Chrysler Imperial 1965 Service – Technical Manual Download Page 1

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Summary of Contents for Imperial 1965

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Page 3: ...AC i CHRYSLH mmoRi CONVEX Fig 965 Imperial and Chrysler Models MyMopar com ...

Page 4: ...scription 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 involved 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 Plym outh Service literature...

Page 5: ...on 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 At tention Parts Catalog Department Shortage of Accessories or Other Equipment on New Cars Before placing an order for missing accessories other parts or equipment on new cars received examine the ve...

Page 6: ...er pump as shown in Fig ure 3 ft e ix 22 4 Fig 2 Vehicle Number 1st Letter 2nd Digit 3rd Digit 4th Digit Make of Vehicle Model of Vehicle Year Built Assembly Plant C Chrysler 1 Newport 5 Newport Station Wagon 5 1965 3 Detroit 2 300 7 New Yorker Station Wagon 6 Delaware 3 New Yorker 9 Police 4 300L Y Imperial 2 Crown 3 LeBaron 5 1965 3 Detroit BODY PLATE NUMBER LOCATION The body number is stamped o...

Page 7: ...Hard Top Convertible Y253100001 Crown 4 Dr Hard Top Y353100001 Le Baron Wheelbase All Models Except Sta Wgn Station Wagon 124 0 121 0 124 0 124 0 121 0 129 Tread Front A l l Models 62 62 62 61 8 Tread Rear All Models 60 7 60 7 60 7 61 7 Length with Bumper All Models Except Sta Wgn Station Wagon 218 2 219 0 218 2 218 2 219 0 Width with Bumper All Models 79 5 79 5 79 5 80 0 Rear Axle with 3 Speed or...

Page 8: ...tem drain C H R Y S L E R N K 5 7 2 EO cc A A E n g i n e C o o l a n t C h e c k level and o r anti freeze D C L Distributor C a m a n d R u b b i n g B l o c k A p p l y to cam a n d rubbing block Distributor O i l C u p a n d C a m W i c k u n d e r Rotor b l o c k C a r b u r e t o r F u e l F i l t e r R e p l a c e with n e w filter C a r b u r e t o r A i r C l e a n e r C l e a n or replac...

Page 9: ... 5 x 1 5 All S e d a n s 9 1 5 x 1 5 Convertibles Front R e a r 2 2 2 2 24 2 4 A Prepacked bearing Cooling system drain IMPERIAL N K 5 7 3 E n g i n e C o o l a n t C h e c k level a n d o r anti freeze D C L Distributor C a m a n d R u b b i n g B l o c k A p p l y to c a m a n d rubbing block Distributor O i l C u p a n d C a m Wick u n d e r Rotor b l o c k C a r b u r e t o r F u e l F i l t e...

Page 10: ...TRIKER ROTOR 22 DOOR STRIKER PLATES 22 DECK LID HINGES 23 TAILGATE TORSION BAR AND CHECK ARM GUIDE PLATE 23 FUEL TANK ACCESS DOOR HINGE 23 THROTTLE LINKAGE 23 SUMMARY OF LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommenda tions for the 1965 Chrysler Corporation built vehi cles have been compiled to provide maximum protec tion for the car owner s investment against all rea so...

Page 11: ...LUBRICATION AND MAINTENANCE Fig 3 Support Locations for Frame Contact Moisting AC l AC 2 AC 3 Models Fig 4 Support Locations for Frame Contact Hoisting Locations AY 1 Models MyMopar com ...

Page 12: ...ice Brake Master Cylinder 18 X 6 Month Service Brake Hoses 18 X 6 Month Service Body Mechanisms 20 X X 10 000 Miles Engine Performance Evaluation 23 X 20 000 Miles Fuel Filter 16 X 20 000 Miles Brakes and Brake Linings 18 X 20 000 Miles Front Wheel Bearings 11 X Every 2 Years Carburetor Air Filter 15 X Every Oil Change Crankcase Ventilating System Fully Closed Type 13 X Every Year Carburetor Air F...

Page 13: ...e found on the container Gear Lubricants The SAE grade number also indicates the viscosity of Multi Purpose Gear Lubricants defined by MIL L 2105B An example is SAE 75 which is a light viscosity lubricant Lubricants Greases Semi solid grease lubricants such as specified for propeller shaft universal joints bear the NLGI des ignation They are further classified as grades 0 or at j Information perta...

Page 14: ...Fig 7 Clutch Torque Shaft and Linkage Lubrication Points Fig 8 Column Mounted Manual Transmission Gearshift Control Lubrication Points bricate the torque shaft bearings lubricate the clutch drive lugs Fig 7 release bearing sleeve and fork fingers and pivots Fill cavity in sleeve and coat lugs fingers and pivots with Multi Mileage Lubricant Part Number 2525035 of Automotive Multi Purpose Grease NLG...

Page 15: ...emoving the con sole top trim panel TRANSMISSION Manual Three Speed Standard The fluid level in the transmission should be main tained to the bottom of the filler plug hole Fig 12 When necessary to replenish refill with Automatic Transmission Fluid AQ ATF Suffix A Part Num ber 1843314 for all ambient temperatures In warm weather however Multi Purpose Gear Lubricant SAE 90 as defined by MIL L 2105B...

Page 16: ...rnal leaks or damage in accordance with the Certified Car Care Schedule The joints should not be disassembled or relubricated unless external leaks or damage has occurred When necessary to lubricate the joints disassemble mm V r KD5936 T Fig 14 Universal Joint Cross and Roller Type completely clean and inspect parts for serviceability Damaged parts should be replaced Repack ball and trunnion joint...

Page 17: ...grade 2 The spline should be lubricated with Automo tive Multi Purpose E P Grease NLGI grade 0 Ap proximately one ounce of lubricant is required REAR AXLE Standard and Sure Grip When checking the lubricant level the car should be in a level position on a wheel or axle type hoist The level should be between the bottom of the filler plug hole to one half inch below If necessary to add use Multi Purp...

Page 18: ...h grease Fig 18 to minimize condensation and grease travel out of the bearing Do Not overfill Adjust the bearings as follows 1 Tighten the wheel bearing adjusting nut Fig 19 to 90 inch pounds while rotating the wheel 2 Position the nut lock on the adjusting nut so one pair of cotter pin slots align with the hole in the spindle Fig 19 3 Back off the adjusting nut and nut lock to the next slot and i...

Page 19: ... for year long operation in many parts of the U S may be used where temperatures occasionally drop as low as 1 0 F Recommended where minimum tempera tures are consistently below 10 F Where temperatures are consistently above 32 F Where temperatures range between 32 F and 1 0 F HK575 Fig 21 Shaded Area Covers Region Where Minimum Temperatures of 70 F are constantly Reached During Winter Months Low ...

Page 20: ... that a Chrysler Corporation Engine Oil Filter be installed to assure most efficient service Fig 22 Engine Oil Filter 383 and 473 Cu In Engines VALVE ASSEMBLY V 8 E N G I N E S 64 X 3 0 7 A Fig 23 Standard Crankcase Ventilation System CRANKCASE VENTILATION SYSTEM Periodic service of the positive crankcase ventila tion system Fig 23 is required to prevent malfunc tion of the system because of combu...

Page 21: ...d every two years On cars with high performance engines equipped with non silenced air cleaners without a wrapper the system should be serviced with every engine oil change and the valve and air cleaner element re placed every year This service will be required more frequently if vehicle is used extensively for short trip driving less than 10 miles with frequent idling such as in city traffic Serv...

Page 22: ... out the dirt from the element with compressed air The air nozzle should be held about two inches from the inside screen Fig 28 If the element is saturated with oil for more than one half of its circumference replace the element and wrapper If noticeable quantities of oil are found on the element the rest of the system should be in spected for proper function Clean the metal container and reinstal...

Page 23: ... Valve Solvent Part Number 1879318 Apply the solvent when the manifold is COOL to be sure that the deposits will dissolve properly When ap plying the solvent at the ends of the shaft Fig 31 move the valve back and forth and in and out to prop erly distribute the solvent to make sure the deposits are dissolved FUEL FILTER Accumulation of large quantities of foreign matter in the fuel filter due to ...

Page 24: ...idled for about two minutes move the gearshift lever slowly through all gear posi tions pausing momentarily in each position and end ing with the lever in N position When the fluid is hot the level should be at the 62x167 Fig 33 Transmission Dip Stick Markings FULL mark or slightly below but never above the FULL mark Fig 33 to avoid foaming of the fluid Fluid should be added or extracted depending...

Page 25: ... accumulated dirt from dropping into the reservoir If necessary to restore the level add Power Steer ing Fluid Part Number 2084329 BRAKES The brakes on all models except for some police cars and high performance models are equipped with self adjusting features which make it unnecessary to perform major brake adjustments When brake linings are inspected for wear the con tact areas of the brake shoe...

Page 26: ...hould be re placed To replace depress the release on the top of the blade bridge and slide out the rubber blade Slide the new rubber blade refill into the bridge to lock it in place Refer to the Parts List for the correct rubber blade refill PARTS REQUIRING NO LUBRICATION There are many points that should not be lubrica ted some because they are permanently lubricated some because lubricants will ...

Page 27: ...f lubriplate directly to the key Insert key into lock cylinder and actuate several times Wipe excess lubricant from key Door Check Arm Rear Door On Imperial models only apply a thin film of Stain less Stick Lubricant directly to upper edge of door frame Deck Lid Latch Apply a thin film of Lubriplate to inner pivot and sliding contact surfaces Fig 41 Hood Hinge Lubrication Points AY 1 Models Door L...

Page 28: ... Check Arm Guide Plate Lubrication Points AC l f AC 3 Models Door Hinges AC AC 2 A C 3 and AY 1 Models On all hinges apply light engine oil sparingly to hinge pin and contact area of bushing and body half of hinge Fig 42 On lower hinges apply light engine oil sparingly to the spring ends Fig 42 On front door lower hinge apply light engine oil sparingly to contact area of pin arm and spacers Fig 42...

Page 29: ...ig 42 Avoid plac ing lubricant on roller surfaces of hinge arm and roll er Door Latch Striker Rotor All Models Apply two or three drops of light engine oil to the rotor inside bearing surfaces Fig 43 Door Lafch Striker Plates All Models Apply Stainless Stick Lubricant sparingly to upper edge of plate on door frame Fig 43 MyMopar com ...

Page 30: ...ade 2 to both ends of the accelera tor shaft where it turns in the bracket and where the nylon roller rolls on it Fig 49 ENGINE PERFORMANCE EVALUATION Engine operating efficiency depends on correct ig nition carburetor adjustments and on valve lash where applicable To obtain best engine performance Chrysler Corporation recommends that the engine be evaluated every 10 000 miles and tuned if necessa...

Page 31: ...lectrical circuit a See Electrical Tests Red Wire PEDAL PRESSURE AT ALL SPEEDS INCLUD ING BELOW 22 MILES PER HOUR AUTOMATIC LATCHING a Insufficient brake switch clearance a Adjust auto pilot brake switch DOES NOT E N G A G E b Brake pedal not returning fully b Test brake pedal for full return Adjust or re W H E N BUTTON IS pair as necessary PULLED OUT c Faulty electrical circuit c See Electrical T...

Page 32: ...ectrical Tests AUTOMATIC BEAM CHANGER UNIT NOT OPERATING a Poor grounding of control units b Electrical circuit not properly wired c Faulty dimmer switch d Faulty tube e Faulty scanner f Faulty control units g Improperly focused scanner unit h Loose cover screws a Clean and tighten all control units b Trace the circuit see the schematic diagram c Replace the dimmer switch d Replace the tube e Repl...

Page 33: ...o to authorized radio service station for repair e Faulty antenna e Test the antenna and correct RADIO RECEPTION IS a Outside electrical interferences a Move the vehicle or eliminate interference NOISY Engine Running b Insufficient or faulty radio capacitors b Install capacitors in ignition system RADIO RECEPTION IS a Static built up in tires a Ground the tires to the wheels with powdered NOISY Ca...

Page 34: ...tton in the center of the control OUT When the desired vehi cle speed is reached the reaction pressure is felt in the accelerator pedal At the point of reaction pres sure the driver s accelerator pedal pressure is relaxed and the accelerator is in the auto pilot automatic reg ulation The auto pilot will automatically advance the accelerator on uphill operation and retard on down grade operation Au...

Page 35: ...coun ter clockwise until it contacts the internal stop 3 Push in lightly on the control cable at the dust shield This will position the control rod to which the inner cable attaches against its upper stop CAUTION Do not force the cable beyond this po sition 4 Make certain that the instrument panel control dial is still against its extreme counterclockwise stop 5 Tighten the screw on the dust shiel...

Page 36: ...s to light inspect the instru ment panel control for proper grounding When the J H G R O U N D O T H E R TEST LAMP lE T j WIRING CONNECTOR 61x290 A AUTOPILOT BRAKE SWITCH ADJUSTMENT NK353 Fig 5 Auto Pilot Brake Switch Fig 4 Testing Wiring Circuits control button is pushed in the lamp should go out if the circuit is wired correctly INSTRUMENT PANEL CONTROL DIAL CALIBRATION 1 On a level stretch of r...

Page 37: ... the dust shield on the housing Push in and turn clockwise Do not tighten the set screw on the end of the dust shield until after the control ca ble is properly adjusted 6 Adjust the control cable 7 Connect the wiring connector at the drive mech anism AUTOMATIC BEAM CHANGE MODELS AY 1 Description The automatic beam changer is an automatic head lamp control unit which senses the headlamp inten sity...

Page 38: ...ore proceeding with the aiming operation Loosen the Phillips head pivot locking screw Fig ure 1 just enough to permit free movement of the scanner through its arc as controlled by the mount ing base Total angular deflection of the scanner unit is 14 degrees Pivot the scanner forward or backwards on base through arc until the leveler assumes a level posi tion Tighten the pivot and locking screws SC...

Page 39: ...the wiring to the clock 3 Install the ash receiver and housing assembly 4 Install the radio 5 Install the upper portion of the glove box 6 Connect the battery ground cable HEATER MODELS AY 1 Description The hot water heating system Fig 1 is controlled by four push buttons and a temperature control lever A fifth push button independently controls the sum mer ventilation system The Temperature Contr...

Page 40: ...he temperature control lever to the WARM position Under particularly severe fogging conditions opening the front vent wings temporarily will speed up the removal of fog from the windows SERVICE PROCEDURES HEATER ILOWER Removal 1 Disconnect the battery ground cable 2 Disconnect the heater ground wire at the wind shield wiper motor mounting bracket 3 Disconnect the heater wires from the harness conn...

Page 41: ... vacuum unit to the housing and one clip at taching the vacuum unit rod to the actuator unit HEATER CORE Removal 1 Disconnect the battery ground cable V A C U U M VENTILATOR ACTUATOR DOOR LINKAGE SCREWS 64 x 130 F i g 3 Adjusting Ventilator Door 2 Drain the cooling system 3 Disconnect the heater hoses at the heater Fig 2 4 Remove the screws attaching the heater core housing to the dash panel 5 Rem...

Page 42: ... hose fittings on the heater This will prevent any coolant from spilling on the inside of the vehicle as the heater as sembly is removed 3 From under the instrument panel remove the bracket from the top of the heater to the dash panel 4 Remove the defroster hoses at the heater and disconnect the vacuum lines at the heater 5 Disconnect the wiring at the heater blower mo tor resistor 6 Remove the gl...

Page 43: ... heater must be removed from the vehicle and disassembled Refer to Heater Removal and Instal lation HEATER CONTROLS AND ADJUSTMENTS 1 Disconnect the battery ground cable 2 From under the instrument panel remove the left defroster hose 3 From under the instrument panel remove the three screws that mount the heater control assembly to the instrument panel Lower the control assem bly below the instru...

Page 44: ...mum FM reception 3 The radio push button adjustment is the same as the standard AM radio It should be noted that a push button adjustment is only good for one station either AM or FM not both at the same time 4 Should a malfunction occur the trouble shoot ing procedures are the same as for the standard AM radio RADIO CAUTION Do not operate the radio with the speak er detached sinee damage to the t...

Page 45: ...ve the grille assembly 3 From the top of the instrument panel remove the four screws that attach the radio speaker to the instrument panel 4 Remove the radio speaker Removal Models AC 1 AC 2 AC 3 1 Disconnect the battery ground cable 2 Remove the radio as outlined in Radio Re moval 3 Remove the upper section of the glove box 4 Reach through the glove box opening and re move the speaker mounting pl...

Page 46: ...urn ON the reverberator unit Push the control IN to turn OFF the reverberator and give normal fader control operation On the 416 417 Models a five position switch speak er fader control is used in conjunction with the rear speaker This feature provides an extremely wide range of sound level variation between the front and rear compartments without the usual degree of pre cise tuning required of th...

Page 47: ...ntenna extended and retracted by a coiled nylon cord actuated by a two direction electric motor The main components of the power antenna are the motor and drive assembly the mast assembly and the support tube assembly The antenna is serv iced as a mast assembly motor and the drive assem r 2V2 LOCATE THIS LINE ON COWL OPENING 6 f LOCATE THIS LINE ON F E N D E R OPENING C E N T E R PUNCH FOR r 8 DIA...

Page 48: ...support tube or lead in assembly d Poor connection antenna lead in assembly or shielding ground The preliminary test may indicate that removing the antenna from the vehicle is necessary for further testing repairs or parts replacement In this event fol low the procedure for antenna removal Removal 1 Fully lower the antenna 2 For front mounted power antenna remove the fender shield cover for access...

Page 49: ...ord has been expelled from the drive To prevent a kink or bend in the nylon cord keep it taut by pulling on the mast CAUTION DO NOT DISASSEMBLE THE MOTOR AND DRIVE ASSEMBLY FOR ANY PURPOSE In order to remove the nylon cord from the dis abled motor and drive assembly place the assembly Fig 7 Removing Bottom Insulator and Water Seal Washer ACCESSORIES RADIO 1 19 SUPPORT TUBE 62x334 Fig 8 Assembling ...

Page 50: ...voltage sup ply separate from the voltage supply to the radio To operate the reverberator turn the radio ON and tune the radio to the desired station Pull the in strument panel reverberator switch out and then ro tate the switch until the desired volume level between FRONT SPEAKER TERMINALS Fig 70 Reverberator Installation the front and rear speakers is achieved With the re verberator switch m nor...

Page 51: ...KR SI OPEN CLOSED S2 A B S3 CLOSED OPEN S4 CLOSED OPEN SHAFT OUT SHAFT IN REVERB SHAFT POSITION NOTES CAPACITORS Unless otherwise specified Values less than one in MF all others in MMF VOLTAGES Measured from point indicated to ground with a VTVM 10 No signal In INPUT VOLTAGE 13 2V DC The exact value to be determined by production process Replace with the same value of the original part All switche...

Page 52: ...lace 9 Solder the bare end of the circuit breaker lead to the motor terminal using rosin core solder 10 Install the pump cover Carefully bend the re taining tabs in place 11 Install the pump 12 Connect the hoses to the pump 13 Connect the electrical terminal 14 Fill the reservoir and test the operation of the washer system Pump Circuit Breaker Replacement 1 Empty the reservoir 2 Disconnect the hos...

Page 53: ...a rately When re lubrication of the ball joints and tie rod ends is required remove the plugs from the assembly and install lubrication fittings After the lubrication is completed reinstall the plugs CAUTION RUBBER BUSHINGS SHOULD NOT BE LUBRICATED AT ANY TIME When replacement of a bushing is necessary water may be used to aid in installation SERVICE DIAGNOSIS Condition Possible Cause Correction F...

Page 54: ... Adjust steering gear h Free up idler arm a Inflate tires to recommended pressure b Adjust brakes c Replace brake shoe and lining as necessary and stop all leaks d Tighten or replace strut bushings e Adjust steering gear control valve f Adjust front wheel alignment g Replace spring a Adjust or replace wheel bearings as necessary b Adjust steering gear c Tighten steering gear to frame bolts d Repla...

Page 55: ...wear The heights should only be measured when the vehicle has the recommended tire pressures a full tank of fuel no passenger load and is on a level floor 1 Clean all foreign material from the bottom of the lower ball joint assemblies and from the bottom of the lower control arm bushing housings between the flanges of the arms 2 Jounce the vehicle several times releasing it on the downward motion ...

Page 56: ...ars are not interchangeable side for side The bars will be indicated as either right or left by an R or L right or left hand side stamped on the end of the bars CAUTION If the vehicle is to be raised on a hoist make sure it is supported so that the front suspen sion is in full rebound under no load Removal 1 Place a jack under the center of the front cross member and raise the vehicle off the floo...

Page 57: ...turn ing the adjusting bolts counterclockwise 3 Remove the lock rings from the rear anchors 4 Remove the nuts two each side attaching the torsion bar rear anchor crossmember to the isolators 5 Remove the crossmember from the torsion bars 6 Remove the nuts attaching the rubber isolator assembly to the engine rear support crossmember and remove the isolator assembly Installation Fig 3 The rubber iso...

Page 58: ...Disassembled Imperial NK385 Fig 7 Removing Outer Tie Rod End Imperial steering knuckle arm Fig 7 or center link by methods other than using Tool C 3894 Imperial Tool C 3742 Chrysler may damage the tie rod end seals 1 Remove the tie rod ends from the steering knuckle arms Use care not to damage the seals 2 Remove the inner tie rod ends from the link 3 Remove the idler arm stud from the link 4 Remov...

Page 59: ... Models are integral with the steering knuckle arms Removal Imperial Models 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 assembly 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 secur...

Page 60: ...steering arm and ball joint assem bly on the steering knuckle and install the two mount ing bolts Tighten the nuts 80 foot pounds 3 Insert the ball joint stud into the lower control arm 4 Install the stud retaining nut and tighten to 115 foot pounds Install the cotter pin and lubricate the ball joint 5 Inspect the tie rod end seal for damage and re place if damaged Connect the tie rod end to the s...

Page 61: ...ut on Chrysler Models 100 foot pounds and on Imperial Models 135 foot pounds Install the cotter pin and lubricate the ball joint 5 Install the wheel and tire and adjust the front wheel bearing Group 22 LOWER CONTROL ARM A N D SHAFT Removal Imperial Models 1 Remove the torsion bar 2 Remove the wheel tire and drum assembly Re move the brake support assembly 3 Disconnect the shock absorber at the low...

Page 62: ...l Chrysler Models 1 Remove the torsion bar from the lower control arm 2 Remove the cotter pin and slide the tie rod end seal protector up the steering knuckle arm Remove the tie rod end from the steering knuckle arm using Tool C 3964 or Tool C 3742 Use care not to damage the seal 3 Remove the sway bar to strut attaching straps 4 Remove the steering knuckle arm to brake sup port bolts and remove th...

Page 63: ...he tie rod end seal pro tector over the tie rod end and install the cotter pin 10 Connect the shock absorber to the control arm and tighten the nut 55 foot pounds 11 Install the torsion bar 12 Install the wheel tire and drum assembly and adjust the front wheel bearings Group 22 13 Lower the vehicle to the floor and tighten the strut nut at the crossmember 40 foot pounds 14 Tighten the lower contro...

Page 64: ...ng and press the bushing out of the arm from inside out Fig 17 Be Fig 17 Removing Upper Control Arm Bushing Chrysler Fig 18 Installing Upper Control Arm Bushing Chrysler sure the control arm is firmly supported if a hammer and drift is used in place of the tool Assembly NOTE When installing the new bushings be sure the control arm is supported squarely at the point where the bushing is being press...

Page 65: ... h Measure and adjust end play 0 Excessive gear lash between drive gear and i Measure and adjust gear lash pinion i Loose drive pinion companion flange nut j Tighten flange nut to 240 min foot pounds torque 00 Damaged gears k Replace gears as required OVER HEATING O F THE a Lubricant level too low a A d d the specified lubricant as required AXLE UNIT b Bearing adjusted too tightly b Adjust bearing...

Page 66: ...ctive sleeve SP5041 over the sealing surfaces of the axle shaft and next to the bearing Fig 2 i f Shelf Disassembled BLOCKS BEARING REMOVING SP 5020 SCREWS SP 5026 WASHERS SP 320 T SLEEVE SP 5041 ADAPTER SP 5021 ADAPTER S P 5 0 1 5 RING BLOCK HOLDING SP 5017 NK360 Fig 3 ftighf Shcrff Disassembled F g 4 T o o Set C 397F MyMopar com ...

Page 67: ... bearing rollers from the section of the flange that was ground away Fig 10 Fig 7 Notching Bearing Retainer Collar Fig 8 Removing Qh RoShir Uletiaineir Fig 9 Flange Ground off the Inner Cone 5 Pull the roller retainer down as far as possible and cut it with a pair of side cutters and remove from the assembly Fig 11 6 Remove the roller bearing cup from the axle shaft F a 70 Removina the Bearina Rol...

Page 68: ... the right axle shaft assembly into the housing carefully to avoid 4 NK362 Fig 13 Installing New Bearing and Collar damaging the new inner seal Install 5 retainer plate nuts 30 35 foot pounds torque 5 Using a dial indicator mounted on the brake support Fig 14 tighten the adjuster until both wheel bearings are seated and there is zero end play in the axle shafts Back off the adjuster approximately ...

Page 69: ...g us ing a suction gun Fig 7 5 C h e c k i n g for Runout and Zero End Play Fig 16 Removing Companion Flange 4 Remove the attaching nuts and lift the rear axle carrier assembly from the axle housing DISASSEMBLY Carrier Disassembly 1 Mount the carrier in Stand DD 1014 and attach the dial indicator Tool C 430 or Tool C 3339 to the differential carrier flange so the pointer of the indi cator squarely...

Page 70: ... pinion bearing cups can be removed from the carrier with a blunt brass drift and hammer Differential Case Disassembly 1 Hold the drive gear in an upright position using brass jaws in a vise With a inch socket wrench remove the drive gear to differential attaching cap screws NOTE The drive gear attaching screws have left hand threads turn clockwise to loosen 2 Remove the assembly from the vise and...

Page 71: ...differential bearing cones and cups for pitting spalling or other visible damage If re placement is necessary remove the bearings from the differential case with puller Tool C 293 and four adap tor plates No 18 Fig 21 3 Inspect the differential case for elongated or en larged pinion shaft holes the side gear counterbores and the four thrust washer contacting surfaces for galling metal deposits or ...

Page 72: ... they are furnished in matched sets only also inspect the pinion bearing spacer for distortion and damage 13 Inspect the companion flange for cracks worn splines pitted rough or corroded oil seal contacting surface Repair or replace the companion flange as necessary 14 Inspect the pinion bearing shim pack for dam aged or distorted shims Replace the shims with the correct shim pack when determining...

Page 73: ... W R E N C H _ r SCREW CROSSBORE TUBE SP 561 V l k SLEEVE SP 2 lk COMPRESS 2920 COMPRESSION j l g V SLEEVE SP 535 M A I N BODY X SP 526 Sl COMPRESSION X NUT SP 533 J SPACER SPACER PINION LOCATING SPACER SP 2919 SP 1730 SP 539 NK68 Fig 24 Rear Axle Setting Gauge Set f o o l C 758 D4 SPACER WASHER 1 SP 1371 A SPACER SP 2921 CENTRALIZING WASHER SP 534 KP13A Fig 25 Seating the Bearing Cups in Carrier ...

Page 74: ...t of Tool C 758 in the differential bearing pedestals of the carrier Fig 28 Center the arbor so that an approximate equal distance is maintained at both ends Position the dif ferential bearing caps and attaching bolts on the car rier pedestals Insert a piece of 002 inch feeler stock between the arbor and each cap and tighten the cap bolts securely 3 Select the washer that will fit between the tool...

Page 75: ... Rotate the assembly several turns in both di rections to align the bearing rollers Retest the torque to 240 foot pounds torque may have diminished as bearing rollers were aligned by rotating PINION BEARING PRELOAD AND PINION SETTING MODELS A C 2 A C 3 AY 1 USING TOOL C 758 D4 Inspect the bearing cups and carrier for grit and dirt Assemble spacer SP 2921 to the main section of the tool followed by...

