Chrysler Imperial 300 1965 Service Manual Download Page 1

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Summary of Contents for Imperial 300 1965

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Page 2: ...7 U S A unless otherwise specified Extra copies of this Manual are available at 5 00 each under Part Number 81 0704150 Order from Chrysler Plymouth Division Service Department P O Box 1658 Detroit Michigan 48231 GROUP INDEX Introduction and General Specifications Lubrication and Maintenance 1 Accessories I Radios Heaters Mirrors 2 Front Suspension 3 Rear Axle c Brakes_S 9 Parking 6 Clutch Cooling ...

Page 3: ...INTRODUCTION AND GENERAL SPECIFICATIONS IMpElAL CROWN 4 DOOR HARDTOP q _ NW YORKER 2 DOO kIADTOp Oo hARDTOP NEWPORT 2 DOO IIAkOTOP Nt4o6 fly 1 1964 ImpeaI and Chrysler Models MyMopar com ...

Page 4: ...ode 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 such as Service Bulletins Service Manuals Owner Manuals Time Schedules W S C s or other Chrysler Plymouth Division Service literature should be ad...

Page 5: ...2nd DIgit Price Class 3rd 4th Digits Body Type 5th Digit Eng Displace 6th DIgit Model Year 7th Digit Assembly Plant ment Cii In E Economy 6 1966 L Low 23 2 Dr Hardtop M Medium 27 Corivertjb le 3 Je Ife son H High P Premium 414 Dr Sedan 42 4 Dr Town Sedan F 383 6 Newark C Chrysler 43 4 Dr Hardtop G 413 V Imperial 45 2 Seat Station Wagon 45 3 Seat Station Wagon J 440 8 Export BODY PLATE NUMBER LOCAT...

Page 6: ...tation Wagon Town and Country Police Car Newport 4 Dr I lard Top Convertible Crown 4 Dr ar Top Le Baron Wheelbase All Models Except Town and Country Town and Country 123 5 121 5 123 5 123 5 121 5 129 Tread Front 62 62 62 61 8 Tread Rear 60 7 60 7 60 7 61 7 Length with All Models Except Bumper Town and Country Town and Country 218 2 219 0 218 2 218 2 219 0 Width with Bumper 79 5 79 5 79 5 80 0 Rear...

Page 7: ...utor Cam and Rubbing Block When servicing breaker contacts apply shin film of lubricant to cam and block surfaces Carburetor Air Cleaner Clean element every 6 months and replace every 2 years Carburetor Choke Shaft Apply solvent to each end of shaft where it enters air horn every 6 months Manifold Heat Control Valve Apply sol vent to each end at shaft every 6 months Crankcase Ventilation System 1 ...

Page 8: ...ars whichever occurs first Distributor Oil Cup Apply 5 or i 0 drops of light engine oil to cup every 6 months Distributor Rotor Felt Wick When servicing breaker contacts apply 2 or 3 drops of light engine oil to wick under rotor Distributor Cam end Rubbing Block When servicing breaker contacts apply thin film of lubricant to ram and black surfaces Carburetor Air Cleaner Clean element every 6 month...

Page 9: ...ion built vehicles have been compiled to provide maximum protection DISTRIBUTOR ENGINE OIL FILTER ENGINE OIL SELECTION OF ENGINE PERFORMANCE EVALUATION FREQUENCY OF OIL CHANGES During Break In Severe Operating Conditions Taxi and Police Operation FRONT WHEEL BEARINGS FUEL FILTER 21 HEADLIGHTS 22 HOISTING 20 HOOD LOCK 20 HYDRAULIC BRAKE SYSTEM 22 MANIFOLD HEAT CONTROL VALVE 23 MATERIALS ADDED TO EN...

Page 10: ...5 26 7 20 SQ MINIMUM FOUR PADS PAD POSITION WITHIN THESE LIMITS SATISFACTORY REAR WHEELS Fig 3 Support Locations for Frame Contact HoistingChrysler Models NH 196 CAR 17 7 17 2 20 50 MINIMUM FOUR PADS t PAD POSITIONS WITHIN THESE LIMITS SATISFACTORY REAR WHEELS Fig 4 Support Locations for Frame Contact HoistingImperial Models N Ni 95 MyMopar com ...

Page 11: ...nder Brake Hoses Body Mechanisms Headlight Aiming Cooling 17 8 7 20 9 9 X X X X X X X Crankcase Ventilator Valve All Systems 12 X Every 12 Months or Engine Performance 12 000 Miles whichever Evaluation X occurs first Brakes Brake Linings and Brake Linkage Bushings 13 7 X X Every 18 Months or 18 000 Miles whichever occurs first Front Wheel Bearings 19 X Every 2 Years Carburetor Air Cleaner 14 X Eve...

Page 12: ...ttempt to raise one entire side of the vehicle by placing a lack midway between front and rear wheels This practice may result in perma nent damage to the body The bumpers are designed to accept a bumper jack in an emergency if it becomes necessary to change a tire on the road Notches are provided in the bumpers for the purpose of raising the vehicle with the bumper jack Front Suspension Ball Join...

Page 13: ...e Range Above 1rF As low as Below 3OF 3GF first The every six other ma in loss of if necessary to change lubricant remove old lubri cant with a suction pump rig 4 The fhuid evel however should be checked every six month When checking the level vehicle 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 To...

Page 14: ...grease such as Multi Mileage Lubricant Part Number 2525035 PARKING BRAKE MECHANISM All models use a foot operated lever Fig 9 Pivot points indicated should be lubricated occasionally to maintain ease of operation Apply a film of smooth white body hardware lubri cant conforming to NLOI grade 1 Lubriplate Part Nmnber 1004700 is a type of lubricant recommended for this purpose When the root pedal can...

Page 15: ...le high quality perma nent type anti freeze is available under Part Number I 3 6209 When vehicle is operated in areas where protection from freezing is not required and vehicle is not equipped with Air Conditioning refill cooling system with clean water and add a high quality corrosion inhibitor such as Chrysler Rust Resistor Part Num ber 2421778 Tbis need not be done until the first yearly se Mce...

Page 16: ...mpanying chart Fig 12 when minimum temperatures may be consistently below 10 F dur ing some winter months oils of the SAE 5W 20 vis cosity may be used If your region is in the shaded area SAE 5W 20 oil should be used during the winter months Lubricants which do not have both an SAE grade number and an MS Service classification on the con tainer should not be used MATERIALS ADDED TO ENGINE OILS It ...

Page 17: ...brief desc iption follows to provide easy identification so that proper service procedures may be applied The Standard VenFilation System l1ig 14 consists of a ventilator valve and cap mounted on the right hand rocker cover a carburetor with drilled passages in the throttle body a hose leading from the valve cap to the throttle body passages and the oil filter pipe breather cap V EREMEIER i_M mis ...

Page 18: ...lator valve hose Fig 14 from cap and NES6 carburetor Inspect it for deposits and clean if IIel es sary Remove breather cap F ig 14 and cughly in kerosene or other suitable move all old oil and dirt Reoll filter SAE 30 engine oil Servico air cleaner filter element every six months as outlined on page 14 and replace filter elemcnt every two years Use a Chrysler Corporation filter element or equivale...

Page 19: ...engine performance Chrysler Corporation recommends that the engine be evaluated every 12 months or 12 000 miles whichever occurs first and tuned if necessary Services per formed during this evaluation should include the fol lov4ng 1 Sperk Plugs Remove and inspect each spark ping Most plugs can be cleaned adjusted and rein stalled Rough idle hard starting frequent engine miss at high speeds or appa...

Page 20: ... small pin point punctures Examine soft plastic seal ng rings on bntli sides of element for smoothness and uniformity Replace if not satis factory t this time also service the Carburetor Choke Shaft as outlined below CARBURETOR CHOKE SHAFT Gum deposits on choke shaft bearings may he re moved by applying a gum solvent Such a solvent is available under Part Number 1043273 Carburetor Cleaner This wil...

Page 21: ...OKE SEAL NKSo5 Cross and Roller Universoljoints When necessary to service universal joint bearings igs 25 and 20 disassembin joints as outlined under Propeller Shaft and Universal Joints Group is Clean and inspect all parts carefully for sertce ability Heptace parts as required Repack joint bear ings uflng Universal Joint Grease NIOl grade O Constant Velocity Universal Joints When necessary to ser...

Page 22: ...SS RA NSMLSE ION YOKE CENTER YOKE N I motive Multi Purpose Grease NLGI grade 2 contaIn ing extreme pressure additives and molybdenum disuiphide spread evenly over the entire area of the splines Multi Mileage Lubricant Part Number 2525035 is suitable for this application Carefully examine rubber seal before installing it In RFTA NER 5EA N 99 S OYE K 1iIT AND POLLE s SE L A SSFM R L Y A P iNC SPL IT...

Page 23: ...level in power steering reservoir every six months When fluid is cold level should be at base of filler neck rig 32 When fluid is hot Level should be helfway up filler neck CAUTION Before removing filler neck cap wipe it carefully to prevent accumulated dirt from dropping into reservoir To restore level if necessary add sufficient hy draulic fluid specially formulated for minimum effect on rubber ...

Page 24: ...dropping into transmission filler tube After engine has idled for about two minutes liiove gearshift lever clowly through all gear positions pau ng momentarily in each position and ending with ever in N position When fluid is OL lcvel should be at the FULL mark or slightly below but nev r above FULL mark I Fig 25 to a void foaming of the fluid Fluid should be added or extracted depending upon the ...

Page 25: ...g hubs make sure all surfaces of hub and outer grease cup interiors are covered with grease IFig 301 to min imize condensation and grease travel out of bearing DO NOT OVERFILL Adjust bearings as rollows U Install wheel and drum assenhlies and tighten wheel nuts to 05 foot pounds 2 Tighten wheel bearing adjusting nut IFig 371 to 90 inch pounds while rotating wheel 13 1 Position nut lock on adjustin...

Page 26: ...st and grit Excess oil or lubricant should be removed Relubricate mechanisms as outlined in the follow ing paragraphs Where Lubriplate is specified use a smooth white body hardware lubricant conforming to NLGI grade 1 A suitable lubricant is available under Part Number 1064768 Where Door Ease Lubricant is specified use a stain less wax type lubricant Such a lubricant is available under Part Number...

Page 27: ...arts and relubricate if necessary remove door or quarter trim panel Apply a film of STRIKER Lubriplate to all pivot and sliding contact areas Door Remote Control Mechanism Imperial Models To inspect this mechanism and relubricate if nec essary remove door or quarter trim panel Apply a film of Lubriplate to all pivot and sliding contact areas and to coils of spring Door Check Arm Rear Door Imperial...

Page 28: ...guide pillars 4 Apply Automotive Multi Purpose Lubricant NK635A NLGI grade 2 to contact surfaces between torsion bar and tail gate hinge or tail gate end face plate right side only To inspect and lubricate tail gate lock and inside remote control handle linkage and window regulator if necessary remove tail gate trim panel Apply Lu briplate sparingly to all pivot and sliding contact sur faces inclu...

Page 29: ...ransmission apply a thin film of the same lubricant to the nylon roller where it contacts the pedal and to the pivot points of both upper and lower transmission linkage bellcranks Throttle Linkage Imperial Models Apply a thin film of Automotive Multi Purpose Grease NLGI Grade 2 to both ends of the accelerator shaft where it turns in the bracket and where the nylon roller rolls on it Fig 51 ACCELER...

Page 30: ...tics and some because lubri Alternator Bearings Rear Springs cants will cause component failures In any event Automatic Transmission Rear Wheel Bearings rubber bushings should not be lubricated not only Controls and Linkage Starting Motor Bushings because lubricants will cause rubber to fail but also Carburetor Air Cleaner Upper and Lower Control will destroy their necessary friction characteristi...

Page 31: ...ished by pushing IN the button in the center of the instrument panel control or turning the igni tion switch to OFF Lubrication All internal working parts of the auto pilot are equipped with self lubricated bearings which have been factory lubricated for the service life of the unit The following mechanical and electrical tests will aid in isolating and correcting malfunction conditions for the au...

Page 32: ...e CARBURETOR DOES NOT RETURN TO NORMAL IDLE Improper auto pilot linkage adjust ment Standard throttle linkage faulty SPEEDOMETER DOES NOT REGISTER OR UNIT DOES NOT OPERATE a Speedometer drive pinion in transmis sion is faulty b Faulty speedometer cable c Faulty drive cable from transmission to the auto pilot drive mechanism d Faulty speedometer a Replace the speedometer drive pinion b Replace the ...

Page 33: ...terminal and other lead of test light in No 3 terminal Fig 4 The test light should light if light fails to light test for an open circuit in black wire circuit between auto pilot and instru ment panel control If light still fails to light inspect instnnr ent panel control for proper grounding When control button is pushed in light should go out if circuit is wired correctJy Dial CaJlb atlen I On a...

Page 34: ...sfrom failing down the cable 3 Loosen set screw at lower end of dust shield It is not necessary to remove screw 14 Turn and pull dust shield from housing and slide dUst shield down cable and slip ball end of howden cable out of socket SLACK INsTRUMENT PANEL WIEJ NG CONNEaOR car BLACK SLUE INSTRUMENT PANEL FUSE IN CONTROL FUSE OCJ UGHTINC CIRCUIT RED A PANEL DASN AUTOPILOT AAKE SWIlCfI NOEMALLY C t...

