Chrysler Imperial 1963 Service Manual Download Page 173

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Summary of Contents for Imperial 1963

Page 1: ......

Page 3: ...ION AND GENERAL SPECIFICATIONS TY 1 IMPERIAL CUSTOM FOUR DOOR HARDTOP TC 3 NEW YORKER FOUR DOOR HARDTOP TC 2 300 TWO DOOR HARDTOP TC l NEWPORT FOUR DOOR HARDTOP Fig 1 1963 Imperial and Chrysler Models MyMopar com ...

Page 4: ...lete description of difficulty corrective action taken your recommendations as to what should be done and the reason for so doing Include Paint and Trim Code Numbers where finish upholstery body or sheet metal is in volved and estimate of net cost of repairs CHRYSLER PLYMOUTH DIVISION With the exception of orders for parts or parts literature all requests for Imperial Chrysler Plymouth or Valiant ...

Page 5: ...n Chrysler Roads Kansas City 15 Kansas Telephone Kansas City Kansas Fairfax 1 3300 Parts Division Literature Request for Parts Division literature such as Parts Books Parts Price lists Parts Bulletins etc should be forwarded direct to Chrysler Motors Corporation P O Box 1718 Detroit 31 Michigan Attention Parts Catalog Department Shortage of Accessories or Other Equipment on New Cars Before placing...

Page 6: ...01 TC 3 New Yorker Town and Country 87 33100001 TC 2 Chrysler 300J 84 33100001 IMPERIAL MODELS TY 1 Custom 91 33100001 TY 1 Crown 92 33100001 TY 1 LeBaron 93 33100001 Model Serial Number The starting engine numbers will be as follows CHRYSLER Newport T 36 7 30 300 T 38 7 30 New Yorker T 41 7 30 Chrysler 300J T 41 7 30 IMPERIAL Custom Crown LeBaron T 41 7 30 Fig 2 Vehicle Number The vehicle number ...

Page 7: ...7 Town Country 60 8 60 8 Four Door hard top 60 9 60 9 60 9 61 7 Tread Four Door Sedan 59 7 59 7 Rear 59 7 59 7f 62 2 Two Door hard top 59 7 59 7f 62 2 Town Country 59 7 60 0 Four Door hard top 59 7 59 7f 59 7 62 2 Length with Four Door Sedan 215 3 215 5 Bumper 215 3 215 3 227 8 Two Door hard top 215 3 215 3 227 8 Town Country 219 4 219 7 Four Door hard top 215 3 215 3 215 5 227 8 Width with 79 0 7...

Page 8: ...stem Add 1 qt for heater Rear Axle Transmission refill TorqueFlite 1 6 qts 4 pts 1 8 pts A Prepacked bearing Cooling system drain IMPERIAL Engine Coolant Check level and or Anti Freeze every 2 months Cooling system pressure 14 pounds with air conditioning 16 pounds DCL Distributor C a m every 6 months E O Distributor O i l Cup a n d Wick under Rotor every 6 months In Line Carburetor Fuel Filter Re...

Page 9: ...lter element Cooling System 1 6 qts Add 1 qt for heater Rear Axle 4 pts Transmission refill TorqueFlite 1 8 pts Manual AVi pts Position for lift adapter A Prepacked bearing Cooling system drain CHRYSLER 6 3 x 4 1 8 Engine C o o l a n t C h e c k level a n d o r Anti Freeze every 2 months Cooling system pressure 14 pounds with air conditioning 16 pounds DCL Distributor C a m every 6 months E O Dist...

Page 10: ...specially during adverse weather conditions These recommendations therefore have been re lated to the best of our ability to time intervals yet limited by mileage where necessary In general semi annual lubrication and maintenance services have been prescribed for most items Exceptions to this include two month intervals between engine oil changes not to exceed 4 000 miles opposed to the front susp...

Page 11: ... 22 14x6K Chrysler 3 TC 3 New Yorker 16 5 23 NA 18 4 8 50x14 4 24 22 14x6K Chrysler 8 TC 3 New Yorker Town and Country 16 5 21 NA 18 4 9 00x14 4 22 24 14x61 2 K Imperial 8 TY 1 Custom 16 5 23 NA 18 4 8 20x15 4 24 24 15x6L Imperial 8 TY 1 Crown 16 5 23 NA 18 4 8 20x15 4 24 24 15x6L Imperial 8 TY 1 LeBaron 16 5 23 NA 18 4 8 20x15 4 24 24 15x6L a Add 1 quart for the Heater b Add 1 quart when the filt...

Page 12: ...par Engine Oil Supplement also has anti scuff properties and should be used during the break in period after a major engine overhaul 3 FREQUENCY O F OIL CHANGE The engine oil change period will vary widely de pending upon the type of operation weather con ditions and other operating variables Chrysler Corporation recommends that engine oil should be changed every two months or up to 4 000 miles wh...

Page 13: ... and forth until gum formation is flushed out Apply the cleaner to the choke shaft where it rotates in the air horn to remove gum and dirt from these surfaces Run the engine at idle to clean out any excess from the system Refer to Air Cleaner for servicing at this time 6 CRANKCASE VENTILATOR VALVE Every 6 months remove the valve and cap as sembly from the rocker cover and detach from the hose Remo...

Page 14: ...y of foreign matter due either to operating conditions or contaminated fuel restricting the flow of fuel to the carburetor If this occurs the filter should be replaced as required 9 MANIFOLD HEAT CONTROL VALVE Every 6 months or more often under adverse con ditions apply Manifold Heat Control Valve Solvent Part Number 1879318 to each end of the valve shaft when the manifold is COOL Work the valve b...

Page 15: ...t to pivots inspect tubing except Im perial Apply directly use sparingly Apply a light film directly Apply to inner surfaces through access hole use sparingly Apply directly to bearing areas Apply directly Do not apply to ramp or out side of roller Apply 2 or 3 drops to outside and inside rotor bearing surfaces Apply directly use sparingly Apply directly Apply directly 13 BRAKES Under normal drivi...

Page 16: ...LUBRICATION AND MAINTENANCE 0 9 Fig 12 Foot Operated Parking Brake Chrysler Disassembled View MyMopar com ...

Page 17: ... holes Stop filling when the lubricant begins to exit from the bleed holes or the seals begin to balloon Reinstall the plugs mm Fig 15 Lubricating the Lower Ball Joint Steering Linkage and Torsion Bars All steering linkage and the torsion bars are per manently lubricated at the factory Every 6 months inspect the seals If any seals are cut or damaged replace the entire joint assembly The service re...

Page 18: ...n to 15 F at the heater core In the winter pro tect for the lowest anticipated temperature range but never use less than 20 glycol type anti freeze to ensure adequate protection against corrosion Coolant with antifreeze concentrations less than 40 should not be used more than one season All models are equipped with a 180 thermostat With this thermostat permanent type anti freeze must be used Shoul...

Page 19: ...mile in spection and semi annually thereafter If a vehicle is to be loaded abnormally such as on a vacation trip or a salesman s vehicle loaded with his products the headlamps should be adjusted Refer to Group 8 Electrical for the service procedures 2 1 PARTS REQUIRING N O LUBRICATION There are many points that should not be lubri cated some because they are permanently lubricated some because lub...

Page 20: ...g the rear axle lubricant level The lubricant level should be between the bottom of the filler hole and V2 inch below Fig 22 Multi purpose Gear Lubricant for Service GL 4 as defined by MIL L 2105 A or B should be used in all rear axles except those equipped with Sure Grip Differential Sure Grip Differential MoPar Hypoid Lubricant Part Number 1879414 should be used for vehicles equipped with Sure G...

Page 21: ...hould be used so that all the tires will wear at approximately the same rate The tires should be examined for unusual wear patterns foreign material and proper inflation pres sure each time the engine oil is changed Such con ditions may reflect unusual driving habits or indicate mechanical corrections may be necessary See the capacities page for the recommended infla tion pressures 2 7 TRANSMISSIO...

Page 22: ...required except when the service is severe as described below If the regular operation of the vehicle is similar to any of the following the transmission should be adjusted and the oil and filter changed approximately every 32 000 miles For extreme severe service it may be necessary to change the fluid as often as every 10 000 miles Fig 26 1 Police vehicles 2 Taxicab operation 3 Frequent towing of...

Page 23: ...alve and the carburetor choke piston are op erating properly and are each re treated with their specific solvent 4 Electrical Inspect the battery specific gravity Clean and tighten the battery terminals and connec tions Test the battery line voltage at the starter Test the starter cranking ability CERTIFIED CAR CARE SEMI ANNUAL MAINTENANCE SERVICE Replace Engine Oil Filter element Lubricate Distri...

Page 24: ...matic brake adjusters 10 Inspect and if necessary adjust the parking brake CERTIFIED CAR CARE FRONT SUSPENSION ALIGNMENT 1 Determine if vehicle needs the front suspension system aligned Three important reasons can indi cate this need a Tire wear pattern and or b Car pulls in one direction on brake application and or c Car leads left or right in normal driving 2 Inflate all tires to the same pressu...

Page 25: ... MILEAGES INCIDE WITH ICE INTERVAL EVERY 5 000 MILES ROTATE TIRES USING SPARE ITENANCE MILEAGES INCIDE WITH ICE INTERVAL EVERY 10 000 MILES TUNE UP ENGINE ITENANCE MILEAGES INCIDE WITH ICE INTERVAL EVERY 16 000 MILES BRAKE MAINTENANCE LINING INSPECTION MILEAGE MAIN HAVE DONE AT INDICATED TO CO TWO MONTH SERV INSPECT FRONT WHEEL BEARINGS MILEAGE MAIN HAVE DONE AT INDICATED TO CO TWO MONTH SERV REPL...

Page 26: ...m Actuator Replacement 11 Service Diagnosis 26 AUTOMATIC EAM CHANGER Aiming the Automatic Beam Changer 12 Operation 12 Aiming the Scanner 13 Service Diagnosis 27 Driver Adjustments 12 MIRROR MATIC ELECTRONIC REAR VIEW MIRROR Driver Adjustment 14 Removal and Disassembly 14 Inspection and Trouble Shooting 14 Service Diagnosis 27 REMOTE CONTROL OUTSIDE MIRROR Operation 15 Removal and Installation 15 ...

Page 27: ...rear speaker fader control if so equipped and the tuning knob are located to the right of the radio dial SERVICE PROCEDURES 1 RADIO CAUTION Do not operate the radio with the speak er detached since damage to the transistors may result If the rear seat speaker is disconnected from the radio insert a jumper wire to the rear seat speaker socket Fig 3 to allow the receiver to operate Removal Chrysler ...

Page 28: ...une the receiver to only strong signal stations Distant push button will tune the receiver to most of the stations within range of the radio For weak stations manual control should be used for precise tuning 3 FOOT SWITCH FOR SEARCH TUNING The foot switch for search tuning on Models 411 and 413 is located on the left forward end of the floor panel By depressing the foot switch it will select a sta...

Page 29: ...g suppression items make certain that all paint and dirt have been removed from the grounding area between the capacitors and the engine or body components Tighten all nuts and bolts se curely Fig 5 Antenna Location Imperial The high tension portion of the engine ignition system uses radio resistance wire as standard equip ment The ignition coil capacitor is installed as shown in Figure 4 The alte...

Page 30: ...enna body tube b Failure of the antenna to raise or lower Gen erally can be traced to a blown fuse faulty electrical connections at the switch or switch lead terminals bent antenna mast rods or a faulty motor and drive assembly Before an antenna is removed the antenna per formance should be tested to determine whether it is a reception problem or an operational problem 9 TESTS Clean the antenna an...

Page 31: ...E DO NOT attempt to service the details of the Motor and Drive Assembly This sub assembly must be serviced as a complete unit 10 MOTOR AND DRIVE OR MAST ASSEMBLY Removal 1 Remove the 2 two screws holding the lead in receptacle 2 Unsolder the pin from the wire 3 Remove the 3 screws which hold the sup port tube to the motor and drive assembly 4 Holding the motor and drive assembly in one hand and th...

Page 32: ... yellow and brown antenna leads and test for up and down operation 11 WIRING DIAGRAMS Refer to Figures 11 and 12 for the radio wiring diagrams HEATER The hot water heating system Fig 13 is controlled by four push buttons and a temperature control lever Fig 14 A fifth push button independently controls the summer ventilation system The Temperature Control Lever operates the water valve through a bo...

Page 33: ...ATED PF MICROMICROFARADS GMV GUARANTEED MINIMUM VALUE TUNING RANGE FROM 535KC TO I605KC I F FREQUENCY 262 5KC DUMMY ANTENNA 40PF SERIES AND 40PF SHUNT AT ANTENNA SOCKET O IUF SERIES TO TRANSISTOR BASE ELEMENTS FOR GAIN MEASUREMENTS VOLTAGE MEASUREMENTS 1 ALL DC VOLTAGES MEASURED WITH A 20 000 OHMS VOLT METER NO SIGNAL INPUT 2 ALL AC VOLTAGES MEASURED WITH AN AC VTVM AT FULL VOLUME I WATT OUTPUT 3 ...

Page 34: ... n m Fig 12 Wiring Diagram Radio Model 411 and 413 MyMopar com ...

Page 35: ...M position Then push in the HI button and leave the temperature control lever in the WARM position for a fast initial car warm up After warm up use the LO button to adjust the speed as desired and adjust the position of the tem perature control lever to maintain desired tempera ture NOTE When the HI button is pushed in sufficient warm air will be forced onto the windshield through the upper air ou...

Page 36: ... at each attaching screw be sure these spacers are installed between the heater housing and the dash panel when installing housing otherwise the housing could be damaged when tightening the screws 3 Reposition the heater water valve capillary coil in the heater housing and install the attaching clips 4 Connect the vacuum hoses at the vacuum unit and install the attaching clips 5 Connect the heater...

Page 37: ... the headlights on bright within approximately V2 sec ond after the approaching car has passed The headlight setting can be interrupted by us ing the conventional dimmer switch If the unit has a bright setting and the driver feels that a dim setting is required he can override the automatic control by depressing the dimmer switch to obtain the dim condition Automatic operation is restored when the...

Page 38: ...battery 2 Disconnect the control box wires at the con nectors 3 Remove the control box attaching screws 4 Remove the control box assembly Fig 18 Scanner Leveling Tool Installation 1 Clean the area around the body where the con trol box spacer is attached to the dash panel to ob tain proper metal to metal ground 2 Mount the control box assembly to the body and install the attaching screws 3 Connect...

Page 39: ... the attach ing pedestal PHOTO CELL W I N D O W BEZEL i x w I ADJUSTMENT WHEEL CASE Fig 19 Electronic Rear View Mirror UPPER LOCATING TABS ADJUSTMENT RETAINING SCREW WHEa STOP HOLEN LOWER LOCATING TABS Fig 20 Mirror Actuating Mechanism 2 Carefully pull the bezel from the case assembly 3 Locate the ball joint in the down position towards the adjustment wheel 4 Bend the top of the case upwards to di...

Page 40: ...ngs and disengaging the mirror from the chassis pivots Fig 23 Aligning the Chassis Tabs 2 5 REASSEMBLY AND INSTALLATION 1 With the ball joint end in the down position install the lead wire through the hole in the rear of the case 2 Position the lower edge of the mirror in the case to allow for easy entrance to the adjustment wheel in the slot 3 Engage the chassis lower locating tabs in the case re...

Page 41: ...k to the instrument base and remove the clock Removal Imperial 1 Remove the three screws attaching the instru ment cluster bezel to the instrument panel 2 Pull the cluster forward from the instrument panel just far enough to allow for disconnecting of the reset cable clock wire and illumination wire Re move the clock attaching screws 28 INSTALLATION OF CLOCK Installation Chrysler 1 Position the cl...

Page 42: ... Fig 1 is a driver operated volun tary speed control It can be used either as a warn ing signal to indicate that a pre set vehicle speed has been reached or as a fully automatic vehicle speed regulator In either operation it helps to reduce driver fatigue contribute to highway safety and im prove fuel economy Speed Warning Operation A convenient dial selector knob located on the dash is used to se...

Page 43: ...ring Assembly Snap R t n g Spacer Wave Washer _ 7 Governor Weights Nylon Gear Serial No Plate Stop Stud Felt Seal Drive Screw Assembly Motor Compressor Rod Guide Terminal Block V J Speedometer A d a p t e r Drive Adapter lock Nut Ball Socket Retaining Ring Dust Shield i r 6 3 x 2 0 0 Fig 26 Auto Pilot Disassembled View MyMopar com ...

Page 44: ...st for a blown fuse and test the entire motor circuit 3 With one test lamp lead grounded touch the other lead to terminal No 2 The circuit is normal if the lamp lights If the test lamp fails to light make the following tests on the automatic cut out circuit Test progressively along the circuit to the power unit starting with the pink wire at the brake pedal switch If the test lamp lights on the pi...

Page 45: ...ing on the am meter indicates more than 7amps the motor is draw ing too much current and should be replaced 7 Disconnect the tester leads remove the lock ing arm gauge install the cover and connect the multiple connector Testing for Damaged Cables and Gears 1 Raise the rear end of the vehicle until the rear wheels clear the floor 2 Start the engine and engage the transmission D button 3 Remove the...

Page 46: ...he governor weights until they are parallel with the drive screw then place the governor weight wedge Tool C 3842 between the gov ernor weights pressing down on the wedge until the weights are held out to their stop position 4 Use a feeler gauge to measure the gap between the contact arm and either contact point on the magnet assembly Fig 31 This gap should be ap proximately one half of the full g...

Page 47: ...hield and unhook the ball on the end of the wire from the baU socket Fig 32 2 Loosen the Allen screw in the selector knob and pull button knob Remove both knobs from the shaft 3 Disconnect the double plug connected to the wire harness 4 Unscrew the attaching nut Remove the selec tor head from the instrument panel 5 Pull the cable through the dash panel from the passenger side Removal of the Select...

Page 48: ...e compressor rod from the housing 5 Remove the screw from the compressor rod guide and remove the rod guide from the housing 6 Disconnect the red and black motor wires at the bottom of the contact points 7 Disconnect the black wires from the upper and lower terminal on the side of the cut out switch 8 Remove the two nuts securing the motor to the housing and remove the motor 9 Disconnect the doubl...

Page 49: ...ess down on the complete assembly until it seats itself in the housing 14 Install the two pintle screws and lockwashers securing the magnet and pintle assembly in the housing 15 Install the locking arm stop stud and lock washer 16 Install the exterior arm on the locking arm shaft with the throttle arm toward the serial num ber plate 17 Install the torsion spring on the exterior arm Using needle no...

Page 50: ...y Then tighten the clamp screw and recheck the gap 34 Remove the locking arm gauge and governor weight wedge 35 Turn the drive screw to move the magnet assembly all the way toward the motor side of the housing to avoid any contact between the contact arm and the contact point on the motor side of the magnet This must be done to prevent preloading of the governor spring by the contact arm before ad...

Page 51: ...oil rubbing on voice core a Install an auxiliary speaker and is Distorted compare Replace if improved b Torn speaker cone b Replace the speaker 44 Search Tuner a Car located in a weak signal area a Move the car to a strong signal Runs Continuously area b Faulty radio tube b Test and replace any faulty tubes 45 Intermittent a Broken lead in wire a Test with a substitute antenna Reception Repair the...

Page 52: ...ve clean and reinstall the control units c Replace the faulty tube d Clean and tighten all electrical connections ELECTRONIC REAR VIEW MIRROR 51 Mirror Does Not Tilt a Broken wire or loose connection 52 Flip Angle Inade quate or Excessive 53 Tube Does Not Light 54 Sensitivity Not Within Specified Limits b Burned out tube or transistor c Mirror not grounded a Chassis stop tab angle incorrect a Low ...

Page 53: ... in the sequence outlined Do not disassemble the Auto Pilot unit or the control assembly until all the diagnosis and adjustment operations are performed and it is proven beyond any doubt that the control assembly or Auto Pilot unit is at fault 60 Speedometer a Cables bent or kinked a Straighten or replace the cables Noise b Lack of cable lubrication b Lubricate the cables c Noisy speedometer head ...

Page 54: ...accelerator linkage adjustment d Improper locking arm latch adjustment e 1 and 2 contact points improperly adjusted a Improper carburetor or accelerator linkage adjustment a Speedometer drive pinion in the transmission damaged b Broken speedometer cable c Broken drive cable from transmission to the drive mechanism a Replace the fuse Locate and cor rect the cause of blowing fuse b Test for current ...

Page 55: ...n u e d Condition Possible Cause Correction d Faulty speedometer e Damaged drive gear or nylon gear in the drive mechanism d Remove and repair the speedom eter e Replace the nylon gear If the metal drive gear is damaged re place the housing assembly MyMopar com ...

Page 56: ...ering HEIGHT All models except Town Country and C 300J High Performance Models Town and Country Models TC 2 C 300J High Performance Side to Side Difference Maximum STEERING AXIS INCLINATION TOE IN TOE OUT ON TURNS THREAD Front inches Rear inches WHEEL BASE inches VA to VA Preferred Vi 0 to 2 Preferred 4 0 to 1 to VA 2 inches Vz inch 2 inches Vz inch 1 inches Vz inch Vz inch 5 2 to 7Vi inch to 5M i...

Page 57: ...n gun only filled with the specified lubricant Use of pressure type lubrication equipment may damage the balloon type seals NOTE All service replacement ball joints are equipped with a Knock Off type lubrication fitting After the ball joint has been lubricated with the specified lubricant knock off that portion of the lubri cation fitting over which the grease gun was installed A special ball chec...

Page 58: ...e vehicle should be jounced in the following manner just prior to tak ing each measurement Height Caster Camber and Toe In Grasp the bumpers at the center rear bump er first and jounce the car up and down several times Release the bumpers on the down cycle after jouncing both rear and front of car an equal number of times 2 FRONT WHEEL BEARING ADJUSTMENT Fig 1 1 Tighten the wheel bearing and adjus...

Page 59: ...aragraph 1 Step 4 5 The reading on both measuring pins should be as follows All models except Town and Country and C 300J 2 inches fc VB inch Town and Country 2 inches fc VB inch TC 2 C 300J High Performance 1 inches VB inch 6 Adjust if necessary by turning the torsion bar anchor bolt clockwise to increase the height and counter clockwise to decrease the height Fig 3 If it is necessary to adjust t...

Page 60: ...de The bars will be indicated as either right or left by an R or an L right or left hand side stamped on the end of the bars Fig 4 Torsion i a r Lock ting ADJUSTING BOLT 60x101 A Fig 5 Torsion Bctr Rear Support Assembly CAUTION If the vehicle is to be raised on a hoist make sure it is supported by the frame only so that the front suspension Js in full rebound under no load Removal 1 Place a jack u...

Page 61: ...is normal and will not affect front end alignment Removal 1 Place a jack under the lower control arm and raise the vehicle 2 Remove the wheel tire and drum assembly and the brake support plate 3 Remove the upper and lower ball joint and nuts Slide Tool C 3564 over the upper stud until the tool rests on the steering knuckle Turn the threaded portion of the tool locking it securely against the lower...

Page 62: ...a new ball joint it is very import ant that the ball joint threads properly engage those of the control arm 1 Screw the ball joint squarely into the control arm as far as possible by hand 2 Using Tool C 3560 or C 3561 according to Model indicated as above tighten until the ball joint housing is seated on the control arm Tighten to a minimum of 125 foot pounds torque on Models TC l TC 2 TC 3 and 15...

Page 63: ...e floor Fig 10 Removing the Lower Control Arm Strut Assembly 2 Remove the torsion bar Paragraph 5 3 Remove the wheel tire and drum assembly Remove the brake support plate assembly 4 Disconnect the shock absorber at the lower control arm bracket then push the shock absorber up into the frame out of the way 5 Remove the nuts lockwashers and bolts that attach the strut to the lower control arm 6 Remo...

Page 64: ...proximate operating position In stall the washer and nut DO NOT TIGHTEN the nut until the full weight of the vehicle is on the wheels 2 Position the new ball joint balloon type seal on the ball joint body and using Tool C 3736 on Models TC l TC 2 and TC 3 and Tool C 3867 on TY 1 install the seals To facilitate installation of the seal the ball joint stud should be perpendicular to the ball joint b...

Page 65: ...h adaptor SP 3233A is the same as Tool C 3710 Fig 13 Removing the Upper Control Arm Bushing 63x413 Fig 14 Installing the Upper Control Arm Bushing Support Sleeve Assembly When installing the new bushings be sure the con trol arm is supported squarely at the point where the bushing is being pressed in Do not use oil or grease to aid in installation 1 Position the flange end of the new bushing in To...

Page 66: ...ke hose attached Do not allow the assembly to hang by the brake hose 3 Remove the ball joint studs from the steering knuckles lift the steering knuckle out and away from the vehicle Installation 1 Position the upper and lower ball joint studs into the steering knuckle and install the lockwasher and nuts Tighten the upper ball joint stud nut to 100 foot pounds torque on Models TC l TC 2 and TC 3 an...

Page 67: ...e stone protector into position and install the cotter pins 4 Measure and adjust the front wheel toe in 13 S W A Y BAR Models so Equipped Removal 1 Remove the two sway bar link retaining nuts and concave washers 2 Remove the two sway bar cushion retaining nuts lockwashers and bolts one to each strut Slide the sway bar out through the control arm struts and away from the vehicle The sway bar cushio...

Page 68: ... tire pressure b Front brake dragging c Grease lubricant or brake fluid leaking onto brake lining d Loose or failed strut bushings e Power steering control valve out of adjustment e Tighten the steering gear mount ing bolts f Replace the worn bushings g Replace the worn bushings h Replace the ball joint i Replace the ball joint j Replace the tie rod end k Adjust or replace the bearings as necessar...

Page 69: ...nd adjust steering gear as necessary Replace the ball joints Replace the ball joints Balance the wheel and tire assembly Rotate or replace the tires as necessary Replace or adjust the wheel bearings as necessary Replace the tie rod ends Replace the strut mounting bushings Adjust the front end alignment f g a Incorrect steering gear adjustment b Loose steering gear to frame c mounting bolts Worn ba...

Page 70: ...ENTIAL Page Assembly 19 Cleaning and Inspection 19 Disassembly 19 Page Identification 16 Installation 18 Removal 18 SPECIFICATIONS MODELS TC ff TC 2 TC 3 TY 1 Type Semi Floating Gear Type Hypoid Ring Gear Diameter 8 75 inch Pinion Bearing Tapered Roller 2 Drive Pinion Bearing Pre Load 20 30 in lbs without seal Adjustment Shim Pack Differential Bearings Tapered Roller 2 Differential Bearing Adjustm...

Page 71: ...using Bolt Nuts 45 Rear Axle Drive Gear to Case Bolts 60 Rear Axle Drive Pinion Companion Flange Nut 240 min Spring Clip U Bolts Nuts 50 GROUP 3 REAR AXLE The rear axle assembly Figs 1 and 2 may be divided into four subassemblies axle drive shafts with related parts differential with drive gear drive pinion with carrier and the axle housing It is not SHAFT necessary to remove the entire assembly t...