Page 76: ...e 20 to 30 inch pounds be fore installing the seal If not within specifications correct as necessary Assembly of Pinion Carrier 9 With the shaft end of pinion facing up install the selected washer on the pinion stem with the cham fered side of the washer facing the drive pinion gear Position the rear bearing on the pinion shaft Make sure the contacting surfaces of the washer pinion gear and rear b...

Page 77: ...backlash existing between the drive gear and pinion KP20 Fig 32 Adjusting Differential Bearings i KP21 Fig 3 3 M e a s u r i n g Backlash Between Drive Gear and Pinion 5 While facing each bearing support cap tighten one bolt 85 to 90 foot pounds torque on each side DRIVE GEAR AND PINION BACK LASH The drive and pinion backlash should be 006 to 008 inch at the point of minimum backlash 1 Attach a di...

Page 78: ...f the tooth pattern is across the length of the tooth face narrow and near the top the teeth will wear thin and roll over or score resulting in excessive gear lash and noise This condition is corrected by installing a thicker washer behind the pinion rear bearing Heavy Flank Contact If the tooth pattern is across the length of the tooth and is narrow and low on the flank the pinion teeth will scor...

Page 79: ...d with a Sure Grip Differ ential or the letter S stamped on the identification pad on the right side of carrier housing or by a metal tag reading Use Sure Grip Lube attached by means of the rear axle housing to carrier bolt below the carrier filler plug If the letter S or tag is not appar ent remove the filler plug and use a flashlight to look up through the filler plug hole to identify the type o...

Page 80: ...ing at Different Speeds SCRIBE MARKS KR718 Fig 39 Case Halves Scribed for Proper Reassembly to disassemble the Sure Grip differential to reinstall them Lubrication Multi purpose Gear Lubricant as defined by MIL L 2105B is used in all rear axles Chrysler Hypoid Lubricant Part No 1879414 is also recommended Anticipated Temperature Viscosity Grade Above 10 F SAE 90 As low as 30 F SAE 80 Below 30 F SA...

Page 81: ... side gear retainer Fig 46 and the clutch plates Fig 47 6 Remove the axle shaft thrust spacer by passing out the lock pin Cleaning and Inspection Clean all the parts thoroughly Inspect all the parts for wear nicks and burrs The inner and outer flat clutch plates and outer flat clutch disc should be re placed if they are worn or distorted If either case half is worn it will be necessary to replace ...

Page 82: ...tes from Differential Case Fig 48 Arrangement of Plates and Discs IMPORTANT Insert the axle shafts from the ve hicle to align the splines Make sure the axle shafts engage the side gear splines With the shafts installed center the cross shafts between the two ramp surfaces in the differential case Tighten the differential case bolts evenly by alternate ly turning opposite bolts until all are tighte...

Page 83: ...d lining e Unmatched brake lining f Restricted brake hose or line g Front end out of alignment h Broken rear spring a Incorrect brake lining b Dust in brakes or scored brake drums c Distorted brake shoes d Bent brake support plate e Broken or weak brake shoe return spring BRAKES PULLING SQUEALING BRAKES a Fill and bleed the master cylinder b Reline and adjust the brakes c Repair or replace self ad...

Page 84: ...gs c Wheel cylinder cups sticking c Recondition or replace the wheel cylinder d Contaminated brake lining d Reline both front or rears or all four brakes BRAKES FADE a Incorrect lining a Replace lining HIGH SPEED b Distorted or out of round brake drums b Grind or replace the drums c Overheated brake drums c Inspect for dragging brakes d Incorrect brake fluid low boiling temperature d Drain flush r...

Page 85: ...e or brake fluid on linings b Sticking actuating valve a Inspect for a leak and replace the lining as required b Free up the valve PEDAL G O E S TO FLOOR or almost to floor a Self adjusters not operating b Air in hydraulic system c Hydraulic leak d Fluid low in master cylinder e Shoe hanging up on rough platform f Broken plunger stem a Inspect the self adjuster operations b Bleed the brakes c Loca...

Page 86: ... brake adjust ing hole and push the adjusting lever out of engage ment with the star wheel Fig 3 while holding the adjusting lever out of engagement back off the star wheel 10 to 12 notches to insure a free wheel with no brake shoe drag NOTE Care should be taken not to bend the ad justing lever 6 Repeat the above adjustment at each wheel The adjustment must be equal at all wheels Install the adjus...

Page 87: ...djuster servicing BRAKE DRUM REMOVAL Removing the Front Brake Drums To aid in the brake drum removal loosen the brake star adjusting wheel Fig 3 1 With the vehicle on a hoist jack or suitable stands remove the rear plug from the brake adjusting access hole 2 Insert a thin screw driver into the brake adjust ing hole and push the adjusting lever away from the star adjusting wheel Care should be take...

Page 88: ...ry and secondary brake shoes and remove the adjusting star adjusting lever adjusting spring cable and cable guide Removing the Rear Brake Shoes 1 With the vehicle elevated on a hoist jack or suitable stand remove the rear wheel and the drum retaining clips Remove the drum CABLE GUIDE ANCHOR PLATE W H S CABLE LEVER S NAIL RETAINER NK494 Fig 5 Removing Brake Shm Retainer Spring and Pins 2 Using Tool...

Page 89: ...ary shoes with the star wheel next to the secondary shoe Fig 1 The star adjusting wheels are stamped R S E R V I C E BRAKES 5 7 X r B J 63x595A Fig 8 Removing or Installing the Brake Shoes right side and L left side and indicate their loca tion 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 o...

Page 90: ...leeding the hydraulic system push the brake pedal down and let it return slowly to avoid air being drawn into the system Bleed intermittently by opening and closing the valve about every four seconds This causes a swirling action in the cylinder and assists in expelling the air Continue the action until the brake fluid is expelled in a solid stream with out any bubbles Continue this bleeding opera...

Page 91: ... in the cylinder with the open end of the cup over the closed end of the return spring 3 Install the secondary cup on the master cylin der piston and install the piston and push rod assem bly in the cylinder with flat brass washer between the piston and the primary cup 4 Install the dust boot on the push rod and install the stop flange screws Installation 1 Reinstall the master cylinder on the fir...

Page 92: ... der attaching bolts then slide the wheel cylinder out of the support Disassembly If the wheel cylinders were not disassembled before removal Fig 10 then proceed as follows 1 Remove the boots and push rods 2 Press in on one end of the cylinder and force out the piston cup piston spring cup and piston Assembly Fig 1 0 NOTE Before assembling the pistons and new cups in the wheel cylinder dip them in...

Page 93: ... Brake Cable from Support Fig 12 Wheel Stud Nut Tightening Sequence the brake assembly 2 Place the support on the spindle support and in stall the attaching bolts washers and nuts Tighten the bottom nuts to 80 foot pounds and the top nuts to 55 foot pounds torque 3 Connect the brake hose to the wheel cylinder and tighten to 25 foot pounds before connecting the brake hose to the frame bracket 4 Ins...

Page 94: ...ts The steel tubing is equipped with a double flare or inverted seat to provide more positive seating in the fitting Replacement or Repair 1 Using Tool C 3478 cut off the damaged seat or damaged tubing Fig 13 2 Ream out any burred or rough edges showing on inside edges of tubing This will make the ends of the tubing square and insure better seating of the flared end of the tubing Place compression...

Page 95: ...he independent rear brake cables are attached to an intermediate cable by C type brackets Fig 15 The cable is adjusted at the equalizer clamp at the center of the intermediate cable The rear wheel service brakes also act as parking brakes on Chrysler models The brake shoes are me chanically operated by a lever and strut connected to a flexible steel cable The wheel brake cable are joined together ...

Page 96: ...ng nut two full turns 3 Apply the parking brake several times then re lease and test to see that the rear wheels rotate freely without dragging REMOVING THE REAR PARKING BRAKE CABLE Should it become necessary to remove the parking brake cable rear for installation of a new cable re fer to Figure 15 or 17 1 With the vehicle jacked up or on a suitable hoist remove the rear wheels 2 Disconnect the br...

Page 97: ... the floor pan 2 Install the cable housing into the underbody mounting bracket 3 Insert the end fitting of the cable into the park ing brake clevis and force the housing and retaining clip into the pedal bracket assembly Refer to Figure 14 or 18 4 Insert the cable through the crossmember and force the housing and retaining clip into the cross member 5 Attach the cable to the equalizer and adjust t...

Page 98: ...5 16 POWER BRAKES BENDIX MyMopar com ...

Page 99: ...heck valve assembly The power unit provides lighter pedal pressure This lighter pressure is obtained in combination with a reduced pedal travel which makes it possible to bring the pedal down to the approximate height of the accelerator pedal which at closed throttle condi tion Thus the driver after closing the throttle can shift his toe from one pedal to the other without lift ing his heel from t...

Page 100: ...y 5 Pry out the housing lock using a screwdriver Fig 24 The lock location is on one of the two long tangs on the housing Do not bend the lock at remov al as it must be reinstalled at assembly 6 Remove the check valve from the cover by pry ing out of the rubber grommet 7 Place Tool C 3281 over the master cylinder mounting studs Fig 25 8 Rotate the tool slowly when removing the cover ATTACHING NUTS ...

Page 101: ... Remove the brake unit from the engine lifting fixture Tool C 3804 11 Remove the air cleaner guide seal and the guide seal retainer from the cover Fig 28 12 Remove the block seal located in the center hole of the housing using a blunt drift CAUTION Care should be used so as not to scratch the bore of the housing which could cause a vacu um leak DISASSEMBLING THE POWER PISTON CAUTION Extreme care s...

Page 102: ... Snap Ring 3 Remove the power piston square seal ring re action ring insert reaction ring and the reaction plate MASTER CYLINDER G U I D E S E A L R E T A I N E R NUT 4 AIR CLEANER PLATE POWER PISTON SQUARE A R CLEANER CHECK VALVE or SEAL RING SNAP RING POWER PISTON D I A P H R A G M RUBBER G R O M M E T COVER ASSY RETURN SPRING PUSH ROD GUIDE SEAL tW T O RING C O N T R O L PISTON ASSEMBLY FELT SE...

Page 103: ...e 4 Install the reaction plate in the power piston aligning the three holes with those in the power pis ton Fig 29 5 Place the rubber reaction ring in the reaction plate Do not lubricate this ring 6 Lubricate the outer diameter of of the reac tion insert with silicone grease and install in the re action ring 7 Install the reaction insert bumper into the guide Several small spots of silicone grease...

Page 104: ...el The forward cover of the vacuum cylinder supports the master cyl inder pressure on the pedal and start the engine If the pow er system is functioning properly the pedal will fall away slightly Vacuum Leak in the Holding Positions With the transmission in neutral or park position stop the engine while holding a moderately heavy load steadily on the brake pedal After 1 minute re lease and apply t...

Page 105: ...er Midland Ross CHECK VALVE DIAPHRAGM FRONT CHAMBER REAR CHAMBER RETAINING RING REACTION RING ATMOSPHERIC VALVE PLUNGER LOAD RING REAR and remove the master cylinder 2 Scribe an aligning mark across the joint of the front and rear portions of the brake assembly This will insure alignment on reassembly 3 Remove the dust boot from the push rod 4 Remove the filter filter retainer and cover 5 Working ...

Page 106: ...ction lever reaction ring and retainer assembly from the valve body and remove the levers from the retainer Fig 39 13 Remove the two plastic rings from the plunger shaft 14 Remove the retaining clip Fig 40 from the plunger shaft remove the load ring and valve return spring Remove the valve Fig 41 15 Remove the plunger from the valve body 16 Remove the plastic rear seal retainer from the plunger Fi...

Page 107: ...r 12 Install the reaction ring with the three raised portions toward the reaction levers Fig 39 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 two plastic rings on plunger shaft 16 Install the master cylinder push rod onto the plu...

Page 108: ...ti freeze and corrosion protection In areas where anti freeze is not required MOPAR rust inhibitor must be added to the water coolant for nor mal corrosion protection Air conditioned cars require year round protection with permanent type anti freeze with a minimum of 15 F protection for summer operation and additional anti freeze in the winter ac cording to the prevailing temperatures SERVICE DIAG...

Page 109: ...ty fan drive unit n Faulty temperature sending unit a Refer to causes listed under Poor Circulation and Overheating 7 b Overfilling c Coolant foaming due to insufficient corrosion inhibitor d Air leak at bottom radiator hose e Blown head gasket a Install a new head gasket b Refer to corrections f g p q r and t listed under External Leakage c Pressure test cooling system replace the cylin der head ...

Page 110: ...elt glazed b Replace belt BELT S Q U E A K AT IDLE a Belt too loose a Adjust belt tension b Dirt and paint imbedded in belt b Replace belt c Non uniform belt c Replace belt d Misaligned pulleys d Align accessories file brackets or use spacers as required e Non uniform groove or eccentric pulley e Replace pulley BELT ROLLED OVER IN a Broken cord in belt a Replace belt G R O O V E b Belt not matched...

Page 111: ... run the en gine and test for leaks Disassembly Fig 3 1 Support the pump body on the hub and remove the impeller by breaking the plastic away from the OUTLET ELBOW THERMOSTAT TEMPERATURE SENDING UNIT BOLT AND LOCKWASHER SHAFT A N D BEARING BOLT AND LOCKWASHER HOUSING GASKET n u u o i m SLINGER Fig 3 383 413 and 426 Cubic Inch Engine Water Pump metal insert as shown in Figure 4 2 Remove the impelle...

Page 112: ...3 Remove the upper and lower radiator hoses us ing pliers Tool C 3250 4 On vehicles with a fan shroud remove the lower half of the fan shroud 5 Remove the radiator attaching screws 6 The radiator can now be lifted free from the engine compartment Care should be taken not to damage the radiator cooling fins or water tubes dur ing the removal Installation 1 Slide the radiator down into position behi...

Page 113: ...hort blasts 6 Allow the cylinder block to fill between the blasts of air 7 Continue this procedure until the water runs clean Test the thermostat and if satisfactory rein stall otherwise replace using anew housing gasket 8 Refill the cooling system and test for leaks Reverse Flushing the Radiator 1 Drain the cooling system and remove the hoses from the engine 2 Install a flushing gun Tool C 3514 o...

Page 114: ...ld be replaced RADIATOR PRESSURE CAP Radiators are equipped with a 14 psi cap as stand ard equipment and 16 psi with air conditioning as shown in Figure 6 Always note the identification number on the cap when replacing WARNING When removing the pressure cap turn counter clockwise to the stop permitting the built GASKET 64 x 186 Fig 6 R a d i a t o r Pressure Cap up pressurefoescape Through the ove...

Page 115: ...appear intermixed with the oil it will indicate a serious internal leak in the engine If there is an internal leak the engine must be disas sembled the leak located and necessary new parts installed ENGINE WATER TEMPERATURE GAUGE For removal Installation and Testing procedures of the water temperature sending and receiving units refer to Gauges Group 8 Electrical Locations ACCESSORY BELT DRIVES PR...

Page 116: ...sed to establish the five pound load See Figure 9 for correct location at which to measure de fletion This method should be used only when it is not possible to use the torque method To adjust 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 V2 inch square drive hinge handle can be used if the acce...

Page 117: ... THAN 25 POINTS 025 Specific Gravity VARIATION Short circuit in low cell Loss of electrolyte by leakage or excessive over charge Improper addition of acid Natural or premature failure Cracked case Try to recharge the battery See Charging the Battery See Adjustment of Acid Gravity Test battery for capacity Install new battery if necessary CELLS SHOWING MORE THAN 1 220 SPECIFIC GRAVITY Satisfactory ...

Page 118: ...on of the stem should be about two inches long Clearance between the float and glass barrel at the smallest diameter should be a minimum of Vfe around all sides and the barrel must be clean NOTE Hydrometer floats are calibrated to indicate correctly only at one fixed temperature The liquid level of the battery cell should be at normal height and the electrolyte should be thor oughly mixed with any...

Page 119: ...es not gas freely on charge Unless electro lyte has been lost through spilling or leaking it should not be necessary to add acid to a battery dur ing its life Acid should never be added unless one is certain that the cell will not come up to normal grav ity by continued charging Always make the tempera ture correction for hydrometer readings as warm electrolyte will read low and this might be mist...

Page 120: ...age of the battery posts while the battery is being fast charged If the total voltage during charge exceeds 15 5 volts the battery is sul phated and should be cycled and slow charged until the specific gravity reaches 1 260 See Slow Charg ing NOTE A slow charge is preferable to bring the bat tery up to a full charge If the specific gravity remains constant after test ing battery at one hour interv...

Page 121: ...er cells that cell is defective and the battery should be replaced Safe slow charging rates are determind by allow ing one ampere per positive plate per cell The proper slow charging rate would be 4 amperes for a 48 am pere hour battery or 5 amperes for a 59 ampere hour battery and 6 amperes for a 70 ampere hour battery The rate of charge for a normally discharged bat tery is one ampere per positi...

Page 122: ...ecific gravity Recharge or replace the battery as required b Test and replace the switch if necessary c Clean terminals and clamps replace if neces sary Apply a light film of petrolatum to ter minals after tightening d Inspect and test all the wiring e Replace the clutch unit f Test and repair as necessary g Test and repair h Test and replace the solenoid if necessary a Test for specified gravity ...

Page 123: ... recharge the bat tery to full charge before proceeding with the test 2 Disconnect the positive battery lead from the battery terminal post Connect an 0 to 30 scale am meter between the disconnected lead and the battery terminal post 3 Connect a test voltmeter with 10 volt scale di vision between the battery positive post and the start er switch terminal at the starter solenoid 4 Crank the engine ...

Page 124: ...i Fig J Starting Motor Cross Section MyMopar com ...

Page 125: ...n speci fications Fig 2 Removing or Installing Brush Terminal Screw Fig 3 Unsoldering the Shunt Coil Lead Wire SERVICING THE STARTING MOTOR Disassembly 1 Place the gear housing of the starter in a vise equipped with soft jaws Use the vise as a support fixture only DO NOT clamp 2 Remove the two through bolts and the starter end head assembly 3 Carefully pull the armature up and out of the gear hous...

Page 126: ...12 Remove the nut steel washer and the sealing washer from the starter battery terminal 13 Remove the starter battery terminal from the holder plate 14 Remove the solenoid contact and plunger from the solenoid 15 Remove the solenoid return spring from the well of the solenoid housing moving core 16 Remove the dust cover from the gear housing Fig 7 Fig 7 Removing the Dust Cover 17 Release the retai...

Page 127: ...of the pinion shaft Fig 9 NOTE Do not spread the retainer ring any greater than the outside diameter of the pinion shaft oth erwise the lock ring can be damaged 19 Push the pinion shaft towards the rear of the housing Fig 10 and remove the snap ring and thrust washers clutch and pinion assembly with the two shifter fork nylon actuators as on assembly Fig 11 Fig 11 Removing or Installing the Clutch...

Page 128: ...e 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 Spring tension should be 32 to 36 ounces Replace springs that do not meet specifications TESTING ARMATURE Testing the Armature for Short Circuit Place the armature in growler and hold a thin steel blade parallel to the core and just above it while slowly rotating the armature...

Page 129: ...and install the new No burnishing or reaming is required to fit the pre sized bushings The C 3944 Tool and its adaptors are designed to service all of the gear reduction motor bushings with the exception of the end head bushing The end head bushing and end head are serviced as an assembly Remove and install bushings as shown in Figures 14 through 16 SERVICING THE STARTER CLUTCH UNIT Do not immerse...

Page 130: ...4 WASHER C S T E E L 62x543 B Fig IF Starter Motor Exploded View MyMopar com ...

Page 131: ...t be positioned on the shoulder of the splines of the pinion shaft be fore the driven gear is positioned 6 Install the driven gear snap ring Fig 8 7 Install the pinion shaft retaining ring Fig 9 8 Bend the four 4 Tangs of the coil retainer up to a measurement of 5 3 2 to 8 h above the sur face of the retainer Fig 20 to ensure higher com pression and a more positive ground N O T E Space the retaine...

Page 132: ...the solenoid stud insulating washer flat washer and nut NOTE Use care when installing the solenoid con tact seal over the tab on the brush plate to prevent tearing the seal 14 Wrap the solenoid lead wire tightly around the brush terminal post as shown in Figure 22 and solder securely with a high temperature resin core solder and resin flux Fig 22 Soldering the Solenoid Winding Lead to the Brush Te...

Page 133: ...y Fig 2 6 S e a l i n g the Brush Holder Plate 23 Clean the area at the joint between the brush holder plate to the field frame and gear housing mat ing joint Apply a bead of brush plate sealer Part NO 2421847 around the four sides of the joint Fig 26 CAUTION Sealer must be flowed continuously to avoid gaps After the bead has been flowed on use a brush or small paddle moistened in mineral spirits ...

Page 134: ...t according to Specifica tions Install new brushes a n d o r slip rings Clean the slip rings and brush holders Install new brushes Test all the field circuit connections and correct as required Inspect all connections in the charging circuit and correct as required Remove the alternator and disassemble Test the stator windings Install a new stator if necessary Remove the alternator and disassemble...

Page 135: ...new stator if necessary a Clean all connections and tighten all connec tions as necessary Adjust voltage regulator as necessary S1RVICE PROCEDURES CONSTRUCTION AND OPERATION The alternator Fig 1 is fundamentally an A C current generator with six 6 built in silicon recti fiers that convert the A C current into D C current D C current is available at the output BAT ter minal A voltage regulator Fig ...

Page 136: ...e upper and lower stationary contact brackets are mounted on a molded plastic bracket which is attached to the regulator frame by a screw Fig 5 The upper con tact bracket is connected to the IGN terminal by a fusible wire The lower contact bracket is connected to ground by another fusible wire The armature is connected to the insulated FLD terminal Three resistance units are used Fig 6 Resistor Fi...

Page 137: ...e field circuit reduce field current and rotor field strength with a corresponding reduction in alternator output voltage This momentarily reduces battery line voltage ap plied to the regulator voltage coil The regulator ar mature spring tension overcomes the magnetic pull of the voltage coil closing the upper contacts When the electrical load requirements are relative ly high the regulator armatu...

Page 138: ...or 64 x 472 Fig 7 Tester Lead Connections LIGHT SWITCH VEHICLE 1 J ADAPTER 64x473A Fig 8 Field Circuit Resistance and Field Current Draw Test 6 Connect the positive lead of the voltmeter to the battery end of the positive battery cable NOTE The Battery Post Adapter BY PASS SWITCH must be open for all charging system tests It is closed only for starting the engine Field Circuit Resistance Test Fig ...

Page 139: ...or the engine ignition system and 3 am peres for field current If the output is slightly less 5 to 7 amperes than that specified above it may be an indication of possi ble open rectifier or other alternator internal prob lem If the output is considerably lower than that specified above it may be an indication of a possible shorted rectifier or other alternator internal prob lems In either case the...

Page 140: ...ns proceed to the lower contact voltage test If the upper contact voltage setting is not within specifica tions remove the regulator cover and adjust the volt age setting as outlined in Regulator Adjustments step number 1 Lower Contact Test 1 Increase the engine speed to 2200 RPM 2 Rotate the tester Control Knob to the VA OHM position only if the tester Ammeter reads over 5 am peres 3 Rotate the t...

Page 141: ...r per cell per one thou sand miles Regulator Mechanical Adjustments Step 1 Adjust the upper contact voltage setting as necessary by bending the regulator lower spring hanger down to increase voltage setting up to de crease voltage setting Use an insulated tool to bend the spring hanger Fig 13 The regulator must be in stalled correctly connected and retested after each adjustment of the lower sprin...

Page 142: ...et and cut off surplus fuse wire NOTE The original fuse wire is machine wound on the upper bracket The replacement fuse should be soldered to the bracket to ensure a good electrical contact ALTERNATOR SERVICING If the alternator performance does not meet cur rent output specifications limits it will have to be re moved and disassembled for further test and servic ing 1 Disconnect the battery groun...

Page 143: ...oned horizontally against the remaining slip ring and is retained in a G R O U N D BRUSH ASSEMBLY holder that is integral with the end shield Remove the retaining screw and lift the clip spring and brush assembly from the end shield Figure 16 CAUTION Stator is laminated do not burr stator or end shield 3 Remove the through bolts and pry between the stator and drive end shield with the blade of a s...

Page 144: ...ect the test lead clip to the rectifier end housing b Touch the exposed connectio of each of the negative case rectifiers with the test prod The test specifications are the same and the test results will be approximately the same as for the pos itive case rectifiers except the meter will read on the opposite side of the scale TESTING THE RECTIFIERS AND STATOR When Tool C 3829 is not available Fig ...

Page 145: ...the other prod to each of the three stator leads The Fig 23 Testing Stator Windings for Continuity ALTERNATOR AND REGULATOR 8 29 Fig 24 Removing Rectifiers test lamp should not light If the test lamp lights the stator windings are grounded g Test the stator windings for continuity by con tacting one prod of the test lamp to all three stator leads at the Y connection Contact each of the three stato...

Page 146: ...shield NOTE The new bearing is lubricated with a pre determined amount of special lubricant and does not require additional lubrication 10 The drive end ball bearing is an interference fit with the rotor shaft Remove the bearing with pull er Tool C 3615 or C 3934 and adapters as follows a Position the center screw of the Tool on the ro tor shaft b Place the thin lower end of the adapters SP 3375 u...

Page 147: ... N G S O L D E R L U G S O L D E R W I T H R E S I N C O R E S O L D E R I N S U L A T E D B R U S H R I N G I S O L D E R L U G 6 2 X 5 2 9 Fig 30 Solder Points S ip Ring Installed OLD SLIP RING CUT WITH CHISEL N V v f Fig 31 Cutting the Old Slip Rings opposite points 180 apart with a chisel Fig 31 d Break the insulator and remove the old ring e Clean away dirt and particles of the old slip ring ...

Page 148: ... the field lead into the solder lug and solder the lead to the lug with resin core solder CAUTION Be sure the solder bead does not pro trude beyond the surface of the plastic material Do not use acid core solder as a short circuit may result and corrosion will definitely occur m Coil the ground brush ring field lead around the solder lug and solder with resin core solder n Test the slip rings for ...

Page 149: ...ol the soldered connection touch a dampened cloth against it This will aid in forming a solid joint 5 After soldering the stator leads must be pushed down into the slots that are cast into the end shield and cemented with MoPar Cement Part Num ber 2299314 to protect the leads against possible in terference with the rotor fans Test each replacement rectifier to make certain the rectifier was not da...

Page 150: ...s in the stator rectifier end shield and drive end shield 16 Compress the stator and both end shields by hand and install the through bolts washers and nuts 17 Install the insulated brush in the rectifier end Place the bronze terminal on the plastic holder with the tab of the terminal in the recess in the plastic holder 18 Place the nylon washer on the bronze terminal and install the lockwasher an...

Page 151: ... leak at tower e Coil tower carbon tracked C O N D E N S E R FAILURE a Normal fatigue b Damaged by excessive engine heat or moisture a Test the alternator setting and adjust as nec essary Inspect the condition of the distributor contacts b Replace coil Inspect the condition of the distributor contacts c Replace the coil d Replace the coil e Wipe the tower clean Test the coil replace if necessary a...

Page 152: ... brator until the Dwell Meter reads on the set line test leads separated 2 Leave the Selector Switch in the CALIBRATE position connect the tach dwell red lead to the dis tributor terminal of the coil and the black lead to a good ground 3 Turn the ignition switch ON Observe dwell meter reading The meter pointer should be well with in the black bar marked DISTRIBUTOR RESIST ANCE If the reading is ze...

Page 153: ...0 rpm then slowly reduce to idle speed while observing the dwell meter reading If the dwell reading varies more than 2 degrees from the initial reading between idle speed and 1500 rpm probable wear in the distributor shaft bushings or contact plate bearing or pivot pin is indicated Re move distributor for complete inspection and testing on a distributor tester NOTE Dwell variation at speeds above ...

Page 154: ...8 38 IGNITION SYSTEM Fig 2 Distributor Disassembled View MyMopar com ...