Page 35: ... Install connector on terminal b Repair or replace the clock as neces sary Cc Replace fuse CHRYSLER MODELS Removal 1 Disconnect battery ground cable 2 Remove ash receiver ash receiver housing upper half of glove box and radio See Radio Remov al Group I 3 Disconnect feed wire and remove light bulb Working through ash receiver housing opening re move the four self tapping screws retaining clock to b...

Page 36: ...uator is opened to route the heated air up to the windshield The Fan Switch determines the speed of the Page Page 9 Rear Seat Heater Blower Motor 11 9 Rear Window Defroster 7 10 Vacuum Actuator Replacement Imperial 10 11 Ventilator Door Adjustment Imperial 9 heater blower motor The Rear Heat button will automatically put the heater in a high blower speed condition regardless of the position of the...

Page 37: ...F button is pushed in the system will not operate The OFF button cuts off the current from the control lever switch and blower motor The ventilation doors are closed pre venting outside air from entering the vehicle VENT Button Opens the ventilation door to al low outside air to enter the vehicle directly It does not operate the blower DEF Button Causes a major portion of the air to be forced onto...

Page 38: ...eater to prevent any coolant from spilling on inside of vehicle as heat a Fill the radiator b Replace thermostat c Replace vacuum line d Replace heater hoses e Correct leak and bleed system f Adjust control cables g Inspect the valve and repair as need ed Test the Bowden cable adjust ment h Adjust control cables i Reposition carpet a Connect or replace cable b Replace thermostat a Check for excess...

Page 39: ...nting plate 10 screws 4 Install motor cooler tube 5 Connect wiring from heater assembly to blower motor 6 Install heater as outlined in Heater Installa tion HEATER DOOR SERVICE For service of the heater regulator door heater de froster door or the heater fresh air door the heater must be removed from the vehicle and disassembled Refer to Heater Removal and Installation BLOWER MOTOR RESISTOR REPLAC...

Page 40: ... There is a spacer at each attaching screw Be sure these spacers are installed between heater housing and dash panel when installing hous ing otherwise housing could be damaged when tight ening screws 3 Reposition heater water valve capifiary coil in heater housing and install attaching clips 4 Connect vacuum hoses at vacuum unit and in stall attaching clips 5 Connect heater wire at harness connec...

Page 41: ... ment and instali the three mounting screws in mount ing bracket Be sure to install motor ground wire terminal to the mounting screw under blower motor 2 Install floor air hoses defroster duct hose and air intake hose 3 Inside car install two heater hoses and clamps to heater 4 Install spare tire 5 Install two heater hoses and tubing support clamp under floor pan 6 Fill cooling system start engine...

Page 42: ...eater chamber NN282 3 Install motor assembly in heater and the four mounting nuts 4 Connect motor feed wire and ground wire FRONT HEATER OUTLET HOSE EE CONNECTORS WATER TUBE FRONT HEATER OUTLET HOSE Fig 2 Rear Seat HeaterHoseConnections HOSE NN283 Fig 3 Rear Seat Heater HoseConnections with Front Air Conditioning MyMopar com ...

Page 43: ...ation 1 II antenna trimming is required place the band selector control in the AM position and proceed with 2 Remove two heater hose clamps and heater hoses from valve 3 Remove the two vacuum hoses and two valve bracket mounting screws Installation 1 Position vacuum actuator and valve assembly on fender well and secure with the two metal screws 2 Install vacuum hoses on actuator The hose with red ...

Page 44: ...e clean antenna sections with a cloth moistened with light oil Before an antenna is removed the antenna per formance should be tested to determine whether it is a reception problem or an operational problem Foot Switch For Search Tuning The foot switch for search tuning on Model 416 and 419 is located on the left forward end of the floor panel By depressing the foot switch it will select a station...

Page 45: ...y clockwise Wi Remove right radio control knobs for access to trimmer control Figs 2 and 3 O Adju d antenna trimmer by carefully tuning back and forth until position is found that gives a peak response in volume Maximum output indicates proper point of antenna trimmer adjustment Push Sultans 1 Extend antenna fully and turn radio on for fif teen minutes iZ Unlock push button by pulling it out and m...

Page 46: ...nd The preliminary test may indicate that removing antenna from vehicle is necessary for further testing repairs or parts replacement In this event ollow procedure for antenna removal Removal I Fiji ly lower antenna 2 For front mounted power antenna remove fend er shield for access For lear mounted power antenna open luggage compartment for acre s c to antenna assembly 3 Disconnect motor loads at ...

Page 47: ... completely expelled from drive 171 Remove bottom insulator and water seal washer Fig 5 from tubular fitting using a wire hook and long nose pliers Assembly Ill If original mast assembly is reused thread nylon cord through bottom insulator with tubular pro PIN cPFOR lOSE 62 334 Fig 6 Assembling Power Antenna jection down Fig Oj mini thread nylon cord tllrough water seal washers The bottom insulato...

Page 48: ... engine compact ment tip lower adapter and lift antenna assembly out through top of fender I sI alit inn 1 Position spacer and lower adapter on antenna La WE ADAPTER mast and insert the assembly in fender mounting hole by tipping adapter 121 Position lower adapter on tangs of spacer Fig 9 131 Install gasket upper adapter and cap nut over top of antenna Index upper adapter locating pins in two smal...

Page 49: ...s in two 3 18 holes in fender Lubricate cap nut threads and tighten with Tool C 3977 Fig 12 61 Insert antenna lead through hole in floor pan and snap grommet in place Route antenna lead over fresh air duct This can be done by disconnecting alligator clip on hose pushing hose to right and lead ing antenna through opening 71 Connect ajitenna lead to radio receiver RADIOS CAUTION Do not operate the r...

Page 50: ...t panel Installation Chrysler Models 1 Install radio in instrument panel opening by in serting radio up through ash receiver opening in in strument panel 2 Install radio to instrument panel mounting bracket 3 Connect speaker leads radio feed wire and an tenna lead cable 4 Install radio mounting nuts 5 Install radio control knobs 6 Install center air conditioning outlet hose if so equipped Install ...

Page 51: ...ivity con trol when the lights are no longer needed the Safe guard turns them off In periods of darkness the headlights taillights and back up lights will remain on for a period of from one to three minutes after the ignition key is turned off depending on the desired setting of the Time Delay Control Switch The system can be disconnected at anytime by pulling the control switch knob out Use of th...

Page 52: ...ALE X 16A 1 6 DARK BLUE X 17 1 6 RED X 18 1 8DARK GREEN X 19l 8GRAY X 20 1 8 BLACK Fig I Safeguard Sentinel Wiring Diagram SERVICE DIAGNOSIS Before any tests are made it should be determined is important that the steps in the service diagnosis be that all driving lights are operating manually first It performed in the sequence shown for each condition Condition LIGHTS FAIL TO LIGHT AUTO MATICALLY ...

Page 53: ...photocell by covering with a dark cloth Start Correction amplifier If lights go out replace amplifier Ca Test circuit for short and replace fuse Cb Test with switch known to be good Be sure to ground switch Replace if necessary c Test with amplifier known to be good Replace if necessary a Repair as necessary Cb Test with switch known to be good Be sure to ground switch Replace if necessary Cc Test...

Page 54: ...chamber flange and disconnect the multiple curl nector Fig 4 Place a jmnper wire from the red wire X 17 to the light blue wire X 5 in the connector on the body wiring side Fig Ii if tIe lights light re place the amplifier Should the lights rail to turn off automatically at day break and the photocell and time delay switch tests are positive disconnect the multiple connector at he amplifier If the ...

Page 55: ...pump The circuit breaker is a serviceable item but the pump and motor are serviced as an assembly only SERVICE DIAGNOSIS TESTS AND ADJUSTMENTS a Nozzle jets plugged b Broken or loose hose c Broken coupling d Faulty pump Ce Nozzle jet under air intake grille a Loose wiring terminals b Corroded terminals Cc Broken wires Cd Faulty switch Ce Faulty motor Cf Poor ground Cg Faulty circuit breaker Ca Cle...

Page 56: ...retaining tabs and remove cover 6 Unsolder circuit breaker lead from motor ter 7 Remove circuit breaker and terminal from pump and motor bracket 8 Install new circuit breaker and terminal In slot in bracket Press insulator firmly in place 9 Solder bare end of circuit breaker lead to motor terminal using rosin core solder 10 Install pump cover Carefully 64x152A tabs in place 11 Install pump 12 Conn...

Page 57: ... assembly should not be replaced for looseness if the axial end play Up and Down movement is under 050 inch Loose ness of this nature is not detrimental and will not affect front wheel alignment or car stability in any way Rubber bushings should not be lubricated at any time On models equipped with disc brakes refer to Group S for brake drum removal and installation procedures SERVICE DIAGNOSIS Po...

Page 58: ...place brake shoe and lining as nec essary and stop all leaks Cd Tighten or replace strut bushings Ce Adjust steering gear control valve Cf Adjust front wheel alignment g Replace spring EXCESSIVE PLAY IN STEERING Ca Worn or loose front wheel bearings Cb Incorrect steering gear adjustment Cc Loose steering gear to frame mount ing bolts Cd Worn ball joints or tie rod Ce Worn steering gear parts Ct Wo...

Page 59: ...nt of car an equal number of times HEIGHT ADJUSTMENT Front suspension heights must be held to specifica tions for a satisfactory ride correct appearance prop er front wheel alignment and reduced tire wear The heights should only be measured when vehicle has he recommended fire pressures a full tank of fuel no passenger load and is on a levei floor 1 Clean all foreign material from bottom of lower ...

Page 60: ...ng bolt Fig 3 counterclockwise 4 Slide rear anchor balloon seal off of rear anchor and remove lock ring and plug from anchor In some instances it may be necessary to use Tool C 3728 to aid in removing torsion bar 5 On Imperial Models slide torsion bar toward rear of vehicle sufficiently to disengage forward end from lower control arm Slide torsion bar forward and down disengaging it from anchor 6 ...

Page 61: ...nspected at all oil change periods Removal of tie rod ends from the steering knuckle arm or center link by methods other than using the recommended tools may damage tie rod end seal Damaged seals require removal of the seals and in spection of the tie rod assembly end at the throat opening If the parts have not lost all the lubricant and are not contaminated worn or rusted use new seals and reinst...

Page 62: ...ysler only on steering knuckle and install mounting bolts and nuts finger tight only 3 Install upper and lower ball joint studs in steer ing knuckle and tighten the ball joint stud nut 100 foot pounds Imperial lower stud nut 115 foot pounds Install cotter pins 4 Tighten steering knuckle upper bolt nuts 55 foot pounds Tighten lower bolt nuts 80 foot pounds and install cotter pin 5 Place a load on t...

Page 63: ...e with protector jaws Install cotter pin 121 Press lower control arm shaft and bushing into lower control arm vih an arbor press or drive into place using Tool 0 8557 and a hammer 3 Press until flanged position of hushing is seated beyond locking groove 14 Install ball joint into flew arm using Tool 0 3561 5 Tighten to a minimum of 150 foot pounds until ball joint is seated the ball joint will cut...

Page 64: ...m pivot shaft 17l Remove rubber portion of bushing from control arm 8 Remove bushing outer shell by cutting with a chisel Use care not to cu Into control arm Assembly Chrysler Models lIt Position new bushing on shaft flange end of bushing first and seat the bushing on shoulder of shaft l2i Press shaft and bushing assembly into control arm using Tool 0 3556 and an arbor press In some instances it m...

Page 65: ...til groove in bushing indexes properly with frame 2 With cupped side out slide washer over threaded end of strut Push strut through bushing in frame position outer washer over end of strut cupped side in and install nut 3 Tighten nut sufficiently to install strut to lower control arm mounting bolts Install bolts lockwashers and nuts and tighten to 100 foot pounds 4 Tighten nut on forward end of st...

Page 66: ... on steering knuckle and install two mounting bolts Tighten nuts 80 foot pounds 13 Insert ball joint stud into lower control ann 4j Install stud retaining nut and tighten to 1 L5 foot pounds Install cotter pin and lubricate ball joint 5 Inspect tie rod end seal for damage and replace if damaged Connect tie rod end to steering knuckle arm and tighten nut 40 foot pounds Slide tie rod end seal protec...

Page 67: ... 3955 SF 3954 R J 511 N G N1al Fig Ta Installing Upper Control Arm Rushing Chrysler making sure it is seated fully down on housing re facilitate installation øf s al the ball loint stud should be perpendiculer to ball joint body Lubricate ball joint 3i Position stud in steering knuckle and iitall washer and nut Tighten nut 100 foot pounds on Chrysler Models and 135 foot pounds on Imperial Models I...

Page 68: ...TER Manual Steering PowerSteerir g HEIGHT nches Standard Suspension Heaw Duty Suspension Limousine Suspension Side to Side Difference Maximum STEERING AXIS NCUNATION TOE IN TOE OUT ON TURNS When inner wheel is 201 outer Wheel Is THREAD Inches Front Rear TORSION BAR Length inches Diameter inches WftI Air Conditioning WHEEL BASE Inches New Yorker Models 6225 CHRYSLER IMPERIAL to Preferred 4 1 O to F...

