638: ...ry Fig 105 Carefully work transmission assembly for ground cable ward over engine block dowels with converter hub 10 Rotate engine with remote control switch and entering the crankshaft opening install the other two drive plate to converter bolts 7 After transmission is in position install bell Tighten bolts to 270inch pounds housing bolts and tighten to 28 foot pounds 11 Install crossmember Fig 1...

Page 639: ...AQ ATFSuffix A or Dexron SPECIFICATIONS 3 SPEED TRANSMISSIONS Taxi Police 273 EngineDisplacement Cu In 170 225 225 318 383 Gear Ratio Transmission Models A 903 A 745 A 745 A 745 First 3 22 2 95 3 02 3 02 2 55 Second 1 84 1 83 1 76 1 76 1 49 Third 1 00 1 00 1 oo 1 00 1 00 Reverse 4 14 3 80 3 95 3 95 3 34 3rd to 2nd 2nd to 1st Capacity Approx 6 1 2 Pts Approx 6 Pts Type Auto Trans Fluid AQ ATF Suffi...

Page 640: ...CAT1ON CLUTCHES Number of Front Clutch Plates Number of Front Clutch Discs Number of Rear Clutch Plates Number of Rear Clutch Discs GEAR RATIOS PUMP CLEARANCES Outer Rotor to Case Bore Outer to Inner Tip End Clearance Rotors PLANETARYASSY END PLAY DRIVE TRAIN END PLAY CLUTCH PLATE CLEARANCE Front CIutch Rear Clutch A 904 A 727 Automatic Three Speed with Torque Converter 1 3 4inches 113 4 inches 10...

Page 641: ...62 to 064 062 to 064 061 to 063 034to 036 Turns Engines Turns BAND ADJUSTMENTS Engines Kickdown Front All Except 170 2 All Except 426 2 Low Reverse Internal All Except 318 3 114 AII 2 170 Cu In 2 518 426 Cu In 1 112 318 Cu In 4 Backed off from 72 inch pounds TIGHTENING Foot ManualA 903 A 745 3 Speed Pounds Back Up Light Switch 15 Extension Housing Bolts 50 Extension Housing to Cross Member Bolts 4...

Page 642: ...olt Oil Pump Hdusingto Transmission A 727 A 904 Pounds Foot Inch 24 40 90 100 29 25 150 150 24 150 Pounds Foot Inch Case Bolt 175 150 40 75 A 727 150 A 904 125 A 727 35 A 904 20 Output Shaft Support Bolt Overrunning Clutch Cam Set Screw Pressure Test Take Off Plug ReactionShaft Support to Oil Pump Bolt ReactionShaft Supportto Oil Pump Bolt Reverse BandAdjusting Screw Lock Nut Reverse BandAdjusting...

Page 643: ... Wide Tread 70 Series Tires 3 WHEELS 5 Tire Wheel Balance 5 Tire and Wheel Runout 6 Wheel Covers 6 speed durability because of cooler operating temper atures Tire wear and vehicle stability are affected greatly by tire size tire pressures wheel rim size distribu tion of load within the vehicle wheel alignment road surface conditions and driver operating habits Tires used at low speeds in cool clim...

Page 644: ...ssures recom mended for all vehicle models have been carefully selected to provide a proper balance between ride handling and tire life See Tire Pressure and Vehicle Load Chart Tire pressures should be checked at least once a month and should be checked and adjusted before any long trips Check and adjust tire pressures with the tires cold if possible It is normal for tire air pres sure to increase...

Page 645: ...ed on the front wheels Not doing this will result in oversteer and could possibly cause spins on wet or icy roads The safest policy is never intermix radial ply tires with conventional crossbias tires Wide Tread 70 Series Tires The use of standard 70 Series wide tread or extra wide tread bias breaker again radial not recom mended tires is acceptable on your vehicle if the size is listed in the abo...

Page 646: ...inue the road test by deflating one tire at a time to normal pressure When the disturbance returns the last tire deflated will usually be the offender Tire thump sometimes referred to as tramp usually occurs in the speed range of 20 40 MPH and can usually be located this way If you have a thumper replace CRACKED TREADS WEAR ON ONE SIDE CONDITION RAPID WEAR AT SHOULDERS CAUSE RAPID WEAR AT CENTER U...

Page 647: ...associated with wear on a car driven mostly at high way speeds without the recommended tire rotation and with unbalance conditions Regardless of the cause of cupped wear on either front tire no align ment or balance job can prevent future excessive wear of the spots Once a front tire acquires flat or cupped spots additional wear will continue at a rapid rate To correct this condition tire rotation...

Page 648: ...e tire valve through the cover valve hole and seat this por tion of the cover completely Apply force 180 from the valve hole to complete the installation When re moving the wheel covers pry completely loose 180 from the valve hole first Continue prying toward the valve hole until covers are loose Do not remove the wheel cover at the valve stem hole The covers are structurally stronger at the outer...

Page 649: ...eel drift and hammer 2 Fill hub grease cavity Fig 9 with recom mended bearing lubricant see Lubrication Group 0 Lubricant should be even with inner diameter of bearing cups 3 Force lubricant between bearing cone rollers or repack using a suitable bearing packer 4 Install inner cone and a new seal with lip of seal facing inward Using Tool C 3893 position seal flush with end of hub The seal flange m...

Page 650: ...70 14 E70 14 7 00 13 D70 14 D70 14 E70 14 Disc Brakes Disc Brakes and Air Condition 6 95 14 6 95 14 6 95 14 6 9514 E70 14 E70 14 6 9514 D70 14 D70 14 E70 14 Standard Convertible Air Conditioned 7 00 13 7 00 13 7 00 13 7 00 13 E70 14 E70 14 7 00 13 D70 14 D70 14 E70 14 Disc Brakes Disc Brakes and Air Conditioning 6 9514 6 9514 D70 14 D70 14 E70 14 E70 14 D70 14 D70 14 D70 14 E70 14 Trailer Towing S...

Page 651: ...ved Ride Luggage Luggage Front Reor Compartment Front Rear Compartment seat Seat Or 3rd Swt Total t Seat Or 3rd Swt Total 6 50 13 6 95 14 7 00 13 7 3514 7 7514 Without Air Conditioning 7 7514 With Air Conditioning 7 75 14 Trailer Towing 8 25 14 8 55 14 Station Wagon Trailer Towing D70 14 D70 14 Trailer Towing E70 14 3 Passengers 3 Passengers 200 Lbs 1100 Lbs 2 Passengers 3 Passengers Maximum Maxim...

Page 652: ...r towing packages do not have increased maximum capacity The allowable passenger and cargo load must be decreased an amount equal to the trailer tongue load on the trailer hitch 7 Because of vehicle limitations oversize bias breaker or 8 ply rating load range D tires do not provide increased vehicle capacity They do however provide an extra margin of tire service tread life etc Do not exceed the m...

Page 653: ...ength to the fore structure and the body MAINTENANCE AND CARE INDEX Page ACRYLIC FINISHES POLISH ING 4 BRIGHT METALS POL1 SHING 4 CONVERT1BLE Backlight 2 Boot 2 Top 1 Well 2 GLASS 5 INTERIOR TRIM Body Cloth Knit Type 2 Cargo Area Station Wagon 4 Carpets and Rubber Mats 4 Color Restoration or Change 4 Door Panels 3 General Instructions 2 Glove Compartment 4 APPEARANCE Page Headliners 3 Luggage comp...

Page 654: ... inches Allow to dry completely a white powder will form Brush or vacuum powder from surface Repeat operation should any stain remain Entire Insert Cleaning Only Waterspots dirt foodstains coffee and other water borne stains Vac uum or brush off as much of the staining material as possible Shield adjacent cushion or back not to be cleaned to prevent wetting Use a wiping motion out ward from the co...

Page 655: ...in with a cloth moistened in luke warm water Remove re maining stains with a regular cleaning solution Shoe PolishCcrub area with a cloth saturated with cold water Remove wax base polishes by sponging with spot remover Grease Oil Lipstick and Related Stains Use spot remover to avoid leaving a ring Clean from outside of spot and work toward center When spot has been removed dry fabric with a clean ...

Page 656: ...urpose cleaner and dry with clean toweling or rags Cargo Area Station WagonLFollow same procedure used for Luggage Compartment Color Restoration or Change Tints and dyes should be applied by reliable experienced personnel Dyes or tints can be applied when stains persist after clean ing or a change in color is desired The instructions for mixing and applying the color must be followed precisely Use...

Page 657: ... face treat metal and refinish The drain holes in the quarter panel well areas are sealed with a removable plastic plug The plugs should only be removed whenever it is necessary to clean or drain fluidsfrom the well area LUBRlCATION To maintain ease of operation the hood door deck lid and tail gate hinges should be lubricated with the recommended lubricants at the recommended intervals Refer to th...