Page 155: ...LATE C O N T A C T SET WASHER SCREW LEAD SPRING SET WASHER BEARING H O U S I N G CLAMP WASHER SCREW OILER m PIN W E I G H T SHAFT CLAMP LOCKWASHER SCREW LOCKRING WASHER SCREW e V A C U U M CHAMBER GASKET PLUG 62 x 310 Fig 3 D i s t r i b u t o r D i s a s s e m b l e d View Prestolite MyMopar com ...

Page 156: ... around the openings and should not be re moved 2 Remove the retainer attaching the vacuum ad Fig 4 Removing or Installing Cam Felt Wick TOOL N Y 6 9 7 A Fig 5 Removing Distributor Housing Upper Bushing vance unit to the contact plate advance arm 3 Remove the two screws and lockwashers attach ing the vacuum advance unit to the distributor hous ing and remove the unit 4 Remove the primary lead wire...

Page 157: ...gh the oil wick hole Remove burrs caused by the drilling oper ation i Install the burnishing tool part of Tool set C 3041 and force the burnisher through both the bush ings Fig 8 The correct bushing inside the diameter is 4995 to 5000 inch ASSEMBLING THE DISTRIBUTOR 1 Test the operation of centrifugal weight and in spect the weight springs for distortion Lubricate the PRESS R A M T O O L DRIVER T ...

Page 158: ...ning the contacts readjust the contact B R E A K E R A R M A N D S P R I N G T O O L S T A T I O N A R Y k P C O N T A C T P U L L S C A L E 61x154 A Fig 9 T e s t i n g Breaker Arm Spring Tension D I A L I N D I C A T O R A R M 6 1 x 1 4 8 A Fig 70 Adjusting Point Clearance with Indicator clearance to specifications using a dial indicator Fig 10 4 Test the dwell angle to show proper degrees of cl...

Page 159: ...e the arrow flashes on the tester degree ring to determine the degrees of ad vance 2 i f thevacuumMvanceisn ove of beKwspeci fications replace the vacuum advance unit Retest the vacuum advance curve INSTALLATION OF DISTRIBUTOR 1 Position the distributor on the engine Align the rotor with marks previously scribed on the dis tributor housing 2 Engage the tongue of the distributor shaft with the slot...

Page 160: ... tor that does not meet specifications Every time an ignition coil is replaced because of a burned tower carbon tracking or any evidence of arcing at the tower the nipple or boot on the coil end of the secondary lead should be replaced Any arcing at the tower will carbonize the nipple so that placing it on a new coil will invariably cause another coil failure If the secondary lead shows any signs ...

Page 161: ...s can t take the place of needed engine overhaul Fig 4 Splashed Fouling Fig 5 Core Bridging NOTE Remember that break in fouling of new engines may occur before normal oil control is achieved In new or recently overhauled jobs such fouling plugs can be cleaned and reinstalled Splashed Fouling Splashed fouling Fig 4 may sometimes occur after a long delayed tune up Here deposits accumulated after a l...

Page 162: ...is is a normal appearance with certain branded fuels Such materials are designed to change the chemical nature of deposits to lessen misfire tendencies Notice that accumulation on the ground electrode and shell areas may be unusually heavy but the material is eas ily flaked off Such plugs can be considered normal Fig 9 Overheating in condition and can be cleaned with standard pro cedures Overheati...

Page 163: ...haust Mechanical Damage Mechanical damage to the firing end Fig 14 is caused by some foreign object in the combustion chamber Since small objects can travel from one cyl inder to another always check the other cylinders to prevent reoccurrence of damage Inspect the distributor cap for oil film or dirt 6 3 x 7 0 7 Fig 73 Chipped Insulator Fig 7 4 M e c h a n i c a l Damage Pressure Type Gap Tool Pr...

Page 164: ...n nection Make necessary repairs d Faulty sealed beam units d Replace sealed beam units HEADLAMPS DIM a High resistance in the headlamp circuit a Test headlamp circuit including ground con engine running above nection Make necessary repairs idle b Faulty sealed beam units b Replace the sealed beam units c Faulty voltage control unit c Test voltage control and alternator Make nec essary repairs HEA...

Page 165: ... in the trunk of vehicle to simulate the weight of the gasoline normally carried in the tank 6 pounds per gallon 9 There should be no other load in the vehicle other than the driver or a substituted weight of ap proximately 150 pounds placed in the driver s posi tion 10 Remove the headlamp front trim panel Do not remove the seal beam retainer rims 11 Thoroughly clean the headlamp lenses F i g I D ...

Page 166: ...s 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 flange and that the aimer target is facing in board 2 Push the release lever forward to expel air from the suction cup and while holding the aimer firmly against the headlamp aim...

Page 167: ...p downward and away from the lens Vertical Adjustment 1 Turn the vertical adjusting screw on the head lamp in a counterclockwise direction to bring the bub ble of the spirit level on the aimer to the vehicle side of center Use care to avoid disturbing the in stalled position of the aimers Then turn the screw clockwise until the bubble is centered for correct aim and elimination of backlash 2 Make ...

Page 168: ...RRECTLY wiring or faulty temperature sending unit in BUT TEMPERATURE engine G A U G E INDICATES HIGHER OR LOWER TEMPERATURE THAN ACTUAL ENGINE TEMPERATURE b Test fuel tank for a good ground NOTE Testing the system with the tank send ing unit positioned for both empty and full is usually sufficient to determine the calibra tion in the range between these positions a Test wiring repair or replace as...

Page 169: ...a Replace cancelling finger b Align cancelling finger properly c Replace switch ENTIRE SYSTEM DOES a Open circuit in feed wire to switch NOT OPERATE b Faulty fuse a Check wiring circuits Refer to Wiring Dia grams b Replace fuse PILOT LAMP ILLUMI NATES BRIGHTLY EXTERNAL LAMPS G L O W S DIMLY WITH N O FLASH a Loose or corroded external lamp ground con a Clean and tighten ground connection nection G ...

Page 170: ...e engine When the oil pres sure is below normal the switch is electrically closed and applies a ground circuit to light the indicator bulb The engine coolant temperature indicator uses two bulbs in the instrument cluster and a coolant tem perature sensing switch on the engine Fig 2 When the coolant temperature is cold the bi metal strip in side the switch makes contact with the G terminal of the s...

Page 171: ...up or down motion of the float through a wiping contact in the gauge body Testing Fuel L e Tncficcifing System in the Vehicle Raise the vehicle on a lift Disconnect the terminal from tank unit Attach one lead of the Gauge Tester Tool C 3826 to the disconnected terminal Connect the other lead of the tester to a good ground With the ignition switch turned on and the gauge tester in the L position th...

Page 172: ...ture send ing unit on the engine Connect one test lead of Test er C 3826 to the terminal and the other test lead to a good ground Place the pointer of the gauge tester on the L position and turn the ignition switch to on The temperature gauge should show C plus or minus Vs inch Thermal gauges are slow in operation Allow time for gauge to heat up Place the pointer on the tester on the M posi tion a...

Page 173: ...e caus ing a resistance change in the sending unit When the engine oil pressure is high the resistance of the sending unit is low allowing a higher current to flow to the instrument panel gauge This causes an indication of high oil pressure on the gauge When the engine oil pressure is low the resist ance of the sending unit is high allowing a lower cur rent to flow to the instrument panel gauge Th...

Page 174: ...sion 4 Remove the two steering column clamp bolts and lower the steering column 5 Remove the steering column upper filler 6 Remove the ignition switch and accessory switch if so equipped from the panel by removing the retaining bezel and pushing the switch clear of the panel 7 Remove the lower cluster trim bezel 8 Remove the upper cluster trim bezel 9 Remove the four screws that mount the cluster ...

Page 175: ...block from the instrument panel lower reinforcement SWITCH TITLE LIGHTING MODEL AY 1 The switch title lenses are illuminated by bulbs lo cated next to the switches The bulbs can be serviced after removing the switch bezel Left Group 1 Perform steps 1 5 of Switches Left Group 2 Remove the screw that attaches the bulb diffuser to the instrument panel 3 Remove the diffuser 4 Remove the bulb from the ...

Page 176: ...heel nut tighten the nut to 24 foot pounds Test the oper ation of the cancelling lever 5 Install the horn blowing actuator steering wheel cover and attaching screws 6 Connect the battery ground cable r Models A C 7 AC 2 and AC 3 Removal 1 Disconnect the battery ground cable 2 Compress and turn the horn button Vk turn counterclockwise to release the buttom from the re tainer 3 Disconnect the horn w...

Page 177: ...urn signal 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 turn signal switch in the steering column jacket tube and install the attaching screws and con nect all wire connections 2 Install the turn signal operating lever 3 Install the steering wheel and the steering wheel nut Tighten to 24 fo...

Page 178: ...Arm Adjustment b Time park switch See Wiper Motor Park Switch Timing c Replace Spring See Wiper Link Assembly d Inspect Wiper Link Assembly a See Wiper Arm Adjustment b Replace faulty part a Replace wiper arm Do not attempt to straighten bent or twisted arm b Install correct wiper blades c Clean the glass MOTOR WILL NOT STOP a Motor park switch failure in the closed posi a Repair or replace motor ...

Page 179: ...learance between the tip of the wiper blade and the wind shield lower moulding should be between X A and 2V4 inches on the left side and between 1 and 3 inches on the right side of the vehicle for Models AC 1 AC 2 and AC 3 and between Va and 2 on the right side for Model AY 1 If the clearance is not in the speci fied range use a suitable tool and reposition the wiper arm and blade assembly Fig 3 S...

Page 180: ...e It is essen tial to thoroughly coat all rubbing surfaces of the spring and pin area Use of any other lubricant than Led Plate such as lubriplate etc will result in noisy operation rapid wear of components and pre mature failure of the parking mechanism WIPER MOTOR Model AY 1 Removal 1 Disconnect the battery ground cable 2 From under the instrument panel remove the left spot cooler hose air condi...

Page 181: ... 3 Remove the parking cam and spring release 4 Remove the coil spring by spreading the ends 5 Disassemble the right hand link in same man ner after removing crank arm to lever nut spacing washers between the link crank arm and lever Installation 1 Install the spring washer concave surface to ward crank arm Install the crank pivot coil spring on the pivot Install the spring release 2 Install the pa...

Page 182: ...oken teeth and re place those showing damage or excessive wear 5 Remove the seal which is pressed into the housing at the output shaft while being careful not to damage the inside diameter of the housing Press in a new seal before reassembling the wiper motor 6 Replace the gasket under the park switch cover Assembly 1 Insert the armature into the motor assembly 2 Install the end head and end head ...

Page 183: ...ground strap Connect another jumper wire between the black wire of the wiper motor and the red wire of the wiper motor The wiper motor should park WIPER PIVOT REPLACEMENT Model AY 1 1 Using a suitable tool remove the wiper arm and blade assembly 2 Disconnect the link from the pivot 3 Remove the pivot and gasket 4 Install a new gasket and pivot 5 Tighten the retaining stud nuts 75 inch pounds 6 Rec...

Page 184: ...minal to the horn button If the horn fails to blow connect a jumper wire from B to H terminal Now if horns operate the relay is defective If horns fail to operate difficulty is in wire to the horns in the horns the wire to horn re lay B terminal or in the grounding of the steering column Adjusting 1 Disconnect the connections at each horn to de termine which horn is not operating 2 Remove horn and...

Page 185: ...ty relay switch or motor b Faulty Motor a Test the red wire at relay with a test lamp If the test lamp does not light check for con tinuity in the red feed wire a faulty circuit breaker or a poor connection between the cir cuit breaker and alternator ammeter If the test lamp lights connect the red feed wire with the red and black or red and green wires from the motor If motor runs relay is faulty ...

Page 186: ...ntrol switch a Test for electrical continuity between the circuit breaker and the control switch Repair or re place as necessary b Test control switch Repair or replace as neces sary SEAT OPERATES HORI a B r o k e n or loose w i r e b e t w e e n the control switch a Test w i r i n g f o r continuity between the control ZONTALLY BUT WILL NOT OPERATE VERTICALLY and the vertical drive motor b Faulty...

Page 187: ... b Master switch and door switch inoperative b Test master switch and door switch for contin SWITCH OR THE INDI uity VIDUAL DOOR SWITCH c Open in wire between motor and switch c Test for continuity between the motor and the switch Repair wiring as necessary d Jammed gear box d Test and repair Inspect motor to gear box alignment e Coupling broken between the motor and the e Replace coupling and tes...

Page 188: ...rrent which also actuates the relay for motor armature current and three wires at tach to solenoids controlling the movement of the front riser rear riser and horizontal movement The right and left tracks are each replaced as an assembly only They cannot be adjusted and are not interchangeable SIX WAY POWER SEATS Description The power seat can be moved six ways forward back up down and tilt The ho...

Page 189: ... in alignment 1 Place the three left cable tubes into the left slave unit Fig 5 Fig 3 R e m o v i n g Cables From Right Slave Unit 63x630A Fig 4 Removing Drive Assembly From Left Slave Unit 2 With the shortest tube on the inside and the longest on the outside install the flexible cables in the tubes Make sure the cables seat in the slave unit 3 Position the drive unit on the left side tubes Make s...

Page 190: ... control switch wires to the motor relay 5 Remove the prop from the left side of the seat cushion Position the seat on the seat adjuster and install the two mounting stud attaching nuts DRIVE UNIT AND SOLENOID ASSEMBLY Disassembly 1 Remove the drive unit from the seat assembly Refer to Removal of Flexible Cables operations 1 4 2 Remove the two screws holding the plate and solenoids to the drive un...

Page 191: ...ld be in the up and forward position 2 Remove the long clevis pin from the front of the guide Fig 7 3 Remove the front rack clevis pin 4 To facilitate the removal of the slave unit re move the slave unit cap Be careful not to lose the springs under the cap The springs are between the racks and the slave cap 5 Remove the nuts holding the slave unit to the guide 6 Remove the slave unit MOTOR RELAY I...

Page 192: ...ront back travel of 5 inches and an up down travel of IV2 inches The control switch is located on the bottom edge of the left side of the driver s seat Power is supplied to the control switch from the 30 ampere circuit breaker mounted behind the left kick panel S E R V I C E P R O C E D U R E S SEAT AND CUSHION ASSEMBLY Removal 1 Remove the two nuts attaching the seat assem bly to the seat track a...

Page 193: ...he clears 2 From underneath the vehicle install the four nuts that attach the seat track and rails assembly to the floor pan Tighten the nuts securely 3 Install the seat and cushion assembly ELECTRIC DRIVE MOTORS Service of the drive motors does not require re moval of the seat and cushion assembly Service pro cedures for both the vertical and horizontal drive mo tors are identical Refer to Fig 2 ...

Page 194: ...e feed wires for the hori zontal drive motor Figs 2 and 3 COUPLING MOTOR TO GEAR HOUSING Fig 1 The coupling transmits the power from the drive motor to the gear housing A coupling is used on both the horizontal and vertical drive mechanisms Removal of the motor allows the coupling to be serviced by pulling the coupling off the end of the drive shaft of the gear housing Service procedures are the s...

Page 195: ...h bolt to the body in ner panel 5 Test the operation of the motor using the win dow lift switch If the motor is faulty replace the mo tor Do not attempt any internal service on the mo tor 6 Disconnect the lead wires to the motor and re move the motor Installation 1 Position the motor on the gear box assembly and install the two mounting nuts 2 Connect the wiring to the motor 3 Test operation of th...

Page 196: ...be serviced on the bench Installation 1 Install the motor and regulator as an assembly in through the access opening in the inner panel and install the three regulator mounting bolts 2 Install the regulator pivot arms into the chan nels 3 Remove the prop that held the window glass and frame in the UP position and lower the assembly down until the regulator pins are in line with the openings in the...

Page 197: ...ELECTRICAL WIRING DIAGRAMS 8 81 PART 9 WIRING DIAGRAMS Figures 1 through 12 shows the various wiring diagrams for the Imperial and the Chrysler Models MyMopar com ...

Page 198: ...R E V E R B E R A T O R f R E A R W I N D O W D E F O G G E R S W I T C Hf CIO A I R C O N D I T I O N I N G C1A A N D H E A T E R W I N D S H I E L D W I P E R S W I T C H S I N G L E S P E E D W I T H B A C K U P L A M P S Fig f Instrument Panel Wirin g Models AC 1 AC 2 AC 3 MyMopar com ...

Page 199: ...H TRACER C7 16 T A N L6 18 YELLOW WITH TRACER C8 16 DARK GREEN L7 18 BLACK C9 16 TAN L8 18 PINK CIO 18 LIGHT GREEN M l 18 PINK c n 18 BLACK M I A 18 PINK CI 2 18 WHITE M l B 16 PINK C20 16 BROWN M2 18 YELLOW C22 16 DARK GREEN M 2 A 18 YELLOW C23 16 LIGHT GREEN M2B 18 YELLOW C23A 16 LIGHT GREEN M3 16 RED C25 16 VIOLET M 3 A 18 PINK D l 18 BLACK M3B 16 PINK D2 18 RED M3C 16 PINK D2A 18 RED M3D 18 PI...

Page 200: ... A R T U R N S I G N A L S W I T C H H O R N S W I T C H H3B J2B 6 J2 T U R N S I G N A L S W I T C H J U M P E R W I R I N G T I L T W H E E L a D O M E S T O P A N D T A I L CLOCK C I G A R L I G H T E R 8 R E D 218 O R A N G E E 2 L I N S T R U M E N T L A M P S CIGAR LIGHTER C10 REAR DEFOGGER D 3 M l TO REAR D E F O G G E R B O D Y W I R I N GC I REAR DEFOGGER SWITCH TO POWER A N T E N N A k F...

Page 201: ...ED C4D 16 BROWN L4 16 BLACK C5 16 DARK GREEN L5 18 RED C5A 16 BLACK L6 18 YELLOW C5B 16 DARK GREEN WITH TRACER C5C 16 DARK GREEN L7 18 BLACK C5D 16 BLACK L8 18 PINK CIO 18 LIGHT GREEN Ml 18 PINK Cll 18 BLACK MIA 18 PINK C12 18 WHITE Ml B 18 PINK C20 14 BROWN M2 18 YELLOW C22 14 DARK GREEN M2A 18 BROWN C23 14 LIGHT GREEN M2B 18 BROWN C23A 14 LIGHT GREEN M2C 18 YELLOW Dl 12 BLACK M2D 18 YELLOW D2 18...

Page 202: ...LACK WITH TRACER J2 16 DARK BLUE J2A 14 DARK BLUE J3 14 BROWN L3 16 RED L3A 16 RED L3B 16 RED L3C 16 RED L4 16 BLACK L4A 16 BLACK L4B 16 BLACK L6 18 YELLOW WITH TRACER L6A 18 YELLOW L6B 18 YELLOW L9 16 WHITE L9A 16 WHITE L9B 16 WHITE L9C 16 WHITE L21 16 BLACK L21A 20 BLACK R3 18 DARK GREEN R5 16 DARK BLUE R6 12 BLACK S2 18 YELLOW S4A 16 BROWN S4B 16 BROWN S5 12 BLACK V10 18 BLACK V10 18 TAN WITH T...

Page 203: ... LAMP TB 2 A 4j B 2 C tfb DO t X P LEFT BACK UP LAMP L 7 A D8 LEFT TAIL STOP A N D TURN SIGNAL LAMP G4 f TO FUEL TANK SENDING UNIT TO RADIO POWER ANTENNA f j X 1 4 SWITCH WIRING X 1 3 X14A X13A Hi TO LEFT A N D RIGHT DOOR SWITCHES q M 2 H R E A R M2J TO M 2 CIRCUIT O N DOME LAMP WIRING Fig 4 Body Wiring Models AC 1 AC 2 and AC 3 CIRCUITS CIR GA COLOR B2 18 VIOLET B2A 18 VIOLET B2B 18 VIOLET B2C 18...

Page 204: ... L M 2 D I LEFT READING LAMP AND SWITCH FOUR DOOR HARD TOP CIGAR LIGHTER X41 1 X42 WINDOW LIFT X 4 2 DECK LID LOCK SOLENOID SIDE COWL CIRCUIT BREAKER RIGHT LAMPS LICENSE LAMP LEFT LAMPS CIR GA COLOR B2 18 VIOLET B2A 18 VIOLET B2B 18 VIOLET B2C 18 VIOLET Cll 18 BLACK CI 2 20 WHITE C13 18 BLACK C13A 14 BLACK C14 14 BLACK C20 16 BROWN C22 16 DARK GREEN C22A 16 DARK GREEN C24 16 BLACK D7 18 BROWN D7A ...

Page 205: ...N K X34A 1 4 P I N K X34B 1 4 P I N K X34C 1 4 P I N K X34D 1 4 P I N K X34E 1 4 P I N K X34F 1 6 P I N K X35 1 8 O R A N G E X35A 18 O R A N G E X35B 18 O R A N G E X35C 18 O R A N G E X35D 1 8 O R A N G E X35E 18 O R A N G E X35F 18 O R A N G E X36 18 P I N K X36A 18 P I N K F R O N T O F V E H I C L E F O R S W I T C H L E F T F R O N T D O O R M A S T E R S W I T C H F R O N T O F V E H I C L ...

Page 206: ... QUARTER WINDOW LIFT MOTOR TO LEFT REAR AUTOMATIC DOOR SWITCH FOUR DOOR HARDTOP TO RIGHT REAR AUTOMATIC DOOR SWITCH FOUR DOOR HARDTOP M I A M I S M I C M I D M M2A M2B M2C M2D M2E M2F M2G M2H M2J M2K M2L M2M M2N W2A W2B W2C Wll W I I A l1 W 1 2 W22 W22A W23 W23A W24 W24A W248 W30 W30A W31 W40 W40A W41 X2 J 3 X3A X3B X3C X3D X3E X32 X32A X32B X33 X33A X33B X33C X33D X33E X33H X34 X34A X34B X34C X34...

Page 207: ...TE L9A 16 WHITE R3 18 DARK GREEN R4 16 BROWN R5 12 DARK BLUE R6 12 BLACK S2 12 YELLOW S4 16 BROWN S4A 16 BROWN S5 12 BROWN V10 18 TAN WITH TRACER NK 753 flgm Engine Compartment Wiring Model AY 1 BACK UP LAMP R SWITCH G R O U N D X2D 0 Z 3 X3A Z Q FEED TO CIGAR LIGHTER GEAR SHIFT SELECTOR LAMP fjjZJT LEFT COURTESY LAMP M 2 B TO CONSOLE WIRING O N INSTRUMENT PANEL TO M 2 CIRCUIT O N DOME LAMP WIRING...

Page 208: ...LAMP WIRING B 2 1 N T d l M 9 A J TO LEFT FRONT M 2 A AUTOMATIC DOOR SWITCH CIRCLE J X INDICATES Y WIRING SPLICE GROUND AT LEFT SIDE COWL NK894 Fig 10 Console Wiring Automatic Transmission and Vacuum Gauge Models AC 1 AC 2 and AC 3 RIGHT COURTESY LAMP GROUND X2D 0 Z 3 X3A S 3 FEED TO CIGAR LIGHTER TO CONSOLE WIRING O N INSTRUMENT PANEL TO M 2 CIRCUIT O N DOME LAMP WIRING TO LEFT FRONT 3 h M 2 A AU...

Page 209: ... TO LEFT FRONT U M 2 A AUTOMATIC DOOR SWITCH CIRCLE L INDICATES Y WIRING SPLICE CIRCUITS CIR G A COLOR 81 18 WHITE B2 18 WHITE E2 18 ORANGE E2A 18 ORANGE E2D 18 ORANGE M l 18 PINK M I A 18 PINK M l B 18 PINK M I C 18 PINK M2 18 YELLOW M 2 A 18 YELLOW M2B 18 YELLOW M2C 18 YELLOW X2 18 BLACK X2A 18 BLACK X2B 18 BLACK X2C 18 BLACK X2G 18 BLACK X3 16 LIGHT GREEN T12B 18 DARK BLUE GROUND AT LEFT SIDE C...

Page 210: ...on ratio 4 bore carburetor uses premium fuel The Firepower 360 has a 10 0 to 1 compression ratio high performance camshaft and valve springs dual exhaust system 4 bore carburetor uses pre mium fuel P A R T 1 S E R V I C E D I A G N O S I S Condition Possible C a u s e Correction E N G I N E E N G I N E WILL N O T START a Weak battery b Corroded or loose battery connections c Faulty starting motor ...

Page 211: ...et 1 Low compression 1 Test compression of each cylinder m Burned warped pitted valves m Install new valves n Plugged or restricted exhaust system n Install new parts as necessary o Faulty ignition cables o Replace any cracked or shorted cables p Faulty coil or condenser p Test and replace as necessary ENGINE MISSES O N a Dirty burned or incorrectly gapped distributor a Replace points and adjust A...

Page 212: ...or torque converter a Check engine oil level Inspect oil pump relief valve damper and spring b Check engine oil l e v e l c Change oil to correct viscosity d Check bearings for correct clearances e Check No 3 main bearings for wear on flanges f Remove crankshaft and regrind journals g Tighten to correct torque OIL PUMPING AT a Worn scuffed or broken rings a Hone cylinder bores if necessary and ins...

Page 213: ...acking cracks and corrosion Inspect the breaker plate contacts lead wire and vac uum advance replace if necessary Adjust to speci fications Test coil and condenser 8 Install the distributor distributor cap and spark plug cables Reset the ignition timing with the vac uum advance line disconnected The ignition timing should be set to compensate for altitudes and or gasoline grades as follows A At lo...

Page 214: ...t the throttle stop screw to specifications Perform a combustion analysis 10 Test the fuel pump for pressure and vacuum Refer to Fuel System Group 14 Specifications 11 Inspect the manifold heat control valve in the right exhaust manifold for proper operation and apply Manifold Heat Control Valve Solvent Number 1879318 to the bushing and shafts 12 Every 6 months remove filter element and blow out d...

Page 215: ...e the vehicle on the hoist and install and tighten the engine front support mounting bolts 7 Install the transmission and the engine rear sup port crossmember 8 Lower the engine into position and install the engine rear support crossmember bolts Remove the engine support fixture Tool C 3487 from the frame 9 Connect the propeller shaft wires linkage ca ble oil cooler lines at the transmission conne...

Page 216: ... der head horizontally and are located at the wide edge of the combustion chambers Removal 1 Drain the cooling system 2 Remove the alternator carburetor and air cleaner and the fuel line 3 Disconnect the accelerator linkage 4 Remove the vacuum control tube at the carbu retor and distributor 5 Disconnect the distributor cap coil wires and the heater hose 6 Disconnect the heat indicator sending unit...

Page 217: ...an assembly and tighten the manifold bolts to 50 foot pounds torque 13 Install the distributor cap Connect the coil wire heat indicator sending unit wire accelerator linkage spark plug cables and the insulators 14 Install the vacuum tube from the carburetor to the distributor 15 Install the alternator and drive belts Tighten the alternator bracket bolts to 30 foot pounds and the alternator mountin...

Page 218: ...e maintained Refacing the Valves and Valve Seats The intake and exhaust valve faces have a 45 de gree angle Always inspect the remaining valve mar gin after the valves are refaced Fig 11 Valves with less than 3 6 4 inch margin should be discarded 1 The angle of both the valve and seat should be identical When refacing the valve seats it is impor tant that the correct size valve guide pilot be used...

Page 219: ...ing is heard Take the reading on the torque wrench at this instant Multiply this reading by two This will give the spring load at the test length Fractional measurements are indicated on the table for finer adjustments The valve springs should test 187 to 203 pounds when compressed to l 1 5 3 2 inch Refer to specifications to obtain specified height and minimum allowable tension Discard the spring...

Page 220: ... oper ate the engine at idle with the cylinder head covers removed 2 Feel each valve spring or rocker arm to detect the noisy tappet The noisy tappet will cause the af fected spring and or rocker arm to vibrate or feel rough in operation NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by applying side thrust on the valve s...

Page 221: ...gns of scoring or wear and the valve is pitted or if the valve seat on the end of the plunger indicates any condition that would TAPPET BODY TOOL PLUNGER SPRING TAPPET PLUNGER NK559 PLUNGER C A P 0 PLUNGER RETAINER SPRING CLIP Fig 17 Hydraulic Tappet Assembly Disassembled View KB971D Fig 18 Testing Tappet Using Tool C 3160 prevent the valve from seating install a new tappet assembly 4 Assemble the...