Page 72: ...necessary the bearings may be removed from the axle shafts with bearing puller Tool C 293 and number 13 adaptors Fig 4 6 Remove the axle shaft inner oil seals with pul ler Tool C 637 Remove the brake support plate outer seal with Tool C 3565 Cleaning and Inspection 1 Using mineral spirits or dry cleaning solvent clean the axle shafts bearings cups shims and shim contacting surfaces as well as the ...

Page 73: ... life Axle Drive Shaft End Play 1 When original axle shafts and or bearings are used start the measurement of the shaft end play with the original shim packs after recording thick ness of each Where either or both the axle shaft and bearing are replaced use shim packs totaling 040 inch per side Shims are available in thickness of 005 0125 015 and 030 inch 2 Install the inner oil seals with Tool C ...

Page 74: ...th the outer end of the hub 2 DIFFERENTIAL CARRIER REMOVAL 1 Remove the axle drive shafts Paragraph 1 2 Disconnect the rear universal joint and sup port the propeller shaft up and out of the way 3 Remove the lubricant from the axle housing using a suction gun 4 Remove the attaching nuts and lift the rear axle carrier assembly from under the vehicle Fig 7 Measuring Drive Gear Runout Fig 8 Scribing ...

Page 75: ...e seal 4 While holding one hand over the companion flange end of the carrier invert the carrier in the stand The oil slinger front bearing cone shim pack and bearing spacer where used will drop from the carrier 5 Withdraw the pinion and rear bearing cone from the carrier Pinion Rear Bearing Removal 1 When removing the pinion rear bearing Fig 11 on a Chrysler Newport carrier use Tool C 293 and four...

Page 76: ...rust washer at that time 12 Remove the two differential side gears and thrust washers 4 DIFFERENTIAL CLEANING AND INSPECTION 1 Clean all parts in fast evaporating mineral Fig 13 Measuring Differential Gear Clearance Fig 14 Removing Differential Bearings spirits or a dry cleaning solvent and with the ex ception of the bearings dry with compressed air 2 Inspect the differential bearing cones and cup...

Page 77: ...the case 2 Through the large side opening of the case insert each of the two pinion and thrust washers ex actly 180 degrees opposite each other so the pinion shaft holes of the two gears and thrust washers are properly aligned 3 Rotate the gears 90 degrees so the pinion shaft holes of the case are in exact alignment with the holes in the two thrust washers and pinions 4 From the pinion shaft lock ...

Page 78: ... tool compression sleeve SP 535 square end out centralizing washer SP 534 and main screw nut SP 533 Turn the carrier in the stand to bring the nut on top Fig 19 6 Tighten the tool nut to 240 foot pounds Torque using holding Tool C 3281 on the compression sleeve to hold the assembly in several positions to make a complete revolution while tightening Remove the Fig 18 Tool C 758 Installed in Housing...

Page 79: ...0 1012 014 016 Fig 20 Installing Gauge Block Fig 21 Installing Arbor and 018 inch After proper pinion bearing preload is established do not remove the tool Depth of Mesh The position of the drive pinion with respect to the drive gear depth of mesh is determined by the location of the bearing cup shoulders in the carrier and by the portion of the pinion in back of the rear bearing The thickness of ...

Page 80: ...carrier 6 Remove the tool and bearings out of the carrier 7 Remove the shims spacer tool sleeve and rear bearing cone from the tool main screw Bearing installation 1 With the shaft end of pinion facing up install the selected correct pinion spacer washer on the pinion gear shaft These washers have a chamfer on one side The chamfer must face the pinion head 2 Position the rear bearing cone on the p...

Page 81: ...nch there fore the correct spacer for final assembly would be 088 inch To correctly read the markings on the end of the drive pinion always remember that the plus symbol indicates a deduction of the required spacer thickness whereas the minus symbol indicates the necessity for a thicker spacer When the correct spacer is selected for the drive pinion disassemble the setting tool from the differ ent...

Page 82: ...ring cups in position in the carrier and drive the cups in place with a suitable drift After properly positioning of the bearing cups in the carrier as semble the drive pinion thrust washer chamfered side down toward gear on the drive pinion stem Install the rear bearing spacer if so equipped and shims on the pinion stem Insert the pinion shaft into the carrier Install the front pinion bearing uni...

Page 83: ...ive DRIVE COAST CORRECT ADJUSTMENT PINION SPACER TOO THICK PINION SPACER TOO THIN GEAR TOO CLOSE TO PINION GEAR TOO FAR FROM PINION Heel Low Heel High Toe High Slightly Lower Slightly Higher 57x21 Fig 26 Measuring Drive Gear and Pinion Backlash 1 PINION SPACER CHANGES AFFECT THE COAST SIDE CONTACT FASTER THAN THE DRIVE SIDE 2 BACKLASH ADJUSTMENTS AFFECT THE DRIVE SIDE CONTACT MUCH FASTER THAN THE ...

Page 84: ...ING WELDING The axle housing should be completely disas sembled if it is to be welded with arc welding equip ment It is also possible to weld the assembled hous ing with gas welding equipment if precaution is taken to protect gaskets and heat treated parts 14 DIFFERENTIAL CARRIER A S S E M B L Y INSTALLATION 1 Using a new gasket install the carrier assembly to the axle housing Tighten the mounting...

Page 85: ...al ramps in the differential case There is additional clearance in the case to per mit a slight peripheral movement of the ends of the pinion shafts within the case 1 5 SURE GRIP DIFFERENTIAL IDENTIFICATION Identification of sure grip type differential assembly A X L E DRIVE GEAR PINION THRUST MEMBER DIFFERENTIAL SIDE GEAR DIFFERENTIAL PINION 58x261 Fig 30 Power Flow Shafts Turning at Same Speeds ...

Page 86: ...t to look up through the filler plug hole to identify the type of differential case The sure grip type differential case two piece construction has at taching bolts The conventional type differential case one piece construction has a domelike shape with no case cap attaching bolts Fig 32 Case Halves Scribed Fig 33 Removing or Installing Differential Case Cap 58x721 Fig 35 Removing or Installing Si...

Page 87: ...and Vz inch below 17 SURE GRIP DIFFERENTIAL REMOVAL AND INSTALLATION WARNIMG Before raising a rear wheel off the ground shut off engine set parking brake tightly carefully block front wheel diagonally opposite the one to be removed against both forward and reward movement Follow the same procedure outlined under removal and installation of the conventional rear axle dif ferential Fig 39 Removing o...

Page 88: ... 2 0 ASSEMBLY 1 Position the clutch plates and discs in their proper location in each half of the case as shown in Figure 41 2 Place the side gears in their retainers Insert splines of the retainers through the splines of the clutch discs 3 Place the aligning pin through one axle shaft thrust spacer Assemble the pinion shafts on aligning pin 4 Place the pinion gears on shafts and install the assem...

Page 89: ...t Before lowering the rear wheels of the vehicle to the floor adjust the rear brakes It is essential that both rear wheels are raised off the floor SERVICE DIAGNOSIS Conditions Possible Causes Corrections 21 Rear Axle Noise a Wheel loose on axle drum a Tighten wheel in sequence outline in Wheels and Tires b Worn drum or worn axle shaft b Replace drum or axle shaft as keyways necessary c Wheel hub ...

Page 90: ...Diagnosis 23 Test for Fluid Contamination 9 Testing Automatic Adjuster Operation 3 Wheel Cylinders 7 Wheel Stud Tightening 9 SPECIFICATIONS TC 1 TC 2 TC 3 TY 1 fype m Duo Servo Single Anchor Drum Diameter 11 in Police Heavy Duty 1 1 i n Number of Brake Shoes 8 Width Front 3 i n g e a r 2 2 in 3 in 3 in Police Heavy Duty Front 3 in Rear 3 in Brake Lining Bonded Moulded Asbestos Front Primary 12V4 F...

Page 91: ...ing duo servo two shoe internal expanding brake The lower ends of the brake shoes are connected by a tubular star wheel adjusting screw as shown in Figures 1 or 2 SERV1CI PROCEDURES 1 ADJUSTING THE BRAKES 1 Jack up the vehicle so all wheels are free to Hydraulic brake adjustment is made by a single turn adjustment at each wheel 2 Remove the rear adjusting hole cover from Fig 1 Self Adjusting Brake...

Page 92: ... 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 apply the brakes vigorously This will provide the necessary inertia to cause the secondary brake shoe ...

Page 93: ...just ing access hole 2 Insert a thin screw driver into the brake adjust ing hole and hold the adjusting lever away from the notches of the adjusting screw 3 Insert Tool C 3784 into the brake adjusting hole and engage the notches of the brake adjust ing screw Release the brake by prying up with the adjusting tool 4 Remove the wheel cover cotter pin and axle nut 5 Install rear wheel hub puller Tool ...

Page 94: ...etween the primary and secondary shoes with the star wheel next to the secondary shoe Refer to Fig 5 The star adjusting wheels are stamped R right side and L left side and in dicate their location on the vehicle 3 Overlap the anchor ends of the primary and the secondary brake shoes and install the adjusting spring and lever 4 Spread the anchor ends of the brake shoes to maintain the adjusting leve...

Page 95: ...e cover of the master cylinder to prevent any dirt from fall ing into the master cylinder reservoir when the cover is removed Using Automatic refiller Tool C 8378 with adaptor C 3494A or the one man bleeder tank C 3496 with adaptor C 3494A provides a convenient means of keeping the master cylinder full while bleeding the hydraulic system NOTE The brakes may also be bled manually by having an assis...

Page 96: ...t have light scratches or show signs of corrosion can usually be cleaned up with crocus cloth However cylinders that have deep scratches or scoring may be honed providing the diameter of the cylinder bore is not increased more than 002 inch A master cylinder bore that does not clean up at 002 inch should be discarded and a new cylinder installed Black stains on the cyl inder wall are caused by the...

Page 97: ...d of the pistons facing the open ends of the cylinder 4 Install the boots over the ends of the cylinder Keep the assembly compressed with the aid of a brake cylinder clamp until the brake shoes are assembled 10 BRAKE SUPPORT PLATE Remover Front 1 With the wheel and brake drum removed re move the four support plate attaching nuts and washers 2 Disconnect the brake line from the brake hose 3 Remove ...

Page 98: ...at the sequence tightening to the specified 55 foot pounds torque 12 TEST FOR FLUID CONTAMINATION To determine if contamination exists in the brake fluid as indicated by swollen or deteriorated rubber cups the following tests can be made 1 Place a small amount of the drained brake fluid into a small clear glass bottle Separation of the fluid into distinct layers will indicate mineral oil content 2...

Page 99: ...re 11 1 With the vehicle jacked up or on a suitable hoist remove the rear wheels 2 Remove the brake drum from the rear axle 3 Remove the brake shoe return springs Fig 11 Parking Brake Cable Routing Imperial Fig 12 Parking Brake Cable Routing Chrysler 4 Remove the brake shoe retaining springs 5 Remove the brake shoes strut and spring from the brake back plate and disconnect the brake cable from the...

Page 100: ...BRAKES 5 11 Fig 14 Parking Brake Pedal Chrysler MyMopar com ...

Page 101: ... driver force the cable housing and attaching clip out of the frame crossmember 2 Refer to Figure 13 and remove the bellcrank clip pivot pin and remove the clevis and cable from the mounting bracket 3 Remove the clevis pin and work the cable up and out of the clevis 4 Disengage the parking brake cable and housing from the anchoring bracket at the transmission and remove the cable assembly from the...

Page 102: ... are 1 A vacuum power section which is composed of a front and rear housing a power diaphragm a return spring and a push rod Fig 15A A G M BOOSTER BRAKE 2 A control valve built integral with the power diaphragm and connected through a valve rod to the brake pedal and controls the degree of brake applica tion or release in accordance with the pressure applied to the brake pedal 3 A master cylinder ...

Page 103: ...s together remove the booster from the vise and carefully separate the two shells 6 Remove the return spring 7 Remove the master cylinder push rod retainer Fig 17 8 Remove the diaphragm and valve assembly from the rear shell 9 Place the diaphragm and valve housing face down and stretch the rubber diaphragm out and over the hub of the valve body Fig 18 10 Holding the valve housing in a vertical pos...

Page 104: ...sert the lock into the housing and valve assembly 6 Dip the diaphragm in mineral spirits and install it on the plate and valve body 7 Install the diaphragm and valve body into the rear housing Fig 20 8 Install the master cylinder push rod and re tainer 9 Supporting the rear housing on blocks or a vise install the return spring with the small end toward the front of the booster assembly 10 Place th...

Page 105: ...and master cylinder from the vehicle Disassembly 1 Remove the four master cylinder attaching nuts and remove the master cylinder 2 Scribe an aligning mark across the joint of the front and rear portions of the booster assembly This will insure correct alignment during reassembly 3 Remove the dust boot from the operating rod 4 Remove the two filter cover retaining screws 5 Remove the filter cover a...

Page 106: ...ve the load ring and valve Fig 31 16 Remove the plunger from the valve body 17 Remove the rear seal retainer from the plung er NOTE Theplunger assembly will be serviced as a unit and need not be dismantled further 18 Using a small screw driver remove the rear seal from the rear seal retainer Remove the 0 CUSHION RING PUSH ROD Fig 28 Master Cylinder Push Rod 63X348 LEVERS 12 BODY Pig 29 Valve Body ...

Page 107: ... into the groove of the plunger 13 Install the levers and fulcrum ring into the rubber retainer 14 Align the indexing tab with the notch in the valve body and insert the assembly into the valve body with the fulcrum ring on the underside 15 Install the two plastic rings onto the plunger shaft 16 Install the master cylinder push rod onto the plunger assembly 17 Install the bellows into the bellows ...

Page 108: ...ne and wheel cylinder line at the tubing connectors on the slave cylinder housing 3 Remove the two retaining screws that secure the slave cylinder housing to the mounting bracket and remove the power brake assembly from the vehicle 4 Remove the filter retaining nut and bolt and re move the filter assembly from the inner side of the fender side shield Disassembly 1 Disconnect the by pass tube from ...

Page 109: ...n are serviced as an assembly Grasp the hub of the control valve piston and with a rotating motion pull the control valve assembly out of its seat in the slave cylinder housing Pry up the corners of the Tinnerman nut to disengage them from the piston hub and remove the Tinnerman nut diaphragm plate and diaphragm from the piston assembly Remove the rubber seal from the counterbore in the hub of the...

Page 110: ...ip screen and hair pad Fig 35 Cleaning and Inspection Wash all internal metal parts that come in contact with brake fluid in alcohol Wipe thoroughly with clean cloths Use compressed air to dry all internal passages Discard all rubber parts and gaskets in cluding the large copper washer m t seals between the end cap and the slave cylinde housing Clean the air filter pad in mineral spirits and air d...

Page 111: ...the unthreaded end of the by pass tube through the grommet in the rear shell and connect the threaded end to the fitting on the control valve cover 17 Install the filter pad wire screen and retain ing clip in the filter housing Installation 1 Position the power brake assembly on the mounting bracket and install the two retaining screws with a flat washer next to the bracket and then a lock washer ...

Page 112: ... h Saturated brake hning a Fill and bleed the master cyhnder b Reline and adjust the brakes c Adjust the brakes and fill the mas ter cyhnder d Recondition or replace the wheel cyhnder and replace both brake shoes e Tighten all brake fittings or re place the brake line f Fill and bleed the hydraulic brake system g Recondition or replace the master cyhnder and bleed the hydraulic system a Fill the m...

Page 113: ...or out of round brake drum a Rough or scored brake drum b Loose support plate a Adjust the brakes and check the fluid b Release the parking brakes c Recondition the wheel cyhnder d Replace the brake shoe return spring e Free up and lubricate the brake pedal and linkage f Recondition the master cyhnder g Properly adjust the master cyhn der push rod h Use compressed air and blow out the rehef port i...

Page 114: ...er approximately one minute there should be enough vacuum left to give power assist for several apphcations 32 Dragging Brakes All Wheels 33 Grabbing Brakes a Brake shoes improperly adjusted b Brake pedal linkage binding c Excessive hydraulic seal friction d Compensator port plugged e Sticking valve plunger f Improper booster push rod length ad justment g Fluid cannot return to master cyhnder a Gr...

Page 115: ...of a Leak in rear housing a Locate and correct the leak Brakes When Engine Starts b Diaphragm out of location in housings b Position the diaphragm and allowing atmospheric pressure into rear chamber c Sticking or unseated actuating valve c Free up and seat properly assembly 37 Grunting Noise in a Air in hydrauhc system a Bleed the brakes Booster on Application Lubricate the plunger b Lack of valve...

Page 116: ... Tube Spacer Transmission Oil Cooler Type Concentric Tube Concentric Tube Rad Bottom Tank Rad Bottom Tank Radiator Pressure Cap Type Pressure Vent Pressure Vent Pressure Setting 14 psj Std 14 psi Std 14 psi Std 16 psi Air Con 16 psi Air Con 16 psi Air Con ditioning Only ditioning Only ditioning Only Fan Standard 4 Blade 18 Dia 7 Blade 18 Dia 4 Blade 18 Dia Air Conditioning 7 Blade 18 Dia 7 Blade 1...

Page 117: ...5 Alternator With Air Conditioning 40 60 Without Air Conditioning TC1 TC2 40 60 TC3 TY1 30 40 Fan Idler Bracket 35 50 N O T E The torque wrench assumes a different position according to the model when adjusting the belt tension BELT DEFLECTION METHOD ALL MODELS Deflection Inches to be Applied ot Midpoint of Belt Segment Under a 5 Pound Load See Figure 10 Accessory Belt in Use New Belt Power Steeri...

Page 118: ...is enclosed by the housing to which the fan is bolted This housing is mounted on the shaft through permanently sealed bearings A nominal clearance space is maintained between the housing and rotor The housing is partially filled with a silicone fluid and the shear resistance of the fluid between the housing and rotor provides the driving force rotating the fan The fan drive has been designed to pr...

Page 119: ...Figure 4 2 Remove the impeller metal insert using a chisel and hammer The shaft and bearing assembly do not have to be removed to service a leaking pump 3 The shaft and bearing assembly should be very carefully inspected to be sure the pump leak has not damaged the bearing 4 Support the body on the fan hub end and press out the shaft and bearing assembly CAUTION The shaft and bearing assembly can ...

Page 120: ...or support bolts 5 Remove the radiator Installation 1 Attach the radiator to the radiator support bolts and reconnect the two oil cooler connections if so equipped 2 Install the fan shroud if so equipped connect the hoses and refill the cooling system Test for leaks 3 Add sufficient oil to the transmission to refill the system If automatic transmission equipped Cleaning 1 Drain the cooling system ...

Page 121: ...s the forcing of water through the cooling system using air pres sure in a direction opposite to that of the normal flow of water Flushing Cylinder Block 1 Drain the radiator and remove the hoses at the radiator 2 Remove the thermostat and reinstall the ther mostat housing 3 Install flushing gun Tool C 311 or other suit able flushing gun to the inlet hose 4 Connect the water hose of the gun to a p...

Page 122: ... through the thermostatic housing 2 Fill the cooling system to IV2 inches below filler neck with water and rust resistor or water and anti freeze as required 7 RADIATOR PRESSURE C A P Radiators are equipped with a 14 psi cap as stand PRESSURE FILLER CAP Fig 7 Radiator Pressure Cap ard equipment and 16 psi with air conditioning as shown in Figure 7 Always note the identification number on the cap w...

Page 123: ...m the spark plugs on one bank and operate the engine on the opposite bank If the needle continues to fluctuate it indicates a leak on the bank still in operation If the needle ceases to fluctuate the leak is in the bank the combustion has been released from 5 If the needle on the dial does not fluctuate race the engine a few times and if an abnormal amount of water emits from the exhaust system at...

Page 124: ...deflection This method should be used only when it is not possible to use the torque method To tension the 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 Vz inch square drive hinge handle can be used if the accessory has a square hole Tighten the mounting bolts and check the deflection See Specificat...

Page 125: ...ket b Refer to corrections f to j listed under External Leakage c Pressure test cooling system re place the cylinder head d Pressure test cooling system re place the cylinder head e Pressure test cooling system re place the cylinder block f Pressure test cooling system re place the cylinder block a Fill radiator to correct level b Replace the hose and spring as necessary c Tighten or replace the f...

Page 126: ...eeze Flush radiator and refill with clean soft water and rust inhibitor a Replace the thermostat b Replace the temperature gauge a Add 202 MoPar Water Pump Lube P N b Replace bearing seal and impeller ACCESSORY BELT DRIVES SERVICE DIAGNOSIS Condition Possible Cause Correction 22 Insufficienty Acces a Belt too loose a Adjust belt tension sory Output Due to b Belt excessively glazed or worn b Replac...

Page 127: ... 22 Resistance and Current Draw 19 Service Diagnosis 82 Starter Clutch Unit 24 Starting Motor Removal and Installation 18 PART 3 A L T E R N A T O R AND VOLTAGE REGULATOR Alternator Servicing 31 Bench Tests 31 Construction and Operation 27 Regular Operation 27 Regular Operating Voltage 30 Regular Servicing 30 Replacing Slip Rings 36 Service Diagnosis 84 Testing the Alternator 34 Voltage Regulator ...

Page 128: ...nosis 89 Testing 59 PART 7 WINDSHIELD WIPERS Assembly of Link Variable Speed 65 Assembly of Motor 62 Bench Testing Motor 64 Disassembling of Links 63 Disassembly of Motor 62 End Play Adjustment 64 Inspection of Motor 63 Installation of Motor Chrysler 64 Installation of Motor Imperial 65 Refacing Commutator 63 Removal of Motor Chrysler 62 Removal of Motor Imperial 62 Service Diagnosis 89 Switch Var...

Page 129: ...d Terminal Negative Negative Negative Model MoPar Std MB 24 59 MB 27 70 MB 27 70 STARTING MOTOR GEAR REDUCTION STARTING MOTOR All 1963 Passenger Vehicles Except TCI TC2 with Manual Trans Starting Motor Model 2095150 Make Chrysler Built Voltage 12 No of Fields 4 3 Series 1 Shunt No of Poles 4 Brushes 4 Spring Tension 32 to 48 Ounces Drive Overrunning Clutch End Play 010 035 Free Running Test Voltag...

Page 130: ...Plus or minus three ampere tolerance is provided to allow for temperature Variation Current output is measured at 1250 engine RPM and 15 volts Voltage is controlled by variable load across the battery such as a carbon pile ALTERNATOR VOLTAGE REGULATOR Alternator Voltage Regulator Number 2098300 Volts 12 Ground Polarity Negative Point Gap 014 inch plus or minus 002 inch Air Gap 048 to 052 inch nomi...

Page 131: ...8212 200567 2095223 62 160 2 Primary Resistance 70 80 F 1 65 1 79 ohms 1 41 1 55 ohms Secondary Resistance 70 80 F 9400 11700 ohms 9200 10600 ohms Ballast Resistor 2095501 Resistance 70 80 F 0 5 0 6 ohms Current Draw Coil and Ballast Resistor in Circuit Engine Stopped 3 0 Amperes Engine Idling 1 9 Amperes 2098690 Chrysler Built 41 3 cubic inch TC 3 TY 1 with 4 Bore Carb 0 310 to 490 0 to 2 490 3 5...

Page 132: ...imary Resistance 70 80 F 1 65 1 79 ohms 1 41 1 55 ohms 9400 11700 ohms 9200 10600 ohms Ballast Resistor 2095501 Resistance 70 80 F 0 5 0 6 ohms Current Draw Coil and Ballast Tesistor in Circuit Engine Stopped 3 0 Amperes Engine Idling 1 9 Amperes 2098313 Auto Lite Built 1BS 4011A with Tachometer Drive and Double Breaker 413 cubic inch TC l TC 2 with 4 Bore Carb 0 325 to 475 0 to 4 0 475 4 5 to 6 5...

Page 133: ... breaker CHART Rear Window Defroster 15 15 Air Cond or Heater 20 20 Rear Air Conditioning 20 20 AH number ratings in amps CIRCUIT BREAKER CHART C Breaker Windshield Wiper Variable Speed Windshield Wiper Single Speed Lighting System Elec Window lifts Six Way Seat Top lift Location Back of Wiper Switch integral with Wiper Switch Integral with Headlamp Switch Behind left front kick panel Chrysler Imp...

Page 134: ...ell The temperature correction amounts Fig 1 Cleaning Inside of Cable Clamp Fig 2 Cleaning Outside of Battery Post to 004 specific gravity points for each 10 degrees Fahrenheit change in temperature The liquid level of the battery cell should be at normal height and the electrolyte should be thor oughly mixed with any battery water which may have just been added by charging the battery before taki...

Page 135: ...able clamps and not the ammeter clips 4 Turn the control knob clockwise until ammeter reading is 200 amperes 5 Maintain the load for 15 seconds voltmeter should read 9 5 volts or more which will indicate battery has good output capacity 6 Turn the control knob to the OFF position 5 CHARGING THE BATTERY If the voltage in High Rate Discharge Test was under 9 5 volt the battery should be test charged...

Page 136: ...autions are taken 1 The battery electrolyte temperature must N E V E R exceed 125 degrees Fahrenheit If this temperature is reached the battery should be cooled by reducing the charging rate or remove the battery from the circuit Fig 5 Fast Charging the Battery 2 As the batteries approach full charge the elec trolyte in each cell will begin to gas or bubble Ex cessive gassing must not be allowed 3...

Page 137: ...olenoid Switch 1 Each connection 0 Replace the faulty cables Clean and tighten all connections Starter Ground Circuit Test 1 Connect the voltmeter positive lead to the starter housing and the negative voltmeter lead to the battery negative post 2 Crank the engine with a remote control start er switch and observe the voltmeter reading The voltmeter reading should not exceed 2 volt A read ing of 2 v...

Page 138: ...ecifications 3 With the applied battery voltage adjusted to 4 volts the stall torque should be 8 5 foot pounds minimum with a current draw of 350 amperes 9 STARTER DISASSEMBLY F i g 6 1 Remove the through bolts and tap the com mutator end head from the field frame 2 Remove the thrust washers from the arma ture shaft 3 lift the brush holder springs and remove the brushes from the brush holders 4 Re...

Page 139: ...r running clutch drive from the armature shaft 12 If it is necessary to replace the field coils re move the ground brushes terminal attaching screw and raise the brushes with the terminal and shunt wire up and away from the field frame Fig 12 Remove the pole shoe screws with a special pole shoe impact screwdriver Tool C 3475 Cleaning and Inspection 1 Do not immerse the parts in a cleaning sol vent...