Page 658: ... the plenum by positioning the duct over the plenum weld studs and securing with nuts 3 With an assistant remove hinge to hood bolts Fig 2 and remove hood assembly Use care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender arms nSfallation install bolts Do not tighten tighten screws to hold in position 1 With an assistant position hood on hinges and 2 Align sc...

Page 659: ...ood hinge 2 Scribe hinge location on hood and remove hinge 3 Support hood at hinge area to hood screws LO CK NP589 Fig 4 Hood Lock und Striker 4 Remove spring nuts from hinge studs Fig 2 and remove hinge 5 Lubricate hinge stud areas with lubriplate and position hinge on studs 6 Using a socket with putty placed on end posi tion a new spring nut on putty and position on stud Press spring nuts on stu...

Page 660: ...amaging paint The fender side reflector and bezel assembly is at RADIATOR YOKE SUPPORT REPLACEMENT Removal 1 Drain and remove radiator 2 Remove hood lock striker horn and head lamp RADIATOR SUPPORT CROSSMEMEMBER NP87A Fig 6 F ender Attachment BEZEL AND GASKET Fig 7 Fender Side Reflector wiring from yoke support yoke support screws Installation screws finger tight yoke support screws finger tight o...

Page 661: ...or inspecting glass fit after ad justments or replacement have been performed IMPACT BRACKET NP98A Fig IO Rear Bumper Attachment ALIGNMENT Up and Down pillar or door hinge halfs Fig 12 Adjustment of the door can be made at either the Fore and Aft Adjustment is made at the door hinge half Adjust only one hinge at a time Raising outer end of door moves upper part of door forward when in closed posit...

Page 662: ...s and tighten screws Rear Door Removal door near the hinges 1 Open rear door and place a padded jack under 2 Remove door interior trim and hardware 3 Scribe aligning marks around hinge plates on door 4 Remove hinge to door screws and remove door installation 1 With rear door inner hardware installed sup port door on a padded jack and position door on hinges 2 Install hinge screws finger tight 3 Al...

Page 663: ...emove control from door and linkage through large opening in door Installation parts with lubriplate 1 Before installing remote control assembly coat 2 Install linkage through door opening and con VIEW IN CIRCLE Z T WATERSHIELDS Y CEMENT VIEW IN CIRCLE Y 9 6 Fig 1 Door Watershhlds LATCH LINK LATCH CLIP Fig l6 Door Latch and Control nect link to the control lever and lock tion LOCK Removal and from...

Page 664: ...ody 2 Connect the cylinder link to cylinder arm and to clip on lock lever 4 door models 3 On 2 door models connect cylinder link to cyl inder position link bracket on door face and install screws Connect lock link to lock OUTSIDE HANDLE Front Door Removal 1 With door glass in up position remove nuts from mounting studs Fig 20 and link from handle to lock 2 Lift handle up and out of door nstallatio...

Page 665: ...er to Figure 21 for the attaching points and The weatherstrip retainers are adjustable through the use of elongated attaching holes The weatherstrip can be moved in or out for the best possible fit and seal along the top edge of the vent frame door glass and quarter glass The glass upstop must be adjusted so the fully raised glass just curls the outer lip of weatherstrip against the inner lip When...

Page 666: ...ve glass looseness without creating a binding condition Tighten adjusting screwsat channel bottom of It may be necessary to readjust the channel lower end in or out to gain channel and rear run alignment Adjust rear runchannel lower end in or out Adjust down stopso glass top edge is flush with edge of open ing in door Vent Wing Replacement Removal 1 Remove nut and washer from lower vent frame stud...

Page 667: ... and washer assemblies When removing the door glass should be fully lowered Slide regulator rear ward to disengage from lift bracket and guide as sembly Lubricate toothed area of regulator when installing HARDTOP CONVERTlBLE MODELS FORE AND AFT UP STOP IN AND OUT PARALLEL ADJUSTMENT IN AND OUT DOWN STOP FORE AND AFT CHANNEL ADJUSTING ROD NP617 Fig 24 Door Glass Adjustments Hardtop Convertible glas...

Page 668: ... corner twist to insert between panels and slide forward 5 Tilt lock face side of assembly upward so vent wing hinge adjusting stud will enter hole in inner ASSEMBLED NU238 Fig 26 Vent Wing and Door Glass Hardrop Convertible SLIDE I WEATHERSTRIP LIFT BRACKET RIVET2 NP613 Fig 27 Door Glass Assembly Hardtop Convertible reinforcement and rear edge of glass fits squarely in rear channel run Fig 28 and...

Page 669: ...s Before installing glass lubricate all moving parts of 1 Install lift bracket on glass 2 Position glass into door opening 3 Install regulator arm roller into channel of glass 4 Position glass into run channels 5 Adjust door glass Regulator Replacement The regulator assemblies are attached by screw and washer assemblies When removing the door glass should be fully lowered Slide regulator rear ward...

Page 670: ...window to 1 2 inch below window opening frame 2 Adjust pivot bracket so top of glass is parallel to window opening frame and tighten nuts 3 Lower window until rear lower edge of glass is 1 4 inch above wheelhouse and tighten regulator down stop nut Glass Replacement Removal remove clip from regulator arm stud pin Fig 35 1 Lower glass and through front access opening 2 Pull regulator arm stud out o...

Page 671: ...un channels Fig 38 are a press fit in Fig 37 Quarter Window Regulator Sedan INDEX POINT NOTCH Fig 38 Quarter Window Glass Run Sedan HARDTOP MODELS Adjustments 1 Raise quarter window 2 inches above belt line 2 Adjust top of front and rear tracks Fig 39 until glass just touches the outer belt weatherstrip and tighten nuts 3 Raise window to the upper weatherstrip and adjust regulator so glass at fron...

Page 672: ...just quarter window Regulator Assembly Hard top models use a two arm regulator Fig 43 To remove the quarter window regulator it is advis able to first remove the glass The regulators are at tached to the inner panels by screws After the regu lator and glass have been installed test the operation of the regulator and adjust the glass q REGULATOR i NP630 Fig 4 I Quarter Glass Replacement Hardtop ROL...

Page 673: ...gulator forward and adjust pivot bracket so glass is parallel to rear edge of door glass and IN AND OUT REAR UP STOP FRONT UP STOP FRONT TRACK NP648 IN AND OUT Fig 46 Quarter Window Adjustments Convertible Fig 47 Quarter Window Replacement Convertible rear roof rail weatherstrips effecting a proper seal 5 Adjust rear stabilizer and front track lower attachments outboard until upper edge of glass s...

Page 674: ...e along the entire length of the arc on the outboard side of the sector and studs on the front and rear studs PIVOT BRACKET __ CONED WASHER REINFORCEMENT Fig 5 I Front Track Convertible Front Track The front track Fig 51 is attached to the inner panel at the top end and to a support at the lower end The upper attachment permits in and out ad justment and the lower end permits fore and aft and in a...

Page 675: ... as it is under a load Disengage torsion bar roller from hinge being removed 3 Remove spring nut retaining hinge to hinge bracket Fig 54 and remove hinge NRlOO SUPPORT SUPPORT WEATHERSTRIP n CEMENT Fig 55 Deck Lid Lock lnstallation 1 Use a new spring nut and install hinge 2 Install deck lid and connect torsion bars 3 Test deck lid adjustment TORSION BAR REPLACEMENT Removal adjustable slot Fig 54 b...

Page 676: ...bar into support bracket and 3 Move deck lid to various open positions and test 4 Adjust bars progressively until lid stays in open Lock Replacement The lock assembly Fig 55 are attached by two screws Scribe location of lock mounting flanges to aid in installation Lock Adjustment Vertical adjustment of the locks is made at the at taching screws Side adjustment is made at the striker attaching bolt...

Page 677: ...0 BODY AND FRAME 23 25 Fig 59 Door and Quarfer Panel Ornamentation MyMopar com ...

Page 678: ...haped clip attached from within the body Weatherstrip Apply an even continuous coat of cement to entire weatherstrip contact surface of deck lid opening Fig 56 Make sure molded corners of weatherstrip are correctly positioned when installing The lock cylinder is retained by a spring steel U EXTERIOR ORNAMENTATION of attaching exterior mouldings and ornaments Refer to Figures 57 58 59 60 and 61 for...

Page 679: ...0 37 40 Trim Panels 38 Weatherstrips Convertible Door 41 Roof Rails 41 Sedan Door 40 Windcords 41 FENDERS Page Replacement 31 Side Reflector 31 Control Cables 28 Routing 28 Ducts 29 Alignment 33 Replacement 33 Alignment 29 Carburetor Fresh Air System 30 Hinge 30 Lock 30 Replacement 29 Garnish Mouldings 46 Adjustments 49 Regulators 50 Replacement 49 51 StabiIizer Track Fron t 50 Adjustments 47 Regu...