Page 69: ...nd refill axle to re quired capacity with proper lubricant See Lubrication section c Excessive spinning of one wheel c Replace scored gears Inspect all gears pinion bores and shaft for scor ing or bearings for possible damage Service as necessary TOOTH BREAKAGE RING a Overloading a Replace gears Examine other gears GEAR AND PINION and bearings for possible damage Re place parts as needed Avoid ove...

Page 70: ...on c Readjust bearings d Check gears for excessive wear or scoring Replace as necessary e Readjust ring gear and pinion back lash and check gears for possible scoring REAR AXLE ASSEMBLY 8 RING GEAR INDEX Axle Shafts and Bearings Axle Shaft End Play Differential and Carrier Removal Differential and Carrier Installation Differential Case Drive Gear and Pinion Backlash Gear Tooth Contact Pattern Lubr...

Page 71: ...of the studs that should be removed at this time 3 Remove parking brake strut ADJLJSIER FLANGE OASKTTS LEFT 1 COLLAR SLTEVE NXS9A SF504 RIGHT LOCK SEAL REARING 4 Attach axle shaft remover Tool C 3971 Ftg 3 to axle shaft flange and remove axle shaft Remove brake assembly and foam gaskets 5 Remove axle shaft oil seal from axle housing using Tool C637 Fig 4 RIJMPfR WASHER 3 3 NOU5 NG SCREW GA5KT N GA...

Page 72: ... with a chisel Fig 7L 3 Grind a section off flange of inner bearing cone Fig 8 and remove bearing rollers Fig 9 4 Pull bearing roller retainer down as far as sible and cut with a pair of aide cutters and remove Fig 10 5 Remove roller bearing cup and protective sleeve SP5041 from axle shaft CAUTION Sleeve SP5041 should not be used as a protector for the s aI journal when pressing off the bearing co...

Page 73: ...oughly and install new gasket followed by brake support plate assembly on left side of axle housing 21 Install foam gasket si the studs of axle housing and carefully slide axle shaft assembly through oil seal and engage aplines in differential side gear 3 Tap end of axle sbaft llghliy vith a non metal lic mallet to position axle shaft bearing in housing bearing bore Position retainer plate over ax...

Page 74: ... Si Disconnect parking brake cable 6 Disconnect propeller shaft at differential yoke and secure in an upright position to prevent damage to front universal joint 7 Remove shock absorber from spring plate studs and loosen rear spring U bolt nuts and remove U belts 8 Remove the assembly from vehicle Installation 1 With body of vehicle supported at front of rear springs position the rear axle assembl...

Page 75: ...ential bearing caps and bearing adjusters for reassembly purposes Fig 17 2 Remove both differential bearing adjuster loc screws and locks 9 With a inch socket loosen bearing cap bolts one on each side and back off bearing adjusters slightly using spanner Tench Tool C 406A to re move differential bearing preload Remove bearing cap bolts caps and bearing adjusters 10 Remove differential and ring gea...

Page 76: ...haft and axle drive shaft thrust block 11 Rotate differential side gears until each dif ferential pinion appears at large opening of case Remove each pinion and thrust washer at that time 121 Remove both differential side gears and thrust washers Cleaning and Inspection Figs 21 0 22 I Clean ali parts in a fast evapurattng mineral spirits or a dry cleaning solvent and with the excep tion of bearing...

Page 77: ... on the shoulder of bearing cup bores incurred in removing pinion cups should be flattened by use of a flat nose punch 11 Inspect drive pinion for damaged bearings journals and mounting shim surface on excessively worn splines If replacement is necessary replace both the drive pinion and drive gear as they are available in matched sets only 12 Inspect companion flange for cracks worn splines pitte...

Page 78: ...ential case flange with a non metallic mallet 9 Position unit between brass jaws of a vise and alternately tighten each cap screw to 55 foot pounds 10 Position each differential bearing cone on hub of differcntial case taper away from drive gear and with installing Tool nD lOGS install bearing cones An arbor press may he used in conjunction with in stalling tool CAU1iONt Never exert pressure again...

Page 79: ...pinion several revolutions in both directions to align the bearing rollers Recheck torque to 240 foot pounds torque may have diminished as bearing rollers were aligned by rotating Correct bearing pr io d reding can only be obtained will nose of carri up 7 Using inch pound torque wrench 1 685 meas ure pinion bearing preload by rotating pinion with handle of wrench floating read the torque while wre...

Page 80: ...ing installing Tool DD ggo press hearing on pinion stem An arbor press may he used hi conjunc tion with tool II Install hearing tubular spacer on pinion stem large bore facing rear bearing conel 12 Install selected shim pack 13 Lubricate front and rear pinion bearing cones with Multi Purpose Gear Lubricant 14 Position front pinion bearing cnne in its cup in carrier 15 Install drive pinion oil sc I...

Page 81: ...shim 086 inch thick is too loose and 088 inch too thick use 086 inch shim Treat other pinion markings in a similar manner Shims are available in two thousandths of an inch increments Mounting shims differ in diameter depending on which pinion they are used on 9 Remove differential bearing caps and remove tool arbor from carrier 10 Reverse carrier in stand so nut of tool is in up right position Loo...

Page 82: ...ed before the drive pinion is installed in the carrier The pinion bearing mounting shims are available in two thousandths increments from 084 to 100 inch To select the proper thickness shim pro ceed as follows It will be noted that the head of the drive pinion is marked with a plus or minus sign followed by a number ranging from 1 to 4 or zero 0 marking Depth of Mesh If the old and new pinion have...

Page 83: ...ap back face side of drive gear Tighten lock screw to IS to 20 foot pounds Differential Searing PreIood 1 turn bearing adjuster tooth side of drive gear Fig 32 in a notch at a tame notch referred to Is the adjuster lock holes until backlash between drive gear and pinion is a miulmum of 006 to 008 inch This will preload differential bearings and establish Cor rect backlash 2 F Tighten the remaining...

Page 84: ...xcessive damage of the entire assembly This condi tion is corrected by moving the drive gear away from the pinion This will increase the backlash making it again necessary to insert a thinner shim behind the HeavyHeel Contact If the tooth pattern is heavy on the heel of the teeth the edges of the teeth may chip resulting in excessive damage to the entire assembly This condi tion is corrected by mo...

Page 85: ...SURE GRIP DIFFERENTIAL INDEX Page Page Assembly 18 Sure Grip Differential 17 Installation 20 Sure Grip Differential Identification 17 Lubrication 21 MyMopar com ...

Page 86: ...nt remove the filler plug and use a flashlight to look up through the filler plug hole to identify the type of differential case The sure grip type differential case two piece construction has attaching bolts The con ventional type differential case one piece construc tion has a dome like shape with no case cap attach ing bolts Whenever the rear axle shafts have been removed from the Sure Grip axl...

Page 87: ... flat clutch disc should be replaced if they are worn or distorted If either case half is worn it will be necessary to replace both halves Assembly 1 Position clutch plates and discs in their proper AXLE DRIVE GEAR PINION THRUST MEMBER DRIVE PINION PLATES DIFFERENTIAL CASE DIFFERENTIAL PINION SHAFT DIFFERENTIAL PINION DIFFERENTIAL SIDE GEAR Fig 3 Sure Grip Differential Cross Section View KR 259 P ...

Page 88: ... K 722 Fig _Ren oyjng Side Gee Cap Side PIN LUN SHAFTS __S DE GEM RETANEP Fig 7 fiemoving or IlIstaiiIng top SMe KR7O A Clutch P n V Fig TO Removing or IntaJJ Pbion 5h0ft5 and or SIDE CMR RFTAINER 510E GEAR Fig B Removing or In tolIjng Side Gent kqton r Cop Side KR 72 I Fig F I_Removing or Iaflolllng Side Bear t ani Dffler WM Ccs MyMopar com ...

Page 89: ...e two ramp surfaces in differential se Tighten differential case bolts evenly by alternately turning opposite bolts until all are tightened to 45 foot pounds To keep splines of side gear and clutch plates in exact alignment during the tightening pro cedure move axle shafts back and forth as bolts are being tightened After assemhly slight misalign ments of the splines can be corrected by moving axl...

Page 90: ...d Roller 2 20 30 in lbs without oil seal Shim Pack Tapered Roller 2 Threaded Adjuster Serviced in Matched Sets Only 005 inch Maximum 005 to 008 inch 001 to 012 inch 4 pints Type Multi Purpose Gear Lubricant as defined by MIL L 2105B is used on all rear Anticipated Temperature Range Above 10 F As low as 30 F Below 30 F Wheel Bearing Axle Shaft and Play axles except Sure Grip Differential such a lub...

Page 91: ...n Axle ratio not limited on vehicles equipped with air conditioning TiGHTENiNG REFERENCE FOOT POUNDS Brake Support Plate to Housing Mounting Bolt Nuts 30 to 35 Differential Bearing Cap Bolts 90 Differential Carrier to Axle Housing Bolt Nuts 45 Rear Axle Drive Gear to Case Bolts 55 Rear Axle Drive Pinion Companion Flange Nut 240 Mm Spring Clip U Bolts Nuts Propeller Shaft Bolts Rear Newport Manual ...

Page 92: ...eplace the master cylinder and bleed the hydraulic system a Fill the master cyli the hydraulic system boiling b Drain flush and refill brake Cc Replace all faulty brake drums Cd Replace nylon pivot bushing BRAKES PULLING Ca Incorrect brake adjustment b Brake drums out of round Cc Brake shoes distorted Cd Contaminated lining Ce Unmatched brake lining Cf Restricted brake hose or line Cg Front end ou...

Page 93: ... Cd Contaminated brake lining Ca Replace the brake lining Cb Clean pack and adjust the wheel bearings Cc Recondition or replace the wheel cylinder Cd Reline both front or rears of all four brakes Ca Replace lining Cb Grind or replace the drums Cc Inspect for dragging brakes boiling Cd Drain flush refill and bleed the hy draulic brake system Ce Reline both front or rear or all four brakes PEDAL PUL...

Page 94: ... secondary shoe and the cable will pull the adjuster lever up Upon release of the brake pedal the lever should snap downward turning the star wheel Thus a definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly If by the described procedure one or more automatic adjusters do not function properly the respective drum must be removed for adjuster se...

Page 95: ...brake hose and tubing should be in cluded in all brake service operations The hoses should be checked for 1 Correct length severe surface cracking pulling seuffing or worn spots Should the cotton fabric cas ing of the hose be exposed to weather by cracks or abrasions in the rubber hose cover eventual deterio ration of the hose can take place with possible burst failure 2 Faulty installation to cau...

Page 96: ...nd of tubing Swing compression disc over gauge and center tapered flaring screw in recess of disc 8 Lubricate taper of flaring screw and screw in until plug gauge has seated on jaws of flaring tooL This action has started to invert the exteuded end c the tubin 9 Remove gauge and apply lubricant to tapered end of Oaring screw and continue to screw down until tool is firmly seated In tubing 10 Remov...

Page 97: ... brake adjusting access 2 Insert a thin screw driver into brake adjusting hole arid hold adjusting lever away from notches of the adjusting screw 3 Insert Tool C 3782 into the brake adjusting hole and engage notches of brake adjusting screw Release the brake by prying up with the adjusting tool 4 Remove the rear wheel and clips from wheel studs that hold the drum on the axle Remove drum 5 inspect ...

Page 98: ... Disconnect the lever spring from lever and dis engage from shoe web Remove the spring and lever 6 Spread the anchor ends of primary and second ary shoes and remove parking brake strut and spring Fig 7 7 Disengage the parking brake cable from park ing brake lever and remove brake assembly 8 Remove the primary and secondary brake shoe assemblies and adjusting star wheel from support In stall wheel ...

Page 99: ...n secondary shoe and SECONDARY SHOE AND LiNING TAP ADRASIINO WHEEL I slide over anchor usmg Tool 0 3785 Be sure the secondary spring overlaps primary refer to Fig 1 Be sure cable guide remains flat against shoe web 11 Place the adjusting cable over guide and en gage hook of cable into the adjusting lever Installing the Broke Drums I Lubricate the wheel bearings and install brake drum and adjust wh...

Page 100: ...aps primary Fig 2 and return spring does not slip between anchor pin and eye of cable 12 Place the adjusting cable in groove of cable guide and engage hook of cable into the adjusting Installing the Brake Drums 1 Install brake drum and retaining clips Install wheel and tire assembly 2 Adjust the brakes as described under Adjust ing the Service Brakes of this section MyMopar com ...

Page 101: ...el 4 Remove the push rod return spring Page Installing the Master Cylinder 10 Removing the Master Cylinder 9 PUSH ROD SPRING SEAT DISASSEMBLING THE MASTER CYLINDER To disassemble the master cylinder refer to Fig 1 then proceed as follows Clean outside of master cylinder thoroughly then drain all the brake fluid 1 Remove the piston stop flange attaching bolts and remove dust boot push rod and pisto...

Page 102: ...ssembling Wheel Cylinders Disassembling Wheel Cylinders Installing Brake Supports REMOVING THE WHEEL CYLINDERS Front or Rear With all the brake drums removed inspect the wheel cylinder boots for evidence of a brake fluid leak A slight amount of fluid on the boot may not indicate a leak but may be preservative oil used on the assembly 1 In the case of a leak remove brake shoes re place if soaked wi...