Page 140: ...n be removed by spread ing the retainers and disengaging the springs from the Fig 13 Testing Armature for Short Fig 14 Testing Armature for Ground retainer legs 9 Measure the brush spring tension with a spring scale hooked under the spring near the end Pull the scale on a line parallel to the edge of the brush and take a reading just as the spring end leaves the brush The spring tension should be ...

Page 141: ... the brush ring are grounded Replace the brush ring assembly if the brush holders are grounded 13 REPLACING THE FIELD COILS A pole shoe impact screwdriver Tool C 3475 should be used to remove and install the field coils to pre vent damage to the pole shoe screws and for proper tightening The pole shoes that are loose and not properly seated may cause the armature core to rub the pole shoes This wi...

Page 142: ...en 40 to 50 inch pounds torque 17 ADJUSTING STARTER DRIVE GEAR PINION CLEARANCE 1 Place the starter assembly in a vise equipped with soft jaws and tighten the vise sufficiently to hold the starter Fig 18 Measuring Starrer Drive Pinion Clearance NOTE Place a wedge or screwdriver between the bottom of the solenoid and the starter frame to elim inate all deflection in the solenoid when making the pin...

Page 143: ...WASHER FRICTION WASHER 62x219 Fig 19 Starting Motor Cross Section MyMopar com ...

Page 144: ...rt eliminated in the test is at fault Maximum allowable voltage loss is as follows Battery ground cable 2 volt Engine ground circuit 1 volt Each connection 0 volt SERVICE PROCEDURES 2 1 STARTING MOTOR Removal 1 Disconnect the ground cable at battery 2 Remove the cable at the starter 3 Disconnect the solenoid lead wire at the sole noid terminals 4 Remove the one stud nut and one bolt attach ing the...

Page 145: ...d the terminal and remove the terminal screw Fig 20 5 Unsolder the shunt field coil lead from the starter brush terminal Fig 21 6 Remove the brush insulator which prevents contact between the brush terminal and the gear housing Fig 22 SHUNT FIELD COIL LEAD BRUSH HOLDER PLATE SCREW STARTER BAHERYlr l r 1 1 w TERMINAL Nff s b L E N O I D TERMINAL 62x200 Fig 22 Removing or Installing Brush Holder Pla...

Page 146: ...ghten the solenoid wire and remove the brush holder plate with brushes as an assembly 12 Remove the ground screw from the starter gear housing 13 Remove the solenoid assembly from the gear housing well Fig 25 14 Remove the nut steel washer and sealing Fig 25 Solenoid Assembly Removed Fig 26 Removing Solenoid Coil Sleeve 62x206 Fig 27 Identification of Solenoid Coil Retainer and Retainer Washer was...

Page 147: ...g 28 21 Release the snap ring that positions the driven gear on the pinion shaft Fig 29 CAUTION The ring is under tension and a cloth should be placed over the ring to prevent the ring from springing away after removal 22 Release the retainer ring at the front of the pinion shaft Fig 30 NOTE Do not spread the retainer ring any greater than the outside diameter of the pinion shaft other wise the lo...

Page 148: ...ons 2 4 TESTING THE ARMATURE Testing the Armature far Short Circuit Place the armature in the growler and hold a thin steel blade parallel to the core and just above it while slowly rotatingthe armature in the growler A shorted armature will cause the blade to vibrate and be at tracted to the core Replace any armature that is shorted Testing Armature for Ground Contact the armature shaft and each ...

Page 149: ...F i g 35 Starter Motor Exploded View MyMopar com ...

Page 150: ... the solenoid moving core and engage the shifting fork Fig 33 3 Enter the pinion shaft into the drive housing and install the friction washer and driven gear 4 Install the clutch and pinion assembly Fig 32 thrust washer retaining ring and the thrust washer 5 Complete the installation of the pinion shaft engaging the shifting fork with the clutch actuators Figure 37 shows the correct relation of th...

Page 151: ...the brush holder with brushes and contacts as an assembly 16 Enter the solenoid lead wire through the hole in the brush holder Fig 39 and solenoid stud insul ating washer flat washer and nut NOTE Use care when installing the solenoid contact seal over the tab on the brush plate to prevent tearing the seal 17 Solder the solenoid lead wire to the brush terminal post Fig 40 Wrap the wire securely SOL...

Page 152: ...assembly and install the starter frame screws and lockwashers Tighten the screws securely 27 Install the starter gear housing dust cover Make sure the dimples on the cover are securely en gaged in the holes provided in the gear housing 28 Install the ground screw in the gear housing 29 Clean the area at the joint between the brush holder plate to field frame and gear housing mating joint Apply a b...

Page 153: ...voltage The voltage regulator accomplishes this by controlling the flow of current in the rotor field coil and in effect controls the strength of the rotor magnetic field 3 0 TESTING THE ALTERNATOR SYSTEM O n Vehicle Field Circuit Resistance Test Fig 491 1 Disconnect the ignition wire at the coil side of HEAT SiNK GROUND BRUSH Fig 46 Alternator Assembly the ballast resistor and connect the positiv...

Page 154: ...rnator Exploded View 4 Turn the ignition switch off disconnect test charged proceed with the tests as follows instrument and reconnect ignition primary wire at NOTE Disconnect the battery ground cable at the the coil side of the ballast resistor battery negative post to avoid accidental shorting Charging Circuit Resistance Test o f f h e fh ging or field circuit when making test Test the condition...

Page 155: ...METER 62x196A Fig 51 Current Output Test TEST V O L T M E T E R IGNITION RESISTOR G R O U N D WIRE IGNITION COIL ItNITIIN SWITCH CARBON PILE R H E O S T A T A M M E T E R IS T A R T E R SOLEMIO 62x197A 13 r y 7 JHflHHflflHHHi Fig 52 Voltage Regulator Test 2 Disconnect the BATT lead at the alternator output BATT terminal 3 Connect a 0 50 ampere scale D C ammeter in series between the alternator BAT...

Page 156: ...mperes output as registered on the test ammeter The volt age should increase and amperage should decrease NOTE There will be a slightly higher voltage at higher engine speeds above 2200 rpm however this increased voltage must not exceed the voltage speci fied by more than 7 volt at any temperature range If the voltage reading is less than 2 volt from read ings in Step 5 under Upper Contact Test te...

Page 157: ...ver Install the regu lator The electrical adjustment must be performed on the vehicle after installation of the regulator 3 2 ALTERNATOR Removal If the alternator performance does not meet cur rent output specification limits it must be removed and disassembled for further test and servicing 1 Disconnect the battery ground cable 2 Disconnect the alternator output BAT and field FLD leads and discon...

Page 158: ...ere not assembled in this order or if the T O O L DRIVE E N D SHIELD STATOR K l m fr EaSDmt 62x108 Fig 57 Separating Drive End Shield from Stator wrong screw was used this could be the cause of the ground condition Disassembly To prevent possible damage to the brush assem blies they should be removed before proceeding with the disassembly of the alternator The insulated brush is mounted in a plast...

Page 159: ... the rotor shaft Remove the bearing with puller Tool C 3615 and adapter as follows Fig 61 Removing the Heat Sink Insulator Fig 62 Removing the Rectifier End Shield Bearing a Position the center screw of Tool C 3615 on the rotor shaft b Place the thin lower end of the adapters SP 3375 under the bearing equally spaced and the upper end of the adapters around the center screw c Hold the adapters and ...

Page 160: ... touch the test prod to the exposed metal connection nearest the rectifier The reading for satisfactory rectifiers will be 1 amperes or more The reading should be approxi mately the same for the three rectifiers When two rectifiers are good and one is shorted the reading taken at the good rectifiers will be low and the reading at the shorted rectifier will be zero Disconnect the lead to the rectif...

Page 161: ...ator for grounding using a 110 volt test lamp Fig 67 Use wood slats to insulate the stator from the rectifier shield Contact one prod of the test lamp to the stator pole frame and con tact the other prod to each of the three stator leads The test lamp should not light If the test lamp lights the stator windings are grounded g Test the stator winding for continuity by con tacting one prod of the te...

Page 162: ...ip ring from the rotor 6 Scrape the ends of the field coil lead wires clean for good electrical contact 7 Scrape one end about 6 inch of a piece of bare wire approx 18 gauge three inches long to be used as a guide wire 8 Tin the scraped area of the guide wire with resin core solder Lap the tinned end of the wire over the field coil lead to the insulated ring and solder the two together 9 Position ...

Page 163: ...le the alternator 15 Position the new grease retainer insulator and grease retainer on the rotor shaft and press the re tainer on the shaft with installer Tool C 3921 Fig 74 The retainer is properly positioned when the in ner bore of the installed tool bottoms on the rotor shaft Fig 74 Installing Bearing Grease Retainer Assembling the Alternator 1 Confirm the rectifier identification to make sure ...

Page 164: ...ectifier to make certain the rectifier was not dam aged by the soldering or pressing operations 5 Support the end shield on Tool C 3925 so that Fig 77 Installing the Rectifier End Shield Bearing Fig 78 Installing the Drive End Shield and Bearing the notch in support tool will clear the raised section of the heat sink and press the bearing into position with Tool SP 3381 Fig 77 NOTE New bearings ar...

Page 165: ...ndary high voltage circuit includes the coil secondary winding the distributor cap and rotor the spark plug cables the spark plugs and the vehicle frame 3 7 SECONDRAY CIRCUIT INSPECTION The coil to distributor cap wire and the spark plug wires should make good clean contact in the ignition coil the distributor cap towers and on the spark plugs Wires that are loose or are not inserted all the way i...

Page 166: ...engine stalling or complaints of creeping and hard shifting on vehicles equipped with automatic transmissions Test procedures are as follows 1 Turn the Selector Switch to the CALIBRATE position and adjust the Dwell Calibrator until the Dwell Meter reads on the SET line test leads sepa rated 2 Connect the red lead of the test unit to the distributor primary terminal at the coil and the black lead t...

Page 167: ...la tion may permit secondary current to arc to ground 3 Start the engine and set the idle to specifica tions rpm engine at normal operating temperature transmission in neutral 4 Using a timing light observe the position of timing mark on the crankshaft damper and check against the specifications 5 Loosen the distributor hold down clamp screw and rotate the distributor housing so that the specified...

Page 168: ...follows a Remove the distributor drive collar retaining pin and slide the collar off the end of the shaft b Use a fine file to clean the burrs from around the pin hole in the shaft and remove the lower thrust washer c Push the shaft up and remove it through the top of the distributor body Remove the upper thrust washer d Remove the shaft oiler and lift out the oiler wick CAUTION On Chrysler Built ...

Page 169: ...ELECTRICAL 8 43 AD P I N y Fig 31 Distributor Disassembled View Chrysler MyMopar com ...

Page 170: ... SPRING CONTACT ROTOR COt 15Eft CONTACT SET WASHE1 SCREW LEAD SraKG SET WASKEi iEAtING BUSHING WASHER COLLAR HOUSING WASH1I SCREW OILER SCREW VACUUM CHAMiEi SPRING WASHER 6 2 x 3 1 0 Fig 82 Distributor Disassembled View Auto Lite MyMopar com ...

Page 171: ...using If the rod cannot be inserted through the housing and the bushing drill a W hole through the upper bushing by drilling through the oil wick hole Remove burrs caused by the drilling operation i Install the burnishing tool part of C 3041 Tool set and force the burnisher through both the bushings Fig 87 The correct bushing inside the diameter is 04995 to 5000 inch TOOL DRIVER PRESS RAM TOOL ADA...

Page 172: ... contact gap 11 Lubricate the felt pad in the top of the dis tributor cam with 3 to 5 drops of light engine oil and install the rotor 4 5 TESTING BREAKER A R M SPRING TENSION 1 Hook a spring scale Tool MTU 36 on the breaker arm and pull in a straight line at right angles to the point surfaces Fig 89 Take a reading as the points start to separate under the slow and steady pull of the scale The spri...

Page 173: ...pri mary and secondary spring on the cam yoke to in crease or decrease the spring tension The governor spring tabs can be reached through the access hole at the breaker plate Rotate the shaft until the proper spring and tab lines up with the access holes Insert a screwdriver blade through the access hole and bend the spring tab toward the distributor cam to decrease spring tension and advance the ...

Page 174: ...ITION COIL The ignition coil is designed to operate with an external ballast resistor The ballast resistor is a fixed resistance in the ignition primary circuit During low speed operation when the primary circuit current flow as high the ballast resistor temperature rises increasing the re sistance This reduces the current flow thereby prolonging ignition point life At high speed oper ation when t...

Page 175: ...t The terminals are the protective type and this should not occur unless you inadvertently touch the terminal of disconnected socket However due to the low wattage it will not harm you 1 Turn on the instrument panel switch and ob serve the instrument lighting If any portion of the instrument panel does not light the unlighted lamps are open and the complete instrument should be replaced 2 If the e...

Page 176: ...voltage to the gauges The constant voltage is provided through the use of a voltage regulator contained inside the fuel gauge case on Chrysler models and inside the tem perature gauge on Imperial models The terminals on the gauge that houses the con stant voltage regulator internally is marked as fol lows A is the output terminal for the controlled voltage from the regulator I is the 12 volt input...

Page 177: ...icating sys tem is identical in operation with fuel system with the exception of the method of varying the resistance of the sending unit When the engine is cold the resistance of the disc in the temperature sending unit is high Low tem perature will be indicated Fig 98 Fig 99 Operation at High Temperature As the engine temperature increases the resistance of the temperature sending unit disc star...

Page 178: ...move the center screw attaching both the ammeter and oil pressure gauge then carefully remove the ammeter 5 Fuel Gauge Remove the one attaching screw at the outer end holding the fuel gauge Remove the center screw attaching both the fuel gauge and the temperature indicator then carefully remove the fuel gauge 6 Temperature Indicator Remove the one at taching screw at the outer end holding the temp...

Page 179: ...l nut 3 Remove the dial plate and back dial 4 Remove the dial lamp and switch retaining nut 5 Remove the switch from rear of instrument panel 6 Disconnect the connector plug and remove switch assembly T U R N S I G N A L I N D I C A T O R S H E A D L A M P S S IJTON 0 1 P R E S S U R E L I G H T E R 1 K U L W A R N I N G L A M P 3 5 W I N D S H I E L D W I P E R S W I T C H Fig T01 Cluster Removed...

Page 180: ... terminal must be disconnected before installation of cluster 1 Position the instrument cluster on the steering column jacket tube in front of the cluster opening in the instrument panel 2 Connect the heater or air conditioning vacuum hoses to the heater or air conditioning vacuum control switch 3 Connect the two printed circuit multi con TO BATTERY POSITIVE POST HEADLAMP SWITCH CLUSTER BASE TURN ...

Page 181: ...ight and accessory fuses The fuse capacity is printed on the fuse block as an aid to replacement require ments 6 4 CIRCUIT BREAKER As a safety precaution circuit breakers are used for the headlamps and wiper circuits They insure that these essential services will continue to function if an intermittent short circuit occurs PART 6 LIGHTING SYSTEM 6 5 DUAL HEADLAMPS The dual headlamp system consists...

Page 182: ...rs Typical Mounting and Adjusting the Aimers Figure 1081 If the aimers are suspected of being out of adjust ment refer to Paragraph 66 Testing and Adjusting Aimer Calibration 1 While holding an aimer in alignment with the lens of one outer headlamp bring the aimer up to and against the headlamp lens NOTE Make certain that the headlamp lens pads are making full contact with the aimer mounting flang...

Page 183: ...EWS HORIZONTAL ADJUSTMENT SCREWS Fig 109 Headlamp Adjustment Points Typical Fig 110 Inspecting the Aimer for Calibration bubble of the spirit level on the aimer to the vehicle side of center Use care to avoid disturbing the installed position of the aimers Then turn the screw clockwise until the bubble is centered for correct aim and elimination of backlash 2 Make the vertical adjustment on the ot...

Page 184: ...3 Disconnect the horn wire at the horn blowing switch 4 Remove the four screws and insulators and remove the horn blowing switch Fig 111 5 Remove the four screws and remove the horn blowing switch mounting plate Fig 112 6 Loosen the steering wheel nut several turns and install the Steering Wheel Puller Tool C 3428 Fig 113 and remove the steering wheel nut and steering wheel 7 Remove the directiona...

Page 185: ...g or wire in the steering column jacket tube as an aid to replacement of the wiring 8 Remove the screws attaching the directional switch to the steering column and remove the switch from the top of the steering column Installation 1 Attach the string or wire that was left in the steering column jacket tube during removal to the directional switch wiring and carefully pull the string or wire down t...

Page 186: ... 8 Connect a test ammeter between the positive post of a 12 volt battery and the horn terminal post Connect a jumper lead from the negative battery post to the horn base Turn the adjusting screw to obtain a reading of eight amperes minimum to ten amperes maximum at 12 5 volts Must not exceed ten amperes maximum SPARTON HORN 1 Disconnect the connections at each horn to determine which horn is not o...

Page 187: ...s an off glass parking feature which is accomplished by reversing the motor and the use of parking cams at the pivot pins of the intermediate crank arm When the switch is turned to the off position the motor reverses direction and at the same time the parking cams rotate 180 degrees lengthening the linkage slightly to park the blades against the windshield moulding The linkage shortens when the mo...

Page 188: ... so as not to bend the links Installation 1 Enter the wiper motor bracket and links through the glove box opening and attach the link arms to the pivot crank pins 2 Install the spring washer and lock clips on the crank pins 3 Install the wiper motor and bracket attaching nuts Tighten the nuts securely 4 Adjust the wiper parking position by moving the wiper motor parking switch plate 5 Connect the ...

Page 189: ...al 11 Check operation of the wipers 7 6 MOTOR LINKS Disassembly 1 Remove the chp holding the left hand link to the crank arm 2 Remove the bevel washers and the link 3 Remove the parking cam and the spring release Variable speed 4 Remove the coil spring by spreading the ends of the spring Variable speed 5 Disassemble the right hand link in the same manner after removing the crankarm to lever nut an...

Page 190: ... is turned off Variable Speed Motor The switch contains a bar resistance plate which provides a means of controlling the amount of cur rentflowto the motor field as the switch control shaft is rotated In addition the switch is designed to pro vide a circuit to the motor to reverse the direction of the current to the field winding thus providing a means of reversing the armature A separate circuit ...

Page 191: ...nstant speed motor on the nylon gear with the slot pointing in the same direc tion as the motor crank arm Install the contact fol lower variable speed motor with open end pointing in the same direction as the motor crank arm Assembly of Wiper Link Variable Speed Install the spring washer concave surface toward the crank arm Install the crank pivot coil spring on the pivot Install the spring releas...

Page 192: ...sembly 5 Disconnect the seat adjuster red feed wire 6 Remove the seat guide attaching stud nuts and remove the adjuster On Imperial remove the nut which holds the strut to the floor pan bracket before removing the adjuster Fig 126 Power Seat Arrangement Installation 1 Install the adjuster and seat guide stud nuts 2 Reconnect the seat adjuster red feed wire 3 Install the front seat and cushion asse...

Page 193: ...right side tubes Make sure the cables seat in the drive assembly 7 Install the right side tubes retainer plate 8 Bolt the left guide assembly to the floor 9 Install the seat and cushion assembly 10 Reconnect the red feed wire and check the operation of the seat 8 4 MOTOR ASSEMBLY Remover 1 Disconnect the motor wires at the relay 2 Remove the two nuts holding the motor to the drive unit 3 Remove th...

Page 194: ...cover and lift out the clutch lever and shaft Assembly 1 Install the clutch lever and shaft Make sure the lever is properly seated on the drive collar 2 Install the cover and screws 3 Install the coil in the coil cover with the coil ground wire next to one of the cover tabs 4 Position the cover tabs in the slots on the coil plate 5 Bend over the tabs and resolder the coil ground wire to the tab an...

Page 195: ...t track shde C 5 Remove the horizontal stops located on the slide at D 6 Separate the seat shde C from the base N by pressing the slide rearward which will allow the rollers A to jump the retaining rivets E F G H thereby separating the shde from the base 7 Remove the rivet F and replace with 6 18 x y2 cap screw 1 as shown to retain in the proper position To reassemble reverse the above sequence NO...

Page 196: ...door hard top models If the ammeter reading fluctuates there is a bind in the glass or in the linkage The down stop should be adjusted so that the window is flush with the gar nish moulding 10 Install the trim panel switch and garnish moulding 9 1 WIRING TEST Disconnect the cable at the battery negative post and remove the two window lift feed wires from the circuit breaker Do not remove the batte...

Page 197: ...ITCH P 6HT REAR DOOR OR QUARTER MOTOR T UP DONN f f I o ij HI 30 AMPERE CIRCUIT BREAKER see mrfit MENT PANEL NIRIN6 FOR CIRCUIT BREAKER FEEO MfB C3 i HttA HMA UP FEED BONN NI4A N 4 H24A HZ4 k H24B f4 lQ3 H A N24B C p Nf A r UP DONN LEFT REAR DOOR SNITCH LEFT REAR DCCR MOTOR SO ecUHPPEO LEFT FRONT DOOR MASTER SWITCH U UP o A o j Nil Nil C jB NllA H2I y HZtA LEFT FRONT DOOR MOTOR NfIA Fo 1 UP H2IA X...

Page 198: ...NEL LOW HIGH TO REAR WINDOW DEFOGGER MOTOR SWITCH WIRING r i T O CIGAR LIGHTER FEED CABLE v 3 r f s y n A ON INSTRUMENT PANFl m _ a j a 1 H T l SIDE COWL CIRCUIT BREAKER TO LEFT FRONT DOOR AUTOMATIC SWITCH XK m 1 N t o INSULATORS VIEWED FROM TERMINAL SIDE 63 x 794 Fig 135 Body and Dome Lamp Except Town and Country Chrysler MyMopar com ...

Page 199: ...P CIRCUITS CIR GA COLOR W 15 12 BROWN W 15A 12 BROWN W 15B 12 BROWN W 15C 12 BROWN W 15D 12 BROWN W 15E 12 BROWN W 15F 12 BROWN W 15G 12 BROWN W 15H 14 DARK GREEN W 15J 12 BROWN W 25 12 YELLOW W 25A 12 YELLOW W 25B 12 YELLOW W 25C 12 YELLOW W 25D 12 YELLOW W 25E 12 YELLOW W 25F 12 YELLOW W 25G 14 BLACK W 25H 12 YELLOW X 3 14 LIGHT GREEN TO RIGHT REAR DOOR SWITCH RIGHT TAIL STOP AND TURN SIGNAL LAM...

Page 200: ... B RIGHT REAR RIGHT BLOWER MOTOR RIGHT TAIL STOP AND TURN SIGNAL LAMP LEFT REAR DOOR AUTOMATIC SWITCH B r c 2 0 INSULATOR TO REAR AIR CONDITIONING SWITCH WIRING ON INST PANEL c n y C 12 RESISTANCE CABLE INSULATOR TO INSTRUMENT PANEL WIRING LEFT FRONT DOOR AUTOMATIC SWITCH TO INSTRUMENT SEE DIAGRAM INSTRUMENT PANEL WIRING PANEL WIRING MENT X ING HJ D 8 B 2 I E GROUND LEFT BLOWER MOTOR C 20C CONVERT...

Page 201: ...HT GREEN X 3D 14 LIGHT GREEN X 32 12 LIGHT BLUE X 32B 16 LIGHT BLUE X 32D 16 LIGHT BLUE X 33 12 ORANGE X 33A 14 ORANGE X 33B 14 ORANGE X 33C 18 ORANGE X 33D 14 ORANGE X 33E 14 ORANGE X 33F 14 ORANGE X 33G 14 ORANGE X 33H 14 ORANGE X 34 12 PINK X 34A 14 PINK X 34B 14 1 PINK LX 34C 1 8 J PINK TO RIGHT FRONT DOOR LOCK SWITCH TO RIGHT FRONT DOOR WINDOW LIFT SWITCH TO RIGHT FRONT DOOR WINDOW LIFT MOTOR...

Page 202: ...REEN H 3 18 BLACK WITH TRACER J 2 16 DARK BLUE J 2A 18 DARK BLUE J 3 18 BROWN L 3 16 RED L 3A 16 RED L 3B 16 RED L 3C 16 RED L 4 16 BLACK L 4A 16 BLACK L 6 18 YELLOW WITH TRACER L 6A 18 YELLOW L 9 16 WHITE L 9A 16 WHITE L 9B 16 WHITE L 9C 16 WHITE R 3 18 DARK GREEN R 4 16 BROWN R 5 18 DARK BLUE R 6 12 BLACK S 2 18 YELLOW S 4 16 BROWN S 4A 16 BROWN THROTTLE SWITCH PREVENTS ENGAGING ON WIDE OPEN THR...

Page 203: ...TE L 9E 16 WHITE R 3 18 DARK GREEN R 4 16 BROWN R 5 18 DARK BLUE R 6 12 BLACK S 2 18 YELLOW S 4 16 BROWN S 4A 16 BROWN S 5 12 BROWN V 10 18 TAN WITH TRACER 1 25 16 RED X 26 16 LIGHT BLUE X 27 16 BLACK RIGHT PARK AND TURN S SIGNAL LAMP LEFT DUAL I HEADLAMPS L L 9 B s r DASH LINE OIL PRESSURE SENDING UNIT NEUTRAL SAFETY SWITCH S 4 A O IGNITION BALLAST ALTERNATOR REGULATOR AUTO PILOT FLD DRIVE MECHAN...

Page 204: ...8 ORANGE E 2D 18 ORANGE E 2E 18 ORANGE E 2F 18 ORANGE E 2G 18 ORANGE E 4 18 YELLOW WITH TRACER E 5 18 ORANGE W I T H TRACER E 5A 18 ORANGE WITH TRACER E 5B 18 ORANGE WITH TRACER CIRCUITS an GA COLOR G l 18 BLACK G 2 18 VIOLET G 4 18 UGHT BLUE G 5 18 DARK BLUE G 6 18 GRAY H 3 18 BLACK WITH TRACER J l 12 RED J 2 16 DARK BLUE J 3 18 BROWN L 1 16 BLACK WITH TRACER L 2 16 UGHT GREEN CIRCUITS CIR GA COL...

Page 205: ... 3 16 BLACK WITH TRACER V 4 16 RED CIRCUITS CIR GA COLOR V 5 16 YELLOW V 6 16 DARK BLUE V 9 16 BLACK V 10 18 TAN WITH TRACER X l 16 RED X 1A 16 RED X 2 16 RED X 2A 14 GREEN X 3 18 BLACK x n 18 BLACK X 11A 18 BLACK CIFiCUITS CIR GA COLOR X 12 18 BLACK X 13 18 BROWN X 14 18 YELLOW X 21 18 GRAY X 24 16 RED X 25 16 RED X 25A 16 RED X 25B 16 RED X 26 16 LIGHT BLUE X 27 16 BLACK RIGHT FRONT DOOR AUTOMAT...