Page 680: ...pped vehicles only the left Attachment The control cables are attached to the instrument KNOB I Routing with Heater Route cables rearward of heater support brace under heater control cables and defroster hoses to the instrument panel attaching points on right side of steering column Fig 3 WithAir Conditioning Lett door only Route cables behind steering column support CONTROL CABLE Fig I Fresh Air ...

Page 681: ... directly to the plenum by positioning the duct over the plenum weld studs and securing with nuts With Heater The right duct part of the heater housing is at SPEEDOMETER CABLE CABLE I CONTRYL CABLE NR129 SPEAKER OUTLET 4 Fig 4 Cable Routingwith Air Conditioning WITHOUT HEATER NR164 Fig 5 Fresh Air Ducts tached to the plenum with a single hook type rod positioned over the plenum flange and secured ...

Page 682: ...Adjustment NP590 Fig 8 Hood Lock and Striker Coronet taches the right and left outer air intake duct door actuator arms The doors are controlled through the use of a single master control cable attached to the lower reinforced portion of the instrument panel The cable looped end is positioned over the right outer duct door actuator arm The cables are retained on the actuator arms with spring type ...

Page 683: ...EPLACEMENT Removal 1 Disconnect battery ground strap 2 Tape leading edge of front door and cowl to 3 Remove front bumper assembly 4 Disconnect head lamp wires and remove grille 5 Remove nuts and screws attaching fender to fender area to avoid damaging paint extension to fender nuts cowl floor sill splash shields and radiator yoke Figs 12 and 1 3 6 Remove fender assembly and if necessary re move fe...

Page 684: ...oval 4 Attach horn and light wires to yoke support 5 Install radiator and hoses fill cooling system with plastic straps and inspect for leaks 1 Drain and remove radiator AIR SHIELD AND CROSS BAR 2 Remove hood lockstriker horn and head lamp Refer to Figure 14 for air shield and bar at wiring from yoke support yoke support screws BUMPERS nSiullution screws finger tight taching points 3 From under fe...

Page 685: ...LIGHT DOOR HEADLIGHT DOOR Removal 1 Remove headlight bezel 2 Remove actuator shaft from door actuator bar 3 Remove retainers from door pivots and remove 4 Remove door actuator bar screws and remove clip Fig 19 door from pivots door from opening Installation 1 Install headlight door actuator bar outer side upper attaching screw circle A Fig 20 into actu ator bar with head of screw on inner side of ...

Page 686: ...not evident test as follows 1 Remove large tube from reservoir and if no vacuum install new tube 2 If vacuum at tube replace on tank and remove small tube 3 Check reservoir connector for vacuum and if not evident install new reservoir 4 With vacuum satisfactory at small tube con nector replace on tank and remove vacuum tube con nector clip and connector at switch 5 If no vacuum at connector inspec...

Page 687: ...est the actuator assembly With switch in the open position vacuum should be felt at the actuator top tube con nector when the engine is running If no vacuum or RETAINING BRACKET SPRING MOUNTING BRACKET A F A R R A W V MEDALLION I VIEW IN DIRECTION OF ARROW X Fig 18 Grille Attachment Charger MyMopar com ...

Page 688: ... panels testing operation of window or inspecting glass fit after ad justments or replacement have been performed ALIGNMENT up and Down Adjustment of the door can be made at either the pillar or door hinge halfs Fig 21 Fore and Aft Adjustment is made at the door hinge half Adlust only one hinge at a time Raising outer end of door moves upper part of door forward when in closed NR466 Fig 20 Door Ac...

Page 689: ...n hinge plates on door and install screws finger tight only 3 Adjust jack to align scribe marks and tighten screws On electric window lifts install the wiring in the doors and attach to the motor and control switch Rear Door Removal On vehicles with electric window lifts disconnect wires from motor control switch and door prior to door removal 1 Open rear door and place a padded jack under door ne...

Page 690: ...screws 3 Insert a wide blade screw driver between trim panel and door next to the retaining clips Snap clips out of door panel and remove trim panel 4 Before installing trim panel make certain the watershield is properly cemented in place Fig 24 5 With escutcheon spring placed on regulator shaft align trim panel retaining clips with holes in door and bump into place with heel of hand 6 Install tri...

Page 691: ...to lock link Figs 27 and 28 ANTI RATTLER VIEW A NN546 Fig 26 Rear Door Remote Control Fig 27 Rear Door RemoteControl andLatch and from lock by pulling link outward from lock 2 Disconnect locking lever rod front door only 3 Disconnect lock control rod from lock 4 Remove lock assembly to door screws 5 Rotate lock and disconnect remote control link 6 Lubricate all moving points of lock assembly when ...

Page 692: ...lnstallation lock link 1 Position handle into door and engage handle to 2 Attach stud nuts and test handle operation REAR DOOR Removal retainer from link at handle connector 1 With door open and glass in up position remove N N S S S Fig 29 DOOr Lock Cylinder Coronet CYLINDER LINK VIEW IN CIRCLE B LOCK CYLINDER FRONT O F CAR NR302 VIEW IN DIRECTION OF ARROW C Fig 30 Door Lock Cylinder fCharger 2 De...

Page 693: ...les The weatherstrip can be moved in or out for the best possible fit and seal aIong the top edge of the vent frame door glass and quarter glass The glass up stop must be adjusted so the fully raised glass just curls the outer lip of weatherstrip against the inner lip When the up stop roof rail weatherstrip and glass are properly adjusted the outer lip of weatherstrip will seal along the top edge ...

Page 694: ...vi 3 Move divisionchannelo f f of glass edge 4 Disconnect the outer belt weatherstrip for a short distance to provide clearance for division channel 5 Tilt top of vent frame toward rear of door and up out of door ns allation install into door lower support 1 Tilt top of vent Wing toward rear of door and 2 Move division channel over glass edge and on 3 Install screw but do not tighten 4 Install ven...

Page 695: ...pin the mounting bracket around the lift pivot The regulator motor assembly is attached to the door inner panel at the top and bottom areas with screw and washer assemblies Electrical Tests Refer to the Electrical Group for tests and wiring diagram on electrically operated window regulators ROLLER LIFT BRACKET Fig 36 Regulator Assembly Glass Run and Channel The glass run Fig 38 is a press fit in t...

Page 696: ...2 Move glass and weatherstrip assembly forward STATIONARY GLASS DIVISION CHANNEL Fig 39 Rear Door Glass Adjustments Sedan APPLICATION AT CIRCLE A NN786 Fig 40 Door Glass Replacement Sedan 3 Inspect the weatherstrip nstallation 1 Position glass and weatherstrip assembly to window opening and move rearward into upper frame 2 Insert division channel run into channel 3 Apply a 1 1 2 inch length of sea...

Page 697: ...k lower screw slightly below belt line outer panel regulator sector stop against bumper r I N AND OUT CHANNEL SUPPORT NN492 INNER BRACKET REGULATOR STOP I FORE AND AFT I Glass Replacement Removal of vent wing leg Fig 4 2 vent wing to belt line pillar support 1 Remove nut and washer from stud on lower end 2 Remove screw and washer assemblies attaching 3 Remove vent wing leg stud from slot in hinge ...

Page 698: ...o this allows the assist spring to spin the mounting bracket around the lift pivot NN791 RI VET LIFT BRACKET 4 Fig 45 Gluss Slide and Weatherstrip Hardtop Convertible Fig 46 Rear Run Channel Hardtop Conve ible Refer to the Electrical Group for tests and wiring Tests diagrams on electrically operated regulators Rear Run Channel door inside panel lock face a tthe top and to a support at the bottom w...

Page 699: ... SEDAN Two door sedan models are equipped with a vent wing type quarter window Fig 51 Elongated holes in the hinge allow correct positioning of the glass as sembly to the opening The release handle assembly Fig 52 is attached to BEZEL AND GASKET RETAINER Fig 49 Quarler Panel Side Reflector NUT AND Fig 50 Air lntuke Ornament Chrger NR377 GLASS Fig 5I Quarter Window Vent Glass Sedan the glass with a...

Page 700: ...el 10 Turn lower rear track sleeve nut counter clockwise until its boss is against outboard side of inner panel Tighten nut 11 Position and tighten regulator stop against regulator sector stop 12 Position and tighten down stop against bumper F i D OUT Glass Replacement Removal to glass lower frame Fig 55 from lower frame 1 Remove retainers attaching regulator arm studs 2 Support window and remove ...

Page 701: ...nto forward upper and lower slots of glass lower frame 4 Position front track brace in panel and install attaching screws loosely 5 Attach brace to front roller track and adjust glass Rear Track The rear track Fig 58 is positioned over the slide in rear slot of glass lower frame and the sleeve nuts are inserted into the openings in inner panel Lock washers and nuts are used to retain the track on ...