Page 103: ...r Rear 1 Slide the wheel cylinder into position in sup port Install attaching bolts and tighten securely 17 to 20 foot pounds 2 Apply sealing putty around the wheel cylinder to prevent any water or dirt from entering brake as a Connect brake tube to wheel cylinder and tighten to 95 inch pounds rear wheels or connect brake hose to wheel cylinder front wheels and tighten to 25 foot pounds before con...

Page 104: ...y a for ward brake cable and equalizer extending to the park ing brake pedal orrelease bandle Figs land 2 The parking brake pedal assembly used Fig 3 on Imperial models is pedal applied but is released by a vacuum valve When the engine is started and vacu um is developed energy is then available to release the parking brake This is controlled by the transmis sion shift lever When the transmission ...

Page 105: ...2 Disconnect brake cable from the equalizer 3 Remove retaining clip from brake cable bracket 63 x 602 A 2 Tighten the cable adjusting nut until a slight drag is felt while rotating wheel loosen cable adjust big nut until both rear wheels can be rotated freely then back off the cable adjusting nut two full turns 3 Apply parking brake several times then re lease and test to see that rear wheels rota...

Page 106: ...of frame crossmember 2 Disengage cable housing from underbody mounting bracket Figs 3 and 4 3 Raise floor mat or carpet and remove rubber grommet holding the cable housing into floor pan 4 Depress the parking brake pedal pulling cable through housing so that when pedal is released cable may be disengaged from clevis 5 Using a screwdriver pry housing out of mount ing bracket and retaining clip 6 Pu...

Page 107: ... remove vacuum valve To instill vacuum valve unit refer to Fig 5 then proceed as follows 1 Move actuating arm on valve against spring to extreme position or until locating holes line up In stall a number 42 drill in hole to properly position valve for installation Fig 5 2 Move transmission shift selector lever into Park position NN705 3 Place valve in position on steering column jacket and install...

Page 108: ...age Installing the Power Brake 20 Removing the Power Brake 16 Service Diagnosis 15 a Adjust the brakes b Free up the linkage Cc Lubricate the seal d Clean out the master cylinder e Free up and lubricate the plunger f Adjust the push rod g Inspect the pedal return and push rod adjustment h Free up as required i Replace valve assembly GENERAL INFORMATION The Midland Ross power brake Fig 1 is located...

Page 109: ...gine turned off apply brakes several times to balance internal pressure of the brake 2 Disconnect the hydraulic brake line from master cylinder 3 Disconnect vacuum hose from power brake 4 From under instrument panel remove nut and attaching bolt from power brake push rod and brake pedal linkage 5 Remove four power brake attaching nuts and washers 6 Remove power brake and master cylinder from vehic...

Page 110: ...ger by hold jog rod firmly and forcing plunger off rod shearing plastic retaining ring If the plm ger is to be used again remove all broken pieces of plastic retaining ring from groove in the plunger 14 Using Tool C S984 turn control hub cloclcwisa while holding power piston Fig 11 Separate the tail stock and the 0 ring from diaphragm 15 Using snap ring pllers remove retainer that holds plunger to...

Page 111: ...ion and water Using air pressure blow out all internal passages All rubber parts should be replaced regardless of condi lion Install new air filter at reassembly Inspect all parts for scoring pitting dents or nkks Small imperfections can be smoothed out using cr0 ens cloth Replace all parts that are badly scored nicked or damaged At reassembly coat all rubber parts including the diaphragm with sil...

Page 112: ...two plastic guides on push rod Install push rod assembly in valve hub so that push rod indexes in valve plunger Fig 10 Slide two bellows support rings over bellows and down into position in Iwo largcr folds Fig 17 11 Slide bellows Over control hub unrn the lip of the bellows slides into recess of the hub Fig a Secure bellows on hub by using a new clamp on the diaphragm end of bellows Fig 17 12 Sli...

Page 113: ...nting nuts to 100 inch pounds INSTALLING THE POWER BRAKE tighten attaching nuts 200 inehpounds 2 Connect brake limo and vacuum hose 3 Install push rod to brake pedal attaching bolt and nut and tighten to 30 foot pounds 4 Refill master cylinder and bleed the brakes SPRING SEAT PLUNGER SPRING RUESEI VALVE CONTROL SPRING ETAINEP NNI9 P EtLOWS SUPPORI RINGS POW PuTON AS5 MPLY NEW ClAMP Fig Ia installi...

Page 114: ...ower brake which is a self contained unit eliminates all external rods and levers and mounts on the engine side of the dash panel The power brake is externally connected to the brake system at three points The unit is connected by a pedal push rod to the brake pedal by a vacuum line to the intake manifold through a vacuum check valve and a hydraulic tube from the master cylinder to the wheel units...

Page 115: ...LING THE POWER BRAKE To disassemble power brake refer to Figs 2 and 12 then proceed as follows 1 Remove master cylinder from power brake Pig 3 2 Remove master cylinder push rod and air cLeaner plate Fig 4 CHECK VALVE ASSEMSLY ak SIEQ CYLINDER GUIDE SEAL GUIDE SEAL J RETAINER PUSH AIR CLEANER AIR CLEANER TF RETURN SPRING GUIDE REACTION RING INSERT REACTION RIb COVER ASSY NK497 Fig 3 Remoyjng or mus...

Page 116: ...r and lift out power piston return spring 10 Remove power piston assembly by slowly lift ing straight up Fig 0 then lay aside on a smooth clean surface Remove brake unit from engine lifting fixture C 3804 11 Remove air cleaner guide seal and guide seal retainer from cover Fig 9 U2 Remove block seal located in center hole of SThR CYLINDER PUSH ROD Fig 4 Removing or Installing the Master Cylinder Pu...

Page 117: ...se a detarier tion of diaphragm Pro tect diaphragm Iron nicks or cuts that might be caused by rough surfaces damaged tools or by drop ping piston 1 Remove power piston diaphragm from power piston and lay it aside on a clean shop towel 2 Remove screws that CLEANING AND INSPECTION _GUilE Thoroughly wash all metal parts In a smtable sol vent and blow dry with compressed air The power diaphragm plasti...

Page 118: ... aligning ponts on power piston Refer to Fig 10 CHECK VALt RUSBER GROMIAET 0 COVEk REACTION RING INSERT REACTiON RING POWU PISTON SQUARS SEAL RPNG 7 ROD REACTION INSERT BUMPt I FOWIR PISTON O RING SCREW PISTON ASSEMBV FELT SEAL GUIDE DIAPkAGM REACTION PLATE PLASTIC AI cILrE Flu P2 Power grakeAssembb DUST BOOT HOUSING ASS HOUSING LOCK Install retaining screws and tighten from 00 to 101 inch pounds ...

Page 119: ...does uot require a vacuum reservoir The Bendix Power l3rake Unit can be identified by the crimped edge method of attaching the housing and cover together The basic elements of the vacuum unit are as fol a The vacuum power chamber consists of a front and rear shell a center plate front and rear dia phragm hydraulic push rod and a vacuum diaphragm return spr ng FIg 1 fr A mechanically acinated contr...

Page 120: ...pedal 4 Attach vacuum hose to check valve 5 Attach brake line to master cylinder 6 Fill master cylinder and bleed brakes 7 Inspect adjustment of stop light switch 6 Remove four master cylinder attaching nuts and washers and remove master cylinder from power brake CAUTION Do not attempt to disassemble brake booster as this unit will be serviced by Manufacturer s Service Station HOUSING SEAL RETURN ...

Page 121: ...Master Cylinder Disassembling the Caliper Disassembling the Master Cylinder Genera Information Installing the Braking Disc and Hub Installing the Caliper Installing the Master Cylinder Removing the Braking Disc and Hub Removing the Caliper Removing the Master Cylinder Service Diagnosis Tightening Reference Page 333632 31 33 35 32 35 29 Page 35 34 36 34 32 35 28 38 MyMopar com ...

Page 122: ...pis tons Groan Brake noise emanating when slowly releasing brakes creep groan linings reinstall Check and free up p15 pres a Not detrimental to function of disc brakes no corrective action required Indicate to operator this noise may be eliminated by slightly increasing or decreasing brake pedal efforts Rattle Brake noise or rattle emanating at low speeds on rough roads front wheels only a Excessi...

Page 123: ...ston seals dust boots and retainers The brake disc is made from high grade east iron and has a series of air vent louvres to provide cooling for the brake assembly The splash shield has a series of stamped vents so designed as to supply additional air for cooling The brake disc is mounted on the front wheel hub by five bolts and is straddled by the caliper which is attached to the steering knuckle...

Page 124: ... COMPRESSION SPRING PISTON GUIDE APrOF PISTON _ _______ WHEEL NOB PISTON NN23 A checked at regular intervals Fig 15 The master cylinder is of the dual resen oir type to compensate for the greater volume of bnke fluid used in the system Fig 15 Special 14 x 4 inch wheels are used on disc brake equipped vefficles SPLASH SHIELD BRAKb SHOE flg I Disc Brake Assembly Cut Away View ANII RATTLE SPRING OUT ...

Page 125: ...nd turn knob on tool until pis tons are fully compressed flg 4 CLEANING AND INSPECTION Cheek for piston seal leaks evident by fluid mois lore around the cavity and for any ruptures of the piston boot Wipe the cavity clean between the Inner aa4 uttar caliper lLousiftgS with a shop towel Check piston boot for proper seating in the piston groove and under the coiled retainer in the caliper groove 0LT...

Page 126: ...rattle springs Disconnect brake line at cali per housing and install a 24 plug 3 Remove bolts that attach caliper assembly to steering knuckle and steering knuckle arm 4 Remove caliper from disc by slowly sliding cali per assembly up and away from braking disc 5 Remove lining pads Insert piston compression Tool 0 3992 between piston insulator pads and turn knob on tool until pistons are fully comp...

Page 127: ...ASSEMBLING THE CALIPER To reassemble the disc brake caliper refer to Fig 6 then proceed as follows 1 clamp caliper housing in a vise and coat cylin der bores witb Dow Corning Pneumatic Silicone Grease or equivalent then install piston return spring Be sure spring is seated in the recess at bot tom of the bore Fig 0 2 Coat outside dinmeter and fill inner diameter of a new piston seal wIth 55 Dow Co...

Page 128: ...OVING THE BRAKING DISC AND HUB Should it become necessary to remove the braking disc for installation of a wheel stud proceed as fol lows 1 Remove wheel cover and wheel and tire as sembly 2 Remove caliper assembly as described under Brake Shoe Removal 3 Remove grease cup cotter pin nut lock nut thrust washer and outer wheel bearing 4 Pull disc and hub off wheel spindle Removing the Braking Disc fr...

Page 129: ...unit and remove from vehicle DISASSEMBLING THE MASTER CYLINDER To disassemble the master cylinder refer to Figs RESERVOIR OASKEI BODY SPRING HThNG F UPPER RESERVOIR RETAINER PLATE PISTON SECONDARY CU WASHER NN31A SECONDARY PISTON CUP NUT COVEn COVER GASRIT CENTER SlijO FITTING 4 PrSlOrJ RETAINER NA 15 and 16 then proceed as follows I Clean outside of master cylinder thoroughly 2 Remove master cyli...

Page 130: ... Install piston return spring in cylinder bore with closed end outward Install primary cup in cylinder bore with open end of cup over closed end of return spring 3 Install secondary cup on master cylinder piston and install piston assembly in bore with flat brass washer between piston and primary cup 4 Install piston retainer and screw to retain piston assembly 5 Place reservoir gasket in position...

Page 131: ...mber of Pistons Piston Diameter Piston Bore Diameter Maximum Allowable After Piston Seals Piston Dust Boots Dust Boot Retainers Piston Return Springs Bleeder Screw Location Cross Over Passage Seals From either top or bottom Caliper Removed 4 Each Assembly 2 368 2 369 2374 2376 002 0 5 Moulded Rubber 1 Per Piston External Moulded Rubber 1 Per Piston Flat Coiled Steel 1 Per Piston 1 Per Piston On In...

Page 132: ...1 87 11 89 723 7 25 005 30 60 Micro Inches 8725 8775 812 5 Bolts Organic Lining 1 2 Nom 2 3 16 5 3 16 Approx 10 Sq Inches Not less than 1 32 at any point Malleable Cast Iron 1 1 8 002 OS None Vented Stamped Steel 3 Bolts to Knuckle Drop Center 15 x 6K Duo Servo Single Anchor 11 4 2 1 2 2 1 2 9 1 4 12 1 8 1 4 5 31 300 and MODEL APPLICATION Newport New Yorker TYPE Duo Servo Single DRUM DIAMETER 11 i...

Page 133: ...all 1 in Rear Wheel Cylinder Bore 15 16 in Rear Whee Cy inder Bore Disc Brake Equipped Vehicles 7 S in MASTER CYLINDER BORE Disc Brake Equipped Vehicles 1 in Standard Vehicles 1 in TIGHTENING REFERENCE FOOT POUNDS Caliper Mounting Bolts 70 80 Caliper Assembly Bolt 7 16 50 60 140 160 Very Important Braking Disc to Hub Bolts 50 60 Splash Shield Bolts 17 MyMopar com ...