Page 206: ...23 14 UGHT GREEN t IA 16 TRACER C 23A 14 LIGHT GREEN L 2 16 LIGHT GREEN D 1 18 BLACK 1 3 16 RED 0 2 18 RED L 4 16 BLACK 0 3 18 PINK 1 5 18 RED 0 4 18 WHITE 1 6 18 YELLOW WITH D 5 18 TAN 1 6 18 TRACER D 6 18 LIGHT C3EEN 17 18 BLACK D 7 18 BROWN L 8 18 PINK D 8 18 DARK GREEN M l 18 PINK D 9 18 TAN M 1A 18 PINK D10 18 UGHT GREEN M 1B 18 PINK E l 18 TAN M 2 U YELLOW E 2 18 ORANGE M 2A 18 BELLOW E 2A 1...

Page 207: ...0 specific gravity but not more than 05 volts variation Cells showing more than 05 volts variation Questionable No correction required if variation among cells is not over 05 volts If variation is more than 05 volts re charge Give high rate discharge capacity test if cells test O K adjust gravity of all cells uniformly Recharge battery Give high rate dis charge test for capacity If cells test O K ...

Page 208: ...e terminals c Internal ground in wiring d Grounded starter fields e Armature rubbing on pole shoes a Starter clutch slipping b Broken teeth on flywheel drive gear c Pinion shaft rusted dirty or dry due to lack of lubrication d Wrong starter pinion clearance a Test for specific gravity and test for dead cell Replace or re charge the battery as required b Test and replace the switch if necessary c C...

Page 209: ...olenoid d Insufficient clearance between winding leads to solenoid terminal and main contactor in solenoid e Faulty relay a Recharge or replace the battery b Test for open circuit wire between the starter relay ground terminal post and neutral starter switch automatic transmission only Also test for open circuit wire be teween ignition starter switch and ignition terminal and starter relay c Test ...

Page 210: ...up c Install new brushes and or slip rings d Clean the slip rings and brush holders Install new brushes e Test all the field circuit connec tions and correct as required f Inspect all connections in the charging circuit and correct as required g Remove the alternator and disas semble Test the stator windings Install a new stator if necessary h Remove the alternator and disas semble Test the rectif...

Page 211: ... connection a Reset the voltage regulator ac cording to specifications b Test the rotor field coil current draw If excessive install a new rotor a Correct the ground connection In stall a new regulator Test the regulator setting and reset if necessary a Properly install and tighten the alternator mounting b Install a new drive belt and adjust See Cooling Group c Remove and disassemble the al terna...

Page 212: ...r setting adjust as necessary Replace and adjust the distributor contact points c Align and adjust points d Test and replace coil if necessary Replace and adjust contact points e Inspect conditions and correctly connect the coil f Test the condenser and replace if necessary Replace and adjust points g Replace the ignition switch h Recondition the distributor i Replace and adjust the contacts a Tes...

Page 213: ...new switch if necessary b Test the power unit See Instru ment Testing with Tool C 3764 b A possible faulty power unit THERMAL TYPE GAUGES a Defective constant voltage limiter stuck a Test the voltage limiter points or open heater coil a Malfunctioning constant voltage limiter a Test voltage limiter or an open circuit on battery side input of limiter a Fuel tank sending unit or instrument a Test fu...

Page 214: ...t in dimmer switch a Charge battery b Test and replace battery if neces sary c Test headlight circuit including ground connection Make neces sary repairs d Replace sealed beam units a Test lighting circuit including ground connection Make neces sary repairs b Replace sealed beam units c Test voltage regulator and alterna tor Make necessary repairs a Tighten connections and check for damaged wiring...

Page 215: ...parts b High resistance in brush to commutator b Test the armature commutator contact or carbon deposits in slots and brushes Repair as necessary c High resistance in ground connection c Test for high resistance in ground connection and or wiring circuit d Faulty control switch d Replace the switch 138 Wiper Fails to a Binding linkage a Relieve the binding condition Add Operate light film of lubri...

Page 216: ...ose rivet joints a Movement between the two sections comprising the front lever assembly Fig 99 a Replace the wiper arm Do not at tempt to straighten a bent or twist ed arm b Install the correct wiper blades c Clean the glass a Inspect and adjust the switch plate spring b Clean the contacts if execessively worn Replace the switch a Test the Wiring repair or replace as necessary a Test the red wire...

Page 217: ... motor burned out g Short in the wiring circuit a Faulty circuit between master switch and door switch b If the window can be moved by rotating the coupling between the motor and the gear box c Lift motor burned out a Repair as follows 1 Remove the seat track assem bly from the vehicle and arc weld as shown L 2 Tighten the rack attaching pins N by arc welding b Replace the slave unit a Replace mas...

Page 218: ... d Short in wiring circuit d Inspect and test all wiring See Wiring Diagram a Short in the feed wire that feeds the a Test the wiring repair or replace right front and rear doors as necessary b A faulty switch b Replace the switch 155 Circuit Breaker Clicks On and t Off Continuously and Window Does Not Operate MyMopar com ...

Page 219: ...Valves and Valve Springs 12 SPECIFICATIONS ENGINE Type 90 V Number of Cylinders 8 Bore TC l 361 cubic inch Displacement 4 125 inch TC 2 383 cubic inch Displacement 4 25 inch TC 3 TC 2 300J TY 1 413 cubic inch Displacement 4 19 inch Stroke TC l TC 2 3 375 inch TC 2 300J TC 3 TY 1 3 750 inch Piston Displacement TC l 361 cubic inch TC 2 383 cubic inch TC 3 TY 1 413 cubic inch Compression Ratio Regula...

Page 220: ...ND BEARINGS Type Length Center to Center TC l TC 2 TC 3 TY 1 TC 2 300J Weight Less Bearing Shells TC l TC 2 TC 3 TY 1 TC 2 300J Bearings Diameter and Length Clearance Desired Bearing Installed I D Minus Journal O D Maximum Allowable Before Reconditioning Side Clearance Bearings for Service Piston Pin Bore Diameter CAMSHAFT Drive Bearings Number Thrust Taken By Clearance Desired Bearing Installed I...

Page 221: ...rance Engine Hot and Running at Idle Intake 015 Exhaust 024 Oversize Available for Service 001 008 inch PISTONS Type Horizontal Slot w Steel Struts Material Aluminum Alloy Tin Coated Land Clearance 032 to 040 Clearance at Top of Skirt 0003 to 0013 Weight Standard Through 040 Oversize TC 1 361 cu in 717 grms TC 2 383 cu in 770 grms TC 2 300J TC 3 TY 1 413 cu in 780 grms Piston Length Overall TC 1 3...

Page 222: ...iameter 2 08 Stem Diameter 372 to 373 Stem Oversizes Available for Service Standard 005 015 030 Stem to Guide Clearance 001 to 003 Maximum Allowable Before Reconditioning 004 Angle of Seat 45 Adjustment None except 015 TC 2 300J Lift All Models Except TC 2 300J 389 TC 2 300J 444 VALVES Exhaust Material Nitrogen Treated Manganese Chromium Nickel Steel Head Diameter 1 60 Stem Diameter 371 to 372 Ste...

Page 223: ...n Filter is Replaced Add 1 Quart 2 21 85 95 lbs 1 860 216 234 lbs 1 43 1 070 to 1 090 Spiral Type Cast in Head 374 375 std Wedge Type 002 45 060 to 085 45 040 to 060 022 Rotor Full Pressure 5 Camshaft 45 to 65 lbs Full Flow 7 to 9 lbs OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS Engine Displacement Condition Identification Location of Identification 36 cu in 383 cu in 413 cu in 001 U S Cranksh...

Page 224: ... Front Mounting to Frame Stud 25 14 13 Exhaust Manifold Nut 30 16 Exhaust Pipe Flange Nut 40 6 20 Exhaust Pipe Clamp Bolt 20 24 Exhaust Pipe Support Clamp Bolt 20 24 Fan Attaching Bolt 15 18 BMA 8 Fan Belt Idler Pulley Nut 45 7Af 20 Fan Belt Idler Pulley Bracket Bolt 30 16 Fuel Pump Attaching Bolt 30 16 Intake Manifold Bolt 50 16 Main Bearing Cap Bolt 85 Vi l 3 Manifold Heat Control Counterweight ...

Page 225: ...ENGINE 9 7 Fig 1 Front End Sectional View Fig 2 Left Side Sectional View MyMopar com ...

Page 226: ...cations Test coil and condenser 8 Install the distributor distributor cap and spark plug cables Reset the ignition timing with the vacuum advance line disconnected The ignition timing should be set to compensate for altitudes and or gasoline grades as follows A At low altitudes with any good grade of the recommended gasoline either regular or pre mium the engine will give its best performance if t...

Page 227: ... fixture Tool C 3466 to the carburetor flange studs on the intake mani fold 2 Attach the chain hoist to the fixture eyebolt 3 Remove the engine from the repair stand and lower the engine carefully until engine is positioned in the vehicle 4 Install the engine support fixture Tool C 3487 on the frame and adjust to support the rear of the engine 5 Remove the chain hoist from the fixture eye bolt 6 R...

Page 228: ... shown in Figure 6 This is nec essary to provide proper lubrication to the rocker assemblies NOTE The 15 angle of the rocker arm lubrication holes is determined from the center line of the bolt holes through the shaft which are used to attach the shaft and bracket assembly to the cylinder head NOTE Use extreme care in tightening the bolts so that tappets have time to bleed down to their oper ating...

Page 229: ...er tighten all cylinder head bolts to 50 foot pounds torque in sequence as shown in Figure 7 Repeat the procedure tightening all head bolts to 70 foot pounds torque 5 Inspect the push rods and replace any worn or bent rods 6 Install the push rods with the small ends in the tappets maintaining alignment using rod as shown in Figure 8 7 Install the rocker arm and shaft assembly starting each push ro...

Page 230: ... The intake valve stem diameter should measure 372 to 373 inch and the exhaust valve stem diameter should measure Fig 9 Compressing Valve Spring Using Tool C 3422 Fig 10 Measuring Valve Stem Guide Clearance Using Tool C 3026 371 to 372 inch If the wear exceeds 002 inch re place the valve 3 Remove the carbon and varnish deposits from the inside of the valve guides with cleaner Tool C 756 4 Measure ...

Page 231: ... of the hydraulic tappet This means that the plunger is operating closer to its bottomed position and less clearance is available for thermal expansion of valve mechanism during high speed driving 4 The design of the valve mechanism includes a safety factor to allow for a limited amount of wear and the refacing of the valves and seats MAXIMUM MEASUREMENT MINIMUM MEASUREMENT 58x144A Fig 13 Measurin...

Page 232: ...any part of the engine INTAKE VALVE 59x51 Fig 15 Valve Assembly Disassembled View Fig 16 Installing Valve and Cup Seals to correct tappet noise read the oil pressure at the gauge and check the oil level in the oil pan The pres sure should be between 45 and 65 pounds at 40 to 50 m p h 2 The oil level in the pan should never be above the full mark on the dipstick or below the add oil mark Either of ...

Page 233: ...ough the push rod opening in the cylinder head and seat the tool firmly in the head of the tappet 5 Pull the tappet out of the bore with a twisting motion as shown in Figure 17 If all tappets are to be removed remove the hy draulic tappets and place them in their respective holes in the tappet and push rod holder Tool C 3068 This will insure installation of the tappets in their original locations ...

Page 234: ...e until normal operating tem perature approximately 180 water temperature has been reached 2 With the engine running at hot idle adjust the intake rocker arms to 015 inch clearance and the exhaust rocker arms to 024 inch clearance 9 VALVE TIMING All Models Except T C 2 3 0 0 J 1 Turn crankshaft until the No 6 exhaust valve is closing and the No 6 intake valve is opening 2 Insert a inch spacer betw...

Page 235: ...ensional reading even with edge of a chain link apply torque in the reverse direction 30 foot pounds with cylinder heads in Fig 20 Removing Vibration Damper Assembly Using Tool C 3688 Fig 21 Measuring Chain Stretch stalled or 15 foot pounds cylinder heads removed and note the amount of chain movement as shown in Figure 21 4 Install a new timing chain if its movement ex ceeds x 4 inch NOTE With a t...

Page 236: ... and nut on the puller Fig 23 Removing Timing Chain Case Cover Oil Seal Using Tool C 3506 Fig 24 Removing the Oil Seal screw Hold the center screw and tighten the puller nut to remove the seal Fig 24 Installation of the Oil Seal 1 Insert the puller screw through the removing and installing plate so that the thin shoulder will be facing up 2 Insert the puller screw with the plate through the seal o...

Page 237: ...135 foot pounds torque 4 Slide the belt pulley over the shaft and attach with bolts and lockwashers 5 Tighten the bolts to 15 foot pounds torque 1 3 CAMSHAFT The camshaft has an integral oil pump and distrib utor drive gear and fuel pump eccentric as shown in Figure 29 The rearward camshaft thrust is taken by the rear face of the cast iron camshaft sprocket hub bearing directly on the front of the...

Page 238: ...the proper size adapters and horse shoe washers part of Tool C 3132A at the back of each bearing to be removed and drive out the bearings Fig 31 Installation 1 Install the new camshaft bearings with Tool TOOL ARM TOOL 1 CRANKSHAFT MAIN BEARING OIL HOLE CAMSHAFTBEARiNG OIL HOLE _ 5 8 x l 6 4 Fig 31 Removing the Camshaft Bearing Using Tool C 3132A C 3132A Place the new camshaft bearing over the prop...

Page 239: ...l No 1 cylinder is at top dead center on the firing stroke 2 When in this position the straight line on the vibration damper should be under 0 on the timing indicator 3 Coat the shaft and drive gear with engine oil Install the shaft so that after the gear spirals into place it will index with the oil pump shaft so that the slot in top of the drive gear will be parallel with the center line of the ...

Page 240: ...from the cylinder walls use resizing hone Tool C 823 with 220 grit stones Usually a few strokes will clean up a bore and maintain the required limits 2 Deglazing of the cylinder walls should be done using a cylinder surfacing hone Tool C 3501 equipped with 280 grit stones C 3501 3810 20 to 60 strokes depending on the bore condition will be suf ficient to provide a satisfactory surface Inspect the ...

Page 241: ... it is to be fitted An inverted piston can be used to push the rings down to insure positioning rings squarely in the cylinder wall before measuring 2 Insert the feeler stock in the gap The ring gap should be between 013 to 032 inch for the com pression rings and 015 to 062 inch for the oil ring steel rails in standard size bores Maximum gap on 005 inch O S bores should be 040 inch for compres sio...

Page 242: ...up over the pilot so that the pilot extends through the piston pin hole Fig 41 Tool Arrangement for Installing Piston Pin Fig 42 Installing the Piston Pin in Connecting Rod 6 Position the connecting rod over the pilot which extends through the piston pin hole NOTE Assemble the rods to the pistons of the right cylinder kink 2 4 6 and 8 with the indent on the piston head opposite to the larger chamf...

Page 243: ... the pistons correctly they are not interchangeable from one bank to an other Each bearing cap has a small V groove across the parting face When installing the lower bearing shell make certain that the V groove in shell is in line with V groove in cap This allows lubrication of the cylinder wall The bearings should always be installed so that the small formed tang fits into the machined grooves of...

Page 244: ...unds torque 2 1 CRANKSHAFT M A I N J O U R N A L S The crankshaft main bearing journals should be Fig 46 Installing Connecting Rod Using Tool C 3221 Fig 47 Upper and Lower Main Bearings inspected for excessive wear taper and scoring Jour nal grinding should not exceed 012 inch under the standard journal diameter DO NOT grind the thrust faces of the No 3 main bearing DO NOT nick the crankpin or mai...

Page 245: ...ssible to use one 001 inch undersize bearing shell with one standard bearing shel or one 002 inch undersize bearing shell with one 001 inch undersize shell Always use the smaller diameter bearing half as the upper Do not use a new bearing with a used bearing and never use an upper bearing half more than 001 inch smaller than the lower bearing half Installation of Upper Main Bearing NOTE When insta...

Page 246: ...he seal retainer grooves 3 Install the seal retainer and tighten screws to 30 foot pounds torque NOTE Failure to pre oil the seals will result in an oil leak 2 5 FRONT ENGINE MOUNTS NOTE Frame bracket studs and torque nuts are used in the place of bolts Heat shields have been added to protect the engine mounts Removal 1 Disconnect the throttle linkage at the trans mission and at the carburetor 2 R...

Page 247: ...tor throttle body The function of the valve is to regulate the flow of crankcase ventilation at various throttle positions The system will operate effectively as long as nor mal maintenance is applied The valve and tube are subject to fouling with sludge and carbon formation due to the nature of the material carried by the ven tilation system A plugged vent system may in turn cause excessive engin...

Page 248: ...distributor cap f Incorrect spark plug gap g Incorrect ignition timing h Faulty ignition cables i Dirt or water in fuel line or carburetor j Carburetor flooded k Incorrect carburetor float setting 1 Faulty fuel pump m Carburetor percolating No fuel in the carburetor n Faulty starting motor a Idle speed set too low b Idle mixture too lean or too rich c Incorrect carburetor float setting d Incorrect...

Page 249: ... Faulty coil or condenser 1 Incorrect ignition timing a High or low oil level in crankcase b Low oil pressure c Dirt in tappets d Bent push rods e Worn rocker arms 32 Engine Misses at High Speed 33 Noisy Valves a Refer to Ignition Timing b Install a new rotor c Install correct vacuum advance unit Adjust the mechanical ad vance d Remove and repair distributor e Remove and repair distributor f Clean...

Page 250: ...and valves Cheek engine oil level Inspect oil pump relief valve damper and spring Check the engine oil level Change oil to correct viscosity Measure the bearings for correct clearances or failures Remove the crankshaft and regrind journals Replace the bent connecting rods Check the engine oil level Inspect the oil pump relief valve damper and spring Check the engine oil level Change the oil to cor...

Page 251: ...h the filter to a series mounted rotor type pump a full flow oil filter oil of oil passages in the engine as shown in Figure 1 pan and the necessary lubrication passages Oil is SERVICE PROCEDURES 1 ENGINE OIL P A N R e m o v a l 1 Disconnect the battery cable 2 Raise the vehicle on a hoist and disconnect the steering linkage from the idler arm and pitman arm 3 Remove the outlet vent pipe and disco...

Page 252: ... the idler arm and at the pitman arm 6 Connect the battery cable 7 Install the drain plug and refill the crankcase 2 OIL PUMP R e m o v a l Remove the oil pump attaching bolts and remove the pump and the filter assembly from the bottom side of the engine Assembly 1 Remove the filter base and oil seal ring 2 Remove the pump rotor and shaft and lift out the outer pump rotor 3 Remove the oil pressure...

Page 253: ... the bolt holes as shown in Figure 6 6 If a feeler gauge of more than 004 inch can be inserted between the rotor and the straightedge replace the rotor 7 Remove the inner rotor and shaft leaving the outer rotor in the pump cavity 51x66A W A M f t t J S Fig 4 Measuring the Outer Rotor Thickness 51x67A Fig 5 Measuring the Inner Rotor Thickness STRAIGHT EDGE Fig 6 Measuring the Clearance Over Rotors ...

Page 254: ...d NOTE When assembling the oil pump be sure to use new oil seal rings between the filter base and the pump body Installation 1 Install a new 0 ring seal on the pilot of the oil pump before attaching the oil pump to the cylin der block 2 Install the oil pump on the engine using a new gasket on the engine and tighten the attach ing bolts to 35 foot pounds torque Fig 9 Removing the Oil Filter 3 Insta...

Page 255: ...aust system is suspended by the exhaust system are located ahead of the mufflers loop type hangers through the propeller shaft tunnel Fig 1 2 3 4 5 and 6 SERVICE I 1 INTAKE MANIFOLD Fig 7 Refer to the Engine Group 9 for removal and installation of the intake manifold 2 EXHAUST MANIFOLD Removal 1 Disconnect the spark plug cables from the spark plugs 2 Remove the alternator from the right cylinder h...

Page 256: ...rt No 1879318 to both ends of the valve shaft With engine idling accelerate the engine and release quickly The counterweight should respond by moving clockwise approximately V inch and return to its normal position Disassembly Fig 8 1 Loosen the counterweight clamp bolt and re move the counterweight lock and stop from the end of the shaft exposing the thermostatic coil 2 Unhook the coil from the p...

Page 257: ...unterweight assembly over the shaft with the weight in the upward position and insert the lock in the shaft slot as shown in Figure 10 If the c o m p o s i t i o n o n t h e s t o p i s w o r n r e p l a c e w i t h a n e w s t o p Center the counterweight on the shaft and turn the assembly clockwise until the stop passes the pin Press the counterweight on the shaft until seated and tighten the cl...

Page 258: ...l 2 Position the shaft into both bushings and check the shaft for freedom of turning Should the shaft fail to turn freely it will be necessary to burnish the bushings 3 Pull the shaft out far enough to position the valve plate on the shaft then slide shaft into position in both bushings 4 Align the hole in the valve plate with the hole in the shaft and insert a drift into both holes to main tain c...

Page 259: ...the flanges should be parallel to each other and perpendicular to the pipe axis 6 Adjust the converter housing bracket so that it is flat against the converter housing and in the proper contact with the pipe tab Tighten screws to 15 foot pounds torque SERVICE DIAGNOSIS Condition Possible Cause Correction 6 Excessive Exhaust Noise 7 Leaking Exhaust Gases 8 Engine Hard to Warm Up or Will Not Return ...

Page 260: ...s attached to the body at ten locations four at brack ets extending down from the cowl panel and six under the front passenger compartment where the frame is joined to the underbody crossmember Shim ming of the stub frame outriggers to keep them in alignment with the balance of the frame is per formed prior to the body being installed on the frame SERVICE PROCEDURES 1 FRAME ALIGNMENT MEASUREMENT a...

Page 261: ...ements may be taken without removing the body from the chassis by using a plumb bob and chalk line on a level floor Attach the line of a plumb bob to one of the rear body bolts The plumb bob should be suspended slight ly above the floor When the plumb bob comes to rest mark the floor directly underneath it The marks made on the floor will represent the various points of the frame to be checked dia...

Page 262: ... as a guide in measuring the frame alignment Measure the distance between the points connected by line A in Figure 2 this distance should agree within Va inch with the distance between the points connected by line B The diagonals shown in Figure 3 represent only one of a few that may be measured Many other diagonals Fig 5 Fender to Cowl Mounting Fig 6 Splash Shield to Cowl Mounting may be measured...

Page 263: ...on push button cable from the transmission Disconnect the exhaust pipe at the front of the muf fler Disconnect the parking brake cable 13 Remove the jacket tube at the instrument panel 14 Disconnect the steering gear tube at the lower coupling Disconnect the coupling from the steering Fig 9 Radiator Support to Frame Yoke Mounting Fig 10 iody to Frame Outrigger Mounting gear by pushing the steering...

Page 264: ...he rear of the frame right side rail 6 Install the steering gear on the frame Install the steering gear arm and link 7 Position the steering gear column tube and coupling on the steering gear worm shaft Position the steering column jacket tube at the instrument panel and tighten the bolts finger tight Tighten the cou pling bolt at the worm shaft coupling Tighten the instrument clamp bolt securely ...

Page 265: ...he center and rear gauges as shown in Figure 15 4 The long and short bar should be placed against each other to determine if any body to frame deflection is evident 5 The top and bottom surfaces of the horizontal bars should be perfectly level across their combined surfaces where they meet however if this condition is not prevailing raise both the long and short bar as a unit until they are perfec...

Page 266: ...rts 15 Disassembling the Carburetor 14 Inspection and Reassembly 15 Setting the Throttle Linkage 22 PART 3 AFB Series Carburetor Automatic Choke Well Type 30 Carburetor Adjustments 27 Cleaning Carburetor Parts 25 Disassembling the Carburetor 22 Inspection and Reassembly 25 Setting the Throttle Linkage 30 PART 4 Fuel and Induction System Carburetor AFB 300J Models 37 Carburetor Adjustments 42 Intak...

Page 267: ...EP UP WIRE DIAMETER Standard 2 Stage STEP UP ROD 2 Stages Standard 1 Size Lean 2 Sizes Lean Ball Ball Dual Downdraft BBD 34765 TC 2 I V I V 120 250S 120 251 120 253 75 1599 032 x 026 Carter 4 Barrel Downdraft AFB 3478S TC 1 Police TC 2 Hi Perf I V I V I V 089 067 65 035 16 217 16 165 16 159 Carter 4 Barrel Downdraft AFB 3256S TC 3 TY 1 I V I V I V I V 089 067 65 035 16 165 16 160 16 173 Carter 4 B...

Page 268: ...400 2100 1775 1825 Fast Idle Speed Cam Index Choke blade opening Aa Drill 3Vi turns Fast Idle Adjustment 020 020 Secondary Throttle Lever Adjustment Secondary Throttle Lockout Adjustment 020 020 Velocity Valve CHOKE Type Well Well Well Well Control Thermostatic Thermostatic Coil Thermostatic Thermostatic Coil Spring Spring Coil Spring Coil Spring Setting 1 Notch Rich 2 Notches Rich On Index 2 Notc...

Page 269: ...TING LEGS SET OF 4 MAIN BODY ACCELERATOR PUMP LEVER BOWL VENT VALVE ACCELERATOR PUMP ROD FAST IDLE FAST IDLE CAM THROTTLE LEVER FAST IDLE ADJUSTING SCREW BOWL VENT VALVE GUARD BOWL VENT VALVE AIR HORN CHOKE PISTON PLUG CLOSED CRANKCASE VENT FITTING CURB IDLE SPEED ADJUSTING SCREW ELEVATING LEGS SET OF 4 63x483 Fig i Carburetor Assembly WWC3 MyMopar com ...

Page 270: ...erhauling the car buretor Using the code number stamped on the air horn adjacent to the fuel inlet refer to the parts catalog and order the correct repair kit for the car buretor being worked on SERVICE PROCEDURES 1 DISASSEMBLING THE CARBURETOR Fig 1 r 2 1 Install four elevating legs Tool T109 287S in the mounting flange holes in the throttle body These legs are used to protect the throttle valves...

Page 271: ... must float free to operate correctly If the choke piston sticks in the cylinder or appears to be gummed from deposits in the air horn pierce the welch plug and remove the plug and piston Clean thoroughly and reinstall the piston Install a new plug 2 MAIN BODY REMOVAL 1 Remove the venturi cluster attaching screws the venturi cluster and gasket as shown in Figure 6 Fig 4 Removing or Installing the ...

Page 272: ...tory results Check the throttle shaft for excessive wear in the throttle body If wear is extreme it is recommended that the throttle body be replaced rather than in stalling a new throttle shaft in the old body IMPORTANT If the commercial solvent or cleaner recommends the use of water as a rinse it should be Fig 8 Removing or Installing the Main Metering Jet Fig 9 Ports in Relation to Throttle Val...