Page 702: ...and roller assemblies 6 Adjust quarter window stabilizer studs into rollers and bushings in glass lower frame Ftg 60 Quarter Window Stabilizer Convertible Fig 6 1 Quarter Window Replacement ConvoHibfo Regulator Assembly The regulator assembly Fig 62 is attached to the inner panel with screw and washer assemblies The replacement procedures are the same as those out lined for Hardtop models Electric...

Page 703: ...t ALIGNMENT Vertical adjustlr made at the hingt ment of the tail gate t o p k adjusted by moving the striker in or out to permit ease of entry of the tail Removal On cars with an electric window remove trim panel and disconnect terminals at control switch Dircon nectwiper and washer electrical leads 1 Remove check arm and torsion bar guide from pillar guide plates 2 Support tail gate on jacks or s...

Page 704: ...andIe to door Fig 66 To remove a handle which is inoperative and ve hicle is fully loaded prohibiting access to tail gate inner panel it will be necessary to remove mounting studs from handle by driIling through handle Refer to Figure 67 for location of drilling points LOCK LINKAGE lnstullutton und Adjustment Fig 68 The lower right to upper right lock link and upper right lock to release regulator...

Page 705: ...ll play in latch remote lever and re lease regulator mechanism arm and adjust link LEFT SIDE I I PY H VIEW CIRCLE A I 1 NK718 Fig 67 Handle Stud Locations threaded end to this point and test operation of tail gate and door assembly GLASS Adjustments Refer to Figure 69 for the tail gate glass adjusting points 1 Remove tail gate trim panel and loosen regu lator and run channel attaching screws and n...

Page 706: ...0 Tail Gate Glass Replacement METAL WASHER RUBBER WASHER SPACER Fig 7I Tail Gate Glass Attachment 4 Remove t a i lgate glass assembly from tail gate 5 Remove rollers from glass lower frame 6 Remove washers spacers and screws attaching glass lower frame and weatherstrip to glass Fig 71 and remove the frame and weatherstrip lnstallation 1 Position outer belt weatherstrip on lower glass frame 2 Posit...

Page 707: ...gate SCREW AND Fig 73 01ass Run Channel 3 Position hinge on tail gate install and tighten screws 30 foot pounds 4 Install bearing and retainer on torsion bar Fig 64 Tighten nut 95 inch pounds 5 Position clamp over end of torsion bar and from outside end of tail gate install and tighten screws 200 inch pounds WEATHERSTRIPS AND RUNS 6 Install trim panel Weatherstrip Tail Gate and Opening Prior to in...

Page 708: ...he wedge move tool completely 2 Carefully loosen weatherstrip from glass on in 3 With an assistant supporting glass on the out on seal and install screws Upper Run and Pillar Run Removal Fig 77 lower opening weatherstrip screw and remove run and retainer fnstcrllation 1 Remove upper run from retainer a press fit 2 Remove run to upper end Of tail gate 3 Remove run and to around weatherstrip forcing...

Page 709: ... 5 With the palm of hand pound glass in an up ward and downward motion to seat it fully 6 Using a fibre tool install locking tab DECK LID Alignment The deck lid hinges Fig 79 permit only slight ad justment at the hinge attaching points The hinge brackets are welded in place and are not adjustable Replacement The deck lid is attached by two screws on each side An assistant s aid is recommended when...

Page 710: ...g nut and install hinge 2 Install deck lid and connect torsion bars 3 Test deck lid adjustment TORSION BAR REPLACEMENT Removal adjustable slot Fig 79 bracket remove from hinge support 1 Remove torsion bar under spring load from 2 Unwind torsion bar and remove from support 3 Push torsion bar out of roller in hinge arm and WEATHERSTRIP CEMENT 2 Hook torsion bar into support bracket and 1 Insert bar ...

Page 711: ...0 BODY AND FRAME 23 59 440 CORONET R T NAME PLATE DELUXE NUT 500 STATION WAGON MOULDING 500 500 STATION WAGON Fig 84 Fender Ornamentation MyMopar com ...

Page 712: ...Fig 85 Door and Pillar Ornamentation MyMopar com ...

Page 713: ...3 BODY AND FRAME 23 61 MOULDING END MOULDINGS STATION WAGON CHARGER WASHER CORONET 2 DOOR NU150 CORONET CHARGER Fig 86 QuaHer Pand Ornamentation MyMopar com ...

Page 714: ...PACERS SIDE MOULDING COVER MOULDIN PILLAR PILLAR MOULDING MOULDING 4 DOOR DRAIN TROUGH MOULDINGS STATION WAGON Y RETAI NER k COVER TAIL GATE NUT DECK LID NU151 4 DOOR Fig 87 k Lid rdl Ocrt Dm n troughOmornontcrtion MyMopar com ...

Page 715: ...e leaks Should system fail to operate entirely remove hose at the release diaphragm in deck lid and con nect a vacuum gauge to hose With engine running actuate button in glove box while a helper observes gauge If no reading can be obtained inspect for a pinched hose A reading of less than 16 inches will indicate a leak in the system Weatherstrip Apply an even continuous coat of cement to entire we...

Page 716: ... 4 are attached to welded brack ets on the floor pan tunnel with screws and bolts To loosen the rear mountings raise the carpet lower edges to expose the screw and bolt All other attaching screws are accessible from within the console barf Models The consoles Fig 5 attach to the front bracket LO WE LEFT NR344 Fig 1 Instrument Punel Trim Pads Coronet outer edge with screws The center and rear attac...

Page 717: ... off of retainers with the putty knife and while maintaining pressure on fabric pull disengaged portion down and out Work only small areas at a time 6 Remove headlining at windshield header and from fasteners at rear window area Fig 8 7 Remove listing wires from side rail retainers and support wire from rear listing wire Fig 9 8 Remove all foreign material and cement from windshield header area an...

Page 718: ...ch material sufficiently to remove all wrinkles while maintaining front to rear alignment The same amount of material should hang down at both sides CORNER MOULDING NR348 Fig Rear Window Trim Mouldings Coronet 6 Insert the remaining listing wires into the roof side rail retainers following the same cautions as in step 5 7 Apply cement to windshield header area and I RETAINER Fig 7 Listing Wire Rot...

Page 719: ...6 ter panel area Fig 8 Rear Window Heudlining Retainers when tacky start at centerline area of windshield and position headlining to cemented area 8 Using a dull putty knife secure liner on barbs at header area do not install material at top of wind shield posts making sure there are no wrinkles and fabric seam is straight 9 Locate sun visor mounting bracket screw holes in header and cut holes in ...

Page 720: ...ining trim Mouldings Dar HARD BOARD LINING Retainer Moulding Replacement The individual hard board headlining sections are held in position with semi flexible type plastic mould ings Fig 15 forced over the retainer sections of the roof bows Starting at either outer end remove the end cap and pry the moulding off the retainer When installing moulding make certain it is fully seated and evenly space...

Page 721: ...arnish mouldings GLOVE BOX The Coronet Charger glove box Fig 16 and Dart glove box Fig 17 are one piece folded units Hinges for glove box doors are positioned through openings in instrument panel and are attached to the doors with screws Figs 18 and 19 Dart model glove box doors incorporate a restraining cable Fig 20 SEDAN NP570 FASTENER E RAIL NN376 4INERS Fig 1 Hard Type Headlining Removal Coron...

Page 722: ...which removed Dart Models on the shelf panel with spring type fasteners shelf panel The shelf trim panel and silencer pad is retained LOCK NU133 rc 7 CABLE NU137 Fig 2 0 4 1 o v e Box Door Cable Dart Installcrtion new panel tion on shelf panel not insert retainers into mounting holes using hand pressure cushion and window garnish mouldings 1 Remove the defogger inlet gated section from 2 Install p...

Page 723: ... 4 Removeknob and clip from end of latch SEAT FRAME FLOOR PAN lnstallation of spring in pivot groove outer end of spring in notch on latch latch assembly REPLACEMENT Front Seat The front seat cushion is an integral part of the seat frame All seat frames are attached to the ad justers by studs and nuts Remove nuts from adjuster 1 Position spring on pivot pin and align inner end 2 Install latch asse...

Page 724: ...an Rear Seat Back The rear seat back Fig 25 is held in place by tangs on the seat frame upper edge being positioned over hangers on the shelf panel support The lower edge incorporates two metal straps which are attached to brackets welded on the floor pan Fig 26 Second Seat Back b KNOB NN507 Fig 27 Second Seat lock STATION WAGON SECOND SEAT BACK Removal 1 Remove seat back to hinge screws Fig 26 2 ...

Page 725: ...MyMopar com ...