Page 134: ...ngs These bear ings do not require periodic lubrication SERVICE DIAGNOSIS CLUTCH SLIPPING DIFFICULT GEAR SHIFTING Possible Cause a Worn or damaged disc assembly b Grease or oil on disc facings c Improperly adjusted cover assembly a Burned worn or oil soaked facings b Insufficient pedal free play c Weak or broken pressure springs a Excessive pedal free play b Worn or damaged disc assembly c Imprope...

Page 135: ...housing pan 2 Disconnect clutch linkage and return spring at clutch release fork Fig 3 4 Remove clutch release bearing and sleeve as semblv from clutch release fork Fig 4 Mark clutch cover and flywheel Fig 5 to main thin their same relative positions during installation of clutch assembly 6 Loosen and back off clutch cover attaching bolts one or two turns at a time in succession to avoid bending t...

Page 136: ...e wear A new transmis sion main drive pinion or C 3181 Bushing Installing NN9S and Burnishing Tool can be used to gauge the size Of the bushing The tool should have a snug fit in bush ing If necessary to replace the bushing proceed as detailed under Crankshaft Transmission Drive Pinion Bushing page 4 5 The end of the transmission main drive pinion should be smooth and bright without grooves and ri...

Page 137: ...n with the springs on the disc damper facing away from the flywheel Do not touch disc facing as clutch chatter may result Insert C ago Clutch Disc Aligning Arbor Tool through hub of disc and into the bushing Fig 6 if Tool C 360 is not available use a spare transmission drive pinion 4 Insert clutch cover attaching bolts after align ing balance punch marks but do not draw down Fig 5 To avoid distort...

Page 138: ...h clutch release rod and install return Spring 6 Adjust clutch linkage as described under Pan graph Adjusting Clutch Pedal Free Play page 2 CLUTCH RELEASE BEARING Removed From Clutch Removal 1 Examine condition of bearing If noisy rough or dry under hght thrust load remove bearing from sleeve 2 Support bearing in a vise or press and carefully press out sleeve 3 Clean sleeve m solvent and remove al...

Page 139: ...nd tighten to 40 foot pounds 4 Install the bearings on fran e end ball stud and force bearings into torque shaft far enough to install the snap ring Fig 3 5 Install the bearings on the engine side ball stud and force torque shaft over bearings 0 Position frame end torque shaft ball stud in slotted bracket Fig 3 7 Install frame end ball tud nut and washer and tighten securely 3 Install clutch relea...

Page 140: ... Relocate the the flywheel using is greater than total indicator reading and the location of the lowest indicator reading i e the point where the indicator dial indicator Fig 10 and rotate Tool C 771 if total indicator read 006 inch note the amount of the arm or follower is extended the furthest 2 To correct excessive runout place proper thick ness shim stock between the clutch housing and en gine...

Page 141: ...DS POUNDS FOOT INCH FOOT INCH Clutch Housing to Engine Bolts 30 Flywheel Screws 55 Clutch Cover to Flywheel Bolts 30 Transmission to Clutch Housing Bolts 50 Clutch Pan Bolts 100 Torque Shaft Stud 40 Clutch Fork Pivot Bolt 200 MyMopar com ...

Page 142: ...and air condittoning systems as necessary to provide protection against overheating for unusually severe operation requirements For internal cooling system protection each cooling system is factory equipped with sufficient permanent type anti freeze for 2OF protection It is recom mended that the coolant be changed annually to in sure adequate anti freeze and corrosion protection In areas where ant...

Page 143: ...or replace the heater core Co Replace the water pump assembly Cp Replace the cylinder head q Replace the cylinder block fl Cr Replace the cylinder block or cylinder head as necessary s Replace pressure cap Ct Tighten or replace as necessary a Install a new head gasket b Refer to corrections Cf Cg Cp Cq Cr and Ct listed under External Leakage Cc Pressure test cooling system replace the cylinder hea...

Page 144: ... Replace the temperature gauge Cc Replace the sending unit WATER PUMP NOISY Ca Seal noisy Cb Bearing corroded Ca Add Water Pump Lube Cb Replace bearing seal and impeller INSUFFICIENT ACCES SORY OUTPUT DUE TO BELT SLIPPAGE ACCESSORY BELT Ca Belt too loose Cb Belt excessively glazed or worn DRIVES a Adjust belt tension Cb Replace and tighten as specified BELT SQUEAL WHEN ACCELERATING ENGINE Ca Belt ...

Page 145: ... I PLUGS GASKET I SEAL SHAFT AND BEARJNG 1 I SiItQ4 BOLT AND LOCrWASHER HOUSING HOuSlNG SLINC K233C GASKET the shaft and bearing ass nbly do not have to removed to service a leaking pump The shaft nd hearing assembly should be very caralvliy inspected to be sure the pump leak has not damaged the bee ring a Remove the rubber portion of the shalt seal and the spring 4 Using Tool CR753 remove the sea...

Page 146: ...aner or equivalent 2 Operate the engine at a fast idle for to hour 4 Pour the conditioner No 2 bottom compart ment into the radiator and run engine for ten minutes 5 Flush the entire cooling system until the water runs clean 6 Refill the radiator with clean 50FF water 7 Use Radiator Rust Inhibitor during the summer months TRANSMISSION OIL COOLER The transmission oil cooler is located in the bottom...

Page 147: ...temperature of the pellet increases the wax expands and opens the valve A 180 thermostat is standard equipment If the thermostat does not close completely when cold the engine will warm up slowly or not at all and heater performance may also be impaired Poor heater performance may also be due to the valve opening at too low a temperature Too high a valve opening temperature or a valve that will no...

Page 148: ... air conditioning the cap should test between 15 to 16 psi The brass vent valve at the bottom of the cap should hang freely If the rubber gasket has swollen and prevents the valve from hanging loosely replace the cap PRESSURE TESTING THE COOLING SYSTEM 1 Wipe the radiator filler neck sealing seat clean The water level should be inch below the neck of the radiator 2 Attach the tester Tool C 3499 to...

Page 149: ...er steering belts are tightened by using Tool C 3832 and torque wrench Tool C 3005 The alternator belts are adjusted by using a special Tool C 3841 and torque wrench Tool C 3005 The special tool should be hooked at the heavily ribbed section of the alternator rectifier end shield Other belts can also be tightened by this method if the adjusting bracket has a square hole To tighten belts by the tor...

Page 150: ... 2 95 Solid 1 72 4 38 10 14 16 Automatic CAP 3 Speed Manual Yes 18 7 2 Torque None 4 38 10 16 Automatic A C 3 Speed Manual N A N A N A N A N A N A N A N A N A N A N A N A Automatic 10 Yes 18V2 7 2 1 4 Thermal None 3 67 6 16 17 A C CAR 3 Speed Manual N A N A N A N A N A N A N A N A N A N A N A N A Automatic 10 Yes 18 7 2 1 4 Thermal None 3 67 6 16 17 Trailer Tow Automatic 12 5 7 2 95 Solid 1 72 438...

Page 151: ...OD Deflection Inches to be Applied at Midpoint of Belt Segment Under a 5 Pound Load ALL MODELS USED BELT NEW BELT Accessory Power Steering 3 16 3 16 Fan Belt Idler 8 1 16 Alternator Without A C With A C A C_Air Conditioning MyMopar com ...

Page 152: ...0 Battery low Recharge battery Make a high rate dis SP CR charge test for capacity If cells test O K recharge and adjust gravity of all cells uniformly Test voltage regulator setting Thoroughly test electrical system for short circuits loose connections and corroded terminals CELLS SHOW MORE THAN 25 POINTS 025 Specific Gravity VARIATION Short circuit in low cell Loss of electrolyte by leakage sive...

Page 153: ...rel Take a reading with eye on level with liquid level in the gauge barrel DO NOT TILT hydrometer Specific gravity of battery electrolyte strength or density varies not only with the quantity of the acid in solution but also with temperature As temperature increases the volume of the electrolyte expands and specific gravity is reduced As temperature drops electrolyte contracts and specific gravity...

Page 154: ...F position 2 Turn Voltmeter Selector Switch to the 16 volt position on test units so equipped 3 Connect test ammeter and voltmeter positive leads to battery positive terminal Connect ammeter and voltmeter negative leads to battery negative ter minal Fig 2 The voltmeter clips must contact the battery posts or cable clamps and not the ammeter lead clips 4 Turn control knob clockwise until ammeter re...

Page 155: ...hange in specific gravity after one hour of FAST charge the slow charge method should be used Remember to use temperature correction when checking specific gravity The manufacturers of high rate charging equip ment generally outline the necessary precautions and some models have thermostatic temperature limiting and time limitiing controls WARNING When batteries are being charged an ex plosive gas...

Page 156: ...successive readings taken at hour ly intervals Make sure hydrometer readings are cor rected for temperature The rate of charge for a sulphated battery should be no more than the normal slow charge rate Many sulphated batteries can be brought back to a useful condition by slow charging at half the normal charging rate from 60 to 100 hour This long charg ing cycle is necessary to reconvert crystalli...

Page 157: ...um die casting Fig 1 The starter utilizes a solenoid shift device the housing of the solenoid is integral with the starter drive end housing SERVICE DIAGNOSIS Condition STARTER FAILS TO OPERATE Possible Cause a Weak battery or dead cell in battery b Ignition switch faulty c Loose or corroded battery cable ter minals Cd Open circuit wire between the igni tion starter switch and ignition ter minal o...

Page 158: ... open circuit wire between starter relay ground terminal post and neutral starter switch Cautomatic transmission only Also test for open circuit wire between ignition starter switch and ignition terminal and start er relay Cc Test and replace the switch if neces sary Cd Test and replace if necessary Ca Test for open circuit wire between starter relay solenoid terminal and solenoid terminal post Cb...

Page 159: ...ltmeter positive lead to battery posi tive post and voltmeter negative lead to solenoid con nector which connects to the starter field coils 1 Cii ON WASHER with BST11 O2x2I9A Check battery electrolyte gravity with a reliable hydrometer Gravity should be not less than 1 220 temperature corrected Or see that battery passes the High Rate Discharge Test shown in the Battery section of this manual Tur...

Page 160: ...ad to starter housing and voltmeter negative lead to battery nega tive post 2 Crank engine with a remote control starter switch and observe voltmeter reading Voltmeter reading should not exceed 2 volt A reading of 2 volt or less indicates the resistance of the ground cable and connections is normal If voltmeter reading is more than 2 volt it indicates excessive voltage loss in starter ground circu...

Page 161: ... old scaler at brush holder plate and gear housing 7 Unsolder solenoid lead wire and unwind wire from starter brush terminal Fig 4 0 Remove screw attaching brush holder plate to starter gear housing Fig 5 Remove nut 11 32 wrench steel washer and Insulating washer from solenoid terminal 10 Straighten solenoid wire and remove brush holder plate with brushes as an assembly 11 Remove solenoid assembly...

Page 162: ...ameter of pinion theft othorwls lack Fin can be damaged 19 Push pinion shaft towards rear of housing Fig 10 and remove retainer ring and thrust washers clutch and pinion assembly with the two shifter fork nylon actuators as an assembly Fig 11 20 Remove driven gear and friction washer 21 Pull shifting fork forward and remove solenoid montig core SOLENOID coNrAa W WASHER Fig 6 Solenoid Assembly Remo...

Page 163: ...on with a spring scaie hooked under the spring ncar the end Pull scale on a line parallel to the edge of brush and take a reading just as spring end leaves the brush Spring tension should be 32 to 36 ounces Replace springs that do not meet specifications TESTING ARMATURE Testing Armature for Short Circuit Place armature in growler and hold a thin blade parallel to the core and just above it slowly...

Page 164: ...act SERVICING THE STARTER BUSHINGS Inspect armature shaft bearing pinion shaft sir faces and bushings for wear Try the bushings far wear by inserting the shafts and test for side play Pro sized starting motor b nhlngs ale available as service bushings Us Tool C3944 to remove old bust rigs and install ft new No burnishing or reaming is required to fit pre ized bushings The C 3044 Tool and its adapt...

Page 165: ...NE I WASHER UI CONTACT SIUD rSPRING r SEAL WASHER NUT I SEAL WASHER _ NUT ROCK P LU NC rO SPRFNO COVER If SHAFT RETAINER i POLES 41 SCREW SPUR H GEP WAHtR CONTACT STUD THRUST WASHER SPRING SCREW CDII INSULATOR SCFEW FRAME AR MA RE INSULATOR to t W S H WASHER WIRER END HEAL WASHER Fig I 7 SInner Exploded Viewl I MyMopar com ...

Page 166: ...thrust washer Fig 11 SI Complete installation of pinion shaft engaging shifting fork with clutch actuators Figure 19 shows Correct relation of parts at assembly The friction washer must be positioned on shoulder of splines of th pInion shaft befor driven gear is positioned 8 Install driven gear snap ring Fig 8 7 Install pinion shaft retaining ring Fig 9 8 Bend the four 4 Tangs of coil retainer up ...

Page 167: ...enter solenoid coil and brush plate assembly into bore of gear housing and position brush plate assembly into starter gear housing Align tongue of ground terminal with notch in brush holder Fig 16 After the brush holder is bottomed in housing install attaching screw Fig 4 Tighten screw to 10 15 NK29 SOtSNOID WINDING thA9 62523A inch pounds Make sure the insulating tape is in posi tion Fig 4 17 Pos...