Page 222: ... crankshaft oil slinger off the end of the crankshaft Fig j R e m o v i n g Vibration Damper Assembly Using Tool C 3688 ENGINE 9 13 Fig 20 Measuring Chain Stretch Testing Timing Chafe for Sfrefcli 1 Place a scale next to the timing chain so that any movement of the chain may be measured 2 Place a torque wrench and socket over the cam shaft sprocket attaching bolt and apply torque in the direction ...

Page 223: ...Puller Blocks Expanded to Puller Position Using Tool C 3506 Fig 23 Removing Oil Seal Using Tool C 3506 retainer lip Fig 22 This is important puller is only positioned at this point 3 Place the sleeve over the retainer and place the removing and installing plate into the sleeve 4 Place the flat washer and nut on the puller screw Hold the center screw and tighten the puller nut to remove the seal Fi...

Page 224: ...ation damper on the FEELER G A U G E CHAIN CASE COVER crankshaft 2 Place the installing tool part of puller set Tool C 3688 in position and press the damper on the crank shaft Fig 27 3 Install the damper retainer washer and bolt Tighten to 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 CAMSHAFT The ca...

Page 225: ...tely disassembled drive out the rear camshaft bearing welch plug 2 Install 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 30 TOOL v A R M TOOL AFT i K Fig 29 Camshaft Holding Tool C 3509 DISTRIBUTOR D R I V E GEAR CAMSHAFT j K R 1 6 2 TOOL 11 memmi SmSmi CRANKSHAFT M A I N BEARING OIL HOLE CAMSHAFT BEARI...

Page 226: ...istributor Timing Before installing the distributor and the oil pump drive shaft time the engine as follows 1 Rotate the crankshaft until 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 O on the timing indicator 3 Coat the shaft and drive gear with engine oil Install the shaft so that after the gear spirals ...

Page 227: ... necessary with 383 and 413 cubic inch engines 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 cylinder walls after each 2...

Page 228: ...e between the piston ring and the ring groove Fig 37 The clearance should be 0015 to 003 inches for the top compres sion ring and the intermediate ring and 001 to 009 inch for the oil control ring for new service rings 4 Install the three piece oil ring in the lower ring groove using the instructions in the ring package 5 Install the tin coated ring in the middle groove and the chrome compression ...

Page 229: ...necting rod over the pilot which extends through the piston pin hole NOTE Assemble the rods to the pistons of the right cylinder bank 2 4 6 and 8 with the in dent on the piston head opposite to the larger cham fer on the large bore end of the connecting rod As Fig 40 Fool Arrangement for Installing Piston Pin Using Tool C 3684 semble the rods to pistons of the left cylinder bank 1 3 5 and 7 with t...

Page 230: ...e 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 the rods The end clearance should be from 009 to 017 inch two rods Limits of taper or out of round on any cranksh...

Page 231: ... NOT grind the thrust faces of the NO 3 main bearing Do not nick the crankpin or main bearing fillets After regrinding re move the rough edges from the crankshaft oil holes and clean out all oil passages CRANKSHAFT MAIN BEARINGS New lower main bearings halves Numbers 1 2 4 5 are interchangeable as shown in Figure 46 New up per main bearing halves Number 2 4 and 5 are also interchangeable Upper and...

Page 232: ...07 inch install a new number 3 main bearing 7 Fit the remaining bearings in same manner It is permissable to use one 001 inch undersize bearing shell with one standard bearing shell or one 002 inch undersize bearing shell with one 001 inch undersize shell Always use the smaller diameter bear ing half as the upper Never use an upper bearing half more than 001 inch smaller than the lower bear ing ha...

Page 233: ...the nuts to 45 foot pounds torque as shown in Fig ures 50 and 51 2 Slide the heat shields over the engine mount bolts and install the second nuts Tighten the nuts to 45 foot pounds torque 3 Lower the engine and install the washers and pre torque nuts on the frame bracket studs Tighten the nuts to 75 foot pounds torque 4 Connect the throttle to transmission and car buretor linkage Removal 1 Disconn...

Page 234: ...er the valve inlet Replace the ventilator valve and cap assembly and remove the inlet breather cap With the engine still running at idle loosely hold a piece of stiff paper or a parts tag over the oil fill pipe Within a few seconds it should be sucked against the oil fill pipe with a holding force If this occurs a final test should be made to be certain the valve shuttle is free A clicking noise s...

Page 235: ...d on the end a flat end or a black end washer With a new valve installed if the vacuum can be felt with the engine idling the system is satisfactory If the vacuum cannot be felt it will be necessary to clean the ventilator hose and the passages in the lower part of the carburetor The carburetor must be removed hand turn a Vi inch drill through the passages to dis lodge the solid particles Blow cle...

Page 236: ...he extension and remove the exhaust pipe 5 Drain the crankcase oil 6 Remove the converter dust shield 7 Remove the oil pan bolts Turn the flywheel un til the counterweight and connecting rods at the front end of crankshaft are at their highest position to pro vide clearance and lower the pan Turn the pan counter clockwise to clear the oil screen and suction pipe as it is lowered Installation 1 Ins...

Page 237: ...valve plunger Fig 57 KB66A Fig 59 Measuring Outer Rotor Thickness Inspection 1 Clean all the parts thoroughly The mating face of the filter base oil pump cover should be smooth Replace the filter base if it is scratched or grooved 2 Lay a straightedge across the oil pump filter base surface Fig 58 If a 0015 inch feeler gauge can be inserted between the base and the straightedge the filter base sho...

Page 238: ...elief valve has a free length of 29 3 2 to 21 9 G 4 inch and is red in color If the oil pressure is low inspect for worn bearings or look for other causes of possible loss of oil pres sure NOTE When assembling the oil pump be sure to Fig 63 Measuring Clearance Between Rotors use new oil seal rings between the filter base and the pump body Installation 1 Install a new O ring seal on the pilot of th...

Page 239: ...1 Install the spin on oil filter by hand finger tight Do not use the tool 2 To obtain an effective seal tighten filter by hand the additional number of turns indicated on the replacement filter Start engine and inspect for leaks MyMopar com ...

Page 240: ...and manifold Figs 6 and 7 Correction Tighten the clamps a t the leaking joints Replace the muffler assembly Replace the exhaust pipe Install a new gasket a n d tighten the exhaust pipe flange nuts to specifications Replace the manifold Tighten the manifold to cylinder block nuts to specifications Tighten the clamps at the leaking joints Replace gaskets as necessary Remove the restriction if possib...

Page 241: ...11 2 EXHAUST SYSTEM VIEW IN CIRCLE B NK947 Fig 1 Exhaust System Single A C J AC 2 A C 3 Fig 2 Exhaust System Dual M 2 AC 3 MyMopar com ...

Page 242: ...EXHAUST SYSTEM 11 3 Fig 3 E x h a u s t System Single AY 1 Sedan fig 4 Exhaust System Dual AY 1 Convertible Models MyMopar com ...

Page 243: ...talling the manifold EXHAUST MANIFOLD Removal 1 Disconnect the spark plug cables from the spark plugs 2 Remove the alternator from the right cylinder head 3 Disconnect the exhaust pipes at the exhaust manifold flanges 4 Remove the nuts that hold the exhaust mani folds to the cylinder heads 5 Slide the manifolds off the studs and away from the cylinder heads 6 Clean the exhaust manifolds in solvent...

Page 244: ...weight on the shaft until it is seated Tighten the clamp bolt to 50 inch pounds us ing Torque Wrench C 3380 Fig 7 Manifold Heat Control Valve Center Outlet Manifold EXHAUST M A N I F O L D INSTALLED POSITION VALVE KR235B Fig 8 Positioning the Thermostat 6 Make sure that the anti rattle spring on the op posite end of the shaft is in place Test operation of the valve Installation Center Outlet Manif...

Page 245: ...il to turn freely it will be necessary to hone the bush ings 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 correct positioning of the valve plate as it is be ing welded to the shaft 5 Remove the drift from the valv...

Page 246: ...ot be connected to the vacuum inlet fitting IMPORTANT If the commercial solvent or cleaner recommends the use of water as a rinse it should be HOT After rinsing all trace of water must be blown from the passages with air pressure It is further advisable to rinse all parts in clean gaso line or kerosene to be certain no trace of moisture remains Never clean jets with a wire drill or other mechanica...

Page 247: ...ion re place assembly Then test fuel pump pressure Refer to Specifications for correct fuel pump pressure h Reset timing POOR ACCELERATION a Accelerator pump piston or plunger leather too hard worn or loose on stem b Faulty accelerator pump discharge ball c Faulty accelerator pump inlet check ball d Incorrect fuel or float level e Worn accelerator pump and throttle linkage f Manifold heat valve st...

Page 248: ... level as necessary to secure the proper level d Test the fuel pump pressure Refer to specifica tions for recommended pressure If pressure is in excess of recommended pressure replace the fuel pump assembly e Disassemble the carburetor Replace the worn metering jet using a new jet of the correct size and type a Instruct owner C H O K E VALVE FAILS T O C L O S E L O W ENGINE OUTPUT 10 F or lower a ...

Page 249: ...or correct carburetor and intake manifold EXCESSIVE STALLS AFTER COLD START CHOKE SYSTEM LEAN a Review items under Poor Starting Choke Valve Fails to Close 7 b Choke vacuum diaphragm adjustment lean b Adjust to Specification ENGINE OUTPUT LOW a Fast Idle speed low b Fast idle cam position adjustment incorrect c Engine lubrication oil of incorrect viscosity d Incorrect timing a Adjust to Specificat...

Page 250: ...the vacuum hose between the carburet or air horn and the vacuum diaphragm 6 Remove the clip from the choke operating link and disengage the link from the diaphragm C H O K E FAST IDLE SPEED A D J U S T I N G SCREW SPRING STAGED C H O K E SHAFT LEVER ACCELERATOR PUMP V A C U U M HOSE L E V E R C H O K E O P E R A T I N G LINK E CLIP C H O K E VALVE B O W L VENT NK418 VALVE C H O K E HUB LEVER V A C...

Page 251: ... D W R E N C H PISTON RETAINER STAKED I N AIR H O R N CHOKE D I A P H R A G M A T T A C H I N G SCREWS DISCHARGE O R I F I C E S GASKEYs i C AIR H O R N X f i J A T T A C H I N G SCREWS SHORT 1 l I i I NK422 Pig 6 R e m o v i n g or Installing the Venturi Cluster ing area or appears to be gummed from deposits in the air horn a thorough cleaning will be required Main Body 1 Remove the float fulcrum...

Page 252: ...led in an old worn throttle body it would be very unlikely that the orig inal relationship of these ports to the valves would be obtained Changing the port relationship would adversely affect normal car operation between the speeds of 15 and 30 miles per hour However if it has been determined that a new shaft or valves are to be installed adhere closely to the following instruc tions To install a ...

Page 253: ...ET CHECK BALL J PUMP MAIN BODY PASSAGE PLUGS 3 Install the power by pass jet and new gasket Tighten securely using Tool 73598 Refer to Fig 7 4 Install the accelerator pump inlet check ball 3 i 6 inch in the pump well as shown in Fig 12 5 Install the accelerator pump discharge check ball Vb inch in the discharge passage as shown in Fig 13 Accelerator Pump Test 1 Pour clean gasoline into the carbure...

Page 254: ...ith the fulcrum pin spring 2 Using Tool 73725 or a T scale measure the float level as shown in Fig 15 There should be 5 3 2 inch from the surface of the fuel bowl to the crown of the float at the center If an adjustment is necessary remove the float and the fulcrum spring Bend the lip of the float le ver either in or out until the correct setting has been obtained CAUTION Do not attempt to change ...

Page 255: ... See Fig 1 3 Inspect the rubber hose for cracks before placing it on the correct carburetor fitting Refer to Fig 2 Do not connect the vacuum hose to the diaphragm fitting until after the vacuum kick adjustment has been made See Carburetor Adjustments CARBURETOR ADJUSTMENTS It is very important that the following adjustments be made on a reconditioned carburetor and in the sequence listed namely Fa...

Page 256: ...ll result in a change of 0 1 0 inch in the choke valve opening As an example if the choke valve opening is 010 inch in error the correction in the link length would be 010 inch SPECIAL G A U G CR D ILL AT W D S T CHOXE OPENING M I N I M U M OF 10 I N C H E S O F V A C U U M REQUIRED O N D I A P H R A G M vj CHOKE OPERATING LINK n Fig 19 Choke Operating Link Measurement A 2 micrometer will be helpf...

Page 257: ...ith the throttle valves held in an open posi tion the choke valve should fall open freely There ROD A S REQUIRED v 4 1 AT ANGLE NK435 Fig 22 Accelerator Pump Travel Accelerator Pump Travel To check the accelerator pump travel refer to Fig 22 then proceed as follows 1 With the throttle valves fully closed measure the pump travel from the fully closed to the fully open throttle 2 This travel should ...

Page 258: ...e Speed Adjustment on the Engine short screw through main body flange Securely tight en Remove the air horn as follows 1 Remove the spring clip and disconnect the choke operating rod 2 Remove the hairpin clip 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 o...

Page 259: ... should exist between the shaft and the hub levers as shown in Fig 25 2 Using a drill or gauge measure the opening The opening should be from 010 to 040 inches 3 If an adjustment is necessary bend the hub le ver tang until the correct opening has been obtained CHOKE OPERATING LINK ACCELERATOR PUMP ROCKER ARM BOWL VENT OPERATING LEVER FAST IDLE CAM CHOKE VALVE STAGING SPRING BOWL VENT VALVE FUEL IN...

Page 260: ...e the vacuum hose between the carburet or throttle body fitting and the vacuum diaphragm 5 Remove the clip from the choke operating link and disengage the link from the diaphragm plunger and the choke lever Refer to Fig 1 6 Remove the vacuum diaphragm and bracket as sembly and place to one side to be cleaned as a special item NOTE A liquid cleaner may damage the diaphragm material 7 Remove the air...

Page 261: ...ring manufacture the location of the idle trans fer port and the spark advance control ports to the throttle valve is carefully established for one particu lar assembly refer to Fig 5 If a new shaft should be installed in an old worn throttle body it would be very unlikely that the origi nal relationship of the ports to the valves would be obtained Changing the relationship of the valves to the po...

Page 262: ... RODS MUST M O V E FREELY NK617 Fig 7 Step Up Rods Free Play 7 Before 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 Fig 7 The step up rods must be straight smooth and free to move for ward and backward from vertical 8 Slide the step up piston gasket down into posi tion in the piston well then install the step up pis to...

Page 263: ...n the fast idle lever and throttle lever Install hairpin clip to se cure that the passage is not plugged with foreign material Leak check the diaphragm to determine if it has internal leaks To do this first depress the diaphragm stem then place a finger over the fitting to seal the opening Release the stem If the stem moves more than Vie inch in ten 10 seconds the leakage is ex cessive and the ass...

Page 264: ...WL VENT ADJUSTMENT BEND STOP TO ADJUST CHOKE FAST VALVE O P E N I N G IDLE C A M SCREW NK620 APPLY CLOSING PRESSURE A G A I N S T CHOKE VALVE SHAFT LEVER CHOKE v OPERATING LINK 4 HOSE TO V A C U U M x SUPPLY DRILL OR G A U G E AT WIDEST CHOKE O P E N I N G D I A P H R A G M STEM PLUNGER RETRACTED 8Y V A C U U M CHOKE DIAPHRAGM TUBE FITTING NK621 Fig 11 Checking th Kick Setting e Vacuum Fig 70 Fast...

Page 265: ...ture C H O K E V A L V E W I D E O P E N C H O K E f V O P E R A T I N G i m w L I N K J C H O K E V A L V E C L O S E D v C H O K E R x O P E R A T I N G L I N K N K 6 2 3 li C L E A R A N C E B U N L O A D E R T A N G y T H R O T T L E y L E V E R A G A I N S T S T O P T H R O T T L E A T W I D E O P E N P O S I T I O N N K 6 2 4 Fig 14 Checking the Choke Unloader Setting If a clearance does not...

Page 266: ...ill assure that the idle has been set to the leanest mixture possible for smooth idle This setting is very important Since the correct speed was originally set using the speed screw the speed obtained after finding the lean est smooth idle will probably be too fast 5 Readjust the speed screw to obtain correct idle speed Repeat steps 2 and 4 above if necessary Measuring Float Setting On the Vehicle...

Page 267: ...rn the fast idle adjusting screw in or out to secure 700 rpm Automatic Transmis sion or 600 rpm Manual Transmission Reposition the cam and throttle after every screw adjustment to apply normal throttle closing torque After Approx 500 Miles If Necessary Spring Staged Choke Adjustment The new spring staged choke shown in Fig 17 is a device incorporated in the choke mechanism which limits the choke b...

Page 268: ...peed systems one ac celerator pump system and one automatic choke con trol system SIRWiCI PROCEDURES DISASSEMBLY To disassemble the carburetor for cleaning or over Tool C 3400 or T 109 287S elevating legs These tools haul refer to Fig 1 then proceed as follows are used to protect the throttle valves from dam 1 Place the carburetor assembly on repair stand age and to provide a suitable base for wor...

Page 269: ...rn Place the air horn in an inverted position on the bench to protect the floats then proceed to disas semble as follows 1 Using a suitable Tool remove the float fulcrum PRIMARY VENTURI A C C E L E R A T O R PUMP CLUSTER I N T A K E C H E C K V A L V E 4 A C C E L E R A T O R PUMP H O U S I N G J E T i A C C E L E R A T O R PUMP D I S C H A R G E P A S S A G E 15 NK587 Fig 3 R e m o v i n g or Ins...

Page 270: ...oca tions in the main body at reassembly 3 Again using Tool T109 58 remove the main metering jets secondary side as shown in Fig 4 4 Remove the screws that attach the primary ven turi choke and pump side to the main body Lift the venturi straight up and away from the main body as shown in Fig 5 Discard the gaskets NOTE The venturi assemblies are not inter changeable side for side and must be reins...

Page 271: ...ir seats then back off one full turn for an approximate adjustment 4 Place new secondary venturi gaskets in posi tion then install the secondary venturi pump and choke side by lowering straight down on gaskets In stall attaching screws and tighten securely NOTE Be sure all the metering holes and vent tubes are clean in both the primary and secondary venturi 5 Place new primary venturi gaskets in p...

Page 272: ... inlet needles NOTE The tip can be compressed sufficiently to cause a false setting which will affect correct level of fuel In the bowl 4 Place a new air horn to main body gasket in po sition on the air horn then install the float needle valve seats Be sure each needle seat and needle is reinstalled in its original position 5 Slide the right and left floats into position in the air horn then insta...

Page 273: ...P P I S T O N S P R I N G 4 2 S T A G E S T E P U P P I S T O N t 3 S T E P S J E T O L D T Y P E S T E P U P R O D C O V E R r S C R E W J E T N E W T Y P E 61x171 Fig 12 Step Up Piston Rod and Jet intermediate speed range To do this there is a new step up piston and spring assembly new metering rods with three diameters and new style primary metering jets as shown in Fig 12 5 Slide the step up p...

Page 274: ...onnect the vacuum hose from the dia phragm and connect the hose from the vacuum sup ply as shown in Fig 14 A minimum of 10 inches of vacuum will be required 3 Insert the specified drill between the choke valve and the wall of the air horn Refer to Fig 14 Apply sufficient closing pressure on the choke shaft lever to provide the smallest choke valve opening pos sible without distortion of the diaphr...

Page 275: ...C T T H E F A S T I D L E C A M T H R O T T L E I N W I D E O P E N P O S I T I O N Fig 16 Choke Operating Link Clearances Fig 17 Checking Choke Unloader Wide Open Kick If a clearance does not exist in both of these posi tions a recheck of the operating link adjustment should be made NOTE Free movement of the choke valve between the closed and open positions is very necessary This free movement sh...

Page 276: ...ondary throttle lever should freely engage in the notch of the lockout dog Refer to Fig 19 If an adjustment is necessary bend the tang on the secondary throttle lever until engagement has been made Use Tool T109 22 for this operation After adjustments have been made reinstall car buretor on engine using a new gasket It is suggested that the carburetor be filled with clean gasoline This will help p...

Page 277: ...above if necessary After the proper idle speed has been obtained move the sliding link to the rear against the stop and tighten the nut securely Fast Idle Speed Adjustment On the Vehicle To set the fast idle speed on the vehicle connect a tachometer to the vehicle then set the curb idle speed and proceed as follows 1 With the engine running and the transmission in the neutral position open the thr...

Page 278: ...ng On the Vehicle If the fuel pump fails to supply fuel properly to the carburetor the following tests should be made before removing the fuel pump from the vehicle Pressure Test If leakage is not apparent test pump for pressure as follows 1 Insert a T fitting in the fuel line at the car buretor as shown in Fig 2 2 Connect a 6 inch piece of hose between the T fitting and gauge Tool C 3411 The hose...

Page 279: ...d from the vehicle FUEL TANK The fuel tank on all models except Station Wagon Models is located at the rear of the body under the trunk compartment floor as shown in Fig 1 In Station Wagon models the fuel tank is mounted in the left rear quarter panel beyond the wheel house as shown in Fig 2 If the vehicle is to be stored for any appreciable length of time the gasoline should be drained from the e...

Page 280: ... Imperial CAUTION Be sure the ignition switch is turned off before disconnecting or connecting the gauge wire Removal 1 Drain the tank into a safety can then discon nect the fuel line and the wire lead to the gauge unit 2 Disconnect the vent tube at the hose connection at the leading edge of the tank 3 Remove the screw that attaches the filler tube bracket to the trunk panel 4 Remove the nuts that...

Page 281: ...and the locator emboss ments on the floor pan 3 Push the tank toward the rear to fully engage the filler spout in the opening 4 Hold the fuel tank in this position and place the hold down straps in position feeding the attach ing studs through holes in the end of the straps In stall the nuts but do not tighten 5 Guide the button head of the studs into the slots in the frame and down into position ...

Page 282: ...d OFF before disconnecting or connecting the gauge wire 1 Drain the tank into safety can then disconnect the fuel line and the lead to the gauge unit under the rear fender behind the wheel house 2 Remove the screws that attach the stone shield to the lower edge of the wheel house at the rear Re move the shield 3 Remove the button plug at the rear of wheel house in front of gauge unit 4 Raise the v...

Page 283: ...d with a screw hole Install the screws and tighten securely 6 Tighten the fuel tank hold down strap bolt squarely 7 Install the stone shield Connect fuel line and lead to gauge unit Reinstall the button plugs Refill the tank and check for leaks 8 Swing the rear axle rearward and connect the rear hangers on both springs 9 Connect the left rear shock absorber For cleaning the fuel gauge refer to the...

Page 284: ...s of the threaded adjust ment at the upper end The ball socket 7 must line up with the ball end with the rod held upward against the transmission stop 14 5 Assemble ball socket 7 to ball end and remove 3 i 6 inch rod 12 from upper bellcrank and lever 6 Hold the carburetor rod 15 forward against the transmission stop 14 and adjust its length by means of the threaded adjustment so that the rear end ...

Page 285: ...lock choke valve in full open position Open throttle slightly to release fast idle cam then return carburetor to curb idle 4 Hold the transmission lever 8 forward against its stop rod or lever must not be moved vertically while holding against the stop and adjust the length of the transmission rod by means of the threaded ad justment 5 at the upper end The rear end of the slot should contact the c...

Page 286: ...ension housing to exclude road splash and other foreign matter The propeller shaft used on AC 3 models is pro vided with a constant velocity universal joint at the front end Fig 5 This joint is provided with a slid ing type yoke similar to that used on AC 1 AC 2 models The rear joint is a single cross and roller type Fig 2 The constant velocity joint incorporates two single joints connected with a...

Page 287: ...o specifications b Inspect for worn parts Recondition if necessary c Replace worn parts and recondition joint PART 1 SERVICE PROCEDURES PROPELLER SHAFT ANGULARITY The quiet smooth operation of the propeller shaft depends upon proper alignment Propeller shaft and rear axle housing angles on all Models may be meas ured using propeller shaft alignment gauge Tool C 3976 The vehicle should be in a leve...

Page 288: ...Hold the gauge on the underside of the propel ler shaft near the rear universal joint Fig 7 and note the location of the bubble in the spirit level The entire bubble should be within one and three gradua tions forward from center Fig 8 4 If it is necessary to adjust the rear joint angle loosen all the U bolts and install two degree tapered wedges between both rear springs and axle housing spring p...

Page 289: ...g Rear Axle Housing Angle Fig 7 Measuring Propeller Shaft Angle NOTE Do not disturb the retaining strap used to hold the bushing assemblies on the universal joint cross CAUTION Do not allow the propeller shaft to drop or hang loose from either joint during removal Wire up or otherwise support the loose end of the shaft to prevent damage to the joint K R 7 0 5 A Fig 8 Bubble Location forward of cen...

Page 290: ... clean the old lubricant from the splines of slip spline yoke Fig 4 Lubricate with approximately one third ounce of Multi Mileage Lubricant Part Number 2298947 spread evenly over all the splined area of the yoke 2 Engage the yoke splines on the end of the out put shaft being careful not to burr the splines Fig 3 Rear Joint All Models 1 Install the rear universal joint cross roller bush ings in the...

Page 291: ... The cross and retainers are serviced as an assembly Cleaning and Inspection 1 Clean all parts in a suitable solvent and dry with compressed air Examine bearing surfaces of the cross They should be smooth and free from ripples and pits If bearing surfaces or seal retainers are damaged replace the cross assembly 2 Examine the rollers in the bushings The bear ings that have operated on a worn cross ...

Page 292: ...the cross assembly Replace with parts contained in replacement packages All parts in the package should be used If the propeller shaft is dam aged or the center stud yoke slinger is bent out of shape replace the shaft assembly to be1 assured of a balanced assembly Assembly 1 Position the centering assembly in the yoke with the large diameter hole up and press it firmly to its seat 2 Apply a film o...

Page 293: ...ntly lubricated They should be inspected for external leakage whenever the vehicle is serviced The joints should not be relubricated unless leakage is observed Refer to Paragraph Propeller Shaft for servicing instructions SERVICE PROCEDURES PROPELLER SHAFT ANGULARITY When measuring the propeller shaft angularity the vehicle should be in a level position and have no ex tra weight except that of a f...

Page 294: ... loosen all U bolt nuts and install two degree tapered Fig 21 Measuring Propeller Shaft Angle K R 7 0 5 A Fig 2 2 B u b b l e Location Forward of center wedges between both rear springs and axle housing spring pads Fig 23 If the bubble is forward of the third graduation Fig 22 install the wedges with the thick edge of the wedge toward the front of the ve hicle Fig 23 5 If the bubble is centered or...

Page 295: ...f the propeller shaft over the frame crossmember and connect the rear universal joint to the pinion yoke Install the stud nuts and washers Tighten the nuts to 300 inch pounds 2 Connect the front universal joint to the trans mission output shaft yoke Install the cross and roll er bushing clamps bolts and washers Tighten the bolts to 170 inch pounds 3 Position the center bearing bracket on the frame...

Page 296: ...ful to avoid damaging cross seals and center stud yoke slinger 8 Remove the remaining set of bearings from the propeller shaft yoke 9 Remove the cross from the propeller shaft yoke Remove the centering stud spring from the propeller shaft Fig 25 10 Remove the four roller bearing assemblies to separate the yoke shaft from the center yoke as pre viously described CENTERING BALL AND SOCKET ASSEMBLY 1...

Page 297: ...stud 9 Position the center universal joint on the cross in the propeller shaft guiding the centering ball on the centering stud applying pressure at the same time Work the center yoke over the cross being careful not to damage the cross seals 10 Install the two bearing assemblies in the rear bores of the center yoke as previously described In stall the snap rings 11 Coat the splines of the center ...

Page 298: ...eaning and Inspection Assembly 1 Coat the inside surfaces of the bearing races with Automotive Multi Purpose E P Grease NLGI grade 2 and install rollers 32 are required Also pack reservoirs in ends of crosses with the same lu bricant 2 Install the cross in the propeller shaft yoke and install the two bearing assemblies as described in Center Universal Joint Assembly Install the snap rings 3 Positi...