Page 726: ... Convertible SECOND SEAT CUSHION Removal ion to floor pan screws lnstallatkn stall screws 1 Position seat back on hinge assemblies and in 2 Test and adjustengagement of seat back catches 1 Raise rear floor hinged panel and remove cush SHOULDER BELT VIEW IN CIRCLE Y NU25 Fig 3I Front Seat Shoulder Belts Dart Convertible MyMopar com ...

Page 727: ... Convertible 2 Move cushion rearward to disengage locking bars brackets on floorpan mounting strapto floorpan screws bars at front bottom side and remove cushion Instcrktion 2 Raise floor hinged panel and install cushion 1 Place cushion in position and engage locking SHOULDER BELT L WASHER REAR LAP BELT VIEW IN CIRCLE Y SHOULDER BELT NU18 Fig 3 3 4ront Seat Shoulder Belts Coronet Convertible MyMop...

Page 728: ...eat back in the UP position remove 2 Remove seat back and support panel assembly 3 The seat back cushion is retained with screws 1 Position cuslun on panel and install screws 2 Position back and support panel assembly on hinge linksand install screws SHOULDER BELT CENTER LAP BELT SHELF PANEL UPPER QUARTER PANEL GARNISH MOULDING REINFORCEMENT VIEW IN CIRCLE Z NU22 FASTBACK HARDTOP SEDAN Fig 35 Rear...

Page 729: ... WASHER AEALwL 3RD SEAT NU20 Fig 36 Rear and Third Seat Lap Belts Coronet Charger SHOULDER BELT SHELF PANEL SHOULDER BELT REINFORCEMENT OUTER LAP BELT VIEW IN CIRCLE X HARDTOP FASTBACK 2 3 VIEW IN CIRCLE Y Fig 37 Rear Seat Shoulder Belts Coronet Charger MyMopar com ...

Page 730: ...rews or drive nails WINDSHIELD AND REAR WINDOW INDEX Page Page REAR WINDOW WlNDSHIELD Except Convertible 78 Cemented In Type 80 Convertible 79 Dart 82 SERVICE PROCEDURE WINDSHIELD Replacement Except Convertible Removal tive covering 1 Cover cowl hood and fender area with a protec 2 Remove windshield garnish mouldings 3 Remove windshield outer mouldings Figs 1and 2 using Tool C 4009 4 Unlock weathe...

Page 731: ...m of hand using an upward motion 8 Insert a fibre tool between weatherstrip and glass at either corner slide tool across top and com ROOF PANEL WEATHERSTRIP Fig Windshield Weutherstrip Dart WEATHERSTRIP Fig 5 Windshield Installation pletely around weatherstrip to seat glass in place 9 Using a fibre tool and working across top down sides and over bottom force weatherstrip locking tab into locked po...

Page 732: ...lass installation use only the recommended adhesive sealer kit or its equivalent Removal 1 Place protective coverings over rear seat cush ion and back shelf panel or shroud and adjacent exterior body surfaces 2 Remove window exterior mouldings using Tool C 4009 and inner garnish mouldings 3 Secure one end of a two foot length of tempered steel wire 028 gauge max to a wooden handle 4 Insert other e...

Page 733: ... on body 8 Remove glass from opening and place on a pro tected surface with inside surface up 9 Primer solution will damage any paint or trim it comes in contact with Using a cheesecloth pad saturated with adhesive primer thoroughly apply to rear window fence and reveal areas 10 The adhesive begins to cure immediately upon exposure to air The working life is limited to a p proximately 15 minutes P...

Page 734: ...clean smooth and straight 2 If polyethylene seal Fig 14 was removed in stall new seals starting at lower end Overlap top seal starting with a 3 4 inch overlap at left side Seal should overlap lower seal at right side by 2 inches maximum If greater than 2 inches trim at a 30 de gree angle Fig 14 3 Flow a continuous ribbon of cement on each lip and around entire length of weatherstrip glass groove 4...

Page 735: ...asurefluid level only when top is lowered After filling reservoir raise and lower top several times to expel air that may be trapped in system Insufficient fluid in the system may cause slow rais ing or noise in the pump and motor Measure fluid level and if low look for a leak due to a broken line or a loose connection Fill reservoir use only AQ ATF Suffix A Dexron type transmission fluid until fl...

Page 736: ... hook should be adjusted to provide prop er compression of the outer weatherseal on the fold ing top header The locking and unlocking effort of the latching mechanisms are adjustable Adjust the header catch to showfive or six threads for initial setting Header Adjustments Inspect top linkage and mouldingsfor sharp edges burrs or screws that are too long which may damage the top material Dressor fi...

Page 737: ... the side rail indicate the amount of cam rotation when adjusting The marks are located at the full forward position of the high side 45 degrees up and 90 degrees up When adjusting the cam high side position can be deter mined by referring to the notch and the triangular marks Before adjusting place top in half raised posi tion to remove all possible strain off the cam Make sure lock nut is loose ...

Page 738: ...erstrip Fig 10 secured to the underside of the top header The forward edge of weatherstrip contacts windshield header outside moulding A rub ber welt is cemented to the header flange Seals and Sealers When repairing or replacing a seal or weatherstrip at the header and pillar areas care should be exer cised to see that seals and weatherstrips are firmly seated in correct alignment and are free of ...

Page 739: ...der The moulding attaching screws are located under the weatherstrip 8 Raise top to the 1 2 open position and remove rear roof rail weatherstrip Fig 9 Mark location of retainer screws on roof rail to aid in reassembling and remove retainer Fig IO lop Header Weathemrips and Welts Fig 1 Rear Bow lacking Strip MyMopar com ...

Page 740: ...pper is serviced as an assembly Prior to installing cover inspect roof bow felt pads for moisture or damage The pads are a press fit in the P K NP533 Fig 14 Cover Tension Cable bows The cover stay pads should be inspected for damage and moisture The stay pads are attached to the header and roof bows with tacks Fig 15 The rear window zipper top half is tacked to the rear bow Fig 12 and the curtain ...

Page 741: ...les to roof rails with screws 18 Cut notches in cover side quarter material at staples reposition centerline marks cover seams and centerline mark NP563 Fig 17 Cover Tacking Strips Dart NP560 Fig 18 Cover Application at Rear tacking strip for bolt clearance Fig 18 19 Apply spacer strips to cover material at belt bar corners and center areas Fig 1 8 20 Raise and prop top header approximately 12 inc...

Page 742: ...visual inspection of an area will indicate DO NOT SPRAY OR FLOW HOLD GUN NOZZLE IN SEALER IN THIS DIRECTION DIRmoN OF 0 O R FLOW MATERIAL ADJACENT TO JOINT APPLICATION OF SEALER BY FLOW O R SPRAY HIDDEN SURFACE HIDDEN SURFACE EXPOSED SURFACE EXPOSED SURFACE WORK SEAL ON SURFACE TO GET APPLICATION OF SEALING PUTTY HOLD GUN NOZZLE IN DIRECTION OF ARROW IN ORDER TO EFFECTIVELY SEAL METAL JOINTS IS IN...

Page 743: ...ists SEALERS AND COMPOUNDS Supew Rubber Cement May be used where a strong bonding of rubber parts to painted or un painted steel surfaces is desired attachment of SEALER NP512 HARDTOP SEDAN Pillar Area Dart weatherstrip on doors and luggage compartment lid or for attachment of felt pads Windshield Rubber Sealer A heavy viscosity rub ber expander Sealer can be used where rubber is NN333 R w r Floor...

Page 744: ...Y AND FRAME 0 Floor Pan and Side Sills Coronet Charger Floor Pan Plugs Dart DASH AND COWL PANEL V RON FLOOR PAN WINDSHIELD SIDE OUTER OPENING FRAME WER PILLAR NU127 Cowl Dash Panel Floor Pan Ana DOH MyMopar com ...

Page 745: ...0 BODY AND FRAME 23 93 STATION WAGON Floor Pon Plugs Coronet Chorger FLOOR GEAR SHIFT OPENING VIEW IN DIRECTION OF DIRECTION I 1 1 Floor Pon Areas Dor MyMopar com ...

Page 746: ...ALER DECK UPPER PANEL Roof Extension ond Quorter Panel OUTER PANEL SEALER VIEW IN DIRECTION OF ARROW B SEALER VIEW IN CIRCLE A UPPER DECK PANEL ALLMODELS VIEW IN DIRECTION OF ARROW U NU122 WHEELHOUSE 3 R FLOOR AN NU129 Quarter Inner Panel Dort MyMopar com ...

Page 747: ...harm drying the sealer forms a tough skin which can be paint or chrome finish and can easily be removed painted with a touch up brush with a cloth before it sets Heavy Sealing Putty For Interior SealingLA heavy fibrous putty like compound which can be formed or rolled into pellets or long string shapes Body Seam Sealers For External Sealing along TIE r EALER SlDk SILL QUARTER PANEL OF ARROW V VIEW...