Page 168: ...s After the bead has been flowed on use a brush or mall paddle rnoistone l in mineral spirits to press adh ive into the loiS Do not get Shesive on the battery and cl solenoid Srminals INSTALLING THE STARTER 1 Before installing the starter make sure starter and flywheel housing mounting surfaces are free of dirt and oil to insure a good electrical contact 2 Position starter to flywheel housing remo...

Page 169: ...urrent generator with six 6 built in silicon recti fiers that convert A C current into D C current D C Page Regulator Testing Essex Wire 26 Replacing Slip Rings 32 Service Diagnosis Specifications Testing the Alternator System On the Vehicle Voltage Regulator Chrysler Built Voltage Regulator Essex Wire current is available at the output BAT terminal The main components of the alternator are the ro...

Page 170: ...emble alternator Test stator windings Install new sta tor if necessary LOW OUTPUT AND a High resistance in charging circuit a Test charging circuit resistance and A LOW BATTERY correct as required b Low regulator setting b Reset voltage regulator to specifica tions c Shorted rectifier Open rectifier c Perform current output test Test the rectifiers and install new rectifiers as required Remove and...

Page 171: ...e type of equipment is shown Follow the instructions of the equipment manufacturers on comparable equipment when mak ing the following tests Preliminary Checks 1 Test the battery condition Perform reliable battery tests to determine condition and state of charge of the battery If battery is defective or not fully charged install a fully charged battery for test purposes 2 Test the alternator belt ...

Page 172: ... field terminal 4 If high resistance is indicated move negative voltmeter lead to each connection along circuit to wards battery A sudden drop in voltage indicates a loose or corroded connection between that point and last point tested To test terminals for Ug1tness at tempt to move the terminal while observing volt meter Any movement of meter pointer indicates looseness Exc slv resistance in regu...

Page 173: ...ems In either case the alternator should be removed and tested on the bench before disassembly 14 Return tester Field Control to OPEN position 15 Return tester Control Knob to DIRECT position Insulated Circuit Resistance Test Fig 6 1 Connect negative lead of Voltmeter to battery end of positive battery cable 2 Set Voltage Switch to 2 VOLT position 3 Adjust Field Control until tester ammeter reads ...

Page 174: ...ground Its function is to reduce arcing at regulator contacts A voltage coiL Fig 8 consisting of many turns Of fine wire is connected in series between the ION terminal of the regulator and ground Thus when the ignition switch is turned ON battery voltage applied to the windings energizes the coil and the magnetic force of the coil tends to attract the regu lator armature ALTERNATOR REGULATOR ELEC...

Page 175: ...utput voltage and the battery line voltage to drop This reduction in voltage will reduce the magnetic pull of the regulator voltage coil to the ex tent that it cannot hold the armature contact against the stationary lower contact The armature moves into a no contact position between the upper and lower stationary contacts This momentarily allows the field current to flow through resistors number o...

Page 176: ... maintain battery in a full state of charge the voltage regulator should be adjusted to provide proper voltage limiting setting according to custom ers driving and load requirement habits as follows a Check entire charging system and battery as outlined in this Service Manual Ii If there are no defects in the charging system or In the battery and the battery was found to he in a low state of charg...

Page 177: ... checked with stationary con tact bracket attachin9 screw fully tightened Voltage Regulator Fusible Wire Replacement I Cut fuse wire above solder connection at the base and unwind wire at top bracket CAUTION if an attempt is made to un old r the eld fine tile very small wire from voltage coil may be damaged 2 Tin end of fuse wire Use resin core solder only 3 folding tinned end of new fuse wire int...

Page 178: ...nator output will be at its maximum for any rotor speed As the battery line voltage incrcases the magnetic pull of the voltage cod overcomes the armature spring tension and opens the lower contacts The station am v contacts at this time do not touch either the upper or lower armature contacts Field current now flows through the regulator N terminal through re sistance number one and number two thr...

Page 179: ...ect negative lead of Tester Voltmeter to battery negative terminal 7 Rotate Tester Field Control to the DIRECT position 8 With engine operating at 1250 RPM rotate Tester Control Knob clockwise until Ammeter reads exactly 15 amperes 9 Rotate Tester Field Control from DIRECT posi tion to OPEN position and then back to DIRECT posi tion to cycle the system 10 Observe Tester Voltmeter Voltmeter now in ...

Page 180: ...7 Regulator MecIrnnIcaI Adjustments more than an ounce of water per cell per one thou sand miles Step One Adjust lower contact voltage aettang as necessary by turning the adjustment screw Figs IS and 17 clockwise to increase voltage or counter clockwise to decrease voltage Step Two Measure upper contact point gap Up per contact gap should be 014 inch plus or minus 004 inch Adjust upper contact gap...

Page 181: ...uch one test prod from a 110 volt test lamp to the alternator insulated brush tenninal and remaining test prod to end shield if rotor assem my or insulated brush is not grounded lamp will nut light 2 If lamp lights remove insulated brush assembly noting how the parts are assembled and separate the end shields by removing the three through bolts 3 Again test by placing one of the test prods to a sl...

Page 182: ... sealIng material is for protaction GROUND LEAD TO END HOUSIM against corrosion Always touch tnt prod to exposed metal connection nearest rectifier The reading for satisfactory rectifiers will be 04 amperes or more Reading should be approximately the same for the three rectifiers When two rectifiers are good and one is shorted reading taken at the good rectifiers will be low and reading at shorted...

Page 183: ... rectifiers open Possible cause of an opem or blown rectifier is a faulty capacitor or a battery that has been Installed ri reverse polarity If battery is installed properly and the roctifien are op test capacitor capacity 50 mnicrofarad plus or minus 20 e Unsolder rectifier leads from stator leads if Test stator for grounds using a 110 volt test lamp Fig 20 Use wood slats to insulate the stator f...

Page 184: ...bearing spring retainer from end 63s III loot tEASING RETA NES 6 117 Fig 33 Removing Beoflng from Rotor Shaft shield with a screwdriver Fig 32 9 Support end shield and tap rotor shaft with a plastic hammer to separate rotor from end shield The new bearing is lubricated with predeter mined amount of special lubricant and do not re quire additional lubrication 10 The drive end ball bearing is an int...

Page 185: ... Cut through rotor grease retainer with a chisel and remove the retainer h Unsolder field coil leads at solder Ings Fig 36 c Cut through copper of both slip rings at oppo site points lo apart with a chisel Fig 37 Id Break insulator and remove the old ring e Clean away dirt and particles of old slip ring from rotor I Scrape ends of field coil lead wires clean for good electrical contact g Scrape on...

Page 186: ... to slip rings Test lamp should not light U lamp lights slip rings are shorted to ground possibly due to grounding insulated field lead when installing slip ring If rotor is not grounded lightly clean slip ring sur faces with 00 sandpaper 0 Position grease retainer on rotor shaft and press retainer on shaft with installer Tool C 3021 FIg 40 The retainer is properly positioned when the inner bore o...

Page 187: ...381 Fig 43 63 728 SEARING IN ER N DRIVE SNO SHIELD 62ll6 New bearings are pre Iubricated additional lubrica tion is not required 7 Insert drive end bearing in drive end shield and install bearing retainer plate to hold bearing in place 8 position bearing and drive end shield on rotor shaft and while supporting base of rotor shaft press hearing and shield into position on rotor shaft with arbor pre...

Page 188: ...ts washers and nuts 17 Install insulated brush in rectifier end shield Place bronze terminal on plastic holder with tab of terminal in the recess in plastic holder 18 Place nylon washer on the bronze terminal and install lockwasher and attaching screw 19 Install ground brush and attaching screw 20 Rotate pulley slowly by hand to be sure rotor fans do not hit the rectifiers capacitor lead and stato...

Page 189: ...ulator set ting adjust as necessary Replace and adjust distributor contacts Cc Align and adjust contacts d Test and replace coil if necessary Replace and adiust contacts Ce Inspect conditions and correctly con nect the coil f Test condenser and replace if neces sary Replace and adjust contacts g Replace ignition switch Assembling the Distributor 41 General Information 35 Ballast Resistor 44 Idle R...

Page 190: ...dry Bend cables to check for brIttle or cracked insulation When testing the secondary cables for punctures and cracks with an oscilloscope follow the inatnic tions of the equipment manufacturers If an oscilloscope is not available the secondary cables can be tested as follows a Engine not running connect one end of a test probe to a good ground other end free for probing hi Disconnect the cable at...

Page 191: ... a Tach Dwell unit to CALIBRATE position and adjust Dwell Calibrator unifi Dwell Meter reads on the set line test leads separated 21 Leave Selector Switch In CALIBRATE position connect Tach Dwell red lead to distributor terminal of coil and black lead to a good ground IS Turn ignition switch ON Observe dwell meter reading Meter pointer should be well within bar marked DISTRmUTOR RESISTANCE If read...

Page 192: ... vacuum hose at distributor 2 Connect secondary lead of Power Timing Light to No 1 spark plug red primary lead to positive ter minal of battery and black primary lead to negative battery terminal Do not puncture cables boots or nipples with test probes Always use proper adapters Puncturing the spark plug cables with a probe will damage the cables The probe can separate the conductor and cause high...

Page 193: ...eplace bushings and or distributor shaft as follows a Remove distributor drive collar retaining pin and slide the collar off end of shaft b Use a fine file to clean burrs from around pin hole in the shaft and remove lower thrust washer C Push shaft ur and remove it through top of distributor body Remove upper thrust washer Id Remove shaft oiler and lift out oiler wick CAUTION Do not drive the bush...

Page 194: ... CONTROL SPRNG NUT C AP 010 _ s_ _ LAD SCREW SET BREAX FR PlATE FELT SNAP RING VERNON WEIGHT SEARING WASH FR SPRING NB1O9B S CAM SHArI SPRING WASHER SEARING SCREW N S R A SE 0 CO LLAR PIN Fig 5_ Osributor mwsn bI d View MyMopar com ...

Page 195: ...hrust washer and drive collar on lower end of shaft Install retainer pin 6 Install oiler wick and oiler 7 Install contact plate assembly Migii condenser lead contact point spring primary lead and install attaching screw N 5 8 Install felt wick in the top of distributor cam 0 Attach vacuum advance unit ann to contact plate Install vacuum unit attaching screws and washers 10 Test contact arm spring ...

Page 196: ...and deposit on the contact surfaces will cause them to burn rapidly This is easy to detect since the oil produces a smudgy line under the con tacts Clogged engine hreather pipes permit crankcase Nc1545 pressure to force oil or vapors up into the distributor Over oiling of the distributor will also cause burning If the contact opening is too small cam angle too large arcing 411 occur between the co...

Page 197: ...vance is not according to specifications corrections car be made by bending the prima and secondary spring tabs on cam yoke to increase or de crease spring tension The governor spring tabs can be reached throogh the access hole at breaker plate Rotate shaft until proper spring and tab hoe up with access holes Insert a screwdrive blade through access hole and bend spring tab toward distributor cam ...

Page 198: ...inue turning engine for two full revolutions of th crankshaft this will pIns the distributor rotor in approximately the initial position CAUTION DO NOT reverse rotation of the crank shaft if you have passed the timing mark as this IGNITION COIL The ignition coil is designed to operate with an external ballast resistor When testing the coil for output include resistor in tests Inspect coil for exte...

Page 199: ... a long period of misfiring may be suddenly loosened when normal combustlou temperatures are restored upon installation of new plugs During a high apeed run these materials shedding off the combus tion chamber are thrown agaInst the hot insulator surface If they happen to short out the plug they can be removed with regular cleaning techniqaes The plugs can then be reinstalled with good results as ...

Page 200: ... preignitioti damage Fig II may be caused by excessive temperatures This produces melting of the center electrode and somewhat later the ground electrode Remember that the spark plug is like an electric fuse when it melts it warns you to look for the causes and for damage to the engine such as scuffed pistons burned pistons or hurned valves In spect for correct spark plug heat range over ad vanced...

Page 201: ...f the ground electrode Note in Figure 16 that the center electrode is usually not worn badly This source of misfiring and rough idle can be cor rected by reversing the primary coil leads An oscillo scope is the surest way to detect reversed polarity While these examples may not be conclusive in all instances they may indicate possible corrective pro cedures and further diagnosis may be necessary C...

Page 202: ...anger as optional equipment See Automatic Beam Changer Accessories Group 1 SERVICE DIAGNOSIS Correction a Test lighting circuit including ground connection Make necessary repairs b Replace sealed beam units Cc Test voltage regulator and alternator Make necessary repairs LIGHTS FLICKER LIGHTS BURN OUT FREQUENTLY LIGHTS WILL NOT LIGHT a Loose connections or damaged wires in lighting circuit b Light ...

Page 203: ... Place split image target in like position at right rear wheel 2 Adjust range screw on transit until target split image coincides or merges into one unbroken line Make sure that line of sight is perpendicular from eye 1e vkwini poll of transit end that target image is cantered ii viewing port of transit 7I lI TARGeT 6463S 7 I WAN Mr S tANG SCREW a partly discharged battery b Faulty battery C High ...

Page 204: ...ition pointer of RIGHT L flT scale at 2 RIGHT MEASURING HEADLIGHT AIM Horizontal Test Thrn the mGH r1zvr scale knob until the split image is in alignment If the RIGHT or LEFT POR TION of scale exceeds the following values lights should be aimed Values given represent inches at 25 feet Left Right No Unit 4 4 No 2 Unit 0 4 Vertical Test Turn DOWN UP scale knob until the spirit level is centered bf D...