Page 299: ...ed NOTE8 Shock absorbers should only be replaced if they have lost their resistance are damaged or if they drip oil Evidence of slight oil moisture on out side of shock absorber is not cause to replace them SERVICE DIAGNOSIS Condition Possible C a u s e Correction SPRINGS AND SHOCK ABSORBERS SPRINGS S A G OR BOTTOM SPRING NOISE SPRING BREAKAGE STRUT CRACKING OR GRUNTING NOISE AT REAR OF IMPERIAL M...

Page 300: ... the installation of the upper bushing dip the bushing in water start it into the frame opening with a twisting motion then press or tap it into place When installed properly the groove in the bushing will index with the opening in the shock absorber tow er 2 Install the steel sleeve in the bushing N K 5 4 2 KP71 Fig 2 R e p l a c i n g Shock Absorber Bushing 3 Using Tool C 3553 press the lower bu...

Page 301: ...tal position other wise air will enter the cylinder tube A steady resistance should be felt when the shock absorber is extended or compressed If no resistance is felt replace the shock absorber REAR SPRINGS Front Pivot Bushing Replacement Removal of the old bushing and installation of the new bushing is performed in one operation using Tool C 3709 Fig 4 1 On bolt SP 3178 position the bearing washe...

Page 302: ... axle hous ing 3 Measure both the right and left sides If these measurements vary by more than inch from side to side it is an indication that one of the rear springs may need replacing It is normal for rear springs to show some reverse arch even with no load so appearance alone should not be the reason for spring replacement Rear Spring Removal 1 With the vehicle body frame supported on the 61 x ...

Page 303: ...ring U bolt nuts 50 foot pounds and shackle bolt nuts 40 foot pounds 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 pounds torque 7 The bushings and shackles should not be lubri cated at any time Measure the vehicle curb height whenever a rear spring or shackle has been replaced MyMopar com ...

Page 304: ...operly adjusted d Steering arm loose on steering gear shaft e Steering gear housing attaching bolts loose f Steering arms loose at steering knuckles g Worn ball joints a Inflate tires to recommended pressures b Lubricate as necessary c Adjust according to instructions d Align the wheels See Front Suspension e See Steering Column Manual Transmission a Inflate tires to recommended pressures b See Fr...

Page 305: ...it to stick in the open or by pass position This fouling can be caused by gum deposits pieces of broken slipped springs burrs or foreign material pieces or rubber dirt or machine chips If no fouling is evident or if the flow control Valve contains pieces of coiled wire broken slipper spring the pump should be disassembled for possible slipper spring replacement f Repair as necessary g Repair and l...

Page 306: ...ctions b Pump output low b Perform the Pump Pressure and Flow Tests also refer to correction e in Diagnosis under Hard Steering c Broken or worn ring on worm piston c See Gear Reconditioning d Piston end plug loose d Replace the worm and piston assembly e Internal leakage in the steering gear valve e Replace the steering gear valve body assem body bly TEMPORARY a Oil level low in pump reservoir a ...

Page 307: ...e and return hose connections and fittings c Reservoir to pump body O ring or mounting screws d Pump shaft oil seal a See Engine Cooling Group 7 b Replace the pulley measure the pump di ameters as follows Shaft diameter 8120 8125 Pulley inside dia meter 8095 8105 If shaft is damaged re place pump c See Fluid Level d Replace the relief valve and perform Pump Pressure Test e Repair as necessary Refe...

Page 308: ... E ADJUSTING S C R E W WORM SHAFT R E C I R C U L A T I N G B A L L NUT CROSS S H A F T 62x458 The torque required to keep the wheel moving should be between IV2 and W2 inch pounds If the reading is not within these limits the adjustment can be made in or out of the vehicle as follows a Loosen the adjuster lock nut b Use the adjuster wrench from Tool C 3884 set and turn the adjuster clockwise to i...

Page 309: ...late to floor pan bolts when remov ing the steering gear If the floor plate bolts are loos ened it will be necessary to realign the steering col umn when reinstalling the gear 4 Remove three steering gear housing mounting bolts and remove steering gear from under vehicle Gear Reconditioning Thoroughly clean the entire outside surface of the N K 4 5 6 Fig 4 Removing Cross Shaft steering gear before...

Page 310: ... shaft bearing adjuster by inserting a blunt punch be hind the seal and tap alternately on each side of the seal until the seal is driven out of the adjuster 12 Remove the wormshaft spacer and upper bear ing cup in the same manner However this must be done carefully to avoid cocking the bearing cup and distorting the adjuster counterbore 13 Remove the lower cup if replacement is neces sary by posi...

Page 311: ...g the seal in the wormshaft adjuster with the lip of seal up Drive the seal into place with a suitable sleeve so it is slightly below the end of the bore in the adjuster 23 Apply a coating of steering gear lubricant to all moving parts during assembly also place lubricant on and around oil seal lips 24 Clamp the holding fixture and housing in a vise with the bearing adjuster opening upward 25 Plac...

Page 312: ...steering shaft coupling 2 Position the steering gear in position from un derneath the vehicle and install the three mounting bolts 3 Tighten mounting bolts to 80 foot pounds 4 With the master serration on the wormshaft aligned with the notch mark on the coupling housing slide the steering column assembly down far enough to engage the column coupling with the wormshaft 5 Align the groove on the ste...

Page 313: ...ut Vi turn and tighten the adjusting screw until backlash just disappears Tighten the screw VA turns from this position and while hold ing adjusting screw in this position tighten lock nut NOTE This is a temporary adjustment to insure that the piston rack and sector teeth are in full alignment Fig 2 2 Operate the unit manually for a minimum of 180 degrees from the center in each direction meas ure...

Page 314: ...nt panel bracket and pull up on the column assembly until the coupling is clear of the steering gear wormshaft about 2 inches 5 Raise the vehicle 6 Remove the cotter key and nut from the steer ing arm at the center link 7 Remove the center link from the steering arm using puller Tool C 3894 8 Remove the three bolts that mount the steer ing gear to the crossmember and remove the gear from under the...

Page 315: ... locknut T O O L K R 3 8 Fig 5 Removing Steering Column Support Nut to facilitate removal and remove the gear shaft cover nut with Tool C 3633 Fig 4 CAUTION Oil will be expelled when the gear shaft and cover are withdrawn from the housing 8 Rotate the worm shaft to the full right turn position then return the worm shaft to the center of travel This will place the piston in the center position Fig ...

Page 316: ...rmshaft from turning then turn the thrust bearing nut with sufficient force to release the staked portions from the knurled section and re move the nut 6 4 x 5 8 1 A Fig 7 Retaining the Bearing Rollers With Arbor Tool Fig 8 Removing Wormshaft Upper Seal NOTE Wire brush the knurled section to remove the chips then blow out the nut and wormshaft to remove any metal particles 15 Remove the upper thru...

Page 317: ... r r H O U S I N G H E A D W P k S E A L 4 _ T O O L l S P A N N E R N U T K R 4 4 B HOUSING HEAD O R I N G R E A C T I O N R I N G KR45A F g 77 installing Reaction Seal Into Housing Head the cover and large 0 ring from the base of the cover Fig 26 CAUTION The needle bearing in the cover con sists of 51 needles originally retained in the cover by heavy lubricant to facilitate assembly This lu bric...

Page 318: ...ng Fluid Part No 2084329 and install the following parts in order a Lower thrust bearing race thick Fig 14 Removing Homing Lower Bearing b Lower thrust bearing c Lower reaction spring with smallhole over the ferrule d Lower reaction ring flange up so the ring pro trudes through the reaction spring and contacts the reaction 0 ring in the cylinder head e Center bearing race f Upper thrust bearing g ...

Page 319: ...N G R I N G R I N G R I N G R E T A I N E R S C R E W W A S H E R B E A R I N G O R I N G S E A L S E A L W A S H E R N U T C O U P L I N G 3 m C O I m m 2 z o o m V A L V E A S S E M B L Y G R O U N D B E A R I N G N Y 1 8 C Fig 1 Steering Gear Disassembled View Models AC 1 AC 2 a n d A C 3 MyMopar com ...

Page 320: ...J O R I N G 6 4 x 7 2 1 A Fig 16 Steering Gear Disassembled View Models AY 1 MyMopar com ...

Page 321: ...earing spacer assembly 50 Install the upper reaction ring on the center bearing spacer with the flange down against the spacer 51 Install the upper reaction pressure spring over the reaction ring with the cylinder head ferrule through the hole in the reaction spring 52 Install the reaction ring without flange inside the upper reaction ring 53 Lubricate the ferrule O ring with petrola tum and insta...

Page 322: ... 4 Expel all the air from the unit by turning the wormshaft several times to the right and then to the left 5 Refill the reservoir before proceeding with the following test and adjustments on the bench a Tighten the steering valve body attaching screws to 7 foot pounds b Install a steering gear shaft arm on the steer ing gear shaft c With the gear shaft on center tighten the gear shaft adjusting s...

Page 323: ...ormshaft NOTE The steering column assembly should be moved down onto the wormshaft until the worm shaft lightly bottoms on the locating pin pre assem bled into the coupling 4 Install the coupling clamp bolt and tighten to 33 foot pounds 5 Align the jacket tube at the instrument panel and install the jacket tube clamp and attaching screws Tighten the screws finger tight CAUTION While the steering c...

Page 324: ... so that the valve lever hole is aligned with the lever opening in the valve body The valve must be perfectly free in the valve body without sticking or binding 6 Install a new seal and end plug if removed Tighten the plug to 25 foot pounds 7 Install the back pressure valve cushion spring in the back pressure valve body Lubricate the back pressure valve piston and insert the nose end of the piston...

Page 325: ...on nut is removed from the gear shaft the oil seal will be pulled from the housing 7 Remove the oil seal snap ring with pliers Tool 3PJ v TOOL t K R 5 3 A Fig 25 Installing Gear Shaft Oil Seal C 3229 and remove the oil seal back up washer and repeat operation a b c d to remove the inner seal 8 Install the gear shaft inner oil seal into the steering gear housing lip of seal toward the needle bearin...

Page 326: ...ension See Cooling System Group 7 2 Disconnect the pump to the steering gear pres RESERVOIR SPRINGS 8 ROTOR RELIEF VALVE sert permit a flow of approximately two gallons per minute to the gear before the valve moves to the right to allow the excess to flow back to the inlet side of the pump Maximum pressure in the system is limited by the pressure relief valve The valve opens into the reservoir whe...

Page 327: ...ve is faulty Replace the relief valve with the correct relief valve known to be in working order and repeat the test in step 7 If the pressures are still below specifications disassemble the pump and inspect the flow control valve for evidence of fouling or slipper spring breakage c With the gauge shut off valve fully open oper ate the steering unit through another cycle this time holding the unit...

Page 328: ...10 psi If the flow pressure reading is less than 10 psi in spect the flow valve operation for sticking if the valve is operating satisfactorily the pump is worn and should be replaced If flow pressure reading is 10 psi or greater and relief valve is operating properly the pump is good F L O W C O N T R O L V A L V E P L U G A N D S N A P R I N G F g 4 Removing Pump Pulley Fig 5 Removing Pump Oil S...

Page 329: ...l dirt around the discharge fitting and tighten the high pressure hose tube nut to 24 foot pounds 2 Start the engine and steer the vehicle from stop to stop to build up pressure If the discharge fitting is leaking disconnect the high pressure hose at the pump and examine the tubing flare for nicks scratches or other damage If the tubing flare or nut is damaged replace the high pressure hose 3 Exam...

Page 330: ...horoughly cleaned and flushed and reassembled NOTE Inspect the flow control valve and valve bore If the valve or valve bore in pump body are badly scored replace the pump assembly less pul ley and reservoir 3 Install the control valve spring seating the spring in the spring socket 4 Remove any burrs with a fine hone or crocus cloth but Do Not round the valve land corners 5 Lubricate with 2084329 p...

Page 331: ... R e m o v i n g Shaft NOTE The cam insert has two machined notches one large and one small on the inside surface these are not to be interpreted as deep scoring 8 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 the seal lip contacts 9 If all parts are in a servi...

Page 332: ...st be installed Fig 16 NOTE Inspect the springs to make sure they are in the pockets and in an upright position under the slipper Fig 17 14 Using a washer of the dimensions shown in Figure 18 drop it over the pulley end of the shaft 6 3 x 6 7 9 Fig 17 Slippers and Springs Properly Installed This washer is used to keep the slippers flush with the end of the rotor NOTE It is important that the slipp...

Page 333: ...in an arbor press align the center punch marks on the front insert and the pump body and using a 1 inch socket with V2 inch drive press the insert into the pump housing Fig 20 23 Install the spanner nut and tighten to the exact Fig 20 Installing Front Insert Into Pump Housing original position in the housing as indicated by the pin punch marks placed on the pump body and span ner nut at disassembl...

Page 334: ...ed by a heavy duty ball bearing in the center of the case The rear end of the mainshaft is supported by a ball bearing pressed on the end of the mainshaft and a snug fit in the end of the exten sion housing The countershaft gear cluster is supported by a double row of needle type roller bearings 38 at each end and the thrust is taken on thrustwashers between the ends of the gear and the transmissi...

Page 335: ...ON a Excessive end play in the countershaft gear a Replace the thrust washers NOISES b Loose synchronizer hub spline fit on mainshaft b Inspect the mainshaft and synchronizer hub and replace parts as necessary c Loose spline fit on low speed sliding gear to c Inspect the low speed sliding gear and main mainshaft spline shaft Replace parts as necessary d Loose spline fit of rear mainshaft flange d ...

Page 336: ... the selector lever on the col umn 5 degrees above horizontal level 5 Slide the clamp and swivel on the end of the 1st and reverse control rod either in or out until the swivel stub shaft enters the hole in the transmission lever Fig 4 Install washers and clip to secure De termine the mid back lash position in the linkage Fig 3 Gearshift Lever Adjustment Fig 4 A 745 Gearshift Controls then tighten...

Page 337: ...al from the lip on the jacket and slide the seal down toward the coupling 4 Exert an upward force on the steering shaft to force the steering column jacket upper bearing and insulator up and out of the counterbore in the bearing housing Remove the insulator from the bearing 5 Using snap ring pliers Tool C 3128 remove the Fig 6 R e m o v i n g Bearing Upper Snap Ring F g 7 R e m o v i n g Steering ...

Page 338: ...ousing retaining bolts and lift the steering col umn upper bearing housing off the jacket assembly Fig 11 16 Lift the gearshift housing and spring washer off the steering column jacket Inspection After cleaning inspect all parts for wear or dam age Note the condition of the pins in the two lower shift levers the shift lever socket at the top end of the shift tube and the inner end of the shift lev...

Page 339: ...I N G SLEEVE C 3879 i 62x52i Pig 12 Holding Selector l e v e r In Neutral Pig 13 Installing Steering Column Upper Bearing 15 Position the gearshift lever in the shift lever housing so it engages the hole in the shift tube plate with the pin hole aligned 16 Support the jacket tube housing in the area around the pin hole Fig 8 and drive the pivot pin in flush with the housing NOTE Before sliding t h...

Page 340: ...ing boot aligns with the gauge hole in the shaft Fig 14 Tighten the steering column bracket clamp screws securely 7 With the coupling centered tighten the column jacket to instrument panel clamp bolts to 95 inch pounds torque 8 Push the floor plate down to contact the toe board and start the floor plate to toe board attach ing bolts leaving them just loose enough so the floor plate can be shifted ...

Page 341: ...d as follows 1 Using Tool C 3281 flange holding tool remove the flange retaining nut and washer 2 If necessary attach puller Tool C 452 and re move the flange assembly 3 Remove the bolts that attach the cover to the case Remove the cover then discard the gasket 4 Using a pair of feeler gauges measure the syn chronizer float The measurement of the float should be taken before any further disassembl...

Page 342: ... L O C K W A S H E R B O L T A N D W A S H E R BOLT A N D WASHER TAPERED P I N G R O M M E T W A S H E R B U S H I N G A X N U T W A S H E R L O C K W A S H E R B U S H I N G L O C K W A S H E R G R O M M E T 61 x 3 2 5 C Fig 16 A 745 Transmission Disassembled MyMopar com ...

Page 343: ... the mainshaft then remove the clutch sleeve the outer synchronizer rings the front inner ring and the 2 3 shift fork Fig 20 3 Remove the clutch gear retaining snap ring us ing snap ring pliers Fig 21 Slide the clutch gear off the end of the mainshaft 4 Slide the second speed gear stop ring and the synchronizer spring off the mainshaft Fig 22 V CLUTCH GEAR NY854A Fig 7 8 R e m o v i n g Drive Pini...

Page 344: ...verse Idler Gears Fig 25 A 745 Shift Forks and Levers of the countershaft to prevent loss of the bearing rollers 4 Remove the countershaft gear thrust washers and the thrust plate from the case 5 Remove the bearing rollers washers and the center spacer from the countershaft gear Reverse Idler Gear 1 Using a suitable drift drive the reverse idler gear shaft towards the rear and out of the case Re m...

Page 345: ...ntact surfaces show signs of gall ing or excessive wear a new mainshaft should be installed Inspect the snap ring grooves for burred edges If rough or burred remove the condition using a fine file or crocus cloth Inspect the synchronizer clutch gear teeth on the shaft for burrs ASSEMBLY Countershaft Gear To reassemble the transmission refer to Fig 16 then proceed as follows NOTE If countershaft ge...

Page 346: ...I N S E R T S H I M A G A I N S T T H I S F A C E Fig 26 Installing Detent Bails Map 4 V Jj ru 6 4 x 4 9 8 Fig 27 Synchronizer Float Shim Location Mainshaft 1 While holding the low and reverse sliding gear in position in fork with the hub extension to rear insert the mainshaft with rear bearing through the rear of the case and into the sliding gear 2 Place the synchronizer spreader spring and then...

Page 347: ...t pounds torque 3 Install the flange assembly and secure with a new washer and nut Tighten the nut to 175 foot pounds torque while holding the flange with Tool C 3281 4 Lightly lubricate the cover gasket surface then install gasket and cover Install the attaching bolts and tighten to 144 inch pounds torque 5 Install the drain plug and back up light switch if so equipped and tighten securely 6 Refi...

Page 348: ...this adjustment Install the swivel stub shafts and secure with the flat washers and spring clip retainers 5 Remove the lever aligning tool 6 With the transmission hand shift lever in the third or fourth speed detent position adjust the lever stop screw front and rear to provide from 020 to 040 inch clearance between the lever and the stops When this adjustment has been made tighten the ad justing ...

Page 349: ...ve by hand 4 Disconnect the left hand exhaust pipe dual ex haust from the exhaust manifold 5 Disconnect the parking brake control cable 6 Disconnect the back up light switch leads at the connector If so equipped 7 Install the engine support fixture C 3487 en gaging the hooks in the holes in the frame side mem bers Be sure the support ends are up against the un derside of the oil pan flange 8 Raise...

Page 350: ...TRANSMISSION 4 SPEED MANUAL 21 17 Fig 30 Transmission Assembly Disassembled MyMopar com ...

Page 351: ...ver 81 Lockwasher Lever 82 Flatwasher Lever 83 3rd a n d 4th Operating Lever 84 Detent Ball 85 Detent Ball Pin 86 Detent Ball Sleeve 87 Detent Ball Spring 88 Detent Ball 89 O i l S e a l 2 90 3rd a n d 4th Lever 91 1st a n d 2nd Lever 92 3rd and 4th Speed Fork 93 1st and 2nd Speed Fork 94 Drain Plug 95 Gasket Shift Control Housing Legend for Figure 3 0 1 Disconnect the gearshift control rods from ...

Page 352: ... using a soft hammer tap on the extension housing in a rearward direction Slide the housing and mainshaft assembly out and away from the case Fig 32 3 Refer to Fig 33 for location of the various gears synchronizer sleeves and clutches before dis assembling the mainshaft 3 R D A N D 4 T H S P E E D S Y N C H R O N I Z E R C L U T C H G E A R Fig 34 Disassembling Mainshaft 4 Using a pair of snap rin...

Page 353: ...ld not exceed 0045 to 028 If measurement is greater than that specified new thrust washers must be installed at reassembly S N A P R I N G L I E R S S T O P R I N G 1ST S P E E D G E A R 2 N D S P E E D G E A R R E T A I N I N G R I N G C L U T C H 1 S T A N D 2 N D C L U T C H S L E E V E G E A R 64x747A J B E A R I N G S N A P R I N G G R O O V E S N A P R I N G G R O O V E S N A P R I N G G R O...

Page 354: ...outer snap ring using a plastic hammer drive the main drive pinion into the case and remove 4 Using snap ring pliers remove the main drive pinion bearing inner snap ring Using an arbor press remove the bearing from the main drive pinion 5 Remove the snap ring and 16 bearing rollers from the cavity in the drive pinion 6 Remove the countershaft gear cluster from the bottom of the case Fig 44 7 Remov...

Page 355: ... contact surfaces show signs of gall ing or excessively worn a new mainshaft should be installed Inspect the snap ring grooves for burred edges If rough or burred remove the condition using a fine file or crocus cloth Inspect the synchronizer clutch gear teeth on the shaft for burrs ASSEMBLY Countershaft Gear and Drive Pinion 1 Using heavy grease coat the inside of the bore of the gear at each end...

Page 356: ...ainshaft synchronizer cone toward the rear and down into position against the shoulder on the shaft Fig 38 2 Slide the first and second clutch sleeve gear as sembly including 2nd gear stop ring over the main shaft with the shift fork slot toward the front and down into position against the second speed gear Be sure the stop ring is indexed with the shift plates Install a new snap ring to secure Fi...

Page 357: ...ubricate the end of the pinion shaft the clutch disc splines or the clutch release levers 1 Remove transmission from the repair stand Shift the transmission into reverse then slide the as sembly under the vehicle 2 With the shift lever side downward and using a suitable jack raise the transmission until the drive pinion shaft is centered in the clutch housing bore 3 Roll the transmission slowly fo...

Page 358: ...hed to the lower side of the valve body assembly Engine torque is transmitted to the torque convert er then through the input shaft to the multiple disc clutches in the transmission The power flow depends on the application of the clutches and bands Refer to Clutch Engagement and Band Application Chart The TorqueFlite Transmission servicing proced ures are in general the same for all Chrysler and ...

Page 359: ... the accumulator for sticking broken rings or spring Repair as required g Remove the valve body assembly and perform air pressure tests Repair as required h Perform the hydraulic pressure tests Adjust or repair as required i Disassemble and inspect clutch Repair or re place as required j Inspect and replace seal rings as required also inspect respective bores for wear Replace the parts as required...

Page 360: ...eplace the seal rings as required also inspect the respective bores for wear Re place parts as required a Adjust the throttle linkage b Adjust the control cable c Adjust the kickdown band d Perform the hydraulic pressure tests and adjust to specifications e Remove and clean the governor Replace parts if necessary f Perform pressure tests to determine cause and correct as required g Inspect the acc...

Page 361: ...red j Disassemble the transmission and repair the overrunning clutch as required k Inspect and replace the seal rings as required also inspect the respective bores for wear Re place parts as required a Refill to correct level with Automatic Transmis sion Fluid Type A Suffix A b Inspect for air leakage into front pump suction passages c Adjust the control cable d Perform the hydraulic pressure test...

Page 362: ...umulator for sticking 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 re place as required f Disassemble the transmission and repair over running clutch as required g Inspect and replace the seal rings J required also inspect the respective bores for wear Re place parts as required a...

Page 363: ...rfaces porous casting and or excessive rotor clearance Replace the parts as required c Remove and recondition the valve body as sembly d Inspect and repair the clutch as required a Drain the fluid to the correct level b Inspect and clean breather vent opening in front pump housing c Replace the oil filter d Inspect for air leakage into front pump suction passages a Refill to the correct level with...

Page 364: ...fig I TorqueFlite Transmission and Torque Converter Chrysler to i MyMopar com ...

Page 365: ...CO O N E P I E C E A L U M I N U M C A S E E N G I N E C R A N K S H A F T N K 1 4 9 Fjg 2 TorqueFlite Transmission and Torque Converter Imperial MyMopar com ...

Page 366: ...sist of a regu lator valve which controls line pressure at a value dependent on throttle opening The torque converter control valve maintains torque converter operating pressure and transmission lubricating pressure The governor valve transmits regulated pressure to the transmission in conjunction with throttle pres sure to control upshift and downshift speeds The throttle valve transmits regulate...

Page 367: ...ift con trol and the transmission manual control valve and the parking lock is obtained through two cables en closed in weatherproof housings The parking lock is applied by moving the selector lever past a gate to the P position CAUTION Never apply the parking lock until the vehicle has stopped otherwise a severe ratcheting noise will occur OPERATING INSTRUCTIONS The transmission will automaticall...

Page 368: ... TORQUEFLITE TRANSMISSION TORQUE CONVERTER 21 35 T O LUB CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING 62x230C OIL FILTER Neutral Hydraulic Circuits MyMopar com ...

Page 369: ...B T C C C O N T R O L V A rrrj C O O L E R fe 1 A C C U M U L A T O R o o o o o o o_o_oq v __r THROTTLE V A f 5 6 5 o o C O O P K I C K D O W N V A _ k M A N U A L V A o 9 o 9 T fo o o o o r TO LUB FRONT PUMP Do o o i o o o r o o o o o ol_ REAR PUMP OIL PRESSURES LINE 75 psi PUMP SUCTION THROTTLE 40 psi GOVERNOR 0 75 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi CONTROL SYSTEM IN BREAKAWAY HALF THR...

Page 370: ...N T C L U T C H j V p L U B K U3L C C O N T R O L V A J COOLER a H H H H 0 0 r j L A C C U M U L A T O R o o o o o o THROTTLE V A L J o o o o o o K I C K D O W N V A M A N U A L V A o o o o o c TO LUB f1 G O V V A E E OIL PRESSURES LINE 75 psi PUMP SUCTION THROTTLE 40 psi GOVERNOR 6 75 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi REAR PUMP CONTROL SYSTEM IN D R I V E S E C O N D HALF THROTTLE 62x2...

Page 371: ...21 38 TORQUEFLITE TRANSMISSION TORQUE CONVERTER Drive Direct Hydraulic Circuits MyMopar com ...

Page 372: ... O N T C L U T C H J N Y L U B T C CONTROL VA 4 C O O L E R fe f re L hri ACCUMULATOR i I i M A N U A L V A TO LUB YT1 HROTTLE V A Y KICKDOWN V A I I J k j j k S T I OIL PRESSURES LINE 90 psi PUMP SUCTION THROTTLE 9 0 psi GOVERNOR 60 65 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi CONTROL SYSTEM IN REAR DRIVE fKICKDOWN P U M P AT 50 M P H 6 2 x 2 3 4 C OIL FILTER Drive Kickdown Hydraulic Circuits ...

Page 373: ...N T C L U T C H L U B COOLER j DO O O O 10 ACCUMULATOR THROTTLE V A II f KICKDOWN V A b o o o o o o B 5 6 d 1 T r u L L J L J L r JL MANUAL V A TO LUB G O V V A FRONT PUMP j O O O o o o o o o r o o l OIL PRESSURES LINE 5 5 psi PUMP SUCTION GOVERNOR 6 55 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi CONTROL SYSTEM IN REAR MANUAL SECOND PUMP CLOSED THROTTLE 62x235C OIL FILTER Selector Lever Second Hy...

Page 374: ...FT V A iL v 1 izn__r p o o o o o 6 o o o o o SHUTTLE V A C O O L E R p X o o L 31 A C C U M U L A T O R THROTTLE V A 1 k p o o o o o o o o o o K I C K D O W N V A T O LUB OIL PRESSURES LINE 55 psi PUMP SUCTION GOVERNOR 0 3 0 psi CONVERTER 30 75 psi LUBRICATION 5 30 psi CONTROL SYSTEM IN MANUAL LOW CLOSED T H R O T T L E 6 2 x 2 3 6 C OIL FILTER Selector Lever Low Hydraulic Circuits MyMopar com ...