Page 748: ...OUGH QUARTER PANEL CENTER PILLAR VIEW IN DIRECTION VIEW IN DIRECTION LOWER OF ARROW D ILLAR 2 DOOR SEDAN QUARTERPANEL 2 DOOR SEDAN VIEW IN DIRECTION OF ARROW D STATION WAGON NU119 Drain frough and Pillar Area Coron Chargor MyMopar com ...

Page 749: ...SIDE FLOOR PAN PAN FRONT FLOOR APPLICATION IN CIRCLE A REAR FLOOR PAN SEALER I EXCEPT STATION WAGON SE VIEW IN CIRCLE T VIEW IN DIRECTION OF ARROW V FLOOR PAN STATION WAGON VIEW IN CIRCLE S OwSEAL 7 VIEW IN CIRCLE P AND W FLOOR PANS NU120 Cowl and Floor Pan Area Coronet Charger MyMopar com ...

Page 750: ...IRECTION OF ARROW F VIEW IN DIRECTION OF ARROW G FLOOR PAN R FLOOR PAN E EXTENSION OFARROW B VIEW IN DIRECTION TIRE WELL AREA INNER LOCK VIEW IN OF ARROW A ILLAR DIRECTION OF ARROW E ARROW H WHEELBASE PANEL TIRE HOUSING VIEW IN DIRECTION OF TAILGATE AND REAR AILGATE AND REAR PILLAR AREA PILLAR AREA TIRE WELL AREA NU121 Station Wagon Rear Area MyMopar com ...

Page 751: ...0 BODY AND FRAME 23 99 NN321 DART CONVERTIBLE VIEW IN DIRECTION OF ARROW Z OF ARROW Y LOWER DRAIN EXCEPT CHARGER DECK DRAIN AND TAIL LIGHT QUARTER PANEL Deck and Tail Gate Area Coronei MyMopar com ...

Page 752: ... aligning centerline marks 5 Apply cement to one half of roof panel and ex tension and to the cover half on same side Figs 2 and 3 6 When the cement becomes tacky position cover on roof panel 7 Repeat steps 5 and 6 for the opposite side 8 Using a new paint roller pressurize cover to the 9 Press cover into windshield and rear window roof working from center area toward drain troughs CEMENT ROOF PAN...

Page 753: ...y 20 Apply a bead of sealer to edge of cover and blend upward to form a seal over staples and cover edge Extend seal across trimmed edge on A post Fig 7 21 Locate and punch holes in cover at roof ex tension belt line 22 Trim cover on a line 1 4inch below belt line moulding holes and curving upward to meet drain trough Figs 9 and 10 23 Apply a bead of sealer to trimmed edge of cover at roof panel a...

Page 754: ...ubble to provide an escape route for en trapped solvent and air 8 After bubble collapses press cover to metal surface starting from one side of bubble and work ing toward opposite side until it conforms to metal surfaces and all raised surfaces disappear 9 Keep car from hot sunlight and other direct heat sources 10 Examine top after a 24 hour period WOOD GRAIN OVERLAY Page Page Application of Over...

Page 755: ...cking removal Thoroughly wet application surfaces of body and the adhesive surface of the overlay with the wetting solution and immediately apply overlay grained side out to the body Adjust overlay so 1 2 inch of ma terial shows beyond all edges and apply wetting solu tiontoouter surface of overlay Fla Sudaces Use a plastic squeegee having a cloth sleeve or is teflon coated and pressurize all flat...

Page 756: ...es must be adhered to the body surface MINOR REPAIRS Minor Scratchesin Clear TopCoat Caution must be taken during the sanding operation If base printed wood grain overlay is damaged during sanding the entire applique must be replaced 1 Using No 400 grit sandpaper lightly sand and feather out damaged area 2 Wipe sanded area with a clean cloth dampened with a clean solvent such as VM and P isopropyl...

Page 757: ...pe finishes Priming the surface and the succeeding product The function of a primer is to form a bond between Puttying A glazing putty is used for filling in small imperfec tions which are too deep to be taken care of by sur facer coats It may be applied either before or after the last coat of surfacer Reducers Reducers are mixtures of volatile liquids used to reduce alkyd synthetic and orthodox m...

Page 758: ...ne bruises or any other minor imperfections Water sand with 360 grit paper or its equivalent 4 Blow off entire car using high pressure air to eliminate dirt or dust from blowing out on to the surface as the paint is applied 5 Mask off the areas not to be painted If a com plete color change is being made mask off interior parts adjacent to door openings to prevent paint spray from soiling interior ...

Page 759: ...nding Color Coats Compound the sanded area that extends around the refinish lacquer and then compound the lacquer blending it into the enamel The hard surface of the acrylic enamel will permit compoundingwithout Ieav ing scratches Paint Code A 4 B3 B5 B7 F3 F5 F8 L1 Q5 R4 R6 T3 T5 T7 w1 x9 Y 2 Y 3 Y 4 Carry over color PAINT CHART EXTERIOR COLORS DART CORONET CHARGER Chryder Silver Metallic AY2EA4 ...

Page 760: ... Saturn Beige Desert Tan Bayou Green Metallic Rally Red Amarillo Gold Chrysler Code AB5EW1 AB5TX9 AB3TX9 AB6EB7 AB5EL1 AB5ET1 AB6EF8 AB5ER6 AB5EY1 Ditzler Code DlA 8745 9028 9293 13670 23059 23079 43929 71687 81685 Remarks Backlite MouldingClip 4 Door Sedan Optional for Seat Adjuster Backlite MouldingClip 4 Door Sedan Backlite MouldingClip 4 Door Sedan Backlite Moulding C l i e Door Sedan Backlite...

Page 761: ...r Hardtop d B Pillar Cap 4 Door Sedan e A Pillar Covers f Windshield Mouldings Convertible Color Name Code Code DIA Chrysler Ditzler Dove White ABlEWl 8743 Jewel Black ABlTX9 9000 Sierra Blue Metallic AB2EB3 13685 Baltic Blue Metallic AB2EB7 13697 Saturn Beige ABlBLl 23075 Golden Tan Metallic AB2ET3 23086 Giallo Gold Metallic AB2EY4 23129 Bayou Green Metallic AB2EF8 43926 Everglade Green Metallic ...

Page 762: ...ver a clean and smooth floor Refer to Figs 1 and 2 and place the line of a plumb bob on point A with the plumbbob just con tacting the floor Mark the plumb bob contact point on the floor Repeat the process at points B C D E and F at both sides of the body Snap a chalk line between points as illustrated Compare dimensions with specifications all match ing point to point dimensions should agree with...

Page 763: ...0 BODY AND FRAME 23 111 BOTTOM VIEW LINE Fig 2 Body Alignment Dimensions Dart MyMopar com ...

Page 764: ...mount of blend is determined by the setting of the temper ature lever on the instrument panel Direction of the blended air is controlled by the Heat Defrost 1 DEFROST SHUT OFF CONTROL CABLE Page Disassembly 5 Doors 5 Installation 6 Removal 5 lever on the instrument panel The blower switch determines the speed of the blower motor and the velocity of the air flow from the heater outlets On Dart mode...

Page 765: ...e control cable See ing Cable Adjustments e Shut off or defroster door improperly e Adjust the Heater Defroster Control adjusted Cable See Cable Adjustments TOO MUCH HEAT a1 b BLOWER MOTOR a b C d e NOT OPERATING Engine thermostat open f Coolant too low 9 Disengaged cable on temperature a door Thermostat stuck in closed position b Blown fuse a1 Faulty electrical connection b Faulty blower switch C...

Page 766: ...in the defrost posi tion Remove the cable clip at the heat defrost door and hold the door in full counterclockwise position Attach clip Be sure that the instrument panel control lever remains in the defrost position while installing the cable clip at the heater Test the heater operation To adjust the Temp control cable remove the cable clip at the temperature control door Place the temperature con...

Page 767: ...ables See Control Cable Adjustments 2 Rotate heater into position onto bulkhead and support heater housing with a suitable block of wood 3 From inside engine compartment install retain ing nuts 4 Install heater hoses Figs 5 6 and 7 5 Under instrument panel install heater to cowl 6 Connect and adjust fresh air control and shut support bracket Fig 6 Heater Hose Connections 273 and 318 Cu In Engines ...

Page 768: ... the heater core or blower motor it is necessary to remove the heater assembly from the vehicle 1 Drain radiator 2 Disconnect heater hoses from heater and re move heater hoses to dash panel seal and retainer plate Fig 8 3 Remove heater motor seal retainer plate and seal from dash panel Fig 8 4 Disconnect heater defroster and temperature control cables from heater assembly 5 Remove heater motor res...