Page 273: ...ixture control DO NOT USE A SCREWDRIVER The idle mix ture screw adjustment should be made with the fingers Turn the screws lightly against their seats then back off one fuE turn for an approximate set ting 3 A C C E L E R A T O R PUMP W E L L 63x493 Fig 12 Installing Accelerator Pump Inlet Check Ball 5 MAIN BODY ASSEMBLY Fig 11 1 Place a new gasket on the throttle body then install main body Insta...

Page 274: ...jet orifice If streams are not identical if either one is restricted or diverted remove venturi cluster and reclean After test pour gasoline from the bowl and re move the pump plunger 6 Check the float for leaks or damage If satis factory for further service install in position in the bowl 7 Assemble the fuel inlet needle valve seat and gasket then insert in the main body Tighten se curely If the ...

Page 275: ...Adjustment 1 Remove the welch plug from the choke piston cylinder and insert a hook gauge 036 to 040 di ameter into the slot in the cylinder wall Rotate the hook end so that it engages the end groove in the piston Apply light closing pressure against the choke valve so that the hook gauge is trapped be tween the groove in the piston and the end of the slot as shown in Figure 17 It should be possib...

Page 276: ...l of the air horn as shown 2 To adjust bend the tang on the throttle lever using Tool T109 214 until correct opening has been obtained 3 Hold the choke valve open and then open and close the throttle valves Failure to obtain full throt 63x497 Fig 20 Accelerator Pump Travel tie operation indicates improper assembly or wrong adjustment of the choke mechanism 4 With the throttle valves held in the op...

Page 277: ...p and disconnect the fast idle rod 3 Remove the hairpin clip that holds the pump rod in the center slot of the pump arm Disconnect the pump rod 4 Remove the remaining two long screws and lift off the air horn Check the float setting as follows 1 Seat the float fulcrum pin by pressing finger against the fulcrum pin spring There should be enough fuel in the bowl to raise the float so that the lip be...

Page 278: ...irst mark to the right of center mark on the bracket Hold in this position with screwdriver while tight ening nut NOTE After adjustment is made and the choke unit installed on the engine lift the cover disc and check to see that the rod has clearance when the choke is opened and closed The rod should have clearance at hole in cover plate Should it become necessary to adjust the throttle linkage re...

Page 279: ... to prevent the leather from drying out 6 Remove the fuel inlet needle valve seat and gasket from the main body 7 lift out the float fulcrum pin retainer and lift out the floats and fulcrum pin 8 Remove the step up piston and retaining screw and slide the step up piston and rods out of well as shown in Figure 23 lift out the step up pis ton spring Remove the step up piston gasket from the bottom o...

Page 280: ...y it would be very unlikely that the original relationship of the ports to the valves would be obtained Changing the relationship of the valves to the ports would adversely affect normal car opera tion between the speeds of 15 and 30 miles per hour If it has been determined however that a new shaft or valves is to be installed adhere to the following instructions 2 Mark the position of the throttl...

Page 281: ...fore installing the step up piston be sure the step up rods are able to move freely each side of the vertical position as shown in Figure 29 The step up rods must be straight and smooth 8 Shde the step up piston gasket down into posi tion in the piston well then install the step up piston spring step up piston and rods Carefully guide the step up rods into the main metering jets Fig 23 Install the...

Page 282: ...Install a new plug 2 Remove the accelerator pump plunger from the gasoline slide the compression spring and spring seat over the shaft Install the assembly in the air horn and engage with the accelerator pump arm 3 Place a new gasket on the main body and in stall the air horn Install attaching screws and tighten securely When installing air horn be sure the leather on the plunger does not wrinkle ...

Page 283: ... Fig 32 Fig 33 Measuring the Choke Unloader Setting Fig 34 Bending the Fast Idle Lever Tang Idle Speed Adjustment Curb Idle To make the idle speed adjustment the engine must be thoroughly warmed up A more reliable idle ad justment can usually be obtained if the car has been driven a minimum of five miles For best results it is recommended that a tachometer be used in this adjustment On vehicles eq...

Page 284: ... to push against the needle as the rubber tip can be compressed sufficiently to cause a false setting which will affect correct level of fuel in the bowl NOTE After being compressed the rubber tip is very slow to recover its original shape It is very important that the float lip be perpendicular to the needle or slanted not more than 10 degrees away from the needle when the float is set correctly ...

Page 285: ...N PLACE 2 DISCONNECT CHOKE AT CARBURETOR OR BLOCK CHOKE IN FULL OPEN POSITION OPEN THROTTLE SLIGHTLY TO RELEASE FAST IDLE CAM THEN RETURN THROTTLE TO CURB IDLE 3 WITH THE LOCK NUTS LOOSE ON THE CARBURETOR AND TRANSMISSION RODS INSERT A 3 16 DIA ROD APPROXIMATELY 10 LONG THROUGH THE HOLES IN THE BELLCRANK BRACKET AND LEVER ASSEMBLY 4 MOVE THE TRANSMISSION LEVER FORWARD AGAINST THE STOP AND TIGHTEN ...

Page 286: ...R CONNECTOR ROD CAM ADJUSTING SCREW THROTTLE LEVER FAST IDLE SPEED ADJUSTING SCREW CHOKE VALVE ACCELERATOR PUMP PLUNGER ACCELERATOR PUMP ARM CHOKE PISTON HOUSING PUMP CONNECTOR ROD IDLE MIXTURE ADJUSTING SCREWS PRIMARY THROTTLE SHAFT ARM OUTER PRIMARY THROTTLE SHAFT DOG PRIMARY THROTTLE SHAFT ARM INNER CLOSED CRANKCASE VENT TUBE FITTING VACUUM ADVANCE TUBE FITTING ELEVATING LEGS SET OF 4 63x499 Fi...

Page 287: ...al systems are two float sys tems two low speed systems primary side only two high speed systems one accelerator pump sys tem and one automatic choke control system SERVICE PROCEDURES 17 SERVICING THE CARBURETOR Dirt dust water and gummy deposits are some of the main causes for poor carburetor operation How ever proper cleaning and the installation of new parts where required will return the carbu...

Page 288: ...e accelerator pump plunger and spring out of the air horn Remove the air horn to main body gasket and discard 4 Place the accelerator pump plunger in a jar of clean gasoline or kerosene to prevent the leather from drying out 5 Remove the fuel inlet fitting and filter screen from the air horn ATTACHING SCREWS 63x501 Fig 39 Removing or Installing the Accelerator Pump Jet Housing Fig 40 Removing or I...

Page 289: ... springs from the throttle body portion of the main casting The carburetor now has been disassembled into two units the air horn and main and throttle body casting The component parts of each have been dis assembled as far as necessary for cleaning and inspec tion It is usually not advisable to remove the throttle shafts or valves unless wear or damage necessitates the installation of new parts Du...

Page 290: ...usting screws lightly against their seats and back off one full turn for an approxi mate adjustment 4 Place the new secondary venturi gaskets in position bleed hole in top toward the center of the carburetor install the secondary venturi pump and choke side by lowering straight down on the gaskets Install the attaching screws and tighten securely NOTE Be sure all the metering holes and vent tubes ...

Page 291: ...pressed sufficiently to cause a 57 x 801 Fig 45 Inspecting the Float Alignment Fig 46 Measuring the Float Height false setting which will affect correct level of fuel in the bowl 5 Shde the right and left floats into position in the air horn and install the float fulcrum pins NOTE Be sure the marked float is installed on the pump side of the air horn 6 After the floats have been installed check th...

Page 292: ...ition Tighten screws securely 6 Slide the choke piston into its cyhnder in the air horn guiding the link into the slot in the choke valve lever Align hole then install attaching cotter pin Place a new welch plug over the cylinder opening and secure by rapping with a hammer Be sure the sealing surface is clean Check the fit of the choke valve in air horn The valve should be evenly spaced on all sid...

Page 293: ...adjusting screw Accelerator Pump Adjustment 1 Move the choke valve to wide open position to release the fast idle cam Back off the idle speed adjusting screw curb idle until the throttle valves are seated in the bores 2 Measure the distance from the top of the air horn to the top of the plunger shaft using a T scale as shown in Figure 52 This distance should be 6 inch 3 If an adjustment is necessa...

Page 294: ...apped in the fuel system from being dis lodged by the free flow of fuel as the carburetor is primed Idle Speed Adjustment Curb Idle I To make the idle speed adjustment the engine must be thoroughly warmed up A much more reliable idle adjustment can usually be obtained if the car has been driven a minimum of five miles For the best results it is recommended that a tachometer be used in this adjustm...

Page 295: ...empt to repair Do not lubricate any parts of the choke or control unit since this causes dirt accumulation which would Fig 56 Closed Crankcase Vent System result in binding of the choke mechanism Do not attempt to change the calibration setting Refer to specifications This is pre determined and should it be changed improper action would result Clean all choke parts using a suitable solvent and the...

Page 296: ...BRACKET AND LEVER ASSEMBLY 4 MOVE THE TRANSMISSION LEVER FORWARD AGAINST THE STOP AND TIGHTEN TRANSMISSION ROD LOCK NUT 5 DISCONNECT ONE END OF THE ACCELERATOR PEDAL ROD ADJUST ITS LENGTH TO PROVIDE A PEDAL ANGLE OF 113 TO 115 REINSTALL THE ROD 6 REMOVE THE 3 16 DIA ROD FROM BELLCRANK BRACKET AND LEVER ASSY 7 MOVE LINK OF CARBURETOR ROD ASSY REARWARD UNTIL THE TRANSMISSION LEVER STOP IS CONTACTED ...

Page 297: ...llows 11 Remove the eight attaching bolts that hold the left fender shield access plate to fender shield then shde plate out of the engine compartment 12 Remove the two bolts that attach the left hand by pass pipe to the lower chamber 13 Remove the two bolts that attach the left hand exhaust manifold elbow to the lower chamber Discard the gaskets 14 Remove the four bolts that attach the intake man...

Page 298: ...r shield access plate into position against fender shield Install bolts and tighten If both intake manifolds were removed continue to install the right hand manifold as follows 6 Place the carburetor in position on the mount ing pad of the intake manifold and connect the choke control Install the carburetor mounting nuts and tighten 7 Place the intake manifold assembly in position on the left hand...

Page 299: ...ft and right hand carburetor 18 Reconnect the fuel hne between the fuel pump and the left hand carburetor 19 Reinstall the right and left carburetor air cleaners CHOKE CABLE RIGHT BANK CARBURETOR ROD ADJUSTING LINK IT LOCKING BOLT AND NUT ACCELERATOR SHAFT TO THROTTLE SHAFT LEVER ROD J LOCKING BOLT W AND NUT ADJUSTING LINK LEFT BANK CARBURETOR ROD SPRING 2 ADJUSTING LINK LOCKING NUT TOP VIEW ACCEL...

Page 300: ...off the anti stall adjusting plunger far enough to allow the bellcrank to be pivoted 3 Pivot the bellcrank until a 6 inch piece of welding rod 3 inches long can be inserted through the bellcrank hole and down into the locating hole in the intake manifold 4 Test each carburetor to be sure the choke valves are open that the fast idle cams are released and that the throttle valves are closed 5 Tighte...

Page 301: ...2 CHOKE LEVER CHOKE CABLE BRACKET STEP UP PISTON COVER PLATE 2 AIR HORN FAST IDLE ROD FAST IDLE CAM ELEVATING LEGS SET OF 4 THROTTLE LEVER SECONDARY THROTTLE OPERATING LEVER ACCELERATOR PUMP CONNECTOR LINK ACCELERATOR PUMP SHAFT ACCELERATOR PUMP ARM ACCELERATOR PUMP CONNECTOR ROD VACUUM ADVANCE FITTING OPENING PRIMARY THROTTLE SHAFT ARM OUTER CARBURETOR IDENTIFICATION STAMPED ON BOSS 63x607 F i g ...

Page 302: ...lf of the carburetor are mechanically connected to the primary valves and open with the primary after an approximate 60 degree lag and continue to open until both primary and secondary throttle valves reach the wide open position at the same time As engine speed increases the forces exerted by the velocity of intake air down through the venturi per mits the off set velocity valves to position them...

Page 303: ...at on the pump side be marked so that the floats can be installed in their original locations 2 Remove the two needle valves after marking the pump side for identification 3 Using a wide blade screwdriver or Tool T109 57 remove the needle valve seats Mark the pump side seat for identification 4 Remove the pump arm pivot screw then dis engage the pump link by removing pump arm Shde pump plunger out...

Page 304: ...and springs from the throttle body casting The carburetor now has been disassembled into two units namely the air horn and the main throttle body casting The component parts of each unit have been disassembled as far as necessary for cleaning and inspection Cleaning the Carburetor Parts The recommended solvent for gum deposits is de Fig 67 Removing or Installing the Velocity Valves ACCELERATOR PUM...

Page 305: ...r approximate setting 6 Install the velocity valves and counterweights Refer to Fig 67 7 Place new secondary venturi gaskets in posi tion then install the secondary venturi Refer to Fig 66 Install screws and tighten securely Be sure each is located in its original place Be sure all the metering holes and vent tubes are clean and clear in both the primary and secondary venturi 8 Place new primary v...

Page 306: ...ipped Fuel Inlet Needle The AFB carburetors are equipped with two syn thetic rubber tipped fuel inlet needles The needle tip is a rubber like material which is not affected by gasoline and is stable over a wide range of tempera tures The tip is flexible enough to make a good seal on the needle seat and to give increased resistance to flooding The use of the needles require that care be used when m...

Page 307: ...down in front bowl side of the float chamber baffles or the air horn will not index correctly with the main body This can cause the floats to hang up Also be sure the leather on the pump plunger does not curl or wrinkle Accelerator pump operation will be affected if this precaution is not observed 4 Install the air horn attaching screws and tighten securely Install the choke cable bracket and atta...

Page 308: ...es on the primary and secondary throt tle levers as shown in Figure 77 If an adjustment is necessary bend the shoe on the primary throttle lever using Tool T109 22 until correct clearance has been obtained It is suggested that the carburetor bowls be filled with clean gasoline This will help prevent dirt that is trapped in the fuel system from being dislodged by the free flow of fuel as the carbur...

Page 309: ... hose between the T fitting and gauge Tool C 3411 The hose should not exceed 6 inches A longer hose may collect fuel and the additional weight would be added to the pressure of the pump and result in an inaccurate reading 3 Vent the pump for a few seconds this relieves any air trapped in the fuel chamber If this is not done the pump will not operate at full capacity and a low pressure reading will...

Page 310: ...od bearing surface Assembly Fig 79 1 Place the airdome diaphragm in position on the valve body or filter housing depending on pump with inlet passage hole over passage 2 Align the scribe marks on the cover or filter housing depending on pump and the valve body then install attaching screws Tighten securely 3 Shde the diaphragm pull rod up into the rocker arm housing Place the valve body in positio...

Page 311: ...connecting the gauge wire Removal 1 Drain the tank into a safety can then discon nect the fuel hne and the wire lead to the gauge unit 2 Disconnect the vent tube at the nose connection at the leading edge of the tank 3 Remove the nuts that hold the ends of the fuel tank hold down straps to the frame Lower the front end of the tank far enough to disengage the filler tube from the rear panel and shd...

Page 312: ...lead wire to the gauge unit 2 Disengage the vent tube from the vent tube hose Refer to Fig 84 3 Using Tool C 3584 hooked into the filler tube cap opening pull the filler tube out of the fuel tank As filler tube is being removed the vent tube on the filler tube will pull out of the connector hose Refer to Fig 84 Shde the grommet off filler tube 4 Loosen the nuts that hold the ends of the fuel tank ...

Page 313: ...engages the rubber hose connection 5 Push the filler tube down until the tube is aligned with the tank neck opening Using a rubber hammer drive the tube into the seal ring until the tube seats on the shoulder of the seal retainer See that the vent tube has entered the hose correctly 6 Connect the vent tube on the forward end of the tank with the rubber hose and vent tube mounted on the floor pan B...

Page 314: ... the tank Fig 82 4 Shde the tank up under the quarter panel with the gauge unit facing front of the vehicle Push the tank up into position Make sure the filler neck is aligned with the opening in top of the quarter panel Attach with the strap and bolt Do not tighten 5 Place a new gasket over the filler tube and down against the flange Insert the filler tube down into neck of tank Drive the tube in...

Page 315: ...eat or release If part is faulty replace e Test the fuel or float level in the carburetor Ad just as necessary to obtain the correct float level f Clean and inspect the needle valve and seat If found to be in questionable condition replace assembly Then test fuel pump pressure Refer to Data and Specifications for correct fuel pump pressure g Disassemble the Carburetor Replace the worn ac celerator...

Page 316: ...ive fuel pump d Test the fuel pump pressure Eefer to Data and pressure Specifications for recommended pressure If pres sure is in excess of recommended pressure re place the fuel pump assembly e Worn metering jet e Disassemble the carburetor Replace the worn metering jet using a new jet of the correct size and type MyMopar com ...

Page 317: ...erline to Cross C e n t e r l i n e 58 85 Diameter TC 1 TC 2 Std Trans 3 00 TC 1 TC 2 TC 3 Auto Trans 2 75 UNIVERSAL JOINTS Front Joint Ball and Trunnion Rear Joint Cross Type Lubrication See Group O Lubrication and Maintenance PROPELLER SHAFT Models TY 1 Length Front Shaft Cross Centerline to End of Spline 25 82 Rear Shaft Cross Centerline to Cross C e n t e r l i n e 33 06 Diameter Both Shafts 2...

Page 318: ...y rea son they should be inspected and repacked with Spe cial Lubricant Part No 2298947 SERVICE PROCEDURES 1 PROPELLER SHAFT A N G U L A R I T Y The quiet smooth operation of the propeller shaft and universal joints depends upon proper ahgnment The propeller shaft and rear axle housing angles may be measured by using an ahgnment measuring gauge Tool J 6485 with the vehicle in a level position and ...

Page 319: ...e third graduation the angle of the rear axle housing should be changed Loosen all U bolt nuts and in UNIVERSAL JOINT PROPELLER SHAFT UNIVERSAL JOINT UNIVERSAL JOINT BODY DUST COVER OR BOOT 49x910 Fig 3 Sliding the Cover Over the Ballhead and Pin Fig 4 Working the Dust Cover Through Body stall two degree tapered wedges between both rear springs and the axle housing pads with the thick end of the w...

Page 320: ... must be centered in the propeller shaft Use Tool C 3567 in a hydrauhc press Pin will be centered when ram contacts the spacer portion of Tool Fig 5 2 Install a thrust washer rollers ball button spring and thrust button on each end of the trun nion pin and position the body over the pin assem bly 3 Position the dust cover on the propeller shaft with the breather pohshed jute parallel to the shaft ...

Page 321: ... the grooves in the bushings 5 Position the other two bushings on the cross and install the retainer strap to hold the bushings on the cross during installation in the vehicle PART II TWO PIECE PROPELLER SHAFT AND UNIVERSAL JOINTS MODELS TY 1 the center universal joint Fig 7 The Imperial two piece propeller shaft has three When the vehicle is in motion the middle universal cross and roller type un...

Page 322: ... bubble Fig 9 NOTE Each time the gauge is used the level must be on the same side of the propeller shaft 5 Hold the gauge tool in contact with the pro peller shaft near the rear universal joint Fig 10 The entire bubble should be within three graduations from center Fig 8 Rear Axle Control Strut Typical Fig 7 Propeller Shaft and Center Bearing Assembly Disassembled View 6 If the edge of the bubble ...

Page 323: ...om of the adapter and the pins on the side of the adapter Fig 12 Note the location of the bub ble in the spirit level NOTE Each time the gauge is used the level must be on the same side of the propeller shaft 4 For each graduation the leading edge of the bubble is forward of center Fig 13 add one shim Fig 10 Measuring the Propeller Shaft Angularity Fig 12 Indexing the Gauge to the Adapter Converti...

Page 324: ...Remove the seal and retaining cap from the yoke Assembly fig 7 1 Clean the lubricant from the internal splines in the front shaft and repack with one ounce of Molydisulphide lubricant Install the slinger ring on the front shaft 2 Install the bearing in the housing and place on the front shaft 3 Instal the shnger and the star retaining washer 4 Lubricate the inside of the grease seal and install th...

Page 325: ... joint flange f Improper height of center bearing Imperial g Improper drive hne angularity h Rear suspension spring center bolt not in seat i Broken rear spring j Rear springs not matched k Worn trunnion pin 1 Trunnion pin not centered m Worn universal joint bearings or missing needle bearings n Worn universal joint housing o Propeller shaft damaged bent tube or out of balance a Propeller shaft fl...

Page 326: ...TC 3 TY 1 Type Semi Elliptic No of Leaves Sedans all 6 6 7 6 Hardtops all 6 6 7 6 Convertibles 6 6 7 6 Town and Country Wagon 7 7 Width inches 2 50 Length i n c h e s 60 60 60 60 Pivot front Rubber Bushing Shackle rear Side Strapped with Rubber Bushed Bolts SHOCK ABSORBERS Type Onflow Double Acting Hydraulic TORQUE REFERENCE Foot Pounds Rear Spring Front Pivot Bolt Nut I 2 5 Rear Spring Shackle Nu...

Page 327: ...RING HEIGHT 1 Jounce the vehicle several times front bumper first Release the bumpers at the same point in each cycle 2 Measure the shortest distance from the highest point on the underside of the rear axle bumper strap at rear of the bumper to the top of the axle housing 3 Measure both the right and left sides If these measurements vary by more than inch it is an indication that one of the rear s...

Page 328: ...t only 2 Install the spring shackles and nuts 3 Install the spring U bolts and nuts Fig 3 Rear Spring Front Hanger Fig 4 Rear Spring Front Interliner 4 Tighten the spring U bolt nuts 50 foot pounds torque and shackle bolt nuts 40 foot pounds torque 5 Connect the shock absorbers 6 Remove the vehicle floor stands and with the vehicle weight on the wheels tighten the front pivot bolt to 125 foot poun...

Page 329: ...ng Tool C 3709 Fig 10 1 On bolt SP 3178 position the bearing washer SP 92 thrust bearing SP 332 bushing adaptor SP 3179 flat side of adapter next to the washer spring leaf bushing and remover adapter SP 3180 2 Insert bolt SP 3178 through the bushing to be removed 3 Install adapter SP3242 on bolt SP 3178 The slot in adaptor SP 3242 should be visible to aid in Fig 7 Positioning the Interliner Fig 8 ...

Page 330: ...h Fig 11 Front Shock Absorber Typical Installation the dust shield or piston rod section upward Extend the shock absorber to the maximum length and turn it upside down Compress the shock absorber Repeat this procedure to make sure all air is removed from the unit Do not extend shock absorber when it is in the upside down or in a horizontal position other wise air will enter the cyhnder tube A stea...

Page 331: ... lower stud nuts to 60 foot pounds torque SERVICE DIAGNOSIS Condition Possible Causes Corrections 7 Spring Sags or a Springs sagged or taken a set a Bottoms b Broken bent or weak spring leaves b 3 Spring Noise a Loose U bolts a b Loose or worn shackle bushings b c Worn or missing interliners c 9 Spring Breakage a Loose U bolts a b Shock absorber inoperative b 10 Strut Noise Cracking a Loose strut ...

Page 332: ...ing Pump 26 Power Steering Pump Discharge Fitting Ferrule Replacement 28 Pressure Test 25 Pump Flow Test 26 Service Diagnosis 37 Slipper Spring Replacement 29 Specifications 1 SPECIFICATIONS MANUAL STEERING Type Worm and Three Tooth Roller Ratio 20 4 to 1 Gear Shaft Bearings 2 Needle Roller Bearings Worm Shaft Bearings Tapered Roller High Point Wheels Straight Ahead Notch on Steering Column Tube S...

Page 333: ...ng Fig 2 which consists of a rubber fabric disc assembled between the two hubs installed be tween the steering gear worm shaft and the steering tube which provides ahgnment of the steering gear to the frame side rail and the vehicle body The steer ing gear chuck has a stub worm shaft which extends up a short distance above the gear housing The flexi ble coupling attaches to the worm shaft by a ser...

Page 334: ...STEERING GEAR 19 3 SCREW 62 x 548A Fig i Steering Gear Disassembled View MyMopar com ...

Page 335: ...e clamp at the instrument panel and remove the clamp 10 Move the trim cap up on the steering jacket tube and release the floor carpet to expose the floor panel 11 Remove the screws attaching the dust pad to thefloorpanel and shde the dust pad up on the jacket tube 12 Remove the two nuts holding the lower jacket tube clamp to the steering column jacket bracket 13 Remove the clamp bolt from the stee...

Page 336: ...prevent unseating the bolt heads from the slots Tighten to 95 inch pounds torque 5 Position the isolator in the inside diameter of thefloorplate and install thefloorplate on the steer ing column with the insulated side down NOTE Before installing the floor plate and isolator on the column jacket lubricate the inside diameter of the isolator with a soap solution or rubber lubri cant This will make ...

Page 337: ... that was left in the steering column jacket tube during removal to the directional switch wiring and carefully pull the string or wire down through the column jacket tube until the directional switch wires can be connected Posi tion the directional switch in the steering column jacket tube and install the attaching screws and con nect all wire connections 9 Install the directional switch lever 10...

Page 338: ...pect all parts for wear Fig 8 installing fhe Oil Seal Protector Fig 9 Installing the Worm Shaft Oil Seal NOTE Assemble parts without lubrication Lubri cation should be done after adjustments are com pleted The needle bearings are grease packed from the factory If either of the worm thrust roller bearings are damaged replace both bearings Use new oil seals W o r m Shaft Oil Seal Replacement 1 Threa...

Page 339: ...er tool contacts the housing K the gear shaft bearings have been removed in stall the gear shaft outer bearing into the housing with Tool C 3786 Fig 12 Drive the outer lower bearing to within y1Q inch or end of counterbore Drive the inner upper bearing Fig 13 flush with the bore face with Tool C 3786 60X803 Fig 11 Installing the Gear Shaft Oil Seal Fig 12 Installing fhe Gear Shaft Housing Outer Be...

Page 340: ...ounting bolts grad ually so that the gear alignment is not disturbed Fig 14 Aligning the Steering Gear with the Flexible Coupling Fig 15 Steering Gear Alignment 7 Position the flexible coupling bolt hole in line with the groove on the worm shaft and install the bolt and lockwasher 8 Tighten the bolt 30 to 35 foot pounds torque NOTE The horn ground is attached to the under side of the coupling by t...

Page 341: ... and away from the vehicle Installation 1 Position the upper and lower ball joint studs into the steering knuckle and install the lock washer and nuts Tighten the upper ball joint stud nut to 100 foot pounds torque on Models TC 1 and TC 2 and 135 foot pounds torque on Models TC 3 and TY 1 Tighten the lower ball joint stud nut to 115 foot pounds TC 1 and TC 2 135 foot pounds TC 3 and TY 1 and insta...