Page 205: ...ght panel Fuel Level Indicating System Fuse Block General Information Heater or Air Conditioning Controls Instrument Clusters Light Bulb Replacement Oil Pressure Indicators Printed Circuit Boards INSTRUMENTS INDICATORS INDEX Page 55 57 50 58 Service Diagnosis Specifications Switches Switch Title Lighting Imperial 54 Tests 55 lnVeh 53 Outof 57 Voltage L ide Vehicle imiter GENERAL INFORMATION Imperi...

Page 206: ...Level Indicating System Chrysler Models The fuel gauge is the thermal type and operates on a principle of constant voltage being applied The gauge is sensitive to changes in fuel level only Fig 3 The oil pressure indicator is controlled by the low oil pressure switch on the engine When the oil pres sure is below normal the switch is electrically closed and applies a ground circuit to light the ind...

Page 207: ...d to the frame b Test Relay a Clean and tighten all electrical con nections and test the gauge operation lmperial Models Only TESTS IN VEHICLE VOLTAGE LIMITER FUEL GAUGE CIRCUIT Imperial Models fuel gauge should fuel gauge should The voltage limiter can be tested in the vehicle or with the instrument cluster removed To quickly test the voltage limiter in the vehicle connect one lead of a voltmeter...

Page 208: ... c 382e to the removed wire terminal 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 Do not start engine The oil pressure gauge should show I plus or minus Inch Thermal gauges are slow in operation Allow time for gauge to heat up When the tester is in the EL position the Sentry Signal on the cluster should be muminated...

Page 209: ... bezel to instrument cluster Remove bezel 3 Remove clock reset knob and temperature con trol level knob 4 Carefully remove lens from cluster 5 Remove screws that attach cluster face plate to cluster Remove face plate 6 Remove desired main group of cluster as fol lows Speedometer Disconnect speedometer and odome ter reset cables from under instrument panel Remove the four screws that attach speedom...

Page 210: ...orm steps 1 5 of switches Right Group 2 Remove the screw that attaches bulb diffuser to instrument panel 3 Remove diffuser 4 Remove the bulb from the socket TEST OUT OF VEHICLE Voltage Limiter To test the voltage limiter out of the vehicle re move the instrument cluster See Instrument Cluster Removal Place the instrument cluster or printed circuit board on a padded work bench to prevent damage Con...

Page 211: ...urnent cluster base Chrysler models or to printed circuit ground strap Imperial models With gaugc tester in U position fuel gauge should show F or minus 3 32 inck The minus tol erance provides a small fuel reserve when fuel gauge is on E position With gauge tester in M position fuel gauge should advance slowly to position With gauge tester in II position fuel gauge should slowly ad vance to F posi...

Page 212: ...board should be replaced SWITCH ES CHRYSLER MODELS All switches on the instrument panel or in the in strument cluster can be serviced from under the in strument panel by removing the switch knob mount ing nut or bezel and disconnecting the wiring to the switch The instrument panel swtiches are located in two groups one group on each side of the steering col umn On the left of the steering column a...

Page 213: ...ut of cluster far enough to discon nect temperature control cable and vactzuth hose con nector Remove control assembly installation 1 Connect vacuum hose connector and tempera ture control cable to control assembly Adjust cable See Control CableAdjustment 2 Position and secure control assembly in cluster with the two mounting screws 3 Install face plate with the four retaining screws 4 Install tem...

Page 214: ...f the bowden a Install a new bowden cable assembly CANCELLING FROM cable are broken loose or pulled off EITHER TURN POSITION b Bowden cable wire loops uncoiled b Install a new bowden cable assembly Cc Override spring or actuator yoke is Cc Install new yoke assembly bent allowing the plastic trigger to pass over top and possibly bind on spring Cd Trigger spring is broken or unat Cd Install new trig...

Page 215: ...8 60 ELECTRICAL TURN SIGNALS LEFT PARK AND TURN LEFT TURN AND STOP RIGHT TURN Fig I Turn Signal Wiring Imperial Models 64x42OA Fig 2 Turn Signal Wiring Chrysler Models MyMopar com ...

Page 216: ...ube during removal to turn signal switch wir ing and carefully pull string or wire down through column jacket tube until directional switch wires can be connected Position turn signal switch in steering column jacket tube and install attaching screws and connect all wire connections 2 Install turn signal operating lever 3 Install steering wheel and steering wheel nut Tighten to 24 foot pounds Test...

Page 217: ...re to cen lever ter mounting screws in slots 6 Place steering column m Down position and Do not distort cable in any way attach coil end to switch post with wire next to switch Install cable clip and screw 8 Install steering wheel assembly and steering 7 Place turn signal lever and switch in neutral column cover MyMopar com ...

Page 218: ...ed wiring Correction a Relieve binding condition b Test switch See Wiper Switch c Repair as necessary Cd Test motor See Wiper Motor Bench Testing Ce Test wiring for continuity Repair as necessary WIPER BLADES NOT PARKING PROPERLY a Arm set at incorrect position b Motor park switch timing incorrect Cc Broken link spring Variable Speed Cd Link spring trip not engaging stop on linkage Variable Speed ...

Page 219: ...ween and 2 on the right side for Imperial Models If the clearance is not in the specified range use Tool C 3982 to reposition the wiper and arm and blade assembly Fig 3 Single Speed Chrysler Models To determine if an adjustment is required apply a constant downward force of 25 ounces parallel to the windshield glass at the end of the wiper arm where the wiper blade is attached to the arm With the ...

Page 220: ...d spring tdp is indicated If they have but have not met the re quirements for proper park position wiper arm ad justment is required End Ploy Adjustment To adjust armature shaft end play turn adjustment screw in until it bottoms then back off turn Fig 4 On Chrysler models this adjustment may be per formedia the vehicle On Imperial models the wiper motor must be removed See Wiper Motor Removal WIPE...

Page 221: ...connect wiring to motor Make certain ground strap is screwed to switch plate and under one mounting nut 3 Position drive crank on motor and install mounting nut and tighten to 200 inch pounds 4 Install cowl grille panel 5 Install windshield lower moulding 6 Install and adjust wiper arm and blade assem blies using Tool C 3982 Wiper Motor Disassembly 1 Remove spring retaining clip and washers on mot...

Page 222: ... strap Connect another jumper wire between brown wire of wiper motor and battery positive terminal The motor should run continuously 2 Connect a jumper wire betwen battery negative post and wiper motor ground strap Connect another jumper wire between brown wire of wiper motor and red wire of wiper motor Connect blue wire to battery positive terminal The wiper motor should park WIPER LINKS Imperial...

Page 223: ...move the wiper arm and blade assemblies the wind shield lower moulding and the cowl grille panel to provide access to the wiper system See Body Group 23 Right Pivot t Remove retainer clip holding connecting link to wiper pivot and remove link from pivot 2 Remove screws mounting the pivot to body of vehicle and remove pivot through cowl grille panel opening 3 Position new or repaired pivot in body ...

Page 224: ...erclockwise until there is no vibration sound 4 Turn tone adjuster clockwise approximately turn at a time until tone has a clear mellow sound Do not turn tone adjuster while horn is sounding Adjustment will only clear up s urid nd cannot diangs horn tone frequency 5 Connect a test ammeter between positive post of a 12 volt battery and horn terminal post Connect a jumper lead from negative battery ...

Page 225: ...SPECIFICATIONS BATTERY Model Usage All Models Capacity Amperes 70 Voltage 12 Number of Plates Per Cell 13 Ground Terminal Negative Model Identification Number 27 MB 70 MyMopar com ...

Page 226: ...d Voltage 12 Volt System Current Output Design Controlled Voltage Output Limited by Voltage Regulator Brushes Field 2 Condenser Capacity 50 Microfarad plus or minus 20 Field Current Draw Rotating Rotor by Hand 12 Volts 2 38 to 2 75 Maximum amperes Current Output Standard With 170 or 225 Cu In Engine Standard All Others Special Equipment Heavy Duty and or Air Conditioning 44 pIus or minus 3 amperes...

Page 227: ... 1 79 Ohms 9400 to 11700 Ohms 0 4 5 to 6 9 5 to 8 10 11 5 to 14 5 14 5 014 to 019 28 to 32 17 to 20 oz 25 to 285 mfd 000 to 003 003 to 017 Counterclockwise 5 ATC 1 8 4 3 6 5 7 2 Chrysler Essex 2444241 1 41 to 1 55 Ohms 9200 to 10600 Ohms 2095501 3 0 amperes 1 9 amperes Service wear tolerance should not exceed 006 inch Set at idle speed See Idle Speed Adjustment Fuel System Mopar P 3 3P J 1OY Champ...

Page 228: ... 11 15 014 to 019 28 to 32 17 to 20 oz 25 to 285 mfd 000 to 003 003 to 017 Counterclockwise 12 5 BTC J 13Y Champion or P 3 5P Mopar i bY Champion or P 3 3P Mopar 14MM 3 a Reach 035 1 8 4 3 6 5 7 2 Chrysler Prestolite 2444242 1 65 to 1 79 Ohms 9400 to 11700 Ohms 2095501 0 5 to 0 6 Ohms 3 0 amperes 1 9 amperes 2095501 0 5 to 0 6 Ohms 3 0 amperes 1 9 amperes In u I C n C I 0 z In rn r ni C I C r 0 4 ...

Page 229: ...000 to 003 003 to 017 Counterclockwise 12 5 BTC i 13Y Champion or Mopar P 3 5P i bY Champion or Mopar P 3 3P 14MM Wa Reach 035 1 8 4 3 6 5 7 2 Chrysler Prestolite 2444242 1 65 to 1 79 Ohms 9400 to 11700 Ohms 2095501 0 5 to 0 6 Ohms 3 0 amperes 1 9 amperes 0 4 5 to 8 6 to 9 12 115 to 145 165 014 to 019 28 to32 17 to 20 oz 25 to 285 mfd 000 to 003 003 to 017 Counterclockwise 5 ATC i 13Y Champion or ...

Page 230: ...Ampere Rating 20 AMP 5 AMP 20 AMP Location Ampere Rating Chrysler Imperial 15 15 20 20 30 30 30 30 5 7 6 BULBS Ash Receiver Auto Pilot Back up Lights Clock Compass or Vacuum Gauge Dome Lights Door and or Pocket Emergency Flasher Fender Mounted Turn Signals Gear Selector with Console Glove Compartment Handbrake Indicator Heater and or A C Control High Beam Indicator Instrument Cluster Illumination ...

Page 231: ...t See Group 23 TO CIGAR LIGHTER CIRCUITS c _ Ri GA COLOR VIOLET WITH TRACER B1A 18 VIOLET WITH TRACER BiB 18 VIOLET 82 18 VIOLET 82A 18 VIOLET 828 18 VIOLET E2 18 ORANGE E2A 18 ORANGE E28 18 ORANGE E2C 18 ORANGE Ml 16 PINK M1A 16 PINK M1B 18 PINK M1C 18 PINK MiD 18 PINK M2 18 YELLOW M2A 18 YELLOW M2B 18 YELLOW M2C 18 YELLOW M2D 18 YELLOW M2E 18 YELLOW x2 16 BLACK X2A 16 BLACK X2B 16 BLACK x2C X2D ...

Page 232: ...iE9 _DUJD ii JIJt I IICsO I OOflw I C0 S Co C 20 Z 0 Co o C zz I 4fl llti10i 0 IH Co n l n 3 o 0 CCoI __T__J __ l 0 9 _____ 9 I ________ 0 TL 1 Co _____________ 0 o0 8 I I I I d 21 0 I Zo 2 CoO 0 1 0 C 0 Z Co C 0 1 0 J_ tC o_ 0 00 Z C E T 1 0 I ow 0 Zo n XXX 1w 4 Co a MyMopar com ...

Page 233: ...TCH AT LAMP POWER ANTENNA _______________ ________ MOTOR WIRING R6 H 05 _________________ AUTOMATIC TRANSMISSION S2 09 L6 H i2 1 BULKHEAD ONNECT O6 SACK UP LAMP IMANUAL TRANSMISSION J3 E I 1 02 XI 2 CONSOLE E2D Xl2 DIO I D3 SWITCH 2 INSTRUMENT LMPS CONSOLE r 20 DOME STOP I I MIA I HEATER B2C _J TO CONSOLE WIRING BODY rf I I I I IGNITION 2 TARTER CCESSORY JERY J2 I IGNITION DID DO I 6 08 D2 2 7 D4 ...

Page 234: ...RECEIVER 1 445P S CI A i A iA R i B IA 5 I B 5 2 S 2A 8 28 R 1C C I C i A C 2 C 4 C 4A C s C 5A C 5B C 6 C 6A C 7 C S C 9 C 9 C ID C Il C 12 C 3D C 3 I C 32 D 1 0 2 D 2A D 3 0 4 D 4A D 5 D SA 0 6 D 6A D 7 D 7A D S D SA D 9 D I0 E COLOR RED _____________ RED VIOLET WITH TRACLE VIOLET WITH iRACEB VIOLET WITH TRACER VIOLET VIOLET VIOlET V IOLE1 BLAcK WIiH tRACER LIGHT GREEN DARK BLUE BROWN BROWN DARK...