Page 769: ... install attaching screws 5 Connect heater hoses to heater Figs 5 and 9 6 On passenger compartment side connect heater 7 Connect wire to heater motor resistor 8 Connectdefroster tubes to heater 9 Fill cooling system start engine and operate un til normal engine operating temperature is obtained 10 Test operation of heater assembly support rod to heater housing AIR CONDITIONING INDEX Page General I...

Page 770: ...use only Def windshielddefroster Temperature Control Slide Lever Maintains any desired temperature by sliding the lever right or left when operating either the heater or air conditioner i 2 NU139 Fig 1 Off PositionSame As Max A C Page Coronet Charger 11 Dart 15 Water Temperature Control ValveTest Fan Switch Permits selection of low medium or high blower speeds used when operating either the heater...

Page 771: ...r conditioning door actuator forces the door closed A coil spring attached to the air conditioning door linkage pulls up on the heater door arm open ing the passage to the heater outlets in the bottom of the housing At the same time a rod between the air conditioning door bell crank and the defroster door pivot bell crank forces the defroster doors open slightly overcoming the defroster actuator t...

Page 772: ...n to avoid an accumula tion of water which would be blown out of the heater or air conditioning outlets Inspect tubes at regular intervals to make certain they are free of any foreign matter ELECTRICAL CONTROLS AND CIRCUITS There are two switches a push button switch air conditioner and heater vacuum switch and a fan switch air conditioner and heater blower switch r LINKAGE L NK13W Fig Heater Core...

Page 773: ... HARGER Satisfactory performance of the combined air conditioning and heating system is dependent upon proper operation and adjustment of all operating controls as well as proper functioning of all refrig eration system units The inspections tests and ad justments should be used to locate the cause of a malfunction The tests in this manual have been ar ranged in a logical sequence that has proved ...

Page 774: ...ocated at the lower right hand corner of the air conditioning housing Remove the radiator cap to minimize pressure in the car s cooling system Move the temperature control slide lever on the instrument panel to the extreme Warm position and then back to the Off position Push the Max A C button in and with the blow er in the Low position run the air conditioning system for five minutes then test th...

Page 775: ... with fresh outside air for added comfort by pushing the A C button and adjusting the fan switch to change fan blower speed If less cooling is desired move the fan switch lever to Low speed and re adjust the cooling outlets for indirect cooling For warmer air move the temperature control lever to the desired temperature Cooling for Special Conditions The air conditioner provides maximum dehumidi f...

Page 776: ...s of doors The blend air door which controls the temperature of the heater output is opened and closed by a bowden cable from the temperature control slide lever in the instrument panel All the other doors and the heater water flow valve are operated by vacuum actuators A single blower serves both heater and air conditioner In fact all of the components in the blower motor circuit are common to th...

Page 777: ...in and the temperature control lever all the way to the right the fresh air door is opened to the cowl ventilation inlet At the same time the fresh air door actuator closes the re circulating door The blend air door is held closed by a bowden cable from the temperature control slide WATER VALVE NU143 Fig 9 Off Position Same As Max A C Dart Fig IO A C Position Dart lever so all the airflow from the...

Page 778: ...malfunction The tests in this manual have been ar ranged in a logical sequence that has proved to be the surest and shortest route to accurate diagnosis It is recommended that they be followed and per formed in the order in which they are presented OPERATION OF ALL CONTROLS Operating must be tested as described in the follow 1 Inspect test and adjust compressor drive belt 2 Remove radiator pressur...

Page 779: ...dispensable test and diagnosis instrument The gauge set manifold Tool C 3740 has two compound suction gauges and one discharge pressure gauge Two accurately cali brated suction pressure gauges are required for the evaporator pressure regulator valve test Refer to Figures 15 and 16 The hoses are shown in the test il lustrations for quick references to distinguish the various adaptations Evaporator ...

Page 780: ... Valve on Coronet and Charger installationsand is not used on Dart installations Fig 16 Center Manifold Outlet provides the necessary connection for a long service hose used when dis charging the system using a vacuum pump to pull a vacuum before charging the system and for con necting the supply of refrigerant when charging the systern DART PUSH BUTTON CONTROL CHART Button Off Max A C A C Heat De...

Page 781: ...noncorrosive except when combined with water The following precautions must be observed when handling Refrigerant 12 CAUTION Wear safety goggles when servicing the refrigeration system Refrigerant 12 evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts For this reason ex treme care must be taken to prevent any liquid re frigerant from ...

Page 782: ...having an open flame A poisonous gas is pro duced when using the flame type leak detector Avoid inhaling the fumes from the leak detector CAUTION Do not allow liquid refrigerant to touch bright metal Refrigerant will tarnish bright metal and chrome surfaces Avoid splashing refrigerant on any surface Refrigerant in combination with moisture is very cor rosive and can cause great damage to all metal...

Page 783: ...44 7 10 14 6 40 37 0 65 63 8 90 99 8 115 146 8 12 15 8 41 37 9 66 65 0 91 101 5 116 148 9 14 1 7 1 42 38 9 67 66 3 92 103 1 117 151 1 16 18 4 43 39 8 68 67 6 93 104 8 118 153 2 18 19 7 44 40 7 69 68 9 94 106 5 119 155 4 20 21 0 45 41 7 70 70 2 95 108 3 120 157 7 21 21 7 46 42 7 71 71 5 96 110 0 121 159 9 22 22 4 47 43 6 72 729 97 111 7 122 161 2 23 23 2 48 44 7 73 74 2 98 113 5 123 164 4 24 23 9 4...

Page 784: ...reas a large flame will detect only large leaks As soon as the reaction plate seen through the window in the burner shield becomes red hot the tester is ready for use 2 Examine all tube connectors and other possible leak points by moving the end of the sampling hose from point to point Since Refrigerant 12 is heavier than air it is good practice to place the open end of NFlO5 Fig 19 Receiver Drier...

Page 785: ...center manifold outlet other end to refrigerant dispensing manifold 4 Close two of the dispensing manifold valves and open remaining dispensing manifold valve Remove protective cap from opened valve 5 Screw a can of Refrigerant 12 to the opened manifold valve Be sure gasket is in place and in good condition Tighten refrigerant can and manifold lock ing nut to insure a good seal Do not over tighten...

Page 786: ...m must be charged through the evaporator suction service port as follows 9 Slowly open the suction service gauge valve Meter flow of refrigerant by adjusting the suction service gauge valve so that pressure registered at the suction service gauge does not exceed 50 psi Keep refrigerant container upright 10 Add refrigerant gas until there is no foam visible at the sight glass As soon as all foam cl...

Page 787: ...rected towards rear of vehicle Operate the air conditioning system until a stabiliz ed condition on the gauges and thermometers has been established One of the most important steps in making the over all performance test is that the en gine must be operated at the RPM as indicated on the above chart for approximately five minutes to allow all the under hood components of the system to reach their ...

Page 788: ... full reheat position Set RPM s at 800 for all 8 cylinder engines 900 for 6 cylinder engines b Operate the system for at least five minutes in order to obtain partial stabilization and sufficient reheat to load the system Pressure at the discharge service port should reach 140 210psi If the head pressure of 140 210psi cannot be obtained check the pressure drop across the EPR valve as described in ...

Page 789: ...ressure should be 17 psi or less If the compression inlet pressure is higher than 17 psi the EPR valve should be replaced EPR Valve not used on Dart Installations If the expansion valve passes Tests a through 0 then the compressor valve plate should be removed and the gaskets and valves inspected Replace gaskets and any damaged valve plate assemblies Make sure that all of the old gasket material i...

Page 790: ... All lines and compo nents in parts stock should be capped or sealed until they are ready to be used All tools including the refrigerant dispensing manifold the gauge set manifold and test hoses should be kept clean and dry The special refrigeration oil supplied for the system is as clean and dry as it is possible to make it Only refrigeration oil should be used in the system or on the fittings an...

Page 791: ...the pump dip radiator cap and both ends of adapter into clean water to assure a tight seal Hold the assembled tester in a vertical position with the radiator cap downward as shown in Figure 29 Stroke the tester pump plunger until the gauge indi cates the pressure cap is relieving pressure It must relieve at a pressure between 14 to 17 psi If within these specifications reinstall on the radiator Th...

Page 792: ...pect the fit of the 7 hole hose connector plug on the control switch Fig 30 This plug must be positioned all the way on the 7 prods on the control switch CAUTION Do not use lubricant on the switch prods or in the holes in the plug as lubricant will ruin the i I A Fig 29 Adjust Vacuum test Bleed Valve 0 H Fig 30 Push Bmon Vacuum Ted vacuum valve in the switch If it is impossibleto prop erly positio...