Page 342: ...e in See Front Suspension Group 2 PART 2 POWER STEERING The power steering gear consists of a gear housing Fig 17 containing a gear shaft with sector gear a power piston with gear teeth milled into the side of the piston is in constant mesh with the gear shaft sector and a worm shaft connects the steering wheel to the power piston The worm shaft is geared to the piston through a recirculating ball...

Page 343: ...remove the steering wheel nut and the steering wheel 12 Remove the directional switch lever Fig 22 13 Remove the steering column lower cover 14 Remove the two screws and disconnect the switch wires at the connection and remove the direc tional switch and wires Fig 23 15 Remove the retainer snap ring Fig 24 from the groove in the steering tube at the top of the bearing using phers Tool C 3229 16 Re...

Page 344: ...l C 3646 up on the arm and place the shoe of the puller behind the steering arm Fig 25 Tightening the tool center screw against the gear shaft will pull the steering arm from the gear shaft CAUTION Do not remove the steering arm by prying with a lever or striking with a hammer as serious steering gear internal damage will result 23 Disconnect the hydraulic brake hne at the master cyhnder and the b...

Page 345: ...UIPPED SUPPORT CLAMP SEAL IF SO EQUIPPED COLUMN TUBE INSULATOR GROUND STRIP IF SO EQUIPPED INSERT PLASTIC 2 STEERING TUBE INSULATOR 60x19 Fig 26 Jacket Tube and Column Tube Cross Section in the holding fixture Tool C 3323 When disassembling each part should be placed in a suitable solvent washed then dried by dry com pressed air Careful handling of the parts must be exercised to avoid the occurren...

Page 346: ...le holding the drift pry on the piston teeth with a screwdriver using the gear shaft as a fulcrum and remove the complete power train NOTE By this procedure the worm will be all the way info fhe piston and fhe power train parts will be resting against fhe piston flange It is imperative that the cylinder head center race and spacer as sembly and fhe jacket support be maintained in close contact wit...

Page 347: ...achining on Imperial supports is different result ing in a difference of reaction feel Fig 32 Removing the Reaction Seal from the Jacket Support Fig 33 Installing the Worm Shaft Upper Seal 2 Remove the large 0 ring from the groove in the jacket support 3 Remove the reaction seal from the groove in the face of the jacket support with air pressure di rected into the ferrule chamber Fig 32 4 Inspect ...

Page 348: ...ings and the center bearing spacer Steering Valve Assembly Disassembly Fig 371 1 Remove the two screws attaching the pres sure control valve body to the steering valve body and remove the back pressure control valve assembly 2 Compress the pressure control valve spring and remove the retainer pin spring pressure control valve piston and back pressure valve cushion spring 3 Carefully shake out the ...

Page 349: ...t hydraulic fluid with the unit in operation CAUTION If for some reason the cover assembly must be removed from the gear shaft the 51 needles will fall out of the cover If any needles 51 become lost it will be necessary to replace the cover and bearing as an assembly Use wheel bearing lubri cant to retain the needle rollers in the cover when reassembling Assembly 1 Lubricate a new small O ring and...

Page 350: ... groove c Place the piston and ring assembly in Tool C 3676 with the lower part of the piston and the ring resting on the land of tool d Press down on the piston to bottom the piston ring in the piston groove forcing the open ends of the ring out for ease of locking the ring The ring should be positioned with ring hooks in hne with the ball guide plug Fig 41 Installing the Gear Shaft Oil Seal 1 Pl...

Page 351: ...Fig 42 Steering Gear Disassembled View MyMopar com ...

Page 352: ...e nut d To test the total staking tighten the nut to 20 foot pounds torque in either direction If the nut does not move the staking operation is satisfactory IMPORTANT Retest the pre load adjustment the torque of 8 16 inch ounces must remain after the adjusting nut is securely locked 7 Install the center bearing spacer assembly over the center bearing race and engage the dowel pin of the spacer in...

Page 353: ...ering housing so that the slots in the valve lever are parallel to the worm shaft in order to en gage the anti rotation pin in the center bearing race NOTE Turn the worm until the piston bottoms in both directions and observe the action of the lever It must return easily to its center position when the worm torque is relieved 7 Install the valve body on the housing making sure that the valve lever...

Page 354: ... the engine compartment and through the opening in the floor panel Install the housing attaching bolts flat washers swivel washers and nuts but do not tight en The swivel washer permits alignment of the hous ing to the dash 3 On Imperial Models inspect the jacket bearing snap ring in the steering tube lower groove Install a new ring if the old ring will not fully seat in the groove Install the spa...

Page 355: ...que 19 Install the steering column lower cover 20 Tighten the front upper and the lower gear housing to the frame attaching bolts to 24 foot pounds torque 21 Install a wedge over the rear bolt Fig 48 between the housing and the frame so that the ta pered surfaces match wedge lightly into place and tighten the three attaching bolts to 50 foot pounds torque Fig 48 Steering Gear Mounting 22 Install t...

Page 356: ...en the pump and the shut off valve all connections must be tight and the shut off valve fully open 3 Remove the oil reservoir filler cap 4 Connect one lead of the tachometer to the distributor terminal of coil and the other to a good ground start the engine and operate at 500 rpm and fill the pump reservoir to the proper level 5 Expel all the air from the unit by turning the steering wheel to the ...

Page 357: ...all the air from the unit by turning the steering wheel to the full right turn and back to the full left turn several times and recheck oil level 8 Increase the engine speed 1000 to 1200 rpm and no steering effort applied oil temperature be tween 150 and 170 degrees F Check the thermom eter in the reservoir the flow pressure gauge in the pump return line should read between 16 and 25 psi If correc...

Page 358: ...f the Fig 53 Removing Pump Shaft Oil Seal Typical Fig 54 Installing the Pump Oil Seal Typical pulley hub b Position the screw shaft and nut with the flange section inside the half collar c Engage the other half collar under the pulley hub and over the flange of the screw shaft nut and install the retainer sleeve over both half collars d Hold the nut from turning and turn the screw inward to remove...

Page 359: ...m the pump and examine the tubing flare for nicks scratches or other damage If the flare or nut is damaged replace the high pressure hose 3 Examine the pump housing in the discharge Fig 56 Installing the Ferrule Extractor Fig 57 Pump Cut Away View area to be sure that the housing has not been damaged by cross threading or over tightening the flare nut If the housing is cracked or if the threads ar...

Page 360: ...a fine hone or crocus cloth but Do Not round the valve land corners 3 Lubricate with 2084329 power steering fluid and install the control valve over the control valve spring and into the bore When all valve lands have cleared the retaining ring groove area work the control valve back and forth against spring pressure until the valve operates smooth and freely 4 Install a new 0 ring on the end plug...

Page 361: ...rings Typical 7 Smooth off burrs or corners on the pulley end of the pump shaft this will prevent shaft oil seal damage when a new seal is installed CAUTION Do not stone or emery the area on the shaft that the seal lip contacts 8 If all parts are in a serviceable condition dis card all eight slipper springs even if they appear to be in good condition 9 Thoroughly flush and clean all parts with cle...

Page 362: ...he dimensions shown in Figure 66 drop it over the pulley end of the shaft This washer is used to keep the shppers flush with the end of the rotor NOTE It is important that fhe slippers remain flush with the end of the rotor throughout the assembly operation 14 Insert the shaft and rotor assembly with flat washer tool and slipper retaining tool into the pump cam insert so that the shppers and rotor...

Page 363: ... inch drive ahgn the center punch marks on the front insert and the pump body and press the insert into the pump hous Fig 69 Loosening the Pump Bracket Mounting Screws Fig 70 Pump Belt Adjustment ing Fig 68 22 Installthe spanner nut and tighten to the exact original position in the housing as indicated by the pin punch marks placed on the pump body and span ner nut at disassembly 23 Install the fl...

Page 364: ...ustment bracket Fig 71 SERVICE DIAGNOSIS MANUAL STEERING Condition Possible Cause Correction 20 Hard Steering 21 Pull to One Side Tendency of the Vehicle to veer in one direction only 22 Wheel Tramp Excessive Vertical Motion of Wheels a Low or uneven tire pressure b Insufficient lubricant in the steering gear housing or in steering linkage c Steering gear shaft adjusted too tight d Front wheels ou...

Page 365: ...s torque f Tighten according to torque specifications g Replace the ball joints as neces sary See Front Suspension POWER STEERING 24 Hard Steering a Tires not properly inflated a Inflate the tires to recommended pressures b Low oil level in pump reservoir usually b See Fluid Level Power Steering accompanied by pump noise Pump c Loose pump belt c See Belt Adjustment d Improper caster and camber d S...

Page 366: ... steering gear repair as necessary 3 Inspect for leakage at the lower sector shaft oil seal the sector shaft cover 0 4 Remove the steering gear and repair as necessary a Inflate the tires to recommended pressures b Repair and lubricate as necessary c See Front Wheel Alignment Front Suspension Section d Remove the jacket tube and re place bearings e See Installation of Steering Gear f Adjust or rep...

Page 367: ...f Assist a Oil leaking past worm shaft oil seal a Remove the steering gear disas 1 One Direction ring semble inspect and replace the parts as necessary b Broken or worn ring on worm piston b See Assembly of the Power Train c Piston end plug loose c Replace the worm and piston as sembly d Reaction seal missing d Remove the steering gear and re pair as necessary 29 Both Directions a Pump belt shppin...

Page 368: ...llows 1 See Gear Shaft Adjustment 2 Remove steering gear disas semble inspect and reassemble See Center Bearing Preload 3 Inspect worm shaft splines for wear Also inspect retaining pin for tighteness c Replace the back pressure valve cushion d Rubber stop worn or missing from pump bracket e Belt not properly adjusted or worn to the extent that belt tension can not be properly adjusted POWER STEERI...

Page 369: ...h will then be forced out of the pump filler cap vent giving a false indication of fluid leakage b Pressure and return hose connections and fittings c Reservoir to pump body 0 ring or mounting screws d Pump shaft oil seal a Replace relief valve and perform Pump Pressure Test b Replace rehef valve and perform Pump Pressure Test a See Fluid Level b Tighten all fittings check hose for deterioration r...

Page 370: ... 34 Measuring Drive Train End Play 48 Operating Instructions 25 Recondition Sub Assemblies 50 Accumulator Piston and Spring 54 Extension Housing Bearing and Oil Seal 54 Front Clutch 58 Front Clutch Retainer Bushing Replacement 58 Front Oil Pump and Reaction Shaft Support 55 Front Pump Bushing Replacement 55 TRANSMISSION Governor and Support 54 input Shaft Bushing Replacement 60 Kickdown Servo and ...

Page 371: ...C O V E R BOLT S Y N C H R O N I Z E R UNIT C O V E R G E A R FIRST A N D REVERSE NUT LOCKWASHER BOLT A N D W A S H E R LOCKWASHER GROMMET 61x325 B Pig i Transmission Disassembled View MyMopar com ...

Page 372: ...Rear Clutch Plates Number of Rear Clutch Discs GEAR RATIOS 1 Low 2 Second D Drive R Reverse N Neutral FRONT REAR PUMPS Type End Clearance DRIVE TRAIN END PLAY CLUTCH PLATE CLEARANCE Front Clutch Rear Clutch 2 55 to 1 1 49 to 1 1 00 to 1 3 34 to 1 AVA Pints Automatic Transmission Fluid Type A Suffix A Helical 006 inch Maximum 008 inch Maximum 007 to 012 inch 057 to 059 inch 062 to 064 inch 002 to 0...

Page 373: ... Pounds Front Bearing Retainer Bolts Extension Housing Bolts 50 Nuts 50 Gearshift Operating Lever Nuts Mainshaft Flange Nut 175 Transmission to Clutch Housing Bolts 50 TORQUEFLITE TRANSMISSION Kickdown Band Adjusting Screw Lock Nut 29 Kickdown Lever Shaft Plug Reverse Band Adjusting Screw Lock Nut 35 Cooler Line Fitting Control Cable Adjusting Wheel Bolt Converter Drain Plug 14 Converter Drive Pla...

Page 374: ... h i c l e 1 Drain the lubricant from the transimission 2 Disconnect the propeller shaft speedometer cable and housing and the gearshift control rods CAUTION Remove the speedometer cable pinion comes out with the cable with hand so that housing is not crushed 3 Remove the back up light switch leads if so equipped 4 Install the engine support fixture Tool C 3806 mounting hooks firmly into the holes...

Page 375: ...g on the pinion shaft using a snap ring pliers Carefully press the pinion shaft out of the bearing using an arbor press Remove the oil slinger Fig 4 4 Remove the 15 rollers from the cavity in the end of the drive pinion gear using a hook Fig 3 Removing the Drive Pinion Assembly BEARING OIL SLINGER X DRIVE PINION Fig 4 Drive Pinion Assembly Mainshaft 1 Remove the mainshaft rear bearing snap ring fr...

Page 376: ... of the lever shaft seals using Tool C 3638 Fig 7 2 Using a small punch remove the low and re verse gear lever shaft tapered lock pin by driving it toward the top of the transmission case 3 Remove the second and third gear lever shafts in the same manner 4 Remove the lever shafts from the transmission case taking care not to lose the spring loaded detent balls 5 Remove the interlock sleeve spring ...

Page 377: ...ion gear 4 Install the bearing retaining snap ring on the pinion shaft using snap ring pliers Tool C 3301 Be sure the snap ring is seated in its groove The snap ring should be selected to eliminated end play 5 Coat the 15 pilot roller bearings with heavy lubricant and install them in the cavity at the rear of the main drive pinion Countershaft 1 Place the bearing spacer in the center of the bore i...

Page 378: ...er date 4 Place the interlock parts in position in the case in the following order ball sleeve spring pin and ball 5 While using the detent ball installer Tool C 3765 as shown in Figure 8 to depress the detent ball against the spring tension push the low and reverse lever shaft firmly into position so it engages the detent ball 6 Remove the detent ball installing tool 7 Install the low and reverse...

Page 379: ...ts to 276 inch pounds torque Extension Housing 1 Install a new seal in the extension housing using Tool C 3837 2 Install the extension housing Tighten the mounting bolts and nuts to 50 foot pounds torque 3 Install the mainshaft flange Install the washer and nut and tighten to 175 foot pounds torque using the flange holding Tool C 3281 4 Install the drain plug in the transmission case 5 Install the...

Page 380: ...Fig 9 Gearshift Controls MyMopar com ...

Page 381: ... each end of the divider shaft and push the divider shaft out of the gearshift support 9 Pull the levers dividers and bushing assembly from the gearshift support NOTE The flatwashers between the outer bushings and gearshift support will drop out at this time 10 Separate the levers from the divider and re move the nylon bushings Inspect all tiie parts for wear or damage and install new parts if req...

Page 382: ...ace the transmission shift levers in the neutral position and refer to Figure 12 for the linkage ad justment 7 TRANSMISSION REAR O I L SEAL Removal and Assembly 1 Disconnect the propeller shaft at the transmis sion flange Secure the shaft 2 Use wrench Tool C 3281 to hold the mainshaft while removing the mainshaft flange nut Remove the mainshaft nut and washer 3 Install puller Tool C 452 on the mai...

Page 383: ... clutches in the transmission The power flow depends on the application of the clutches and bands Refer to Clutch Engagement and Band Application Chart 1 HYDRAULIC CONTROL SYSTEM Figures 2 through 9 shows the position of the various valves with color coded passages to indicate those under hydrauhc pressure for all operations of the transmission The hydrauhc control system makes the transmis sion f...

Page 384: ...MyMopar com ...

Page 385: ...21 16 TRANSMISSION Fig 2 Neutral Hydraulic Circuits MyMopar com ...

Page 386: ...TRANSMISSION 21 17 62 x 231 Fig 3 Drive Breakaway Hydraulic Circuits MyMopar com ...

Page 387: ...21 18 TRANSMISSION Fig 4 Drive Second Hydraulic Circuits MyMopar com ...

Page 388: ...TRANSMISSION 21 19 Fig 5 Drive Direct Hydraulic Circuits MyMopar com ...

Page 389: ...Fig 6 Drive Kickdown Hydraulic Circuits MyMopar com ...

Page 390: ... I C K D O W N v Z 1 L 1 i OIL PRESSURES LINE 55 psi PUMP SUCTION G O V E R N O R 6 55 psi C O N V E R T E R 30 75 psi LUBRICATION 5 30 psi T O LUB CONTROL SYSTEM IN MANUAL SECOND REAR PUMP CLOSED THROTTLE 62 x 235 Fig 7 Push Button Second Hydraulic Circuits MyMopar com ...

Page 391: ...Fig 8 Push Button Low Hydraulic Circuits MyMopar com ...

Page 392: ...TRANSMISSION 21 23 REAR CLUTCH KD r S E R V O FRONT CLUTCH T O LUB FRONT PUMP REAR PUMP CONTROL SYSTEM IN REVERSE 6 2 x 2 3 7 Fig 9 Reverse Hydraulic Circuits MyMopar com ...

Page 393: ...UNS 2 SECOND 1 45 to 1 DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS 2 SECOND KICKDOWN TO LOW 2 45 to 1 DISENGAGED ENGAGED RELEASED RELEASED HOLDS 1 LOW 2 45 to 1 DISENGAGED ENGAGED RELEASED APPLIED PARTIAL HOLD 1 LOW RETARDING 2 45 to 1 DISENGAGED ENGAGED RELEASED APPLIED NO MOVEMENT R REVERSE ENGAGED DISENGAGED RELEASED APPLIED NO MOVEMENT 2 20 to 1 SHIFT PATTERN SUMMARY CHART Condition Vehicle ...

Page 394: ...fts is very important All shifts should be smooth responsive and with no noticeable engine runaway Mountain Driving When driving in the mountains with either heavy loads or when pulling trailers the 2 second or 1 low position should be selected on upgrades which requires heavy throttle for Vz mile or more Lower ratios reduces the possibility of overheating the trans mission and converter under the...

Page 395: ...21 26 TRANSMISSION SCREW 3 63x361 Fig 10 Removing or Installing Gearshift Control Unit Chrysler SCREW 2 Fig 11 Removing or Installing Gearshift Control Unit Imperial MyMopar com ...

Page 396: ...hat they are adequately lubri cated Fig 12 Adjusting Lever Nose Contact at Neutral Slide Pin LEVER STOP SCREW 6 2 x l 9 2 A Fig 13 Adjusting Lever Heel to Neutral Slide Pin Clearance 2 Hold the neutral slide in against the rocker bar with about 5 to 10 pound load 3 Loosen the lock nut and rotate the cam so the lever nose just touches the neutral slide pin as it passes over the pin when moving the ...

Page 397: ...n ap proximately two quarts offluidfrom the transmission 2 Remove the gearshift control cable to trans mission adjusting wheel lock screw 3 Pull the gearshift cable out of the transmission case as far as possible back off the adjusting wheel a few turns if necessary 4 Insert a small screwdriver above and slightly to the right of the gearshift cable Fig 14 Disengage the cable adapter lock spring by...

Page 398: ...ee Periodic Ad justments and the fluid and the filter changed ap proximately every 32 000 miles For extreme severe service it may be necessary to change the fluid as often as every 10 000 miles NOTE Police cars taxicabs and cars which frequently tow trailers operate in heavy traffic in hot weather or operate continuously with abnormal loads should have more frequent periodic maintenance The trans ...

Page 399: ...nd apply only enough inward force approximately two pounds to bottom the assembly at the reverse detent While holding the cable bottomed rotate the adjustment wheel clock wise until it just contacts the case squarely 5 Turn the wheel clockwise just enough to make the next adjustment hole in the wheel line up with the screw hole in the case 6 Counting this hole as number one continue turning the wh...

Page 400: ...inch pounds torque Do not use pliers or similar tool to pull outward on fhe cable as the cable cover might be damaged causing an oil leak 7 Inspect the adjustments by allowing the vehicle to roll slowly on a slight incline The parking sprag should fully engage the parking gear with the lever in ON position and there should be no ratcheting noise with the lever in the OFF position 12 BAND ADJUSTMEN...

Page 401: ...DAL ASSEMBLY TO BODY W I T H A 3 16 DIAMETER R O D APPROXIMATELY 10 LONG IN THE HOLES PROVIDED IN THE ACCELERATOR SHAFT BRACKET A N D LEVER ADJUST THE PEDAL ROD LEJiGTH TO PROVIDE A PEDAL ANGLE OF 113 TO 115 INSTALL PEDAL APPLYJ SHAFTf THIN FILM OF M S 3 6 0 8 LUBRICANT TO THE ACCELERATOR WHERE IT TURNS IN THE FIREWALL BRACKET ASSEMBLE CARBURETOR ROD PARTS BUT D O NOT TIGHTEN A D J U S T M E N T L...

Page 402: ... LEVER ASSEMBLY 4 MOVE THE TRANSMISSION LEVER FORWARD AGAINST THE STOP AND TIGHTEN TRANSMISSION ROD LOCK NUT 6 5 DISCONNECT ONE END OF THE ACCELERATOR PEDAL ROD ADJUST ITS LENGTH TO PROVIDE A PEDAL ANGLE OF 113 TO 115 REINSTALL THE ROD 6 REMOVE THE 3 16 DIA ROD FROM BELLCRANK BRACKET AND LEVER ASSY 7 MOVE LINK OF CARBURETOR ROD ASSY REARWARD UNTIL THE TRANSMISSION LEVER STOP IS CONTACTED TIGHTEN C...

Page 403: ...tighten the locknut A securely This positions the accelerator shaft c Unsnap the accelerator pedal to shaft rod Turn the threaded end of the rod either in or out until CHOKE CABLE RIGHT BANK CARBURETOR ROD ADJUSTING LINK T LOCKING BOLT AND NUT ACCELERATOR SHAFT TO THROTTLE SHAFT LEVER ROD LOCKING BOLT AND NUT ADJUSTING LINK LEFT BANK CARBURETOR ROD SPRING 2 TOP VIEW ADJUSTING LINK LOCKING NUT J AC...

Page 404: ...ssion fluid must be at operating temperature 150 F to 200 F 1 Install an engine tachometer raise the car on a hoist and position the tachometer so it can be read under the car 2 Connect two O 100 psi pressure gauges Tool C 3292 to pressure take off points at the side of the accumulator and at the front servo release Fig 24 3 With the control in D drive position speed up the engine slightly until t...

Page 405: ...changes in m p h and should return to 0 to VA psi when the vehicle is stopped High pressure at standstill above 2 psi will prevent the transmission from downshifting If governor pressures are incorrect at the given vehicle speeds the governor valve and or weights are probably sticking Throttle Pressure No provisions are made to test the throttle pres sure Incorrect throttle pressure should only be...

Page 406: ...he throttle valve is completely bottomed inside the valve body 5 As force is being exerted to compress the spring tighten the throttle lever stop screw finger tight against the throttle lever tang with the throttle lever cam touching the tool and the throttle valve bottomed Be sure the adjustment is made with the spring fully compressed and the valve bottomed in the valve body 6 Remove the tool an...

Page 407: ...oved for repairs without removing the transmission from the vehicle The removal reconditioning and instal lation procedures for these components are covered here except valve body reconditioning which is described in Paragraph 31 Heli Coil inserts are recommended for repairing damaged stripped or worn threads in aluminum parts Refer to Paragraph 27 17 SPEEDOMETER PINION Removal and Installation 1 ...

Page 408: ...n the open ing of the extension housing with Up of seal facing inward Drive the seal into the housing with Tool C 3837 Fig 34 5 Install the transmission output shaft flange Install washer with its three projections toward the flange and the nut with its convoluted surface con INNER Fig 31 Speedometer Pinion Disassembled Fig 32 Removing or Installing Output Shaft Flange Nut tacting the washer Hold ...

Page 409: ...e a new bearing in the opening of the ex tension housing Using Tool C 3204 drive the bear ing into housing Fig 36 Install bearing retaining snap ring 4 Place a new seal in the opening of extension Fig 35 Removing Output Shaft tearing 62x179 Fig 36 Installing Output Shaft Bearing housing lip of seal facing inward Using Tool C 3837 drive the seal into housing until tool bottoms Fig 34 Installation 1...

Page 410: ...sembly on output shaft Align the assembly so the governor valve shaft hole in governor body aligns with the hole in the output shaft then slide the assembly into place Install snap ring behind the governor body Fig 37 Tighten body to support bolts to 100 inch pounds torque Bend ends of lock straps over bolt heads 3 Assemble the governor weights and spring and secure with snap ring inside of large ...

Page 411: ...tall the oil pump cover with the retaining bolts threaded in a few turns Slide the aligning fixture Tool C 3864 all the way in until it bottoms against rotors Fig 40 then retighten the cover bolts evenly to 140 inch pounds torque 4 Install the governor and support See Para graph 20 5 Install the extension housing transmission flange and connect the propeller shaft 6 Connect the parking lock cable ...

Page 412: ...st the starter for operating in all push but ton positions If it should operate in any position other than neutral readjust the gearshift control c a b l e Refer to Paragraph 9 In some cases If may be necessary to align the valve body neutral finger with t h e switch plunger R e f e r t o Paragraph 24 24 VALVE BODY ASSEMBLY AND ACCUMULATOR PISTON Removal 1 Remove the drain plug from the transmissi...

Page 413: ...lar tool as the drive plate might become distorted Also the starter should never be engaged if the drive plate is not attached to the converter with at least one bolt or if the trans mission case to engine block bolts have been loosened 8 Disconnect the negative ground cable from the battery 9 Remove the starting motor assembly 10 Disconnect the wire from the neutral starting switch 11 Remove the ...

Page 414: ...for full engagement by placing a straight edge on the face of the case Fig 45 The surface of the converter front cover lug should be at least V2 inch to the rear of the straightedge when the converter is pushed all the way into the transmission 3 Attach a small C clamp to the edge of the converter housing to hold the converter in place during transmission installation Installation 1 Inspect the co...

Page 415: ...front of the con verter assembly 17 Refill the transmission with Automatic Trans mission Fluid Type A Suffix A NOTE To completely adjust the throttle linkage push button control cable and neutral starting switch refer to Maintenance Adjustments and Tests Para graphs 9 10 and 13 RECONDITION TRANSMISSION UNIT OUT OF VEHICLE The following reconditioning paragraphs cover the In the event that any part...

Page 416: ...om most automotive parts jobbers 2 8 FRONT PUMP OIL SEAL Replacement The front pump oil seal can be replaced without removing the front pump and reaction shaft support assembly from the transmission case 1 Screw seal remover Tool C 3861 into the seal Fig 47 Tighten the screw portion of tool to with draw the seal 2 To install a new seal place the seal in the opening of the pump housing lip side fac...

Page 417: ... input shaft Fig 50 Fig 49 Transmission Installed in Repair Stand Fig 50 Measuring Drive Train End Play 2 Chuck the input shaft in and out to obtain end play reading 3 Record the indicator reading for reference when reassembling the transmission End play specifications are 030 070 inch Extension Housing 1 Hold the transmission flange with Tool C 3281 and remove the retaining nut and washer Fig 32 ...