Page 375: ... lo o o o o 1 2 SHIFT V A trd L J i_n_r 0 o o o o A i n T SHUTTLE V A I T C CONTROL V A J COOLER j y 1 w 31 ACCUMULATOR THROTTLE VA V 4 b o cTo O O P o o o o o o KICKDOWN V A 1 I TO LUB OIL PRESSURES LINE 2 3 0 2 6 0 psi PUMP SUCTION CONVERTER 3 0 7 5 psi LUBRICATION 5 30 psi CONTROL SYSTEM I N REYEftSE 6 2 x 2 3 7 C OIL FILTER Reverse Hydraulic Circuits MyMopar com ...

Page 376: ...e use of Heli Coils Essentially this repair consists of drilling out the worn or damaged threads tapping the hole with a special Heli Coil Tap and installing a Heli Coil Insert into the tapped hole This brings the hole back to its original thread size The following chart lists the threaded hole sizes which are used in the aluminum case and valve body and the necessary tools and inserts for the rep...

Page 377: ... ONE PINT mark Fig 4 CAUTION To prevent dirt from entering the trans mission make certain that the dip stick cap is fully seated onto the filler tube Periodic Adjustments The following adjustments should be performed at 32 000 mile intervals or more frequent under se vere operating conditions 1 Adjust the kickdown band Refer to Page 52 2 Adjust the gearshift control cable Refer to Page 50 3 Adjust...

Page 378: ...ing shaft Fig 5 2 Tap the steering shaft downward through the upper column bearing then remove the shaft and lower bearing from the column 3 Remove the back up lamp switch Fig 6 Loos en the locking nut on the operating lever then slide the lever out of the groove on the gearshift tube 4 Remove plate and seal washer from the sprag lever pivot at lower end of the column Fig 7 Re move the cable lock ...

Page 379: ...urn signal switch retainer from the bearing housing and lift the switch upward out of the way Fig 12 Remove four screws from inside the bearing housing to separate it from the shift lever gate Slide the gate out of the column jacket If neces sary tap the column bearing out of the bearing hous ing N K 3 0 5 H O U S I N G S U P P O R T E D B E A R I N G H O U S I N G Fig 9 Removing or Installing Gea...

Page 380: ...ube assembly into the column making sure the spring will easily push the tube outward when hand pressure is released 7 Refer to Figure 10 and install the detent plate with screws finger tight Install the detent pawl and sprag lever Do not install the pawl spring Install nylon washer and sprag lever pivot Press the pivot inward by hand against spring tension far enough to start the three screws thr...

Page 381: ...flexible coupling either up or down to align the clamp bolt or roll pin hole then install the bolt or roll pin Position the steering column assembly so that the flexible coupling disc assumes an unstressed position and the column is properly aligned with the instru ment panel bracket then tighten the clamp bolts se curely 5 Chrysler Models Connect the gearshift indica tor link slotted end to the o...

Page 382: ...her electrical connections then lift off the console assembly 5 Disconnect the two cable and housings from the unit Disconnect the back up lamp switch wires Fig 17 6 Attach a piece of soft wire about four feet long L E V E R B R A C K E T N K 2 5 8 M O U N T I N G L E G S 4 B A C K U P L A M P S W I T C H D E T E N T A S S E M B L Y G E A R S H I F T C O N T R O L C A B L E N K 1 4 7 Fig 17 Consol...

Page 383: ... Pull the cable outward just enough to allow the fluid to drain into a container 3 Pull the cable out of the transmission case as far as possible back off the adjusting wheel a few turns if necessary 4 Insert a small screw driver above and slightly to the right of the cable Fig 19 Disengage the ca ble adapter lock spring by pushing the screw driver handle to the right while pulling outward on the ...

Page 384: ...e to roll slowly on a slight incline The parking sprag should fully engage the parking gear with the lever in PARK position and there should be no ratcheting noise with the lever in the NEUTRAL position NEUTRAL STARTING SWITCH Adjustment and Test The neutral starting switch Fig 22 should operate in both the PARK and NEUTRAL selector lever posi tions 1 To test the switch disconnect the wire from th...

Page 385: ...in this position and tighten the lock nut to 29 foot pounds torque Low and Reverse Band 1 Raise the vehicle drain the transmission fluid and remove the oil pan 2 Loosen the adjusting screw lock nut and back off the nut approximately five turns Fig 23 Inspect the adjusting screw for free turning in the lever 3 Using wrench Tool C 3380 with adapter C 3705 tighten the band adjusting screw to 47 to 50...

Page 386: ...n Eng 1 Apply a thin film of multi purpose grease on both ends of the accelerator shaft 1 where it turns in the bracket and nylon roller 2 where it contacts the pedal 2 Disconnect choke 3 at carburetor or block choke valve in full open position Open throttle slightly to release fast idle cam then return carburet or to curb idle 3 Loosen the cable clamp nut 4 then adjust the position of the cable h...

Page 387: ...front servo release pressure must not be more than 3 psi below line pressure 4 Disconnect the throttle linkage from the trans mission throttle lever and move the throttle lever gradually to full throttle position Line pressure must rise to a maximum of 90 96 psi just before or at kickdown into low gear Front servo release pressure must follow line pressure up to the kickdown point and should not b...

Page 388: ... the Governor Pressure Chart 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 sus pected if the part throttle shift speeds are either very delayed or occur too early in relation to vehicle speeds In which case the ...

Page 389: ...pletely bottomed inside the valve body 5 As force is being exerted to compress the spring tighten the throttle lever stop screw finger KICKDOWN VALVE LINE PRESSURE TO ACCUMULATOR THROTTLE LEVER LOCK NUT P rrz STOP S C R E W N K 155 F g 30 Throttle Pressure Adjustment 6 2 X 8 FRONT SERVO APPLY FRONT SERVO RELEASE i f w i FRONT PUMP SUCTION FRONT PUMP PRESSURE I I FRONT CLUTCH I JP v APPLY i REAR CL...

Page 390: ...and slide the pinion assembly off the cable Install a new seal on the cable housing 3 If transmission fluid is found in the cable hous J V C L I P v N Y 1 8 6 Fig 32 Removing or Installing Speedometer Pinion P I N I O N I N N E R S E A L O U T E R C A B L E C L I P R E T A I N E R B O L T 6 1 X 3 5 9 Fig 33 Speedometer Pinion Disassembled ing replace the seal inside the pinion bore Fig 33 Pry the ...

Page 391: ...mission output shaft yoke In stall washer with its three projections toward the yoke and the nut with its convoluted surface con tacting the washer Hold the yoke with Tool C 3281 V T O O L 62x178 and tighten the nut to 175 foot pounds torque 6 Connect the propeller shaft to the transmission yoke EXTENSION HOUSING AND BEARING Removal Chrysler Models To remove the extension housing it will be neces ...

Page 392: ...on the bottom rear end of the extension housing Spread the large snap ring and remove the bearing from the housing Remove the bearing front snap ring from the output shaft 5 Install a snap ring in the innermost groove on the output shaft Install a new bearing on the shaft with its outer race ring groove toward the front Fig 39 Press or tap the bearing tight against the front snap ring then install...

Page 393: ...om the exten sion housing Drive the bearing rearward out of the housing with Tool C 3275 Fig 40 3 Place a new bearing in the opening of the ex tension housing Using Tool C 3204 drive the bearing into the housing Fig 41 Install the bearing retain ing snap ring 4 Place a new seal in the opening of the exten sion housing lip of seal facing inward Using Tool C 3837 drive the seal into housing until th...

Page 394: ... and governor assembly on output shaft Align the assembly so the governor valve shaft hole in the governor body aligns with the hole in the output shaft then slide the assembly into place Install snap ring behind the governor body Fig 42 Tighten body to support bolts to 100 inch pounds torque Bend ends of lock straps over the bolt heads 3 Assemble the governor weights and spring and secure with sn...

Page 395: ...parking lock cable PARKING LOCK COMPONENTS Removal 1 Remove the extension housing See Page 58 or 60 2 To replace the governor support refer to Page 61 3 Remove the parking lock cable adapter cover from the bottom of the extension housing 4 Remove the plug from the extension housing slide out the shaft to remove the parking lock lever 6 4 x 1 8 A Fig 45 Aligning Rear Oil Pump Cover Fig 46 Removing ...

Page 396: ...Place the selector lever in the PARK position 3 Remove the cover plate from in front of the converter assembly to provide access to the converter drain plug and mounting bolts Installation 1 Clean mating surfaces and inspect for burrs on both the transmission case and the valve body steel plate 2 Install the accumulator piston in the transmis sion case 3 Position the accumulator spring on the valv...

Page 397: ...slightly 19 Remove the crossmember attaching bolts and remove the crossmember 20 Place a transmission service jack under the transmission to support the assembly 21 Attach a small C clamp to the edge of the converter housing to hold the converter in place dur ing the removal of the transmission 22 Remove the converter housing retaining bolts Carefully work the transmission rearward off the en gine...

Page 398: ...eter welding rod and a weld ing current of 80 to 125 amps d Direct the arc at the intersection of the gear and front cover from an angle of 45 degrees from the rear face of the gear 4 Inspect the gear teeth and remove all nicks where metal is raised weld metal splatter etc in order to ensure quiet starter operation FLUSHING THE TORQUE CONVERTER In the event that any part has failed in the trans mi...

Page 399: ...asure the drive train end play The Imperial transmission U joint yoke must be installed when measuring the drive train end play This will usu ally indicate when a change in the thrust washer be tween the reaction shaft support and front clutch re tainer is required to properly adjust end play during assembly except when major parts are replaced 1 Attach a dial indicator to the transmission bell ho...

Page 400: ...al stop ring off the shaft 4 Remove the output shaft bearing rear snap ring Wipe the output shaft splines clean and dry then wrap the splines with 3 or 4 layers of masking tape to protect the extension housing bushing during output shaft bearing removal 5 Temporarily reinstall the extension housing to provide a means of removing the output shaft bear ing Spread the large snap ring in the housing a...

Page 401: ...d out of the case 2 Slide the front clutch assembly out of the case Input Shaft and Rear Clutch 1 Grasp the input shaft and slide the input shaft and rear clutch assembly out of the case T R A N S M I S S I O N V E N T Fig 56 Removing Front Oil Pump and Reaction Shaft Support Assembly Fig 57 Compressing Kickdown Servo Spring CAUTION Be careful not to lose the thrust washer located between the rear...

Page 402: ...for replace ment for most all bushings in the TorqueFlite trans mission The two bushings in the sun gear are not serviced because of the low cost of the sun gear as sembly If the bushings are found worn or scored they should be replaced as outlined in the following reconditioning procedures The bushing replacement tools listed by SP num bers are part of Tool Kit C 3887 The use of crocus cloth is p...

Page 403: ...E E L B A L L S LR W R F R O N T P U M P C H E C K V A L V E Fig 6 0 F r o n f Pump Check Valve and Steel Ball Locations T H R O T T L E L E V E R V S T O P S C R E W M A N U A L V A L V E D E T E N T E C L I P S H U T T L E V A L V E C O V E R P L A T E G O V E R N O R P L U G E N D P L A T E N K 1 6 6 Fig 61 Valve Body Controls Assembled View shaft Fig 61 Remove any burrs from the shaft then whi...

Page 404: ...ings for distortion and col lapsed coils Inspect all valves and plugs for burrs nicks and scores Small nicks and scores may be re moved with crocus cloth providing extreme care is taken not to round off sharp edges The sharpness of these edges is vitally important because it prevents foreign matter from lodging between the valve and the valve body thus reducing the possibility of stick ing Inspect...

Page 405: ... the retaining E clip on the throttle shaft Fig 61 11 Position the valve body assembly on the repair stand 12 Place the six steel balls in the valve body chambers with the large ball in the large chamber Fig 60 Place the front pump check valve and spring in the valve body 13 Position the transfer plate assembly on the valve body Install the 14 retaining screws starting at the center and working ou...

Page 406: ...ges or other damage Replace as re quired Assembly 1 Position the parking sprag and spring in the housing and insert the bolt and washer gasket Fig 47 Make sure the square lug on the sprag is toward the support gear and the spring is positioned so as to lift the sprag away from the gear 2 Position the lock lever adapter and spacer in the housing and install the lever shaft Fig 46 The lever roller m...

Page 407: ...d water or with ice Quickly position the body over the pilot studs and drive it firmly into the case with a wood block and hammer Remove the pilot studs FRONT OIL PUMP AND REACTION SHAFT SUPPORT Disassembly Figure 66 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 oi...

Page 408: ...ed knife or similar tool re move the high points or burrs around the staked area Fig 68 Do not use a file or similar tool that will re move more metal than is necessary 9 Thoroughly clean the pump housing before in stallation T O O L HANDLE SP 3549 FRONT PUMP HOUSING REMOVAL TOOL HANDLE SP 3549 I N S T A L L A T I O N 6 2 X 3 4 7 Fig 6 7 R e p l a c i n g Front Pump Bushing Fig 68 Staking Front Pu...

Page 409: ... tighten to 150 inch pounds torque 3 Place a new oil seal in the opening of the front oil pump housing lip of seal facing inward using Tool C 3860 drive the seal into housing until the tool bottoms FRONT CLUTCH Disassembly Figure 70 shows a disassembled view of the front clutch assembly 1 Using a screw driver remove the large snap ring that secures the pressure plate in the clutch piston retainer ...

Page 410: ...all the handle Tool SP 3549 in the removing head Fig 72 B U S H I N G mkmmMmmdm 62x350 Fig 7 2 R e p l a c i n g Front Clutch Retainer Bushing Fig 73 Front Clutch Piston Return Springs Location 2 Drive the bushing straight down and out of the clutch retainer bore Be careful not to cock the tool in the bore 3 Lay the clutch retainer open end up on a clean smooth surface Slide a new bushing on the i...

Page 411: ...t 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 discs Re place discs that are charred glazed or heavily...

Page 412: ...f 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 3636 and start them in the bore of the input shaft 8 Stand the input shaft upright on a clean smooth surface and install handle Tool SP 3549 in the install ing head Fig 76 Drive the bushing into the shaft 62X351 Fig 76 Replacing input Shaft Bushing until the...

Page 413: ...easuring End Play of Planetary Gear Assembly Sun Gear and Driving Shell NOTE Rear clutch plate clearance is very impor tant in obtaining proper clutch operation The clearance can be adjusted by the use of various thickness outer snap rings Snap rings are available in 060 062 074 076 and 088 090 inch thickness PLANETARY GEAR ASSEMBLIES SUN GEAR AND DRIVING SHELL Measure the end play of the planetar...

Page 414: ...hrust faces of the planetary gear carriers for wear scores or other damage replace as required Inspect the planetary gear carrier for cracks and pinions for broken or worn gear teeth and for broken pinion shaft lock pins Inspect the annulus gear and driving gear teeth for damage Replace dis torted lock rings Assembly Refer to Figure 80 for parts reference 1 Position the rear planetary gear assembl...

Page 415: ...e piston bore in the case for scores or other damage Inspect the fit of the guide on the piston rod and the piston spring for distortion Inspect the band lining for wear and bond of lin TOOL S E T S C R E W SEAL RING s p R N G 1 PISTON ROD SEAL RINGS 2 SNAP RING PISTON ROD GUIDE SPRING P I S T O N 62 x 168 F g 8 3 K i c k d o w n Servo Disassembled ing to the band and the lining for black burn mar...

Page 416: ...sure the long link and anchor assembly is installed as shown in Figure 85 to provide a running clearance for the low and reverse drum Install the low reverse drum Kickdown Servo 1 Carefully push the servo piston into the case bore Install the piston rod the two springs and the guide Fig 83 2 Compress the kickdown servo springs by using eninge valve spring compressor Tool C 3422 then in stall the s...

Page 417: ...ing shell Front Band Figure 87 shows a disassembled view of the kick down band assembly 1 Slide the band over the front clutch assembly 2 Install the band strut screw in the adjuster just enough to hold the strut and anchor in place F g 88 Installing Front Pump and Reaction Shaft Support Assembly Front Oil Pump and Reaction Shaft Support If difficulty was encountered in removing the front oil pump...

Page 418: ...sary Extension Housing Imperial Models 1 Using a new gasket carefully slide the exten sion housing into place Install the retaining bolts and washers tighten bolts to 24 foot pounds torque 2 Install the transmission flange install washer with its three projections toward the flange and the nut with its convoluted surface contacting the wash er Hold flange with Tool C 3281 and tighten the nut to 17...

Page 419: ...ng the crank shaft opening 7 After the transmission is in position install the converter housing bolts and tighten 25 to 30 foot pounds torque 8 Install and tighten the two lower drive plate to converter bolts and tighten to 270 inch pounds torque 9 Install the starting motor and connect the bat tery ground cable 10 Rotate the engine with the Remote Control Switch and install the other two drive p...

Page 420: ...eft side of the transmission 17 Place the selector lever in the park position Insert the control cable in the transmission case push inward on the cable making sure the lock spring engages the cable Install the control cable adjusting wheel lock screw 18 Connect the wire to the neutral starting switch 19 Install the cover plate in front of the convert er assembly 20 Refill the transmission with Au...

Page 421: ...H E E L S B E A R I N G S TIRES SIDE WEAR a Outside all wheels excessive cornering speed b Outside front excessive positive camber c Inside front excessive negative camber d Outside and inside under inflation or vehicle over load a Driver instructions b Adjust camber to specifications c Adjust camber to specifications d Inflate tires to specified pressure and check vehicle for overload CENTER RIBS...

Page 422: ...al runout wobble B should not exceed 050 inch NOTE Under no circumstances should point indi cated by C be used for measuring runout as this metal has been sheared in the manufacturing proc ess and is not an even surface F g 2 Runout Checking Area WHEEL BALANCE The need for balancing the wheels is indicated by heavy vibration of the steering wheel of the car when driving at speeds above 40 miles an...

Page 423: ...tion and grease travel out of the bearings Do Not Overfill 6 2 x 4 1 A Fig 3 Wheel Hub Grease Cavity 3 Force lubricant between bearing cone rollers or repack with a suitable Bearing Packer 4 Install the inner cone and a new seal with lip of seal facing inward Using Tool C 3893 drive the seal flush with the end of the hub The sealflangemay be damaged if the tool is not used 5 Clean the spindle and ...

Page 424: ... should be rotated at the recommended intervals and in the recommended se quence Fig 6 LEFT FRONT RIGHT FRONT Fig 6 Tire Rotation Repairing Leaks Leaks between the tire and wheel require the re moval of the tire Leaks in the tire can often be re paired without removing the tire Always follow the equipment manufacturers recommendations Any tools used for dismounting and mounting tires must be smoot...

Page 425: ...WHEELS BEARINGS A N D TIRES 22 5 Fig J J Spoffy Wear MyMopar com ...

Page 426: ...cements are used in the doors to keep them correctly aligned and to maintain proper door adjustment The radiator yoke fender side shields and cowl panels are attached to the body to add structural strength to the fore structure and the body assembly An integral fore structure assembly extending for ward of the front passenger compartment is bolted to the Unibody Condition SERVICE DIAGNOSIS MANUAL ...

Page 427: ...ES NOT RELEASE THE LOCK a Lock adjustment set too high b Outside handle to lock link disconnected c Ineffective release lever spring or damaged transmitter or detent actuator a Adjust lock b Be sure flattened end of link is not too wide spreading the clip File edge of the flat so that the clip fits freely Install link c Install a new lock INSIDE HANDLE DOES a Remote control assembly improperly adj...

Page 428: ...a Folding top header torsion bar not properly a Adjust folding top header torsion bar to ac AT WINDSHIELD HEADER adjusted complish a 30 pound locking handle effort PART 1 MAINTENANCE AND CARE SERVICE PROCEDURES CLEANING CONVERTIBLE TOP AND BACKLIGHT Frequent brushing and vacuuming will keep the top free of abrasive dust and dirt When washing the convertible top material should be thoroughly wet Fo...

Page 429: ... to loosen it Then clean with fabric cleaner as recommended Mud or Clay Allow the mud or clay to dry com pletely Then brush it off with a soft bristled brush Clean with a one half of 1 solution of detergent in water When cleaning by any of the outlined methods never squeeze the liquid from the cleaning cloth back into the container of cleaning fluid and never dip the cleaning cloth back into the c...

Page 430: ...brication and Maintenance Group for the type of lubricant to be used and the lubrication points PART 2 B U M P E R S G R I L L E F E N D E R S EXTERIOR M O U L D I N G S BUMPERS Front Bumper Removal Chrysler 1 Support the bumper at the center section and remove the bolts attaching the bumper supports and braces to the frame Fig 1 2 Remove the bumper assembly 3 Remove the support brackets braces an...

Page 431: ...ame 3 Connect the parking lamp wires 4 Carefully position the bumper assembly on the inner and outer supports and install the mounting bolts Do not tighten the mounting bolts and nuts un F g 4 Front Bumper Imperial V I E W C N K 1 0 0 0 Fig 5 R e a r Bumper Imperial til the bumper is correctly aligned Tighten the bolts securely 5 Remove the hydraulic jack Rear Bumper Removal Imperial 1 Support the...

Page 432: ... bolts 3 Install the nuts on the grille outer sections re taining studs under the front fenders 4 Install the grille to the center support bracket screws Removal Chrysler Refer to Figures 7 and 8 for the grille attaching points 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 grille assembly Installation Chrysl...

Page 433: ...sual difficulties except that the cowl to fender bracket studs and nuts should be re moved to facilitate the removal of the fender assem bly Removal 1 Raise the hood 2 Tape the leading edge of the front doors and cowl to fender area to avoid damage to the finish 3 Remove the fender to splash shield radiator yoke grille bar outer wheel housing Chrysler Mod Fig 7 0 F e n d e r Wheelhouse Chrysler el...

Page 434: ...BUMPERS GRILLE FENDERS 23 9 Fig 11 Exterior Mouldings Chrysler MyMopar com ...

Page 435: ...23 10 BUMPERS GRILLE FENDERS MyMopar com ...

Page 436: ...BUMPERS GRII IE FENDERS 23 11 MyMopar com ...

Page 437: ... E R S R E F E R E N C E B J y F R O N T D O O R R E F E R E N C E D y Q U A R T E R P A N E L R E F E R E N C E F S I L L R E F E R E N C E C R E A R D O O R R E F E R E N C E E Fig 12 Exterior Mouldings Imperial N K 1 0 2 3 F E N D E R F R O N T M O U L D I N G W A S H E R N K 1 0 2 7 MyMopar com ...

Page 438: ...th the plastic straps 4 When all attaching screws have been installed tighten them progressively to their specified torque readings 5 Install the radiator core radiator hoses and fill the radiator EXTERIOR MOULDINGS Exterior mouldings are held in place by spring type R E T A I N E R R E T A I N E R clips T bolts brackets and by plastic retainers The plastic type retainer has expanding legs that ex...

Page 439: ...nd bump into place with the heel of the hand 7 Install the trim panel to door panel screws 8 Install the escutcheon washer handles and arm rest Quarter Window Trim Panel To remove the quarter window trim panel Fig 13 it is first necessary to remove the rear seat cushion and back The quarter window trim panels are re tained with screws and clips When installing the trim panel make certain the water...

Page 440: ...g Each bow is held in place by an attaching loop pressed into each roof rail Fig 17 and spring into F R O N T D O O R Q U A R T E R W I N D O W T A P E T A P E N K 8 4 6 Fig 16 Poor and Quarter Panel Watershields Chrysler INTERIOR TRIM AND SEATS 23 15 6 4 x 4 4 2 A Fig 17 Headlining Bows place when installed to keep the headliner taut 1 Remove the rear seat cushion dome light as sembly sun visors ...

Page 441: ...ends to prevent wrin kling at the seams when it is tucked or cemented in place Cut the listing from the end up to the clip Use care to prevent cutting the listing too far up the bow and ruining the fit of the headlining 12 After the listings are cut start at the front and trim the headlinings so that only V f c to 1 inch of material hangs down below the rear window opening 13 Use a dull putty knif...

Page 442: ...ning from the small spring type clips at the outer edges Fig 23 Instrument Panel Trim Pad Chrysler Fig 24 Instrument Panel Trim Pads Imperial 6 Before installing the headlining section inspect the edges of the section to be sure they are not dam aged then position the plastic headlining onto the small retainer clips on each side of the car 7 Push the headlining up at the center and prop erly cente...

Page 443: ...de the console over the shift lever and con nect the backup lights tachometer and body wires to their respective connectors 2 Lift the sides of the carpets on the console to expose the slots in the console Fig 25 and position the console on the mounting screws 3 Tighten the screws securely and install the two screws and washers attaching the console to the floor brackets Console Carpet Replacement...

Page 444: ... engages into a slotted bracket welded to the floor pan The rear seat back is held in place by two tangs of the upper edge of the seat frame being inserted into slots in the package shelf The lower edge of the seat back is held in place by two metal strips of the floor pan being bent over the lower edge of the seat back frame RECLINING SEAT Seat Spring Tension Adjustment 1 Remove the seat cushion ...

Page 445: ... gear tooth area and the end of the spring retainer that fits into the seat cushion stanchion 2 Start the spring retainer into the seat back gear and position the springs on the retainer 3 Tap the retainer fully into position Fig 33 4 Position the cover over the mechanism and in stall the retaining screw 5 Lubricate sparingly the inner surfaces of the handle around the holes and the inner surface ...

Page 446: ... second seat back to the hinge assemblies Fig 35 2 Release the catches from the seat back and re move the seat back assembly Installation Second Seat Back 1 Position the second seat back on the hinge as semblies 2 Install the hinge to seat back screws and tighten to 80 120 inch pounds 3 Test the engagement of the seat back catches on the seat back and adjust as necessary Removcrf Second Seat Cushi...

Page 447: ... With the original seat cushion cover removed Fig 38 Seat Cushion Build Up Bench Type position the cushion right side up on a clean working surface 2 Inspect the spring pad and pad cover for dam age and also make certain the pad and pad cover Fig 38 are centered on the spring assembly 3 Insert the listing wires Fig 38 into the new cushion cover 4 Center the new cover on the cushion assembly and dr...

Page 448: ...er housing on the glove box lower half and install the attaching screws 5 Set the glove box upper half in position on the lower half and install the attaching screws 6 Install the tissue container retainer 7 Position the map drawer in the housing and Fig 41 Glove Box Door Imperial Fig 42 Glove Box Installation Imperial push into place 8 Install the glove box drawer and connect the vacuum lines to ...

Page 449: ...irst Hood to Cowl 1 Inspect alignment at the cowl for tightness looseness uneven gap and high or low elevation at the corners 2 Scribe the hinge position on the hood 3 Loosen the hood attaching bolts Fig 44 or 45 and move the hood to the desired position to correct alignment at the cowl 4 Tighten the attaching bolts 180 inch pounds 5 After Step 4 if the rear of the hood and fender are not flush it...

Page 450: ...od just opposite the 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 Hood Removal 1 Place a protective covering over the cowl and fender area 2 Mark the outline of the hinges on the hood to aid in installation 3 With an ...

Page 451: ...od alignment and adjust as neces sary Tighten the hood to hinge screws Fig 49 Hood Lock Application Chrysler Hood Hinge Replacement Imperial 1 Prop the hood open to relieve the tension on the hinge springs and scribe the hinge location on the hood 2 Loosen the bolts attaching the hood to the hinge plate Fig 44 3 Remove the hinge to cowl attaching bolts 4 Remove the hinge to fender shield bolt and ...

Page 452: ... properly adjusted and one fender is still below the level of the hood at the front the fender should be raised 1 Raise the hood then loosen the screws attach ing the fender to the radiator support 2 Place a wood block or cloth pad on the lifting pad of a service jack and install under the front lower corner of the fender 3 Raise the jack slowly until the fender is in alignment Leave the jack in p...

Page 453: ...lower hinge to pillar attaching bolts 6 Raise or lower the jack until the lower part of the door is in the desired position Lowering the jack Fig 52 Door Lock Rofor and Striker Fig 53 Rear Door Hinge Attachment Chrysler moves the door into the door opening 7 Tighten the attaching bolts 8 Close the door and observe the alignment of the door panel with the body sill fender cowl and B post 9 Adjust t...