Page 793: ...functioning properly However it is possible that a vacuum con trol system that operates perfectly at the high vacu um provided at engine idle speed may not function properly at high engine speeds Before starting this test stop the engine Start the vacuum pump Tool C 3652 and connect to the vacuum test set Tool C 3707 Adjust the bleed valve on the test set to obtain exactly 8 inches of vacuum with ...

Page 794: ... drop is still in excess of 3 4 inch remove connector plug from switch Insert the vacuum test prod alternately in each of the connector holes except the source hose connector hole Fig 36 Note the amount of vacuum drop below 8 inches after each actuator has operated If the vacuum test gauge comes back to 8 inches at each of the 6 holes the hoses and actuators are not leaking The control switch is f...

Page 795: ... to 20 foot pounds 5 Connect field lead wire 6 Install belts and tighten to the specified tension Warner Plate Type and Pitts Zlectro Lock Disassembly 1 Remove the small snap ring from the drive hub with Tool C 3128or equivalent 2 On Warner clutch install drive hub puller Tool C 3787aligning the three pins of the Tool in the three holes in the hub and shoe assembly Tighten the hex head bolt down u...

Page 796: ...ing type designed specifically for the Chrysler Air Condi Fig 42 Installing Bearing in PulleyAssembly Typical tioning System Service parts are available so that the compressor can be repaired in the field Figure 43 is a disassembled view of the compressor with the nomenclature of the parts Some parts are serviced individually and some are serviced in pack ages which include two or more service par...

Page 797: ...oil must be kept in a sealed con tainer until ready for use to prevent entrance of moisture and dirt Never use engine oil as a substi tute for refrigerant oil EPR VALVE Evaporator Pressure Regulator Dart model installations do not use an EPR valve Removal 1 Remove the two EPR Valve suction line fit ting bolts the fitting which also contains the com pressor suction screen spring and the gasket 2 Re...

Page 798: ...boil off and then measure the oil in the compressor by inserting a dipstick made up as shown in Figure 45 through the crank case oil filler hole Measure the height on the dipstick and determine the amount of oil in the unit by refer ring to the following chart 1 8 27 BRASS PIPE FITTING WITH THREADS 3 16 ROD 4 3116 2 D DIPSTICK FOR USE IN COMPRESSOR CRANKCASE NU6 FROM FRONT OF PRESsoRt3 CAR VIEW OF...

Page 799: ...and rod as sembly from cylinder Inspection Inspect piston and rings for score marks Inspect rod bearing for pits and for chipping Replace parts if damaged m REED VALVE ASSEMBLY Fig 47 Valve Plate lnstalled Position 4 VALVE PLATE GASKET R Fig 48 lnstalling Valve Plate and Cylinder Head Installation 1 Remove bearing cap and install piston in bore Use piston ring compressor to prevent ring damage 2 I...

Page 800: ...e micro finish sealing surface of the face plate Tap the sleeve lightly until the seal seat is fully seated in the housing 2 Before installing the cartridge type assembly inspect the assembly to make sure that the tangs of the carbon seal are indexed in the slots of the mating steel part Fig 51 3 Immerse the seal assembly in clean refrigerant oil carbon ring up 4 Hold the seal assembly firmly at t...

Page 801: ... washer is on the rear bearing journal before placing crankshaft in the crankcase 3 Rotate crankshaft to engage the oil pump shaft in the crankshaft slot 4 Install new gas seal and crankshaft bearing housing Use a suitable tool as shown in Figure 52 to assure free axial movement 5 Install pistons and connecting rods 6 After pistons and connecting rods are installed turn the crankshaft to check fre...

Page 802: ...connect electrical connections from resistor block 7 Remove the two screws attaching the water by pass valve to heater cover and remove the operating link attaching screw Fig 58 8 Disconnect air conditioning door actuator from mounting bracket and remove the two support braces 9 Remove five retainer spring clips and ten screws attaching cover to the case 10 To remove the cover and heater core it w...

Page 803: ...strument panel outlets 12 Install glove box assembly 13 Connect the heater hoses Figs 60 61 and 62 and fill cooling system For summer operation as well as winter operation be sure the system is pro tected with the proper type and amount of antifreeze 14 Install air cleaner and connect battery cable 15 Start engine operate until normal engine operating temperature is obtained and test operation of ...

Page 804: ...clips 9 Remove Ranco valve sensing tube and brace at center of housing 10 Remove the five mounting stud nuts at the firewall 11 P u l l the unit towards rear of car until all studs are clear of firewall then move the unit towards the right tilting the unit down and remove from and fresh air hose under the instrument panel and to the work bench for disassembly 12 Removethe floor air actuator bracke...

Page 805: ...d nuts but do not tighten until all nuts have been installed and studs centered in their respective holes 6 Install blower motor wires and air tube 7 Use new 0 rings with clean refrigerant oil on all connections then install the suction line and the expansion valve to the evaporator fittings Use two wrenches to prevent rotation and twisting of the lines 8 Connect the heater hoses Figs 60 61 and 62...

Page 806: ... Install air tube motor ground wire and connect the feed wire 3 Test operation of blower MOUNTING PLATE i AIR TUBE Fig 65 Blower Motor lndalled Removal The system must be completely discharged before opening any of the refrigerant lines 1 Remove equalizer tube from evaporator suction line fitting Fig 66 2 Disconnect expansion valve from elbow assem bly and liquid line Use two wrenches to loosen ea...

Page 807: ...re the four attaching screws 1 Place a small bead of sealer in heater housing 2 Install heater core in the heater housing and 3 Cement the weatherseal on the inner lip of heater core flange Fig 69 4 Place a small bead of sealer on heater housing cover 5 Position both housing halves together and in stall the eleven retainer spring clips Remove any ex cess sealer 6 Cement fresh air inlet seal into p...

Page 808: ...vaporator housing with the evaporator inlet and defroster doors To remove the evaporator as sembly it is necessary to remove the heater assembly See Heater Removal The system must be com pletely discharged before opening any of the refriger ant lines Removal 1 Disconnect elbow assembly and suction lines from evaporator Use two wrenches to loosen each of these connections Cap all the refrigerant op...

Page 809: ... motor wires and air tube 7 Use new 0 rings with clean refrigerant oil on all connections install the inlet elbow assembly and suction line Use two wrenches to prevent rotation and twisting of the lines 8 Install actuator hoses hose with red stripe to rod side 9 Install heater as described in Paragraph Heater Installation 10 After the evaporator and heater assemblies are installed in the vehicle i...

Page 810: ...or components the system must be complete ly discharged Whenever the system has been opened it must be swept with a partial charge and the entire system tested for leaks Compressor oil level should be checked and adjusted if necessary See Oil Lev el The drier should be replaced and the system evacuated using a vacuum pump to remove all air and moisture The system should be charged with the proper ...

Page 811: ...Fig 73 Removing Evaporator Core Typical small amount This will allow the refrigerant vapor to discharge slowly CAUTION Do not allow the system to discharge rapidly since this would sweep some of the refriger ant oil out of the compressor 7 Allow the system to discharge until the dis charge pressure gauge registers zero Open the left hand valve to release any vapor trapped at the suction side of th...

Page 812: ...lete leak test must be made to make sure the system is sealed Also if the system has accidentally lost its charge it will be necessary to perform a leak test while the sweep test charge is in the system Stop the engine and disconnect the test hoses and adapters from the compressor service ports TESTING THE SYSTEM FOR LEAKS The leak detector torch Tool C 3569 is a propane gas burning torch used to ...

Page 813: ...nditioning components have been re moved add the necessary refrigerant as described under Correcting the Low Refrigerant Level If any parts of the refrigerant system were disconnected remove the sweep test charge Close the refrigerant manifold valve so that any refrigerant remaining in the container is sealed Remove the long test hose from the refrigerant manifold Insert the free end of this test ...

Page 814: ... shown in Fig ures 75 and 76 2 Open both gauge set manifold valves and the needle valve 3 Start the vacuum pump and operate until the evaporator suction gauge registers at least 26 inches of vacuum If system is tight and pump in good condi tion vacuum will go as low as 28 inches 4 Allow vacuum pump to operate with the suction gauge registering 26 to 28 inches of vacuum for a minimum of five minute...

Page 815: ...old nuts to 6 to 8 foot pounds 3 Turn three refrigerant manifold valves com pletely clockwise to puncture the cans and close the manifold valves 4 Turn refrigerant manifold valves counterclock wise to open them 5 Momentarily loosen the charging hose at the gauge set manifold to allow the refrigerant gas to purge air out of the charging hose 6 Place the three cans of refrigerant into a pan containi...

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Summary of Contents for Dodge Coronet 1969 Series

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Chrysler Dodge Coronet 1969 Series, Service Manual, Page: 599 / 816

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Summary of Contents for Dodge Coronet 1969 Series

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