Page 418: ...t shaft and rear clutch assembly out of the case CAUTION Be careful not to lose the thrust washer located between the rear end of input shaft and for ward end of output shaft Planetary Gear Assemblies Sun Gear Driving Shell 1 While supporting the output shaft and driving shell carefully slide the assembly forward and out through the case CAUTION Be very careful not to damage the ground surfaces on...

Page 419: ...iderable mileage install new seal rings on parts requiring their usage NOTE Coat each part with Automatic Transmission Fluid Type A Suffix A during assembly 3 1 VALVE BODY ASSEMBLY Disassembly NOTE Never clamp any portion of the valve body or transfer plate in a vise Any slight distortion of the aluminum body or the transfer plate will result in sticking valves excessive leakage or both When re mo...

Page 420: ...Fig 57 Remove any burrs from the shaft then while holding the manual lever detent baH and O N E LARGE STEEL BALL FIVE SMALL STEEL BALLS 60x370A Fig 56 Front Pump Check Valve and Steel Ball Locations spring in their bore with Tool C 3765 or similar tool slide the manual lever off the throttle shaft Remove the detent ball and spring 10 Remove the manual valve carefully slide it out of the valve body...

Page 421: ...tion 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 the manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose onits shaft it may be silver soldered only or the lever and shaft assembly should be re placed CAUTION Do...

Page 422: ...r plate and tighten the four retaining screws to 28 inch pounds torque 5 Install the 1 2 and 2 3 shift valves and springs Fig 59 Install the shift valve end plate and tighten the three retaining screws to 28 inch pounds torque 6 Install the regulator valve throttle pressure plug sleeve under cut on sleeve toward end plate and the line pressure plug Fig 59 Install the regulator valve end plate and ...

Page 423: ...ottoms Fig 34 34 PARKING SPRAG AND LEVER Disassembly 1 Remove the parking lock cable adapter cover from bottom of the extension housing 2 Remove the plug and slide the shaft out of the extension housing to remove the parking lock lever adapter and shim Fig 41 3 Slide bushing sleeve out of housing to remove the sprag and spring Fig 42 Inspection Figure 61 shows the parking sprag and lever disas sem...

Page 424: ...irmly into the case with a wood block and hammer Remove the pilot studs 3 7 FRONT OIL PUMP AND REACTION SHAFT SUPPORT Disassembly Figure 62 shows the front oil pump and reaction shaft support disassembled 1 Remove bolts from the rear side of the reaction shaft support remove the vent baffle and lift the support off the oil pump 2 Remove the rubber seal ring from the front pump body flange 3 Drive ...

Page 425: ...DLE SP 3549 REMOVAL INSTALLATION 62X347 Fig 63 Replacing Front Pump Bushing Reaction Shaft Bushing Replacement 1 Assemble the remover Tool SP 3632 the cup Tool SP 3633 and the hex nut Tool SP 1191 CAUTION Do not clamp any part of the reaction shaft or support in a vise 2 With the cup held firmly against the reaction shaft thread the remover into the bushing as far as possible by hand Fig 65 3 Usin...

Page 426: ...he threads on the bushing re mover 6 Shde a new bushing chamfered end first on the installing head Tool SP 3634 and start them in the bore of the reaction shaft Fig 67 Removing or Installing Front Clutch Spring Retainer Snap Ring 7 Support the reaction shaft upright on a clean smooth surface and install handle Tool SP 3549 in the installing head Fig 65 Drive the bushing into the shaft until the to...

Page 427: ...es plates must travel freely in the grooves Inspect the band contacting surface on the clutch retainer for scores Note the ball check in the clutch retainer make sure the ball moves freely Inspect the seal surfaces in the clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of neoprene rings Inspect the clutch retainer bushing for wear or scores Inspect the i...

Page 428: ...sure plate clutch plates and inner pressure plate out of the retainer 2 Remove the piston spring snap ring and remove the spring 3 Invert the clutch piston retainer assembly and bump on a wood block to remove the piston Remove seals from the piston 4 If necessary remove the snap ring and press the input shaft from the clutch piston retainer Inspection Inspect the facing material on all driving dis...

Page 429: ... threads in the bushing 5 Turn the hex nut down against the cup to pull the bushing from the input shaft 6 Thoroughly clean the input shaft to remove the chips made by the remover threads Make certain the small lubrication hole next to the ball in the end of the shaft is not plugged with chips Be sure no chips are lodged next to the steel ball 7 Slide a new bushing on the installing head Tool SP 3...

Page 430: ...g 73 Be sure the snap ring is fully seated in the groove 6 Install the inner pressure plate in the clutch retainer with raised portion of plate resting on the spring 7 Lubricate all clutch plates install one lined plate followed by a steel plate until all plates are installed Install the outer pressure plate and snap ring 8 With the rear clutch completely assembled in sert a feeler gauge between t...

Page 431: ...ust washer from inside the driving shell Remove snap ring and steel washer from the sun gear rear side of driving shell and slide the sun gear out of the sheU Remove front snap ring from the sun gear if necessary Note that the front end of the sun gear is longer than the rear 6 Remove the thrust washer from forward sicje of the rear planetary gear assembly remove the planetary gear set from the re...

Page 432: ... end of the output shaft 4 1 OVERRUNNING CLUTCH inspection Inspect the clutch rollers for smooth round sur faces they must be free of flat spots and chipped edges Inspect the roller contacting surfaces in the cam and race for brinelling Inspect the roller springs for distortion wear or other damage Inspect the cam set screw for tightness If loose tighten and restake the case around the screw Overr...

Page 433: ...king If the lining is worn so grooves are not visible at the ends or any portion of the band replace the band Inspect the band for distortion or cracked ends 4 3 L O W A N D REVERSE SERVO AND BAND Disassembly 1 Remove the snap ring from the piston and re move the piston plug and spring Fig 80 Inspection Inspect the seal for deterioration wear and hard ness and the piston and piston plug for nicks ...

Page 434: ... Band Link ADJUSTING SCREW AND LOCKNUT Fig 82 Low Reverse Band and Linkage 2 Compress the low and reverse servo piston spring by using the Engine Valve Spring Compressor Tool C 3422 then install the snap ring 3 Position the rear band in the case install the short strut then connect the long lever and strut to the band Fig 82 Screw in the band adjuster just enough to hold the struts in place Be sur...

Page 435: ...mp installation Using a suitable heat lamp heat the case in the area of front pump 62x17 Fig 83 Kickdown Band and Linkage Fig 84 Installing Front Pump and Reaction Shaft Support Assembly for a few minutes prior to installing the front pump and reaction shaft support assembly NOTE If the drive train end play was not within specifications 030 070 inch when measured in Para graph 29 replace the thrus...

Page 436: ... burrs on both the transmission case and valve body trans fer plate 2 Install the accumulator piston in the transmis sion case and place the piston spring on the accumu lator piston 3 Carefully position the valve body assembly in the transmission case install the retaining bolts and tighten finger tight With the neutral starting switch installed place the manual valve in the neutral posi tion Shif...

Page 437: ...it Place the welds alternately on op posite sides of the converter to minimize distortion 3 The following suggestions are offered as an aid in making the weld a Do not gas weld b Use a D C welder that is set at straight po larity or an A C welder if proper electrode is avail able c Use a Vs inch diameter welding rod and a weld ing current of 80 to 125 amps d Direct the arc at the intersection of t...

Page 438: ...cifications d Perform pressure tests to deter mine cause and correct as required e Inspect the accumulator for stick ing broken rings or spring Repair as required f Remove the valve body assembly and perform air pressure tests Re pair as required g Perform the hydrauhc pressure tests Adjust or repair as required h Disassemble and inspect clutch Repair or replace as required i Inspect and replace s...

Page 439: ...e tests and adjust to specifications e Remove and clean the governor Replace parts if necessary f Perform pressure tests to deter mine cause and correct as required g Inspect accumulator for sticking broken rings or spring Repair as required h Remove the valve body assembly and perform the air pressure tests Repair as required i Perform the hydraulic pressure tests adjust or repair as required j I...

Page 440: ...hrottle hnkage d Adjust the control cable e Perform the hydrauhc pressure tests and adjust to specifications f Remove and clean the governor Replace parts if necessary g Clean the oil strainer h Perform pressure tests to deter mine cause and correct as required i Remove the valve body assembly and perform air pressure tests Repair as required j Perform the hydrauhc pressure tests adjust or repair ...

Page 441: ... pressure tests and adjust to specifications e Adjust the low reverse band f Perform pressure tests to deter mine cause and correct as required g Remove the valve body assembly and perform air pressure tests Re pair as required h Inspect the servo for damaged seals binding hnkage or faulty band hning Repair as required i Perform the hydrauhc pressure tests adjust or repair as required a Refill to ...

Page 442: ...e tests to deter mine cause and correct as required c Inspect the accumulator for stick ing broken rings or spring Repair as required d Remove the valve body assembly perform air pressure tests Repair as required e Disassemble and inspect clutch Repair or replace as required f Disassemble the transmission and repair overrunning clutch as required g Inspect and replace the seal rings as required al...

Page 443: ...nt clutch plate clearance in f front and or rear clutches f Inspect the condition of the over running clutch and replace parts as required a Adjust the kickdown band b Adjust the low reverse band c Remove the extension housing and replace the bearing d Inspect the condition of the gov ernor support and repair as required e Inspect the condition of the pump and repair as required f Disassemble and ...

Page 444: ...itch c Broken lead to neutral switch a Refill to the correct level with Automatic Transmission Fluid Type A Suffix A b Adjust the low reverse band c Remove and recondition the valve body assembly d Inspect and repair the rear oil pump as required e Inspect the servo for damaged seals binding hnkage or faulty band hning Repair as required f Disassemble and inspect clutch Repair or replace as requir...

Page 445: ...0 14 8 50 14 Size Special 8 50 14 8 50 14 Size Town Country 8 50 14 9 00 14 Ply 4 Std 4 Std 4 Std TIRE PRESSURE COLD Pounds Rear 22 2 2 22 Town and Country 24 24 Pounds Front 24 24 24 Town 8t Country 22 22 With Town and Country fully loaded increase rear tire COLD pressure to 28 pounds TC 2 300J High Performance 15 x 6K wheel TC 2 300J High Performance 760 x 15 Tire Size TC 2 300J High Performance...

Page 446: ...2 New Yorker Town Country 22 24 Imperial All Models 24 24 Town Country fully loaded increase rear tire air pressure to 28 lbs C 300J 24 p s L front and rear Inspect tire pressures regularly including the spare when the tires are cool or cold Inflate to specified pressures They should also be inspected for damage and embedded foreign matter at the same time 2 TIRE ROTATION With the increased road s...

Page 447: ...es it should be trued up or replaced Under no circumstances should point indicated by C be used for checking runout as this metal has been sheared in the manufacturing process and as a result is not an even surface 4 WHEEL BALANCE Static balance is equal distribution of the weight of the wheel and tire around the spindle in such a manner that the wheel assembly has no tendency to rotate by itself ...

Page 448: ...Tire Bead Breaker Tool C 3455A should be used to force the tire beads over the raised rim sec tion However the car jack may be used as an alter nate method See Fig 5 Fig 6 Expanding Tire Beads Mechanical Tool 3 While holding one bead in the center section pry the other bead off the wheel Remove the re maining bead to complete the removal Cleaning and Inspection 1 Eliminate any rust inside the whee...

Page 449: ...ene mineral spirits or other similar cleaning fluids 2 Examine the bearing cups for pits brinell marks or other imperfections If cups are damaged Fig 8 Fill Cavity with Wheel Bearing Lubricant Fig 9 Adjusting Front Wheel Bearings drive them from the hub with a soft steel drift posi tioned in the slots in the hub 3 The bearing cup areas in the hub should be smooth without scored or raised metal whi...

Page 450: ...e zero no preload to 003 end play 5 Clean the grease cap coat the inside with wheel bearing lubricant do not fill and install SERVICE DIAGNOSIS Condition Possible Cause Condition 8 Side Wear a Outside all wheels excessive cornering a Driver instructions Fig 10 and 11 speed b Outside front excessive positive b Adjust camber to specification camber c Inside front excessive negative c Adjust camber t...

Page 451: ...oe in to specifications c Inspect for bent arm or knuckle replace parts as required A w Fig 14 Spotty Wear 11 Abrasive Roughness a Excessive cornering speed Across Tread 12 Heel and Toe Wear 13 Uniform Spotty Wear Fig 14 14 Irregular Spotty Wear a High speed driving b Severe use of brakes a Lack of tire rotation b Tires and wheels out of balance a Tires and wheels out of balance b Under inflation ...

Page 452: ... 35 Deflector Chrysler Models 24 Page Description Imperial 3 MAINTENANCE Paint Finish Care 6 Rear Window Convertible Coupe 6 I and Hinge Removal 14 Forward or Back Front Door 9 djustment Imperial 1 3 djustment Chrysler 14 fments 10 Adjustments Hard Top Imperial 13 Adjustments Hard Top Chrysler 1 3 ir Doors Front Doors 9 Door Glass Adjustment 1 2 s 55 Luggage Compartment Sealing 1 9 Rear Quarter Pa...

Page 453: ...8 Rear Seat Back 28 Rear Window Glass 39 Service Diagnosis 00 Windshield Glass All Models 36 PART 6 MAJOR BODY SERVICING Application 48 Paint Refinishing 47 Preparation 47 Refinishing 48 Removing Old Finish 47 Replacement of Body Panels 46 Sub Assemblies All Models 46 PART 7 CONVERTIBLE COUPE TOP Adjusting the Convertible Coupe Top 48 Care and Cleaning of Top 51 Fluid Level in Reservoir 50 Operati...

Page 454: ...ig 3 ex tending forward of the front passenger compartment is bolted to the Unibody with ten body bolts eight of these he in a fore and aft position and two in a transverse position The fore structure with box section side rails and Y section reinforcements at the front end has three crossmembers The first crossmember supports the diagonal struts for the front suspension control arms the second cr...

Page 455: ...23 4 BODY AND SHEET METAL FORE STRUCTURE ASSEMBLY UNDER BODY FLOOR PAN 60x1275 A Fig 3 Underbody Construction MyMopar com ...

Page 456: ...tain a certain amount of bleach cau tion should be exercised as to the amount used Some of the most common upholstery stains can be removed as follows 1 Candy Chocolate or Ice Cream Stains Scrape off as much of the staining matter as possible with a dull knife Clean with a one half of 1 solution of a laundry detergent in warm water General Instructions Use a piece of clean cotton cheesecloth appro...

Page 457: ...n the paint surfaces for any length of time in the presence of moisture a chemical reaction will take place re sulting in the metal particles eating into the paint surface Early removal of this material by a thorough washing will prevent this from happening When the above described condition is encountered in the field it is often mistakenly diagnosed as rust coming up from the metal below the pai...

Page 458: ...atch is attached by two attaching screws Fig 5 Aligning the Hood ot the Cowl Fig 6 Hood Latch Assembly The attaching screw holes are oversize to permit movement of the latch to assist in alignment of the hood Fig 6 The latch engages a striker bar attached to the upper radiator grille support Fig 7 Unequal Spacing Between Rear of Hood and Fenders 1 Loosen the four hinge to hood attaching bolts on e...

Page 459: ...he low spot on the hood 2 Close the hood slowly With the hands placed just ahead of the block gently apply pressure to the hood 3 Repeat this operation about every six inches until the contour of the fender and hood conform evenly Fender Below Level of Hood at Front End If the hood has been properly adjusted and one fender is still below the level of the hood at the front the fender should be rais...

Page 460: ...ther pull or push the upper portion of the door in the desired direction 3 Tighten the hinge bolts and inspect the fit 4 When correct reinstall the door trim panel 5 To remove the lower portion of the door for ward or rearward trim panel removed loosen the lower hinge bolts and either pull or push the lower portion of the door in the desired direction 6 Tighten the hinge bolts and inspect the fit ...

Page 461: ... on the opposite side until the lid fits flush with the body panel and is equally spaced all around 14 CORRECTING DECK LID CAMBER The incorrect camber of the deck lid should not be confused with the deck lid being improperly located Fig 11 Deck Lid Adjusting Points on its hinges The deck lid spacing across the top must be uniform but at the same time must be flush with the body quarter panels The ...

Page 462: ... with the body panels A test for proper fitting and seal of the deck lid can be made with strips of paper Insert the strips of pa per about an inch wide along the edge of the deck lid opening and close the lid See Fig 14 If the pa pers fit snug all along the edges of the lid as they are Fig 13 Deck Lid Striker Fig 14 Testing the Deck Lid Seal pulled out a good seal is evident If the papers fit loo...

Page 463: ...e the top of the vent frame out board turn the adjusting stud clockwise 8 With the vent frame in position at the A post and making a good weather seal at the roof rail tight en the division bar adjusting stud lock nut and washer 30 to 50 inch pounds torque and retighten the two forward attaching screws 80 to 120 inch pounds torque 9 Run the door glass to the up position and test for ease of operat...

Page 464: ... and moving the adjusting screws out will move the glass outboard 8 Run the glass up and down several times and and retest the glass ahgnment Tighten the adjuster lock nuts 9 Install the weather shield and connect the win dow regulator switch and install the upholstering trim panel 10 Install the remote control handle and remote lock lever 18 REAR DOOR GLASS ADJUSTMENT HARDTOP Fig 1 8 Chrysler Wit...

Page 465: ...s inboard and counter clockwise to move the glass outboard 5 Move the guide tracks forward to ahgn the quarter glass to the rear of the door glass 6 Tighten the locking nuts of the guide sleeve nuts 7 Run the glass up and down several times and test the up and down stops 8 Install the weather shield trim panel the reg ulator handle rear seat back and seat cushion 2 1 HOODLOCK AND HOOD Removal and ...

Page 466: ...or core support Figs 6 and 7 PART 4 BODY SEALING 2 4 WEATHERSTRIP ADHESIVE This cement may be used where a strong bonding of rubber parts to painted or unpainted steel surfaces is desired It can be used for such purposes as the attachment of weatherstripping on doors and luggage compartment lid or for the attachment of felt pads NOTE Before sealing always clean all surfaces to be cemented with unl...

Page 467: ...ip of the rubber weatherstrip where it con tacts the body metal and use a nozzle type applica tor sealer gun to force the sealer deeply around the entire edge It is rarely necessary to reseal be tween the glass and the weatherstrip unless the glass has been replaced If faulty sealing of the glass to the weatherstrip has caused a leak remove the wind shield finish moulding and apply sealer as far d...

Page 468: ... the weatherstrip overlaps If the weatherstrip is severely damaged install a new vent window weatherstrip Leaks around the pivots can be corrected by the use of black mastic sealer Fill the openings in the weatherstrip where the vent pivot goes through the weatherstrip Seal around the upper pivot bracket at the door frame and at the junction of the division bar and door frame The first and most im...

Page 469: ...NDOW FRAME WEATHERSTRIP WEATHERSTRIP SCREW WEATHERSTRIP DO NOT APPLY CEMENT BEYOND THIS POINT SCREW VIEW IN DIRECTION OF ARROW E 60 x 1273 Fig 27 Door Ventilator Wing Sealing Hard Top Models CEMENT CEMENT U j 6 0 x 1 4 5 1 Fig 28 Cowl Panel Plenum Chamber Sealing MyMopar com ...

Page 470: ... If the seams are rough large or deep metal finish smooth with adjoining surfaces Then apply cold solder with a spatula or putty knife smoothing it down as much as possible and let it completely set up Finish off with a sander and paint Minor Leakage Note particularly the metal seam joints and the coach joints at the junction of the floor side sill to floor pan and the A B and C pillars Water and ...

Page 471: ...re water testing the deck lid make certain that the deck hd is properly fitted Start the water test at the bottom and work slowly toward the top of each side Then work across the top of the lid In spect the two upper and lower welded joints for prop er sealing Leakage around the hd is usually caused by insuf ficient contact between the deck lid and the weather strip which may indicate the need for...

Page 472: ...medallions CAULKING PUTTY SEALER on the rear quarter panel results in more chps and bolt holes which may leak Leaks from this area will generally appear in the luggage compartment floor extensions near the quarter panel Seal around all attaching chp and bolt holes tail lamp reinforcement seams and rear quarter panel IMPERIAL MODELS IMPERIAL MODELS HOOP FINISH MOULDING FILL SKIPS IN TROUGH WITH CAU...

Page 473: ...ccasionally this seal is incomplete or broken Use precedure as out lined above for repair When correcting a water leak at the front end of the roof be sure to fill the joint of the roof to A pillar and the slotted notches and skips in the seam in the A pillar flange with body caulking sealer RETAINER MOULDING RETAINER SECTION A A FOUR DOOR HARDTOP AND SEDAN SECTION B B 63 x 723 Fig 36 Exterior Mou...

Page 474: ...n the grille in its opening and install the grille to the stone shield bolts 3 Install the nuts on the grille outer sections retaining studs under the front fenders 4 Install the grille to the center support bracket screws 4 0 GRILLE CHRYSLER MODELS Removal 1 Remove the grille moulding 2 Remove the grille to splash shield bolts 3 Remove the grille to fender tie bar support bolts 4 Remove the grill...

Page 475: ...remove the fender side shield to core support attaching screws 5 Remove the core support to frame attaching screws 6 Remove the radiator core support up out of the engine compartment Installation 1 Position the radiator core support down into the engine compartment Install the frame to core support attaching screws finger tight 2 From under the fenders install the fender side shield to core suppor...

Page 476: ...nce or flange by lightly tapping it into place with a block of wood or soft faced hammer 3 Butt the two ends of the weatherseal together and install the step plate and attaching screws 49 HEADLINING Removal f All Models Except Hardtops and Convertibles 1 Remove the dome light assembly and rear seat cushion assembly as well as the sun visor and the upper windshield garnish moulding 2 Pull the rear ...

Page 477: ...1 2 Notch the headlining at the front and rear ends to indicate the center of the material by mak ing small V shaped cuts as shown in Figure 42 Use these marks as guides to properly center the headlining 3 Starting at the rear of the vehicle apply cement to the window opening Fig 43 Install the rear bow tension spring 4 Install the bows in the correct location since bows are of different length an...

Page 478: ... to the other complet ing one section at a time make certain that the seams are straight As the work progresses the ma terial should be kept free of wrinkles until all of the headlining is tucked in place between the roof rail and the retainer 13 Install the rear window glass moulding dome light side and the upper windshield mouldings 14 Install the rear package shelf and rear cush ion 15 Seal and...

Page 479: ...in each seat base 2 The hortizonal slots allow a fore or aft move ment of 1 inches 3 The vertical slots allow up down or tilt move ment of IVfe inches 4 Position the seat as desired and tighten the bolts to lock it in place 51 FRONT SEAT Removal 1 The front seat cushion is an integral part of the seat frame From under the vehicle remove the 4 nuts attaching the seat base to thefloorpan 2 Remove th...

Page 480: ... door aligning procedure and in stall the weather shield trim panel and inside han dles NOTE Prior to this installation on electric window lifts install the wiring in the doors and attach to the motor and control switch 56 REAR DOOR ALL MODELS Removal 4 Door Sedan 1 Open the rear door and place a padded jack under the door near the hinges 2 Remove the inside handles and door lock re mote lever uph...

Page 481: ...a small screw through the center of the hub into the Fig 49 Inside Door Handle Attachment center of the end of the shaft The knob is posi tioned on the shaft by spline teeth on the O D of the shaft and the ID of the hole in the knob Installation 1 On all models position the locking control knob on the splined shaft 2 Insert the small screw through the center of the hub into the center end of shaft...

Page 482: ... take the nut off the locking lever assembly and remove the assembhes from the panel Rotate the bottom of the lock forward to disconnect the remote and lock control P Fig 51 links Take the lock out of the door On Imperial front doors it is easier to get the remote control disconnected from the lock if the glass rear lower guide channel bottom attach ing screw nut is removed and the channel pushed ...

Page 483: ... KEY CYLINDER LINK KEY CYLINDER TO LOCK T LEVER REAR DOOR LOCK BLOCKING K LEVER DETENT ACTUATOR L LOCKING LEVER TRANSMITTING LINK x A I j ACTUATOR TRANSMITTING LINk jp LOCK LOCKING CONTROL LINK LINK DOOR LOCK REMOTE LEVER DOOR LOCK RELEASE GIX316A Fig 51 Manual Door Lock and Linkage MyMopar com ...

Page 484: ...e handles trim panel and weathershield 2 Using a screwdriver through the access hole of the door inner panel pry the U shaped retainer off of the back of the lock cyhnder 3 Withdraw the lock cyhnder part way out of the door panel and with a rotating motion of the lock cyhnder body disengage the lock cylinder arm from the link Installation 1 Hold the lock cyhnder link in alignment with the lock cyh...

Page 485: ...ass from regulator 4 Remove the regulator attaching screws Fig 55 and remove the regulator Figs 56 and 57 and pivot links Fig 58 through the door opening Installation 1 Install the pivot link and regulator assembly Figs 56 or 58 2 After installing the regulator turn the handle so the arm is in the raised position 3 Engage the regulator arm in the door glass LOCK DRIVE CUP PINION 60x1201 60x1311 Fi...

Page 486: ...ed bolt holes in the hinge brackets 6 5 DECK LID Removal Adjustment of the deck lid is obtained by loosening the bolts and shifting the hd from side to side or front to rear It is often possible however to prop erly fit deck hd by adjusting the striker plate latch or both Should it become necessary to remove the deck hd for replacement or repair refer to Figure 11 1 Raise the deck hd remove one of...

Page 487: ...at hold the hinge to the deck hd Do not tighten just snug down 3 Remove the prop and lower the lid to check fit 4 Make the necessary adjustments Check the adjustment of the latch and striker After adjust ments have been made prop the hd open and install the torsion bar WINDSHIELD AND WINDOWS 67 WINDSHIELD G L A S S A L L MODELS The windshield and rear window weatherstrip are of the one piece type ...

Page 488: ... helper supporting the opposite end f A x 743 Fig 63 Removing or Installing the Lower Windshield Moulding Fig 64 Unlocking the Windshield Weatherseal of the windshield exert pressure to force the wind shield out of the weatherstrip and carefully remove the windshield glass from the vehicle A windshield which has a crack originating from under the weatherstrip indicates the possibility of a pressur...

Page 489: ...p Fig 67 Locking the Windshield Weatherseal using an upward motion until glass is fully seated in the channel of the weatherstrip at top bottom and sides of glass After properly seating glass in the weatherstrip strip in glass with a wedge shaped tool of hardwood or fibre Fig 67 inserted between the weatherstrip and glass at either corner to strip glass into weather strip Shde the toof across the ...

Page 490: ...d on the convertible in the same manner as described in Windshield Glass In stallation then continue as follows 1 Shde the header cap moulding up against weatherstrip 2 Force the moulding against the weatherstrip then press the rear edge down over the header 3 Install the screws to hold in position then tap lightly with a rubber hammer to seat Be sure the cap is evenly spaced across the header 4 I...