Page 454: ... door interior trim and hardware CAUTION Prior to this installation on electric window lifts install the wiring in the doors and at tach to the motor and control switch 5 Connect the battery ground cable Rear Door Removal All Models 1 Open the rear door and place a padded jack un der the door near the hinges 2 Remove the door interior trim and hardware 3 Scribe aligning marks around the hinge plat...

Page 455: ...through the upper access hole of the inner door pan el 3 Lift the handle up and remove from the door 4 Install the outside handle into the door open ing Engage the link from the handle to the lock 5 Attach the retaining nuts and test the opera tion of the handle 6 Reinstall the watershield escutheon spring trim panel inside handles and arm rest Door Lock Replacement Fig 56 1 Remove the door trim p...

Page 456: ...pan N K 8 7 6 Fig 58 Door lock Cylinder N K 8 7 5 Fig 59 Deck Lid Hinge and Torsion Bar el escutcheon springs and watershield 2 With the window in the up position and through the upper access hole of door panel disconnect the retaining clip from the connecting rod and lock as sembly 3 Remove the connecting rod from the lock cyl inder and door lock assembly 4 Slide retaining clip out of the lock cy...

Page 457: ...er Replacement The deck lid lock cylinder is retained in the body by a spring steel U shaped clip attached from with in the body Deck Lid Lock Replacement The deck lid lock assembly Fig 60 is attached to the deck lid by two screws Scribe the location of the lock mounting flanges to aid in installation Deck Lid Lock Adjustment Vertical adjustment of the deck lid lock is made at the lock attaching s...

Page 458: ...stment The tailgate inside handle adjustment can be made by removing the plug located near the rotor in the lock facing of the tailgate Loosen the hex bolt in the lock assembly and adjust the ratchet levers to allow the lock rotor to spin freely when the actuator rod is in the open position Tighten the hex bolt after the adjustment has been made This adjustment must be made on both sides of the ta...

Page 459: ...ng assembly 8 Remove the plastic rivet attaching the lift bracket and guide assembly to the glass and remove the assembly Fig 65 Installation 1 Position the lift bracket and gasket on the door glass and install the retaining rivet Fig 65 2 Assemble the door glass to the vent wing as sembly and install the cotter pin at the lower end of the division channel 3 Lubricate the sliding surfaces of the l...

Page 460: ... entire length To raise the front of the glass lower the front of the pivot bracket and to lower the front of the glass raise the front of the pivot bracket 3 On manual operated regulators run the win dow down so the top of glass is even with or slightly below the belt line 4 Position the stop on the regulator plate against the stop on the regulator sector and tighten the nut 5 Operate the window ...

Page 461: ...ont and rear arms before installing Rear Door Glass Run The glass run Fig 72 is a press fit into the door Fig 71 Rear Door Glass Regulator Chrysler Sedan Fig 72 Rear Door Glass Run Chrysler Sedan panel When installing the glass run the index point notch should be installed first to assure correct align ment of the run STATIONARY QUARTER WINDOW Removal Chrysler Four Door Sedan 1 Remove the garnish ...

Page 462: ...rack attachment to al low alignment with the glass 9 Run the glass down so top of the glass is even or slightly below the belt line of the door outer panel F O R E A N D A F T F O R E A N D A F T N K 8 8 6 Fig 74 Front Door Glass Adjustments Chrysler Hard Top Convertible Fig 75 Vent Wing and Door Glass Attachment Chrysler Hard Top Convertible 10 On manually operated windows position the stop on th...

Page 463: ...ysler The service procedures for the front door regulator and vent wing regulator assembly are the same as those for the sedan models Gloss Run Channel Two Door Models Chrysler Removal 1 Remove the inside handles trim panel and wa tershield 2 Loosen the vent attaching screws and adjusting stud nut and move the glass forward out of the glass run channel 3 Remove the run channel reinforcement plate ...

Page 464: ...n 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 wash er 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 operation 10 Turn the upper rear roller track ...

Page 465: ...s down and tip the vent wing to the rear 5 Pull the vent wing frame assembly up and out of the door frame Installation Imperial 1 Insert the vent wing assembly down into the door frame 2 Install the vent wing attaching screws finger tight 3 Install the vent wing lower adjusting screw lock nut and washer 4 Close the door and inspect the vent wing align ment with the A post and the roof rail weather...

Page 466: ... attaching screws and re move the regulator and pivot links through the door opening TRACK ASSEMBLY SCREW AND WASHER NK1069 Fig 85 Door Glass Guide Track Imperial Installation Imperial 1 Install the pivot link and regulator assembly 2 After installing the regulator turn the handle so tne arm is in the raised position 3 Engage the regulator arm studs in the door glass pivot channel Lower the glass ...

Page 467: ...d side of the inside panel 13 Test the window for ease of operation and in spect the alignment 14 Install the watershield trim panel and inside handles Glass Replacement Removal Chrysler 1 Remove the inside handles trim panel and wa tershield 2 Remove the down stop from the glass lower frame Fig 87 3 Remove the spring nuts from the regulator arm studs 4 Support the window assembly and remove the r...

Page 468: ...ttom of the track through the attaching hole in the inside door panel and install the nut and washers finger tight only 5 Install the door glass and adjust as necessary 6 Install the watershield trim panel and inside handles Rear Track Assembly Removal Chrysler 1 Remove the door glass assembly 2 Remove the screw and washer assembly attach T R A C K Fig 90 Rear Door Glass Rear Track Chrysler Hard T...

Page 469: ...p is forward against the front door glass 9 Adjust the door glass up stops 10 Lower the window until the top edge of the Fig 9 2 R e a r Door Glass Replacement Imperial glass is slightly below the belt line of the door out side panel 11 Adjust the lower track until the boss of the track sleeve nut is against the inside panel 12 Adjust the door glass down stops 13 Operate the door window and inspec...

Page 470: ...rial Fig 95 Rear Door Rear Roller Track Imperial Installation Imperial 1 Insert the stabilizer into the door through the large access opening in the door inner panel and in sert the stud on the inner stabilizer into the attach ing hole in the door inner panel Fig 94 2 Install the nut and washers on the stud but do not tighten 3 Position the outer stabilizer to the attaching hole in the outside pan...

Page 471: ... the roof rail Turn the sleeve nut counterclockwise to move the window in and clock wise to move the window out 6 Adjust the pivot bracket so the top of the win dow is fully against and parallel to the roof rail weath erstrip To raise the front of the window lower the front of the pivot bracket 7 Move the upper front track attachment forward so the weatherstrip of the window is against the front d...

Page 472: ...uds are retained in the glass lower frame rollers with spring nuts Fig 99 Lubricate the regulator tooth contact area approximately V2 inch wide along the entire length of the arc on the outboard side of the sector and to the front and rear arm roller window touches lightly on the cats whiskers studs QUARTER WINDOW Front Track Assembly Removal Chrysler 1 Remove the regulator handle trim panel and w...

Page 473: ...support on the inside panel 4 Install the nut and washers attaching the track Fig 101 Quarter Window Rear Track Chrysler Hard Top Fig 102 Quarter Window Adjustments Chrysler Convertible to the belt reinforcement 5 Test the window for alignment and ease of oper ation 6 Install the watershield trim panel and regula tor handle QUARTER WINDOW Convertible Chrysler Adjustments Refer to Figure 102 for th...

Page 474: ...ssem bly 2 Remove the spring nuts from the regulator arm studs Fig 103 and remove the studs from the rollers 3 Remove the rollers from the glass lower frame slots 4 Raise the glass and lower frame assembly out Fig 104 Quarter Window Regulator Chrysler Convertible of the quarter panel 5 Inspect the regulator arm stud rollers and the glass track rollers for damage or excessive wear Installation Chry...

Page 475: ...Window Stabilizer Chrysler Convertible Fig 707 Quarter Window Adjustments Imperial attached to the quarter inner panel at the upper end and to the side sill outer panel and reinforcement at the lower end Fig 106 The adjusting stud at the upper end of the stabilizer allows in and out movement to position the top edge of the glass against the cat whiskers The attachment at the lower end permits in a...

Page 476: ...atershield trim panel regulator Fig 109 Quarter Window Regulator Imperial handle rear seat back and seat cushion Regulator Assembly Removal Imperial 1 Remove the rear seat back cushion regulator handle trim panel and watershield 2 Remove the spring nuts attaching the regulator arm studs in the roller assemblies Fig 109 3 Support the window assembly and remove the regulator arm studs from the rolle...

Page 477: ... 3 Remove the stabilizer assembly through the large access opening in the quarter panel 4 Remove the nut and washers attaching the sup port assembly to the inner stabilizer and remove the support 5 Remove the sleeve nuts from the inner stabiliz er studs Fig 111 Quarter Window Stabilizer Imperial 6 Remove the screw and washer attaching the inner stabilizer to the outer stabilizer Installation Imper...

Page 478: ...tail gate glass assembly from the tail gate 5 Remove the rollers from the glass lower frame 6 Remove the washers spacers and screws attach ing the glass lower frame and weatherstrip to the glass Fig 114 and remove the frame and weather strip Glass Installation 1 Position the outer belt weatherstrip on the lower glass frame 2 Position the tail gate glass on the weatherstrip and lower frame and inst...

Page 479: ...ger tight only 3 Install the upper bracket retaining screw and washer finger tight only 4 Install the tail gate glass assembly and adjust the assembly Fig 116 Tail Gate Glass Run Channel Fig 117 Tail Gate Glass Upper Run Retainer and Seal Upper Run Retainer and Seal Removal 1 Remove the five screws attaching the glass run retainer to the roof rear header and remove the re tainer Fig 117 2 Remove t...

Page 480: ...ng it into the retainer 4 Adjust the pillar glass runs as necessary WINDSHIELD Removal Chrysler 1 Cover the cowl hood and fender areas with a Fig 1 7 9 C o w Grille Panel F g 120 Windshield Seals protective covering 2 Remove the windshield wiper arms and blades 3 Remove the outside windshield mouldings and the inside garnish mouldings 4 Remove the cowl grille panel Fig 119 5 Using a fibre wedge lo...

Page 481: ...arting at one of the lower corners alternately pull the ends of the twine halfway up the sides seating the weatherstrip on the fence 5 Applying constant hand pressure to the glass sides seat the balance of the weatherstrip on the fence 6 Pressurize the weatherstrip to the seal with Fig 121 Windshield Installation Fig 122 Windshield Mouldings Imperial hand pressure to insure proper seating in the o...

Page 482: ...with a cloth moistened with solvent 11 With an assistant s aid set the glass in position on the windshield weatherstrip 12 Slide the upper edge of the glass into the chan nel of the weatherstrip 13 Pound the glass with the heel of the hand un til glass is fully seated in the channel of the weather strip at top bottom and sides of glass 14 After properly seating glass in the weather strip force the...

Page 483: ... sealer 4 Apply the upper seal starting with a inch overlap maximum at the left hand side 5 Apply the balance of the seal and when fully installed the seal should overlap the lower seal at the right side by two inches maximum 6 If overlap is greater than two inches trim off the excess amount at approximately a 30 degree angle Fig 126 7 Hand pressurize both seals to avoid wrinkles and puckers Insta...

Page 484: ...a 3 Push the cover assembly upward to release the cover from the retention clips and remove the cover assembly 4 Remove the quarter window garnish mouldings 5 Remove the front upper pillar glass and weath erstrip lock retainer screws and retainer Fig 129 6 Remove the rear upper pillar glass and weath erstrip retainer screws and retainer 7 Remove the glass and weatherstrip belt bar re tainer screw ...

Page 485: ...trace powder and a test bulb to test the sealing between the body and the weatherstrips When the powder is sprayed at the point where a leak is suspected it will leave a trace line through the point of leakage In hard to reach points such as the dog leg at the A post blue carpenter s chalk applied to the weath erstrip will transfer to the A post when the door is closed if a good contact exists Roo...

Page 486: ...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 at tachment of felt pads Windshield Rubber Sealer A heavy viscosity rub ber expander this sealer can be used where rubber is confined between a glass and metal channel ...

Page 487: ...llets or long string shapes TYPICAL SECTION REAR DOOR NK1079 Fig J 35 Door and Quarter Window Belt Weatherstrips Imperial LOCK PILLAR T W O DOOR HARD TOP CONVERTIBLE STARTING POINT RIVET FOUR D O O R HARDTOP RETAINER D l f VIEW APPLICATION 7 n TO BODY FOUR DOOR SEDAN NK959 Fig 136 Door Windcords Chrysler NK1080 VIEW A A Fig 737 Door Windcords Imperial WEATHERSTRIP NK964 Fig 138 Quarter Window Belt...

Page 488: ...OOD ADHESION EDGE MUST BE FEATHERED AS SHOWN HIDDEN SURFACE EXPOSED SURFACE SEALER MUST BE APPLIED AS ILLUSTRATED TO LOCK1 SEAL IN PLACE FORCE SEAL BEYOND HOLE HIDDEN SURFACE SEALER INCORRECTLY APPLIED APPLICATION OF SEALING PUTTY HOLD GUN NOZZLE IN DIRECTION OF ARROW IN ORDER TO EFFECTIVELY SEAL METAL JOINTS DO NOT HOLD GUN NOZZLE IN DIRECTION OF ARROW SEALER APPLIED AS SHOWN IS INEFFECTIVE 1 4 3...

Page 489: ...ow Seam Sealing Note particularly the metal seam joints at the junc tion of the floor side sill to floor pan and the A B and C pillars Water and dust can get through this joint and under the sill scuff plate It is recommended to seal under the full length of the seam and around the joints using liquid body sealer applying it with a dispensing gun Front Door Vent Window Leaks through the vent windo...

Page 490: ... of the moulding mark the clip holes by placing balls of sealer to the rear of each moulding hole This helps align the trim moulding re taining studs with the holes and avoids the possibility of moving the sealer or damaging the paint Re move balls of sealer when moulding is installed Fig 145 Deck Lid Opening Chrysler side and then across the top of lid Inspect the two upper and lower welded joint...

Page 491: ...rain trough and weatherstrip SEAL VIEW I N DIRECTION OF A R R O W X WASHER WEATHERSTRIP l T E E N U T SCREW SPACER VIEW I N CIRCLE U CEMENT TAILGATE PILLAR RETAINER VIEW I N CIRCLE Y BUTT JOINT SEAL GLASS WEATHERSTRIP M O U L D I N G RETAINER COVER SCREW SEAL BUTT JOINT CEMENT CHANNEL SEAL VIEW I N CIRCLE W NK880 VIEW I N CIRCLE y SEAL Fig 148 Tail Gate Seals and Weatherstrips SEALER SILL PANEL SE...

Page 492: ...o the seams to effect a proper seal Spare Tire Compartment Apply a inch bead of sealer to the seam of the rear lower pillar to wheelhouse front support and to rear floor pan to rear crossmember extension and spare tire housing lower panel Fig 150 Apply a inch bead of sealer to the seam of the spare tire housing lower panel and wheelhouse inner panel to the sill extension Apply sealer to the seam o...

Page 493: ...motor a pump and reservoir as sembly and a double throw rotary switch The wir ing and motor are protected by a separate circuit breaker The cylinders are serviced only as an assembly The reservoir end plate 0 ring is replaceable The pump cover plate is serviced as an assembly and the rotors are serviced as a package with the 0 rings TOP ADJUSTMENTS Convertible top adjustments are of two general cl...

Page 494: ...e made after the correct roof side rail alignment to limit the upward travel of the glass and to assure effec tive sealing between the roof side rail weatherstrip and glass SHIM BODY BOLT HERE TO CORRECT THIS FIT KP705 A Top Header Latching Mechanism and Locating Dowels Good weather sealing at the frontal area is depend ent upon proper positioning of the top header on the windshield header The hea...

Page 495: ...The set screw is also used as a means of eliminating noise at the front hinge by progressively tightening until the noise disappears On Imperial Models the front hinge set screw is ac cessible from the top surface of the front rail and angles downward to the rear It contacts the steel drive stud in the center rail to open or close the hinge as required Front Hinge Adjustment CAUTION To avoid strip...

Page 496: ...Bow Adjustment Imperial which when loosened permit forward or rearward movement It is important that the links on both sides be in the same position rearward otherwise it would cause the power piston rod on one side to start to actuate the linkage slightly ahead of the piston rod on the opposite side This can cause one side of the top to twist slightly The rearward position of the link also increa...

Page 497: ...dings Mark the screw locations on the tape to aid in reassembly Remove the moulding screws moulding retainer screws and retainer Stretch the backlight and quar ter trim to remove the wrinkles Trim off excess back light and quarter trim material that extends beyond the retainer Install the retainers and mouldings Testing the Top Control Switch Disconnect the black wire at the top control switch Fig...

Page 498: ...at the rear seat back supports 5 Install the drain tube connector and retainer to the liner attaching edges 6 Install an even coat of cement to the bottom edge of the liner attaching edges 7 Position the new well liner in the well and press the attaching surfaces to the cemented surfaces 8 Slit the liner 2 places on the rear seat back sup port for the tension cables and attach the tension ca bles ...

Page 499: ...strip contacts the windshield header outside finish moulding TOP AAATERIAL v WINDSHIELD HEADER WINDSHIELD UPPER M O U L D I N G UPPER GARNISH M O U L D I N G CORNER FRAME UPPER SEAL HEADER OUTER PANEL HEADER INNER PANEL WEATHERSTRIP LOCK PILLAR QUARTER PANEL V I E W I N DIRECTION O F A R R O W Y UPPER FRONT PILLAR 6 INCHES CEMENT I RETAINER UPPER PILLAR U P P E R P L L A R PILLAR SEAL M O U L D I ...

Page 500: ... the location of the top cover ends at the rear window on the masking tape 6 Remove the retainers at the quarter panels and at the corners 7 Mark the location of the rear curtain material end and the three end attaching screws Fig 167 on the masking tape at the quarter panels and rear win dow areas 8 Remove the screws from the ends of the mould ing on the rear boss Fig 168 Fig 167 Rear Curtain Low...

Page 501: ...staples The rear window zipper top half is attached to the Fig 169 Top Cover Fronf Locking Flaps V I E W I N C I R C L E A V I E W I N C I R C L E B Fig 170 Cover Tension Cables rear bow with staples 1 Inspect the cables in the cover listings Use the cords to install the cables in the original cover 2 Locate and mark the center line on the top head er rear bow and at each end of the new cover 3 Po...

Page 502: ...lower front edge of the cover and one long tack through the cover beading to the header 27 At the rear roof bow on the same side make certain the center line marks of the cover and roof bow are in alignment and tack the cover into position spacing the tacks approximatelyx k inch apart 28 Install a large tack through the roof beading at the rear bow 29 Repeat steps 27 and 28 for the opposite side 3...

Page 503: ...ocation of the holes on the masking paper 3 Apply a thin film of cement to the center four inches of the roof panel and vinyl cover 4 When the cement becomes tacky but not wet to the touch position the vinyl cover on the roof panel aligning the centerline marks 5 Apply cement to one half of the roof panel and extension and to the vinyl cover half on the same side Fig 172 6 When the cement becomes ...

Page 504: ...el secure in place using the body clamps Fig 175 Fig 175 Roof Side Cover Retainers Imperial N K 9 8 2 Fig J 76 Trimming Cover at Sides 17 Install the sealing screws 15 per side and remove the body clamps 18 Trim the cover along the drain trough using the inboard face of the drain trough as a guide Fig 176 NOTE Steps 19 through 23 apply to Chrysler Mod els only 5 19 Trim the cover on a line VA inch...

Page 505: ... side panel aligning holes in top of cover to holes in the roof side panel 29 Smooth out all wrinkles and apply pressure to the nameplate and medallion to effect a good seal 30 Press the front and rear edge of the cover into the C pillar and down into the face of the rear window reveal Fig 180 Fig 179 Installing Sealer Anti Rattlers Fig 180 Positioning Cover on Extension Panel Fig 181 Installing C...

Page 506: ... 184 4 Work all wrinkles out starting from the cen ter and working toward the drain trough 5 Press the fabric into the windshield reveal Fig 184 using a dull pointed tool 6 Locate and position the front rear and outside moulding retainers to the roof panel Fig 185 and install the sealing screws 130 required 7 Trim the excess material at the retainers Fig 185 at the inboard and rear sides by cuttin...

Page 507: ... body Snap a chalk line between points as illustrated Compare dimensions with specifications all match ing point to point dimensions should agree within X A inch NOTE Care should be taken that all diagonals com pared represent corresponding measuring points In making any body opening measurements always compare the matching measurements of both sides of the vehicle All dimensions must be measured ...

Page 508: ... Y O K E Q U A R T E R PANEL PILLAR W H E E L H O U S E R O O F RAIL n i t 1 A D W Y Y t I V 7 V D O O R P A N E L W H E E L H O U S E C O W L T O P P A N E L v U A I I C C R O C K E R P A N E L OUTER C O W L L O W E R P A N E L A REAR P A N 0 Fig 187 Sheet Metal Replacement Panels Chrysler 1 1 F R O N T P A N N K 1 1 7 8 MyMopar com ...

Page 509: ...PROTECTION Prior to applying any paint to the sheet metal clean the entire area to be repainted with a good wax and grease remover Eliminate all fingerprints Chemically treat all bare metal using a good metal conditioner This conditions the exposed metal to resist rust PRIMING THE SURFACE This operation is the backbone or foundation for the finish color It primes the metal to insure adhesion and f...

Page 510: ... PAINT CODE DITZLER CODE CHRYSLER NUMBER USED O N COLOR NAME AA 1 22461 AAY2Y6 Chrysler Regal Gold Poly BB 1 9300 TAY1X9 Chrysler Imperial Formal Black Formal Black CC 1 12894 AAY1B1 Chrysler Imperial Ice Blue Ice Blue DD 1 12763 VAY2B6 Chrysler Nassau Blue Poly EE 1 12896 AAY2B9 Chrysler Imperial Navy Blue Poly Navy Blue Poly FF 1 12895 AAY2B4 Chrysler Imperial Mist Blue Poly Mist Blue Poly GG 1 ...

Page 511: ...een Poly Pink Silver Poly Pink Silver Poly Moss Gold Poly Moss Gold Poly Black Plum Poly Mauve Poly Patrician Gold Poly DITZLER CODE 8293 9000 13001 22535 71424 STONE SHIELD CHRYSLER Argent Silver AAQ6S2 DX 8555 CHRYSLER INTERIOR COLORS GLOSS FINISH COLORS Used On Windshield Upper and Side Garnish Instrument Panel Lower Roof Rail Backlight Moulding Station Wagon Quarter Window Tail Gate Gar nish S...

Page 512: ...t Bucket Seat Tracks Also Convertible Top Except Steering Column and Cover Except Steering Column and Cover Except Bucket Seat Tracks Except Bucket Seat Tracks Except Steering Column and Cover Except Bucket Seat Tracks Except Bucket Seat Tracks Dark Red Poly Dark Red Poly CHRYSLER INTERIOR COLORS LOW GLOSS FINISH COLORS VAB6R7 71362 AAB6R8 71441 Except Bucket Seat Tracks Except Steering Column and...

Page 513: ... AAB6L8 AAB6L3 VAB6F9 AAB6M9 VAB6R7 DITZLER CODE 9028 12925 12926 12928 12933 22452 22489 43137 50674 71362 REMARKS Convertible Top Mechanism Rear Shelf Air Condition only Rear Shelf Air Condition only Rear Shelf Air Condition only SUEDE FINISH COLORS Used On Instrument Panel End Extension Right and Left Lower Windshield Garnish Moulding Steering Column Jacket Instrument Panel Air Condition Defros...

Page 514: ...derable value to the service man Condition Possible C a u s e Correction BLOWER NOT OPERATING BLOWER AND COM PRESSOR OPERATING N O C O O L I N G BLOWER OPERATING PARTIAL C O O L I N G LOW SUCTION AND LOW DISCHARGE PRESSURE a Blown fuse broken wire faulty switch motor loose or dirty connections a Low refrigerant moisture frozen stuck or faulty expansion valve stuck or faulty EPR valve b Low compres...

Page 515: ...ch direct air flow through the combination heater and air condi tioning unit is by means of vacuum diaphragm units called vacuum actuators The vacuum source is the engine intake manifold Vacuum lines connect to each side of the vacuum actuator diaphragm with the push button serving as a switch valve to admit vacuum to one side or the other of the vacuum actuator dia phragm The diaphragm is connect...

Page 516: ...rator is dependent upon the controls used to operate the front unit The evapora tor of a trunk unit of a dual installation will cool only when the MAXIMUM COOL or the FRESH COOL push button of the front unit control is de pressed to energize the magnetic compressor clutch The blower circuit of the trunk unit is entirely independent of the front unit Fig 3 Antifreeze Required for Summer Operation T...

Page 517: ...ioning of all refrigeration system units Testing the Operation of All Controls Operating controls must be tested as described in the following sequence 1 Inspect compressor drive belt tension and ad just if necessary 2 Open the vehicle windows 3 Move the temperature control lever to the OFF position 4 Start the engine and adjust engine speed to 800 rpm Use a reliable tachometer Remove radiator cap...

Page 518: ...ture Control Valve Adjustment Move the temperature control lever on the instru ment panel to the extreme WARM position and if then back to the OFF position At the same time inspect the control cable action and the movement of the water temperature control valve lever The valve should be moved to the wide open position and back to the fully closed position Figure 5 shows the valve in the fully clos...

Page 519: ...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 93 104 6 118 152 7 18 19 7 44 40 7 69 68 8 94 106 3 119 154 9 20 21 0 45 41 7 70 70 1 95 108 1 120 157 1 21 21 7 46 42 6 71 71 4 96 109 8 121 159 3 22 22 4 47 43 6 72 72 8 97 111 5 122 161 5 23 23 1 48 44 6 73 74 2 98 113 3 123 163 8 24 23 8 49 45 6 74 75 5 99 115 1 124 166 1 25 24 6 50 46 6 75 76 9 100 116 9 125 16...

Page 520: ... may be added to the system as follows Maintaining the discharge pres sure at 225 to 250 psi add refrigerant gas through the suction side of the system until foam is cleared from the sight glass Then add exactly one half 2 pound of refrigerant TEST 3 TESTING THE SYSTEMS FOR LEAKS The Leak Detector Torch Tool C 3569 is a pro pane gas burning torch used to locate a leak in any part of the refrigerat...

Page 521: ...e refrigerant system were disconnected remove the sweep test charge Close the refrigerant manifold valve so that any refrigerant remaining in the container is sealed Remove the long test hose from the refrigerant manifold Insert the free end of this test hose into an exhaust system outlet Open the right hand gauge set manifold valve a fraction of a turn to let the sweep test charge escape slowly A...

Page 522: ...ys tem is performing up to standard This test also pro vides valuable clues to the possible cause of trouble Performance Test Preparations The Gauge Set Manifold should be connected as shown in Fig 9 according to instructions covered in Gauge Manifold Connections Test 1 Move the temperature control lever to OFF position Start the engine push in the FRESH COOL but ton and push the blower switch to ...

Page 523: ...5 5 5 5 5 6 5 6 5 6 5 7 5 7 5 8 5 8 5 9 6 0 61 61 6 2 6 3 6 4 6 5 6 6 6 6 6 7 68 6 9 7 0 70 71 72 73 92 s 5 5 5 5 5 5 5 5 5 6 5 6 5 6 56 5 6 56 5 6 5 6 5 7 5 7 5 8 58 5 9 5 9 6 0 61 6 2 6 2 6 3 6 4 6 5 6 6 6 6 6 7 68 6 9 7 0 70 71 72 73 9 3 J 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 7 5 7 5 7 58 5 8 5 9 5 9 6 0 61 61 6 2 6 3 6 3 6 4 6 5 66 6 6 6 7 68 6 9 70 70 71 72 7 3 94 5 7 5 7 5 7 5 7 5 7 5 7 5 7...

Page 524: ... 0 6 0 61 6 2 6 3 6 3 6 4 6 5 6 6 6 7 6 8 6 8 6 9 70 71 7 2 72 73 74 7 5 9 2 5 7 5 7 5 7 5 7 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 9 5 9 6 0 6 0 61 61 6 2 6 3 6 4 6 4 6 5 6 6 6 7 6 8 6 8 6 9 7 0 71 7 2 7 2 7 3 74 7 5 9 3 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 8 5 9 5 9 5 9 6 0 6 0 61 61 6 2 6 3 6 3 6 4 6 5 6 5 6 6 6 7 6 8 6 8 6 9 7 0 71 7 2 72 7 3 74 75 94 5 9 5 9 5 9 5 9 5 9 5 9 5 9 5 9 5 9 5 9 5 9 5 9 6 ...

Page 525: ...5 6 5 7 5 8 5 8 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 2 5 2 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...

Page 526: ...EVAPORATOR PRESSURE REGULATOR VALVE TEST TEST 6 is divided into two parts to simplify the Fig 14 Trunk Unit Performance Test Fig 15 Pressure EPR Valve Open test procedures As both parts of the test must be made progressively it is important that both parts be read thoroughly before proceeding with the test PART I The EPR Valve is calibrated to produce maxi mum cooling without causing frost or ice ...

Page 527: ...button to increase the heat load on the evap orator This will increase suction pressure causing 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 rapidly Both suction gauges should again stabi lize at a pressure of 26 psi or slightly higher within a few minutes If the mi...

Page 528: ...okay No further testing is necessary If the temperature Js below the minimum the ex pansion valve is flooding the evaporator and the expansion valve should be replaced If the temperature is above the maximum either the compressor or the expansion valve is faulty in which case the system will have to be discharged Test the compressor and expansion valve separate ly using Tests 7 and 8 which follow ...

Page 529: ...l the discharge line 2 Disconnect the evaporator suction line hose from the suction muffler Use a inch fitting cap to close off the suction line fitting Seal the suction line The compressor is now isolated from the system and sealed at both the suction and the discharge sides Refer to Figure 17 and make the following gauge set manifold connections 3 Disconnect the test hose and adapter from the co...

Page 530: ...ntly builds up to a mini mum of 230 psi at exactly 450 rpm is delivering rated capacity Reconnect the evaporator suction line to suction muffler and the discharge line to muffler dis charge fitting When connecting these lines use a new gasket and lubricate both male and female threads and the turning surface of the female nut with refrig erant oil Proceed with the Expansion Valve Test TEST 8 EXPAN...

Page 531: ...illustrated in Figure 19 Then proceed with the following preparation steps 9 Remove the grommet retainer and grommet located behind the expansion valve from the evapo rator housing 10 Remove the expansion valve thermal bulb from its well inside the evaporator housing 11 Prepare a large pan of water heated to 125 degrees F and place the refrigerant can upright in the water Use enough water to provi...

Page 532: ...nsure good thermal contact Install the rubber grommet and the grommet re tainer at the evaporator housing To put the system into operation it will be necessary to sweep test for leaks vacuum and recharge the system SERVICE PROCEDURES SAFETY PRECAUTIONS The refrigerant used in all 1965 air conditioning in stallations is Refrigerant 12 It is transparent and colorless in both the liquid and vapor sta...

Page 533: ...re should be followed 1 Any belt that has operated for a minimum of a half hour is considered to be an in use belt Adjust air conditioning drive belts at the time of new car preparation If the torque method is used tension should be 40 foot pounds If the deflection method is used deflection should be inch at the mid point under a 5 pound load 2 Measure the drive belt tension at regular serv ice in...

Page 534: ...22 Fresh Air Door Connecting Rod Fig 23 Adjust Vacuum Test Bleed Valve Vacuum Control System Test The test of the push button operation determines whether or not the vacuum and electrical circuits are properly connected and the controls are functioning properly However it is possible that a vacuum con trol system that operates perfectly at the high vac uum provided at engine idle speed may not fun...

Page 535: ...re than inch first re check the tester for reading exactly 8 inches If cor rect inspect the fit of the 7 hole hose connector plug on the control switch Fig 25 This plug must be po sitioned all the way on the 7 prods on the control switch CAUTION Do not use lubricant on the switch prods or in the holes in the plug as lubricant will ruin the vacuum valve in the switch If it is impos sible to properl...

Page 536: ...tch field assembly The electro magnet clutch field assembly does not rotate elimi nating the need for collector rings and brushes TESTING THE CLUTCH FIELD ASSEMBLY To test the coil for a short or open circuit connect an ammeter 0 10 ampere scale in series with a fully charged 12 volt battery and the field coil lead The current draw at 12 volts should be 2 7 to 3 1 amperes at 68 temperature Removal...

Page 537: ...g counter clockwise to remove from the hub 4 Remove the bearing snap ring from the pulley assembly 5 Place the pulley assembly on an arbor press with the pulley side down and the bearing hub cen tered on Tool C 3835 Install Tool SP 3496 on the in ner race of the bearing and press the bearing from the pulley assembly See Fig 30 NOTE Remove the bearing only if it is rough or dry Assembly 1 Install t...

Page 538: ...l assembly is positioned so that the lead wire points to the left of the compressor as viewed from the front Install the three mounting screws and tight en to 17 inch pounds 2 Insert the woodruff key in the crankshaft 3 Insert the clutch assembly onto the crankshaft 4 Install the washer and a new self locking bolt and tighten to 2 foot pounds 5 Connect the field lead wire and retainer clip 6 Insta...

Page 539: ...ant oil 61 x 9 3 Fig 35 Removing the EPR Valve EPI VALV1 Removal 1 Remove the two EPR Valve suction line fit ting bolts the fitting which also contains the com pressor suction screen spring and the gasket 2 Remove the EPR Valve and 0 ring from the compressor using Tool C 3822 by rotating the valve counterclockwise slightly as shown in Figure 35 Installation 1 Install the 0 ring on the EPR Valve 2 ...

Page 540: ...aces of the cylinder 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 cylinder head M 6 1 x 9 4 Fig 37 Valve Plate Installed Position is damaged replace using a complete compressor valve plate replacement package Installation 1 The valve plate and t...

Page 541: ...the cylinder heads 4 Turn the compressor upside down Install the pilot studs gasket oil pressure relief ball and spring 5 Install the sump over the pilot studs Fig 39 making sure that the oil pressure relief spring de presses uniformly as the sump is lowered on the case 6 Tighten the sump bolts finger tight to prevent spring misalignment then tighten 15 to 19 foot PSLOT STUDS SUMP Fig 4 0 R e m o ...

Page 542: ...ace plate Tap sleeve lightly until the seal face is fully seated in the housing 6 Install the bearing housing oil seal using plenty of refrigerant oil 7 Install the housing making sure that it is in proper alignment 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 foo...

Page 543: ... Tighten the bolts 10 to 13 foot pounds torque EXPANSION VALVE HEATER CORE EVAPORATOR BLOWER REMOVAL AND INSTALLATION EXPANSION VALVE The expansion valve is a factory calibrated trouble free unit It should not be removed or replaced unless a complete test has proved it to be faulty It is recom mended that Test 8 Expansion Valve Test be per formed before replacing the expansion valve Removal The sy...

Page 544: ...attaching screws Be careful to maintain the gasket alignment to insure an air tight seal at this point 5 Connect the by pass door actuator rod and vac uum lines 6 Connect the heater hoses and refill the cooling system For summer operation as well as winter op eration be sure the system is protected with the proper type and amount of antifreeze EVAPORATOR ASSEMBLY The evaporator assembly includes t...

Page 545: ...or damage to the assembly 3 Install the heater core and cover Install the temperature control valve sensing bulb in the engine Fig 47 Evaporator Installed in the Trunk side housing Connect the heater hoses 4 Reconnect the by pass door and recirculating door vacuum actuators After the evaporator assembly is installed in the vehicle it will be necessary to connect the expansion valve sweep the syste...

Page 546: ...Fig 5 0 R i g h t Spot Cooler Outlet Installation NOTE If the blower is removed from the mounting plate be sure the mounting grommets are installed at the attaching bolts 1 Install the blower motor and mounting plate to the distribution duct Be sure the blower wheel is free and does not rub 2 Test the operation of right spot cooler outlet by applying vacuum to actuator away from the rod side If th...

Page 547: ...entire system tested for leaks The drier should be replaced and the system evacuated us ing a vacuum pump to remove all air and moisture The system should then be charged with the proper amount of refrigerant Detailed instructions for per forming these operations follow DISCHARGE THE SYSTEM 1 Be sure the valves of the gauge manifold set are closed before attaching the gauge set manifold suction te...

Page 548: ... cause the flame to change color in proportion to the size of the leak A very small leak will produce a flame color varying from yellowish green to bright green A large leak will produce a brilliant blue flame 1 Open the torch valve until you hear a faint hiss of escaping gas Light the test torch and adjust the valve until the flame is very small A small flame will detect large as well as small le...

Page 549: ...se abnormally high dis charge pressures Air in the system will reduce the condenser s ability to condense the refrigerant gas and supply adequate liquid refrigerant to the evapo rator To Evacuate the System 1 Connect the gauge set manifold to the compres sor and the long test hose from the gauge set mani fold center connection to the vacuum pump Tool C 3652 as shown in Figure 51 2 Open both gauge ...

Page 550: ...r clock 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 completely clockwise to puncture the cans and close the manifold valves 4 Turn the ...

Page 551: ... 7 Rear inches 60 7 62 2 TORSION BAR Length inches 47 48 6 Diameter inches 0 96 1 11 With Air Conditioning 0 98 1 11 WHEEL BASE Inches 1 2 3 5 1 2 9 AC 3 Models 62 25 REAR AXLE MODEL APPLICATION Type Gear Type Ring Gear Diameter Pinion Bearing Drive Pinion Bearing Pre Load Adjustment Differential Bearings Differential Bearing Adjustment Drive Gear and Pinion Drive Gear Runout Drive Gear and Pinion...

Page 552: ... 23 3 23 Optional 8 75 3 23 3 23 2 76 2 76 Chrysler AC 3 Chrysler AC 3 Imperial AY 1 Chrysler AC 1 2 3 Chrysler AC 3 Chrysler AC 3 413 Cu In 413 Cu In 413 Cu In 383 413 4 1 3 Cu In 413Cu In Engine Engine Engine Cu In Engine Engine Engine Trailer Towing 2 76 2 93 3 23 3 23 3 23 x 3 23 2 76 2 76 Differential Lubricant Capacity Type x 2 76 3 23 Except Station Wagon Station Wagon Special Cam x Axle st...

Page 553: ... cu in standard 413 cu in spec equip Transmission Type Standard 3 Speed or 4 Speed Manual CLUTCH DISC Facing Type Moulded Woven Asbestos Outside Diameter IOV2 Thickness 135 Disc Springs number 10 Disc Spring Color 5 Green 5 Tan CLUTCH COVER Pressure Springs number 12 Spring Color 6 Tan 6 White Spring Pressure lbs 160 ea 245 ea Total Spring Pressure lbs Vh 2511 Number of Levers 3 Pedal Free Play at...

Page 554: ...ut A C 4 38 Dia 10 Blade A C 3 67 Dia 6 Blade FAN SHROUD TYPE Trailer P a c k a g e Full Box with Air Conditioning and Trailer Package Full Box AY 1 Pressure Vent 12 15 psi 15 16 psi 15 16 psi 4 Blade 18 Dia 7 Blade 18 Dia Silicone Fluid Filled Thermal Control Yes Pellet 177 183 F Centrifugal Ball Bearing 4 38 Dia 10 Blade 3 67 Dia 6 Blade Full Box Full Box ACCESSORY BELT DRIVES Torque Method Torq...

Page 555: ...pacity Amperes 70 Voltage 12 Number of Plates Per Cell 13 Ground Terminal Negative Model Identification Number 27 MB 70 STARTING MOTOR SOLENOID SHIFT Reduction Gear Type All Models Starting Motor Identification No 2095150 Make Chrysler Built Voltage 12 No of Fields 4 3 Series 1 Shunt No of Poles 4 Brushes 4 Spring Tension 32 to 36 Ounces Drive Overrunning Clutch End Play 010 045 Free Running Test ...

Page 556: ...load carbon pile across the battery ALTERNATOR VOLTAGE REGULATOR Alternator Voltage Regulator Identification Number 2098300 Volts 12 Ground Polarity Negative Point Gap 014 inch plus or minus 002 inch Air G a p 048 to 052 inch nominal setting Measure gap with gauge back of stop Contacts close with 052 inch gauge installed Contacts open with 048 inch gauge installed Temperature in Degrees 47 F 70 F ...

Page 557: ...nce 70 80 F 0 5 to 0 6 ohms Current Draw Coil and ballast resistor in the circuit 3 0 amperes 1 9 amperes Service wear tolerance should not exceed 006 inch A C 1 r 2 or 4 BBI Carb A C S AY1 VEHICLE MODEL AC2 4 BBI 413 Cu In Engine APPLICATION 383 Cu In Engine 4 Barrel Carburetor 383 Cu In 413 Cu In 2444676 2444867 Advance Automatic Distributor 0 250 to 450 0 310 to 490 0 t o 2 4 5 0 0 to 2 490 2 5...

Page 558: ...4002 Sealed Beam Hi Beam 4001 4001 Tail Stop Turn Signal 1034 1034 Park Turn Signal 1034A 1034A Back Up Lamps 1073 1073 License Lamp 67 67 Trunk and or Under Hood Lamp 1004 1004 Glove Compartment 1891 1891 Radio 1893 1893 Handbrake Indicator 158 57 Dome Lamp 1004 1004 Map Lamp 1004 1004 Ash Receiver 53X 53 Auto Pilot 57 Ignition Switch 57 Models A C 1 AC 2 BULB and AC 3 Switch Titles Heater and or...

Page 559: ...gine 9 2 1 20 psi 383 and 413 cubic inch Engine 10 0 1 25 psi Firing Order 1 8 4 3 6 5 7 2 Basic Timing 10 B T D C CYLINDER NUMBERING FRONT TO REAR Left Bank 1 3 5 7 Right Bank 2 4 6 8 CYLINDER BLOCK Cylinder Bore Standard AC 1 AC 2 4 2495 4 2515 AC 2 AC 3 AY 1 4 1870 4 1890 Cylinder Bore out of round Maximum allowable 005 Cylinder Bore Taper Maximum allowable 010 Reconditioning Working Limits for...

Page 560: ...GS Diameter after reaming No 1 No 2 No 3 No 4 No 5 VALVE TIMING Intake Opens BTC Intake Closes ABC Exhaust Opens BBC Exhaust Closes ATC Valve Overlap Intake Valve Duration Exhaust Valve Duration 002 to 007 No 3 Main Bearing Diagonal Knurling Upper Nos 2 4 5 Lower Nos 1 2 4 5 001 002 003 010 012 Drop Forged I Beam 6 356 to 6 360 6 766 to 6 770 812 4 G M S 846 4 GMS Steel Backed Babbitt 2 376 x 927 ...

Page 561: ... Depth No 1 AC 1 A C 2 3 8 3 cu in 220 In AC 2 AC 3 A Y 1 4 1 3 cu in 216 in No 2 AC 1 A C 2 3 8 3 cu in 220 in A C 2 AC 3 A C 1 4 1 3 cu in 216 in No 3 AC 1 A C 2 3 8 3 cu in 208 in A C 2 AC 3 A Y 1 4 1 3 cu in 206 in Pistons for Service Standard 005 020 040 Oversize PISTON PINS Type Press Fit in Rod Diameter 11 111 1 1 1 1 0935 to 1 0937 Length 3 555 to 3 575 Clearance in Piston 00045 to 00075 I...

Page 562: ...le Before Reconditioning 018 Angle of Seat 45 Adjustment None Lift All Models Except A C 2 389 AC 2 only 430 VALVE SPRINGS AC 1 AC 2 AC 3 AY 1 A C 2 A C 3 Number 16 16 Free Length 2 34 2 34 Intake 2 21 Exhaust Load when compressed to Valve closed 95 105 lbs l 5 f W 95 105 l 5 5 6 4 Load when compressed to Valve closed 187 203 lbs l 1 5 3 2 187 203 lbs l 5 3 2 Surge Damper None Intake only Valve Sp...

Page 563: ...r Rotor Length Outer Rotor Diameter Inner Rotor Length Clearance Over Rotor Outer Inner Outer Rotor Clearance Tip Clearance Between Rotors OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS Engine Displacement Condition Identification Location of Identification 383 cu in 413 cu in 001 U S Crankshaft 001 U S Crankshaft Maltese Cross Maltese Cross M 2 3 etc indicating 2 3 main bearing journal and or R...

Page 564: ... 065 063 040x 075 ADJUSTMENTS Idle Mixture Both Screws Idle Speed rpm with Air Conditioning ON Fast Idle Speed rpm Fast Idle Cam Position Adjustment Accelerator Pump Travel throttle fully closed Bowl Vent Valve throttle at curb idle Vacuum Kick drill size Float Setting Unloader Adjustment wide open kick 1 Vi Turns Open 500 500 700 4 1 11 1 2 l 6 32 1 7 5 1 1 64 1 Vi Turns Open 500 500 700 4 1 7 l ...

Page 565: ...djustment 21 16 2 Un Secondary Throttle Lockout Adjustment 020 020 Float Setting 7 zi 7 zi Float Drop Idle Mixture both screws open 1 2 turns 1 2 turns CHOKE Type Well Well Control Coil Spring Coil Spring Setting 2 Notches Rich 2 Notches Rich After Approx 500 Miles If Necessary 4 Barrel Downdraft AFB 3858S AFB 3859S AFB 3860S 413 383 413 383 413 New Yorker 300 High Performance l 7 l 6 l 9 l 6 I 3 ...

Page 566: ...ats 5 i 6 5 i Vacuum Kick Adjustment 1 1 22 Fast Idle Cam Position Adjustment 3 5 3 5 Bowl Vent Valve at curb idle Vi Vie Choke Unloader 14 W Idle Mixture Screws Turns Open Idle Speed RPM Curb Idle 500 500 Air Conditioning ON 500 500 Fast Idle Speed RPM 600 700 CHOKE Type Well Well Control Thermostatic Coil Spring Thermostatic Coil Spring Setting 2 Notches Rich 2 Notches Rich After Approx 500 Mile...

Page 567: ... bearing bores to centerline of rear bearing bores M O D E L APPLICATION AY 1 PROPELLER SHAFT Length Inches Front Shaft Cross Centerline to End of Shaft 26 59 Rear Shaft End of Spline to Rear Cross Centerline 40 81 Diameter Inches Front Shaft 2 25 Rear Shaft 3 00 UNIVERSAL JOINTS Front Cross and Roller Center Constant Velocity R e a r Constant Velocity SPRINGS AND SHOCK ABSORBERS SPRINGS M O D E L...

Page 568: ...gh high spot Sector Mesh Adjustment Preload Torque Includes Worm Bearing Preload out of car 7 to 11 in lbs Pull through high spot POWER STEERING GEAR Ratio 16 to 1 Fluid Capacity of Hydraulic System 2 Quarts Type of Fluid Power Steering Fluid Part No 2084329 Steering Arm Length Centerline to Centerline of Holes Approximately 6 7 1 6 inches POWER STEERING PUMP Type Constant Displacement Maximum Pum...

Page 569: ... O O L I N G METHOD LUBRICATION CLUTCHES Number of Front Clutch Plates Number of Front Clutch Discs Number of 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 A C 2 383 413 A 833 1 39 1 00 2 58 Approx 7Vi Pts Warm Climate Multi Purpose Gear Oil SAE 140 Cold Climate Multi Purpose Gear Oil S...

Page 570: ...Rear Planetary Gear to Driving Shell 062 to 064 inch Front Planetary Gear to Annulus Gear Support 062 to 064 inch Front Annulus Gear Support to Driving Shell 062 to 064 inch Front Clutch Retainer to Rear Clutch Piston Retainer 061 to 063 inch Green S P E E D O M E T E R P I N I O N C H A R T S M A N U A L T R A N S M I S S I O N S A 745 3 SPEED A 833 4 SPEED OUTPUT SHAFT DRIVE GEAR 8 TEETH Tire Ax...

Page 571: ...on 26 24 22 24 22 22 26 22 24 Convertible 22 24 Convertible Rear tire pressure on heavily loaded station wagons should be increased 6 psi from that shown above For sustained highway speeds long trip driving or trailer towing increase inflation pressure 4 psi front and rear from specified pressures Oversize tires on Station Wagon use same pressure as specified For 15 tires used in place of 14 tires...

Page 572: ...el Container Location Front of Radiator REFRIGERANT Refrigerant Refrigerant 12 Total Charge Front Unit Only 4 lbs Dual Units 4 lbs 14 ozs to 5 lbs 2 ozs BLOWER MOTOR Type Centrifugal Location Dash Panel Capacity 250 to 265 cubic feet of air per minute of high speed Current Draw Approximately 14 17 amps at 14 Volts MyMopar com ...

Page 573: ...ront AC 1 Manual 20 AC 2 Manual 20 AC 1 Automatic none AC 2 Automatic 14 AC 3 Automatic 25 AY 1 Automatic 14 REFERENCE REAR AXLE Continued F O O T INCH POUNDS Rear AC 1 Manual 14 AC 2 Manual 14 AC 1 Automatic 14 AC 2 Automatic 14 AC 3 Automatic 14 AY 1 Automatic 25 BRAKES SERVICE BRAKES Axle Shaft Nut 145 Brake Hose front 25 Brake Support Nuts front upper 55 Brake Support Nuts front lower 80 Brake...

Page 574: ...fold Nuts 30 Exhaust Pipe Ball Joint Bolt 20 Exhaust Pipe Support Clamp Bolt 95 Hanger U Bolt Nuts 100 Heat Control Valve Counterweight Clamp Bolt 50 Exhaust Pipe Flange Bolt Nut 35 F O O T INCH POUNDS Front Companion Flange Nuts 30 Front Transmission Yoke Clamp Bolts 170 Front Slip Spline Yoke Stud Nuts 300 Rear Pinion Yoke Clamp Bolts 170 Rear Pinion Yoke Stud Nuts 300 Center Bearing Bracket Bol...

Page 575: ...ing Screw Lock Nut 29 Kickdown Lever Shaft Plug 150 Reverse Band Adjusting Screw Lock Nut 35 TRANSMISSION Continued F O O T INCH POUNDS Cooler Line Fitting 75 Control Cable Adjusting Wheel Bolt 40 Converter Drain Plug 14 Converter Drive Plate to Crankshaft Bolt 55 Converter Drive Plate to Torque Converter Bolt 270 Extension Housing to Transmission Case Bolt 24 Extension Housing to Insulator Mounti...

Page 576: ...TAL FOOT INCH POUNDS Body Mounting Tightening References See Figures 1 and 2 Door Hinge Bolts 180 Deck Lid Hinge Bolts 180 Fender Attaching Bolts 60 Hood Hinge Bolts 180 Hood Hinge to Cowl Bolts 180 Hood Latch Bolts 180 WHEELS BEARINGS AND TIRES Wheel Bearing Nut With Wheel Spinning Wheel Stud Nut 65 AIR CONDITIONING 90 Compressor Bearing Housing Bolt 10 13 Compressor to Bracket Bolt 50 Fig 2 Body...

Page 577: ...plate Bolt 20 24 Compressor Discharge Adapter Bolt 4 18 Compressor to Engine Bolt 30 AIR CONDITIONING Continued FOOT INCH POUNDS Compressor Oil Pump Cover Bolt 10 13 Compressor Oil Pump 15 19 Compressor to Strut Bolt 30 Compressor Suction Adapter Bolt 10 14 Magnetic Clutch to Compressor Bolt 20 O RING NUT TIGHTENING REFERENCE Line Size Foot Pounds Line Size Foot Pounds MyMopar com ...

Page 578: ...3 H o i s t i 9 Description 12 H o o d L o c k s 2 Heater Blower Motor 13 Lubrication and Maintenance Services 5 A d j u s t m e n t s 1 3 Lubrication and Maintenance Services Heater Core 13 S u m m a r y o f Heater Door S e r v i c e 13 Manifold Heat Control Valve 16 H e a t i n g V e h i c e 1 2 Parts Requiring No Lubrication 19 W i n d o w 1 3 Propeller Shaft and Universal Joints 9 A n t e n n ...

Page 579: ...edures 23 Service Brakes 4 Bleeding the Brake System 8 GROUP 5 BRAKES Continued Page Brake Drum Removal 5 Brake Hose and Tubing 12 Brake Shoe Installation 7 Brake Shoe Removal 6 Brake Support Servicing H Cleaning and Inspection 6 Grinding Recommendations 7 Master Cylinder Servicing 8 Wheel Cylinder Servicing 9 Service Diagnosis 1 GROUP 6 CLUTCH Cleaning and Inspection 2 Clutch Fork Installation 4 ...

Page 580: ...cuit Ignition 35 f Service Diagnosis 35 Shaft and Bushing Wear Test 40 Spark Plugs 44 GROUP 8 ELECTRICAL Continued Page INSTRUMENTS INDICATORS Fuel Level Indicating System 55 instrument Cluster Model AY 1 57 Instrument Cluster Models AC 1 AC 2 AC 3 58 Oil Pressure Gauge Model AY 1 57 Oil Pressure Warning Lamp Models AC 1 AC 2 AC 3 57 Service Diagnosis Instruments 52 Service Diagnosis Turn Signals ...

Page 581: ...1 AC 2 AC 3 65 Wiper Motor Park Switch Timing 63 Wiper Parking Operation Test 64 Wiper Pivot Replacement 67 Wiper Switch 66 GROUP 8 ELECTRICAL Continued Page WIRING DIAGRAMS Body Wiring Model AY 1 88 Body Wiring Models AC 1 AC 2 AC 3 87 Console Wiring Models AC 1 AC 2 AC 3 91 92 93 Engine Compartment Wiring Model AY 1 91 Engine Compartment Wiring Models AC 1 AC 2 AC 3 86 Instrument Panel Wiring Mo...

Page 582: ...agnosis 2 Throttle Linkage Adjustment 39 GROUP 16 PROPELLER SHAFT AND UNIVERSAL JOINTS Ball and Trunnion Universal Joint AC 1 AC 2 5 GROUP 16 PROPELLER SHAFT AND UNIVERSAL JOINTS Continued Page Constant Velocity Front Universal Joint AC 3 6 Cross and Roller Universal Joint AC 1 AC 2 AC 3 Description AC 1 AC 2 AC 3 1 Description AY 1 8 Propeller Shaft AC 1 AC 2 AC 3 Installation 5 Removal 3 Propell...

Page 583: ... 58 Extension Housing and Bearing Imperial Models 60 GROUP 21 TRANSMISSIONS Continued Page Gearshift Cable Trans End 50 Governor 61 Hydraulic Control Pressure Adjustments 55 Hydraulic Control Pressure Tests 54 Lubrication 43 Neutral Starting Switch 51 Output Shaft Oil Seal 57 Parking Lock Cable Trans End 50 Parking Lock Components 62 Rear Oil Pump 61 Speedometer Pinion 57 Steering Column and Gears...

Page 584: ...31 Removal 29 Rotor and Striker 29 Exterior Mouldings 13 Fenders 8 Wheelhouse 8 General Information 1 GIOUP 23 BODY AND SHEET METAL Continued Page Glass Door 33 Convertible 37 Hard Top Front 37 R e a r 41 Sedan Front 33 Rear 35 Tail Gate 52 Quarter Window Convertible 48 Hard Top 46 Sedan Stationary 36 Station W a g o n 59 Rear Window 57 Station W a g o n Quarter Window 59 Tail Gate 52 Stationary Q...

Page 585: ...nt 30 Gauge Set Manifold Installation and Tests 4 GROUP 24 AIR CONDITIONING Continued Page Handling Tubing and Fittings 19 Heater Core 31 Inspection and Adjustments 4 Operation 2 Push Button Control Chart 5 Radiator Pressure Cap 20 Refrigerant Service 33 Remove Sweep Test Charge 35 Replace the Receiver Drier Strainer 36 Safety Precautions 1 Service Diagnosis 1 Servicing the Heli Grip Clutch 23 Swe...

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Chrysler Imperial 1965, Service – Technical Manual

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