Page 491: ...ass as shown in Fig ure 74 Make sure the glass is properly seated by tapping the glass with palm of hand Do not use a rubber mallet when installing rear window glass Fig 72 Removing the Rear Window Lower Moulding Fig 73 Rear Window Moulding Attaching Clips 6 Lay a bead of sealer in the glass groove all around the rear window 7 Moisten the edge of the locking strip with water 8 Starting at the cent...

Page 492: ... CORNER CAP LOCKWASHER K l l I T ATTACHING N U T BOLTS ADJUSTING STUDS LOCKWASHER LOCKWASHER NUT _ c n 63x750 Fig 76 Ventilator Adjustments Chry Hard Tops Convertible and Town and Country VENT WING LOCKWASHER BOLT ADJUSTING STUD NUT LOCKWASHER 63x751 Fig 77 Front Door Ventilator Adjustments Chrysler 4 Dr Sedan door frame 2 Install the ventilator attaching screws finger tight 3 Install the ventilat...

Page 493: ... the clips from the regulator arms and Fig 79 Removing the Glass Run Channel Chrysler remove the washers and arms from the glass lower frame 4 Raise the glass up and out of the door frame Installation 1 Enter the glass into the run channels and lower the glass to the down position 2 Lubricate the regulator am rolers and glass lower frame guides 3 Instal the regulator arms into the glass frame and ...

Page 494: ...es remote door lock lever arm rest if so equipped the trim panel and weathershield Fig 82 Rear Door Glass Assembly Chrysler 4 Dr Sedan 63x759 Fig 83 Convertible Quarter Glass Assembly 2 Run the door glass to the down position and remove the regulator arm attaching retainers 3 Disengage the regulator arms from the glass lower channel 4 Remove the glass stops and raise the glass and channel up out o...

Page 495: ... be carefully controlled because of the difference of the gauge of the metal in the sub frame of a unibody and the stress points de veloped in a single welded unit construction It is possible to pull damaged areas back into ahgnment with the use of light weight jacks and hydrauhc body equipment without heating the metal Any attempt to cold straighten severely bent floor pan side rails or brackets ...

Page 496: ...ses it may be difficult to obtain proper body ahgnment when repairing a body that is dam Fig 88 Aligning Body at Centerline of Center Pillar New Yorker aged on both sides In these instances horizontal and vertical measurements may be taken from a body of the same body style Once these basic dimensions are taken and established on the damaged body alignment can be made by diagonal measurements take...

Page 497: ...ent parts plus labor as against cost of repairs labor only Satisfactory de cisions can be derived only by becoming familiar with the various replacement panels and subassem blies available With proper equipment an experienced body re pair man can repair a damaged area in a body panel by one of three methods 1 External or surface damage that can be bumped out or refinished 2 External damage that ca...

Page 498: ...to try and do a touch up on a large surface The use of lacquer for spot painting will usually prove unsatisfactory as the sheen or gloss of lacquer and enamel do not match Lacquer has a tendency to oxidize and fade over long exposures to weather 7 8 PREPARATION The surface to be finished must be thoroughly cleaned and free from oil grease rust moisture polishes and waxes containing silicone resins...

Page 499: ...vehicle is in motion It is advisable to raise and lower the top at least once a month to keep the top mechanism in working condition To Raise to Top Unsnap the top boot at the sides and rear and fold into the storage compartment Turn the top control switch to the left and hold in this position until the header rests on the windshield Zip up rear curtain Pull the top down firmly on the top header P...

Page 500: ...ront side rail hinge adjusting screws counter clockwise until the joints are closed If after making this adjustment the clearance between the door glass and the side rail is increased or decreased adjust the rear ad justing screws to obtain the desired clearance Power Link Adjustment Chrysler Only With the top and all door and quarter window glasses in the raised position carefully inspect both do...

Page 501: ...are protected by a separate circuit breaker as shown in Figure 94 The pump is a two direction reversing motor type and is connected to the cylinders by flexible lines and tubing A valve and port assembly in the reservoir directs flow offluidin the system The motor pump and reservoir assembly can be replaced as a unit or the electric motor can be replaced separately The cylinders are sealed units a...

Page 502: ...he pump motor 8 9 REAR W I N D O W CONVERTIBLE COUPE The rear window is made from flexible vinyl plastic material and special attention should be given to cleaning and storage of the window To clean the window rinse with a cold water spray to remove grit and dirt Lather the surface with suds of a mild soap such as Castile using the palm of the hand Rinse thoroughly and allow to air dry Do not use ...

Page 503: ...he inside trim panel 4 With an assistant holding the instrument panel switch in the up position operate the control switch on the left side of the tail gate and support the glass as it emerges 5 Remove the retaining clips and the regulator arms from the window frame and remove the glass from the tail gate Installation 1 Insert the glass into the tail gate run channels deep enough to engage the reg...

Page 504: ...of glass up 8 Starting at the lower center of the weather strip insert a pull cord in the flange groove with the ends of the cord crossed 9 With an assistant holding the glass weather strip and moulding assembly in approximate position in the window opening slowly work the weatherstrip over the window fence by pulling the cord 10 Position the glass into place by bumping glass with the palm of the ...

Page 505: ...el Press a bead of rope type seal into moulding seams and clean off surplus While rear pillar garnish moulding is removed inspect the outer D shaped opening if necessary seal This opening should be filled with caulking putty 101 TAIL LAMPS Water test tail lamp area for possible leakage into the luggage compartment Water may enter between the tail lamp housing and quarter panel openings To obtain a...

Page 506: ...panel and the hub of the remote control handle Test by pressing the trim panel away from the remote control handle a Add or remove shims in back of the strik er to remove the interference b Adjust the striker so that the top of the lock housing moves parallel to the bottom surface of the striker teeth and the door is not raised or pulled down as the lock engages the striker c Relocate the moulding...

Page 507: ...mote to lock link Properly lubricate the remote control mechanism and the lock assembly using MoPar Lubriplate a Properly adjust the lock adjusting screw b Be sure the flattened end of the link is not too wide spreading the clip File the edge of the flat so the clip fits freely In stall the link c Install a new lock a Adjust the control mechanism until it will completely lock and release the lock ...

Page 508: ...uum distributor to main tee hoses according to the color code of the hoses and fittings f Remove the small diameter hoses from the switch Start the engine and operate the control switch If there is no vacuum at the switch connections the switch is at fault Install a new switch g Remove the distributor to main tee hose from the distributor connection Start the engine Operate the switch to lock and ...

Page 509: ... in the unmarked hose system to the actuator f Install a new hose g Remove the door inside trim panel In spect the actuator Install a new actuator if the connector is broken 114 Door Locks Operate a Small hoses reversed on the a Connect the hoses correctly 115 Opposite to That of the Switch Operation Doors on One Side Lock While the Doors on the Opposite Side Unlock control switch b Hoses reversed...

Page 510: ...ent of the folding top header a Improper adjustment of the number 1 roof bow a Folding top header torsion bar not properly adjusted a With the top in the up position and the header locked in turn the square head screw at the front side rail hinge and the set screw at the rear side rail hinge until they contact the head a Adjust by moving the serrated adjustment plate up or down to hold the side ra...

Page 511: ...t 6 Evaporator Pressure Regulator Valve Test 15 Test 7 Compressor Capacity Test 16 Test 8 Expansion Valve Test 19 Vacuum Control System Adjustments and Tests 22 SPECIFICATIONS COMPRESSOR Location Left of Center on Cylinder Block Type 2 Cylinder V Type Bore 2Vu inch S t r o k e VA inch Displacement 9 45 cubic inches Type V a l v e Reed Type Speed depends on axle ratio and tire size Approximately 12...

Page 512: ...n for the Town and Country Models only It consists of the combination dash mounted unit and a special roof mounted evaporator assembly installed at the rear of the Town and Coun try Models The dash mounted front unit is the basic factory installed option The rear unit mounted in the lug gage compartment and the roof unit for the Town and Country Models are not available as single units without the...

Page 513: ... for the clutch control circuit and one for the blower motor speed control circuit The push button switch assembly controls the clutch circuit The push button switch also con trols the feed circuit to the blower motor speed control switch mounted on the temperature control lever Push Button Control The power feed circuit connects directly to the air conditioning terminal of the fuse block Fig 2 Th...

Page 514: ...unit Figs 3 and 4 Antifreeze Required f o r Summer Operation The Air Conditioning system requires the engine s cooling system to be protected to 15 F with a permanent type anti freeze for summer operation This is to prevent freezing of the coolant In the heater core Bug Screens Bug screens should not be installed on cars equipped with air conditioning A bug screen in stalled in front of the conden...

Page 515: ...o Electrical Controls and Cir cuits Test the Push Button Operation Reduce the engine speed to normal idle With the engine operating at idle speed the vacuum will be high and the vacuum actuators should operate quickly If the actuator operation is slow check the source hose connection at the engine manifold Push each button to test the over all operation of the electrical and vacuum controls The Pu...

Page 516: ... and or sub cooler will decrease heat dissipation from the condenser decrease the effi ciency of the condenser and in turn decrease the evaporator s efficiency These conditions result in in creasing the discharge pressure and horsepower load on the engine The use of a bug screen is not recom mended as it too will decrease the free flow of air Inspect the condenser and sub cooler for bent or damage...

Page 517: ...Temp Pressure F PSI F PSI F PSI F PSI F PSI 0 9 1 35 32 5 60 57 7 85 91 7 110 136 0 2 10 1 36 33 4 61 58 9 86 93 2 111 138 0 4 11 2 37 34 3 62 60 0 87 94 8 112 140 1 6 12 3 38 35 1 63 61 3 88 96 4 113 142 1 3 13 4 39 36 0 64 62 5 89 98 0 114 144 2 10 14 6 40 36 9 65 63 7 90 99 6 115 146 3 12 15 8 41 37 9 66 64 9 91 101 3 116 148 4 14 17 1 42 38 8 67 66 2 92 103 0 117 151 2 16 18 3 43 39 7 68 67 5 ...

Page 518: ...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 the tube connectors and other possible leak points by moving the end of the sam pling hose from point to point Since Refrigerant 12 is heavier than air it is good practice to place the open end of the samphng hose directly bel...

Page 519: ...F Place the pan of water containing the refrigerant can on an accurate scale Tool C 3429 so that the amount of refrigerant added can be weighed Open the refrigerant manifold valve 2 Slowly open the suction service gauge valve Meter the flow of refrigerant by adjusting the suc tion service gauge valve so that the pressure regis tered at the suction service gauge does not exceed 50 psi Keep the refr...

Page 520: ...that the engine must be operated at 1250 rpm for a sufficient time to build up to operating temperatures and al low all the under hood components of the system to be subjected to the under hood operating tempera ture for a period of time Partially close the needle valve located below the discharge pressure gauge to minimize oscillation of the discharge gauge pointer Do not close the needle valve c...

Page 521: ...57 57 58 58 59 60 6l 61 62 63 64 65 66 66 67 68 69 70 70 71 72 73 92 55 55 55 55 56 56 56 56 56 56 56 56 57 57 58 58 59 59 60 61 62 62 63 64 65 66 66 67 68 69 70 70 71 72 73 93 56 56 56 56 56 56 56 56 56 57 57 57 58T 58 59 59 60 61 61 62 63 63 64 65 66 66 67 68 69 70 70 71 72 73 94 57 57 57 57 57 57 57 57 57 57 57 57 58 58 59 60 60 61 61 62 63 63 64 65 66 66 67 68 69 70 70 71 72 73 95 57 57 57 57 ...

Page 522: ...9 60 60 61 62 63 63 64 65 66 67 68 68 69 70 71 72 72 73 74 75 92 57 57 57 57 58 58 58 58 58 58 58 58 59 59 60 60 61 61 62 63 64 64 65 66 67 68 68 69 70 71 72 72 73 74 75 93 58 58 58 58 58 58 58 58 58 59 59 59 60 60 61 61 62 63 63 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 94 59 59 59 59 59 59 59 59 59 59 59 59 60 60 61 62 62 63 63 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 95 59 59 59 59 59 59...

Page 523: ...5 7 5 8 5 8 5 9 6 0 6 1 6 2 6 3 6 3 6 4 6 5 6 6 6 7 6 7 6 8 6 9 7 0 9 2 52 5 2 5 2 5 2 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 4 5 4 5 5 5 5 5 6 5 6 5 7 5 8 5 9 5 9 6 0 61 6 2 6 3 6 3 6 4 6 5 6 6 6 7 6 7 6 8 6 9 7 0 9 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 3 5 4 5 4 5 4 5 5 5 5 5 6 5 6 5 7 5 8 5 8 5 9 6 0 6 0 61 6 2 6 3 6 3 6 4 6 5 6 6 6 7 6 7 6 8 6 9 7 0 9 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4...

Page 524: ...1 61 62 62 63 63 64 65 66 66 67 68 69 70 71 71 72 73 74 75 75 76 77 78 92 60 60 60 60 61 61 61 61 61 61 61 61 62 62 63 63 64 64 65 66 66 67 68 69 70 71 71 72 73 74 75 75 76 77 78 93 61 61 61 61 61 61 61 61 61 62 62 62 63 63 64 64 65 66 66 67 68 68 69 70 71 71 72 73 74 75 75 76 77 78 94 62 62 62 62 62 62 62 62 62 62 62 62 63 63 64 65 65 66 66 67 68 68 69 70 71 71 72 73 74 75 75 76 77 78 95 62 62 62...

Page 525: ...ATOR V A L V E TEST The EPR Valve is cahbrated to produce the maxi mum cooling possible without causing frost or ice on the evaporator fins and tubing If for any reason the factory calibration has been disturbed the EPR valve may restrict the flow of refrigerant at an evaporator pressure which is either too high for maximum performance or too low to prevent coil freeze up AIR CONDITIONING 24 15 Fi...

Page 526: ...4 to 28 psi Again determine the pressure at which the valve is fully open 5 Turn the blower on high and push the FRESH COOL button to increase the heat load on the evaporator This will increase suction pressure caus ing the EPR valve to open fully 6 Watch both the evaporator suction and the compressor inlet pressure gauge The pressure regis tered at the compressor inlet gauge will increase quite r...

Page 527: ...st 15 minutes This will cause most of the compressor oil in the system to be re turned to the compressor crankcase It will also insure that fhe compressor is up to op erating temperature which is very important when making this test Discharge the System When making the Compressor Capacity Test the compressor must be disconnected from the rest of the system That means the system must be dis charged...

Page 528: ...ng the pressure regis tered at the discharge gauge when the compressor is driven at an engine epeed of exactly 500 rpm THE TACHOMETER USED MUST BE ACCURATE The compressor capacity test results are dependent upon controlling the engine speed at exactly 500 rpm Test Pressures and Results 1 Start the engine and adjust speed to exactly 500 rpm ENGINE EXACTLY 500 RPM VALVE CLOSED 190 PSI MINIMUM OPEN 6...

Page 529: ... VALVE IN ITS IN STALLED POSITION A compressor which does not pass the compres sor capacity test may have leaking reed valves or a fractured head gasket Such a leak would allow re frigerant gas used in the expansion valve test to leak from the discharge side of the compressor An internal leak between the discharge and suction side of the compressor will upset the expansion valve test results Test ...

Page 530: ...at and humidity the temperature of the ice and water may not be reduced to 32 degrees F Use a thermometer to test the actual temperature If it is necessary to lower the temperature of the ice and water add small quantities of salt while stirring until the de sired temperature of 32 degrees F is obtained Maximum Flow Test Thermal Bulb Warm 1 Warm the thermal bulb by holding it in your hand This wil...

Page 531: ...ty goggles Tool C 333S when servicing the refrigeration part of the air condition ing system Keep a bottle of sterile mineral oil and a weak solution of boric acid handy when working on the refrigeration system Should any liquid re frigerant get into the eyes use a few drops of min eral oil to wash them out Refrigerant 12 is rapidly asborbed by fhe oil Next wash the eyes with the weak solution of ...

Page 532: ... under a 5 pound load for ALL MODELS 2 Measure the drive belt tension at regular serv ice intervals using the deflection method and re adjust as needed 3 On all new belt installations new belt tension specifications should be used when the belt is first installed to obtain the proper tension Thereafter these replacement belts should be serviced according to the above procedure Always replace belts...

Page 533: ...ovided at engine idle speed may not function properly at high engine speeds Before starting this test stop the engine Make certain that the vacuum source hose at the engine intake manifold is tight on its connector 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 a finger blocking the p...

Page 534: ...leaking The control switch is faulty and must be replaced If excessive vacuum drop shows up at one or more holes in the connector block iso late the faulty hose or actuator If the vacuum drop occurs at numbers 5 or 7 holes first check the tee connectors under the instrument panel that tie numbers 5 and 7 hoses to the bypass door and deflector hoses If the tee connections are all right inspect the ...

Page 535: ...ing from the Pulley Assembly 2 Install the drive hub puller Tool C 3787 align ing the three pins of the Tool in the three holes in the hub and shoe assembly Tighten the hex head bolt down until the drive hub is removed from the bearing See Fig 34 3 Remove the bearing snap ring from the pul ley assembly 4 Place the pulley assembly on an arbor press with the pulley side down and the bearing hub cent...

Page 536: ...w self locking bolt and tighten to 20 foot pounds torque 5 Connect the field lead wire 6 Install the belts and tighten to the specified ten sion 13 SERVICING THE COMPRESSOR The compressor is a two cylinder reciprocating type designed specifically for the Chrysler Air Condition ing System Service parts are available so that the compressor can be repaired in the field Figure 37 is a disassembled vie...

Page 537: ...om pressor suction screen spring and the gasket 2 Remove the EPR Valve and 0 ring from the compressor using Tool C 3822 by rotating the valve counterclockwise slightly as shown in Figure 38 Installation 1 Install the 0 rinfe on the EPR Valve 2 Lubricate the 0 ring with refrigerant oil and install the EPR Valve in the compressor with Tool C 3822 and rotating the valve counterclockwise 3 Install the...

Page 538: ...ving hght scor ing scuffing or scratches with a crocus cloth After conditioning the cyhnder bores clean the surfaces of the cyhnder block valve plate and head thoroughly with mineral spirits Use care to remove all shreds of old gasket from plate block and head surfaces Clean attaching stud holes in the block If the valve plate or cyhnder head is damaged replace using a complete compressor valve pl...

Page 539: ... as the sump is lowered on the case 6 Tighten the sump bolts finger tight to pre vent spring misalignment then tighten 15 to 19 foot pounds torque 7 Refill with new refrigerant oil after the com pressor is installed on vehicle Do not re use the oil that was previously drained PILOT STUDS C 590 SUMP RELIEF SPRING 62x370 Fig 43 Removing fhe Crankshaft Bearing Housing 18 CRANKSHAFT BEARING HOUSING AN...

Page 540: ...g sure that it is in proper ahgnment with the screw holes The gas seal assembly may be damaged if the bearing housing is rotated after the housing seal contacts the carbon seal 8 Install the bolts and tighten 10 to 13 foot pounds torque 19 CRANKSHAFT AND BALL BEARING Removal 1 Remove the cyhnder heads and the valve plates 2 Remove the pistons and connecting rods 3 Remove the crankshaft bearing hou...

Page 541: ... complete test has proved it to be faulty It is rec ommended that Test 8 Expansion Valve Test be performed before replacing the expansion valve Removal The system must be completely discharged before opening any of the refrigerant lines 1 Remove the equahzer hne from the evapora tor suction hne fitting 2 Disconnect the valve from the inch inlet hne and from the V2 inch outlet hne Use two flare wre...

Page 542: ...vaporator housing so it will seal both the core to cover flange and the cover to evaporator housing joint Cement the gasket in place to facihtate installation 4 Install and tighten the heater core and cover attaching screws Be careful to maintain the gasket ahgnment to insure an air tight seal at this point 5 Connect the by pass door actuator rod and vacuum lines 6 Connect the heater hoses and ref...

Page 543: ...allation of the evaporator assembly Also make sure there is an air tight seal between the engine side housing and the cast evaporator housing 1 Close the fresh air door and install the evap orator assembly as shown in Figure 49 Make sure the rear edge of the rain shield is folded upward 2 Install all evaporator assembly attaching screws and tighten hghtly After all screws are installed tighten alt...

Page 544: ...se dual installa tions If the bulk tank method of charging is used an accurate scale must be used to insure charging with the proper amount of refrigerant COMPLETE SYSTEM DISCHARGE AND RECHARGE Before the system can be opened for replacement of hnes or components the system must be completely discharged It is also necessary to discharge the sys tem before performing the compressor capacity test an...

Page 545: ...e directly below the point being tested Be careful not to pinch the samphng tube since this will shut off the air supply to the flame and cause a color change 3 Watch for a change in the color of the flame Small leaks will produce a green and large leaks a bright blue color If leaks are observed at the tube fittings tighten the connection using the proper flare wrenches and retest 2 9 TEST PRECAUT...

Page 546: ...nd the needle valve 3 Start the vacuum pump and operate until the evaporator suction gauge registers at least 26 inches of vacuum If the system is tight and the pump in good condition the vacuum will go as low as 28 inches 4 Allow the vacuum pump to operate with suction gauge registering 26 to 28 inches of vacuum for a minimum of five minutes 5 Close both gauge set manifold valves turn off the vac...

Page 547: ...ck wise so that they are fully open Remove the protec tive caps from the refrigerant manifold 2 Screw the refrigerant cans into the manifold Be sure the manifold to can gasket is in place and in good condition Tighten the can and the manifold nuts 6 to 8 foot pounds 3 Turn the three refrigerant manifold valves com pletely clockwise to puncture the cans and close the manifold valves 4 Turn the refr...

Page 548: ...alve justment 35 Blower Operating Partial Cooling a Moisture low refrigerant low compressor capacity a Replace strainer drier add refrigerant test for leaks and correct repair or replace the compressor b Slipping clutch b Repair or replace c Water valve out of adjustment or c Adjust the cable or replace faulty d Obstruction of condenser d Clean the condenser repair and replace 36 Low Suction and L...

Page 549: ...oisture in system b Expansion valve froze or stuck open c Expansion valve equalizer tube plugged d Bad compressor valves e Not enough oil a Change the strainer drier recharge b Change the strainer drier recharge clean or replace expansion valve c Clean or replace the expansion valve d Replace the valve plates e Add oil MyMopar com ...

Page 550: ...tant Push Buttons 1 3 Manual Antenna 1 4 On Off Switch and Volume Control 1 2 Push Button Adjustment 1 3 Radio Controls 1 2 GROUP 1 ACCESSORIES RADIOS HEATERS MIRRORS Continyed Page Radio Removal and Installation 1 2 Service Diagnosis 1 25 Wiring Diagrams 1 7 Heater Heater Blower 1 11 Heater Core 1 11 Heater Vacuum Actuator Replacement 1 11 Rear Window Defroster 1 10 Vent Deflector Replacement 1 1...

Page 551: ...1 GROUP 5 B R A K E S Booster Brakes Booster Brake Bendix 5 13 Booster Brake Midland Ross 5 16 Remote Power Brake C 300J 5 19 Service Diagnosis 5 25 Parking Brakes Parking Brake Adjustment 5 10 Parking Brake Cable Front 5 12 Parking Brake Cable Rear 5 10 Service Diagnosis 5 22 Service Brake Adjusting the Brakes Bleeding the Brake System Brake Drums Brake Shoe Installation Brake Shoe Removal GROUP ...

Page 552: ...ndary Circuit Inspection 8 35 Service Diagnosis 8 85 Spark Plugs 8 48 GROUP 8 ELECTRICAL Continued Page Part 5 Electroluminescent Lighting instrument Testing 8 49 Operation 8 48 Service Diagnosis 8 87 Part 5 Instruments Circuit Breakers 8 55 Cluster Bulb Replacement Chrysler 8 51 Cluster Installation Chrysler 8 54 Cluster Installation Imperial 8 54 Cluster Removal Chrysler 8 51 Cluster Removal Imp...

Page 553: ... 9 21 Cylinder Heads 9 10 Distributor Drive Shaft Bushings 9 21 Engine Assembly 9 9 Front Engine Mounts 9 28 Hydraulic Tappets 9 14 GROUP 9 E N G I N E C o n t i n u e d Page Main Bearings 9 26 Measuring the Connecting Rod Bearings Clearance Plastigage Method 9 25 Mechanical Tappets Model 300J 9 16 Piston and Connecting Rod Assembly 9 26 Rear Main Bearing Oil Seal 9 27 Rear Engine Mounts 9 29 Rock...

Page 554: ...ushing 17 5 Measuring Rear Spring Height 17 2 Rear Shock Absorber Replacement 17 6 Rear Springs 17 2 Rear Spring Interliners 17 3 Rear Spring Front Pivot Bushing Replacement 17 4 Service Diagnosis 17 6 Specifications 17 1 GROUP 19 STEERING GEAR PUMPS STEERING GEAR ARM IDLER ARM Page Part 1 Manual Steering Roller Tooth and Worm Adjustment 19 10 Service Diagnosis 19 33 Specifications 19 1 Steering C...

Page 555: ...sion in Vehicle 21 38 Extension Housing Removal and Installation 21 39 Bearing Replacement 21 40 Governor Removal and Installation 21 40 Neutral Starting Switch 21 43 Removal and Installation 21 43 Output Shaft Oil Seal Replacement 21 39 GROUP 21 TRANSMISSION TORQUE CONVERTER Continued Page Parking Lock Components 21 42 Removal and Installation 21 42 Rear Oil Pump Removal and Installation 21 41 Sp...

Page 556: ... Front Door Glass Four Door Sedan 23 42 Front Door Ventilator 23 40 Front Seat 23 28 Grille Chrysler Models 23 23 Grille Imperial Models 23 23 Headlining 23 25 Lock Cylinder 23 33 GROUP 2 3 B O D Y AND SHEET METAL Continued Page Outside Door Handle and Key Cylinder 23 31 Radiator Core Support 23 24 Rear Deck Lid Convertible 23 35 Rear Deck Lid Hinges and Locks Removal Installation Alignment 23 35 ...

Page 557: ...agnetic Clutch 24 24 Operation Air Conditioning 24 2 Radiator Pressure Cap 24 22 Safety Precautions 24 21 GROUP 2 4 A I R CONDITIONING Continued Page Service Diagnosis 24 38 Specifications 24 1 Test 1 Test System Pressure 2 4 6 Test 2 Refrigerant Level and Moisture 24 7 Test 3 Testing the System for Leaks 24 8 Test 4 Correcting Low Refrigerant Level 24 9 Test 5 Performance Test 24 10 Test 6 Evapor...

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Summary of Contents for Imperial 1963

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Chrysler Imperial 1963, Service Manual, Page: 173 / 557

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Summary of Contents for Imperial 1963

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