Page 235: ... IS BLACK L7G 18 BLACK L7H lB BLACK L7j 18 BLACK L7K IS BLACK L7L 18 BLACK MI IS PINK MIA 18 PINK MIB 18 PINK MIC 18 PINK M2 18 YELLOW M2A 18 YELLOW M2B I 8 YELLOW M2C IS YELLOW M2D lB YELLOW M2E là YELLOW M2F 18 YELLOW CIRCUITS M3 18 BROWN CIR GA COLOR W5 12 RED WISE 14 BLACK W5A 12 RED WISP 12 BROWN WSB 12 RED W25 I 2 YELLOW W5C I 2 RED W25A 12 YELLOW WI 5 12 BROWN W256 12 YELLOW W1SA 12 BROWN W...

Page 236: ... DARK BLUE VIOLET VIOLET DARK BLUE DARK GREEN TAN TAN TAN TAN LIGHT GREEN LIGHT GREEN VIOLET GRAY GRAY GRAY WITH TRACER BLACK DARK GREEN DARK GREEN BLACK WITH TRACER DARK BLUE WITH TRACER DARK BLUE BR OWN RED RED RED RED SLACK BLACK YELLOW WITH TRACER YELLOW BLACK WHITE WHITE WHITE DARK GREEN DARK BLUE WITH TRACER BLACK YELLOW BROWN BROWS I BROWN BROWN RED DARK GREEN DARK BLUE BRO bD 4 FENDER TURN...

Page 237: ...ER HOUSING GROUND TO MOTOR SUPPORT HIGH T4 C B2 XA2 TO REMOTE DECK LID LOCK SWITCH 15 AMPERE WIRING SIDE COWL CIRCUIT BREAKER 30 AMPERE SWITCH M2C LEFT READING LAMP AND SWITCH LEBARON ONLY I LEGEND WIRING SPLICE INSULATORS VIEWED FROM TERMINAL SIDE I MALE FEMALE MALE FEMALE CIR GA COLOR 92 iS VIOLET 1K TW VIOLET B2B 18 VIOLET B2C iS VIOLET B2D 18 VIOLET CII IS BLACK Cl U WHITE C13 BLACK CI3A SLACK...

Page 238: ...DARK GREEN H3 18 BLACK WITH TRACER J2 2 DARK BLUE J2A 1 2 DARK BLUE J28 12 DARK BLUE J2C 12 DARK BLUE J3 12 BROWN L3 6 RED L3A 6 RED LSB 6 RED L3C 61 RED L4 L4A 6 6 BLACK BLACK LAB L6 6 18 BLACK YELLOW WITH TRACER LOA 18 YELLOW 19 6 WHITE L9A 16 WHITE RD 18 DARK GREEN PA R5 16 1 2 BROWN DARK BLUE R6 52 12 1 2 BLACK YELLOW 54 16 BROWN S4A 16 BROWN 55 1 2 BROWN V10 18 TAN WITH TRACER NK753A Fig 7 En...

Page 239: ...ER BODY WIRING Ci 2 REAR DEFOGGE CH TO POWER ANTENNA1 I BODY WIRING E2L xii _ __ TURN _________ DA SIGNAL I SWITCH I WITHOUT ________ TILT __ LE2 ______ STOP LAMP x24_ UTO PILOT L87 LEFT REAR ______________ FRONT X25A DB TO 325 Do AUTOI I flAKE DID I PILOT D5 D9 ITCH 326 J2kt I 1TURN SIGNAL _ FLASHER RIGHT FRONT H3 IADA LEFT TURN I I D A b RIGHT REAR SIGNAL D6A H3A ______ ______ RIGHT TURN Go __ _...

Page 240: ...W LIFT WIRING L7 CSC 6 DARK GREEN L7 1 BLACK CSD lb BLACK LB PINK ClO I B LIGHT GREEN Mi 1 PINK Cli 1 BLACK MIA 1 PINK Cj i WHITE M1B JB PINK C2O 4 BROWN M2 I S YELLOW C22 A DARK GREEN 8 BROWN C23 A LIGHT GREEF M2B 1 BROWN C23A A LIGHT OREEF M2C J YELLOW Dl BLACK M2D J YELLOW 02 RED M2E J YELLOW D2A RED M3 i PINK D2B WHITE 02 12 BLACK Dl lB PINK 02A 12 BLACK DA WHITE 5T 12 RED WITH TRACER K WHITE ...

Page 241: ...regular tappets The engines vary in compression ratio piston fuel displacement camshaft valve springs carburetor manifold arrangement SERVICE DIAGNOSIS Condition ENGINE ENGINE WILL NOT START a Weak Battery b Corroded or loose battery connections c Faulty starting motor d Moisture on ignition wires and distri butor cap e Faulty ignition cables f Faulty coil or condenser g Dirty or corroded distribu...

Page 242: ...ter Ch Adjust float level Ci Install a new pump j Refer to Checking Valve Timing k Install new head gasket Cl Test compression of each cylinder Cm Install new valves or regrind Cn Install new parts as necessary 0 Replace any cracked or shorted cables p Test and replace as necessary ENGINE MISSES ON ACCELERATION ENGINE MISSES AT HIGH SPEED butor rotor butor shaft Condition Correction Adjust bowl of...

Page 243: ... stuck Ch Oil pump suction tube loose bent or cracked Ca Check engine oil level Cb Install new sending unit Cc Install new oil filter Cd Replace worn parts or pump Ce Change oil to correct viscosity Cf Measure bearings for correct clear ance Cg Remove valve and inspect clean and reinstall Ch Remove oil pan and install new tube if necessary Refer to the Electrical and Instrument Group 8 for service...

Page 244: ...ut and keep nozzle 2 inches away from ele ment to avoid damaging Fig 1 Clean the metal hous ing and replace the element Every two years install a new factory recommended MoPar filter element Service the unit more frequently when driving under severe conditions such as in dusty areas 13 Inspect crankcase ventilation system as out lined on page 00 14 Inspect and adjust the accessory belt drives refe...

Page 245: ...2 Remove hood 3 Drain cooling system and remove battery 4 Remove all hoses the fan shroud disconnect oil cooler lines end remove radiator 5 Disconnect fuel lines and wires atlached to en gine units Remove air cleaner and carburetor 6 Attach engine lifting fixture Tool 0 3466 to carburetor flange studs on intake manifold 7 Raise vehicle on a hoist and install engine sup port fixthre Tool 0 3487 on ...

Page 246: ...ehicle 14 Fill engine crankcase and transmission Refer to Lubrication Group 0 for quantities and lubri cants to use and check entire system for leaks and correct as necessary Whenever art enin is rebuilt end a new camshaft and or new tappet are installed add one quart of factory recommended oil additive to engine oil to aid break in Engine Oil Additive No 1879406 or quiv lent The oil miwlure shoul...

Page 247: ...lin der head cover and heater hooting 11 Remove exhaust manifolds 12 Remove rocker arms and shaft assembly 13 Remove push rods and place them rn their re spective slots in holder Tool C HUGO 14 Remove the 17 head holts from each cylinder head and remove cylinder heads 15 Place cylinder head in holding fixture Tool 0 8626 Installation 1 Clean gasket surfaces of the cylinder block and cylinder head ...

Page 248: ...and exhaust valves operate in guides that are cast integral with the heads Removal 1 With the cylinder bead removed compress valve springs using Tool 0 3422 Fig 10 2 Remove valve retaining locks valve spring re tainers valve stem cup seals and valve springs 3 Remove any burrs from valve stem lock grooves to prevent damage to the valve iide when valves are removed Valve Inspection 1 Clean valves th...

Page 249: ... valve with llgjit pressure H the blue s transferred to the center of the valve face the con tact is satisfactory If the blue is transferred to the top edge of the valve face lower the valve seat with a 30 stone If the blue is transferred to the bottom edge of the valve face raise the valve seat with a 60 stone 3 When the seat is properly positioned the width of the intake seats should be 1 16 to ...

Page 250: ...ition in cylthder head 2i Install new cup seals on the intake and exhaust valve stems and over valve guides Figs 6 and It and install valve springs and retainers 3 Compress valve springs with Tool C 3422A In stall the locks and release tool If the valvet and or seats ar reground measure installed height of springs Make sure meesurement Is taken frQm the bottom of spring seat In cylinder head to bo...

Page 251: ...r by foreign particles becoming wedged NK559 TAPPEI BODY _FtUNGEP SflFNG TAPPET FLU NOER PLUNGER CAP PLUNGER ETAlNR 5PnNG CLIP between the plunger and the tappet body causing the plunger to stick in the down position This heavy click will be accompanied by excessive clearance between the valve stem and rocker ann as valve closes In either case tappet assembly should be removed for inspection and c...

Page 252: ...event damage engine must not be run above driulic tappets have filled with quiet VALVE TIMING All Models 1 Turn crankshaft until the NO 6 exhaust valve is closing and NO 0 intake valve is opening 2 Insert a Unch spacer between rocker arm pad and stem tip of NO 1 intake valve second valve on the left bank 3 Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular a...

Page 253: ...und both sprockets 3 Turn crankshaft and camshaft to line up with the keyway Iocatioa on crankshaft sprockct and dowel holes in the camshaft sprocket 4 Lift sprockets and chain keep sprockets tight against chain in position as described 5 Slide both sprockets evenly over their respec tive shafts 0 Use a streight edge to measure alignment of timing marks Fig 23 7 Install washer and camshaft sprocke...

Page 254: ...e se I retainer and cr nkshaft oil slinger after seal has been In operatIon Installing the Chain Case Cover I Be sure mating surfaces of chain case cover and cylinder block are clean and freefrom burrs 2 Using a new gasket slide chatn case cover over locating dowels Install and tighten bolts 15 foot pounds Installing Vthration Damper 1 Place damper hub key in slot in the crankshaft and slide vibra...

Page 255: ... drive gear and shaft Fig 31 4 Hold tool in position with distributor lock plate Screw This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in the rear of cylinder block The tool should TSEThSjEI installed until camshaft end crankshaft sprockets and timing chain have been i flats lIed Whenever en engine is rebuilt and a new camshaft and or new tappe...

Page 256: ...e and between NO 6 and NO cylinders to NO 4 camshaft bearing and on the right bank above and between NO and 7 cylinders to NO 4 camshaft bearings If camshaft hearing oil holes are not in exact register remove and reinstall them cor rectly Use Tool C SO to install a new welch plug at rear of camshaft Be ure this plug does not leak DISTRIBUTOR DRIVE SHAFT BUSHING Removal 1 Insert Tool C4052 into the...

Page 257: ...e connecting rod bolt and protector over the other bolt and push each pis ton and rod assembly out of cylinder bore 4 After removal install the corresponding bear ing cap on the rl Cleaning and Inspection 11 Clean cylinder hiock thoroughly and inspect all core hole plugs for eridence of leaking 2 If new core hole plugs are installed coat the edges of plug and core hole with a suitahle sealer and d...

Page 258: ...hape It is important that old or new pistons be measured for taper and elliptical shape before they are fitted into the cylinder bore Fig 36 Finished Pistons All pistons are machined to the same weight in grams regardless of oversize so piston balance can he maintained For cylinder bores which have been honed or rehored pistons are available in standard and the following oversi2esl 005 020 and 040...

Page 259: ...T TOOL PSTON PISTON PIN MAIN SCREW TOOLI GUIDE SMALL CONNECTING ROO GUIDE LARGE Fig 42 Tool An engentent for Installing Piston Pin Using Tool C4684 sliding fit in the piston at 70 degrees F Piston pins are supplied in standard sizes only 2 Lubricate piston pin holes in the piston and connecting rod 3 Arrange Tool C 3684 parts for installation of piston pin Fig 42 4 Install spring inside the pilot ...

Page 260: ...ODS IMPORTANT A Maltese Cross stamped on engine numbering pad Fig 45 indicates that engine is equipped with a crankshaft which has one or more coiinecting rods and or main bearing burial finished 001 inch oversize The posifion of the undersize our naP or journals is stamped on a machine surface of the NO 3 counterweight FIg 46 A MALTESE CROSS followed by n X indicates that all connecting rod and m...

Page 261: ...ther and above the piston pin holes 3 immerse piston head and rings in clean engine oil slide ring compressor Tool C 385 over the piston and tighten with special wrench part of Tool CaBS 4 Be sure the position of rings does not change during this operation Screw connecting rod bolt pro tector part of Tool C 3221 on one rod bolt and insert rod and piston into cylinder bore Rotate crankshaft so conn...

Page 262: ...SURING MAIN BEARING CLEARANCE 3 Smooth edges of a x inch piece of brass shin stock 001 Inch thickness 4 Install bearing in center main bearing cap bearing tang in groove in cap lubricate bearing and position shim stock across the bearing install cap tighten bolts to 85 foot pounds II a slight drag is felt as crankshaft is turned moved no more than 44 turn in either direction clearance is 001 inch ...

Page 263: ...tainer grooves 3 Install the seal retainer and tighten screws to 30 foot pounds Failure to pre cil the seals will result in an oil leak GENERAL INFORMATION ENGINE OILING SYSTEM The engine oiling systems consists of an externally mounted rotor type pump a full flow oil rnter oil pan and the necessary lubrication passages Oil is forced by the oil pump through the filter to a senes of Oil passages in...

Page 264: ...verter dust shield 4 Connect exhaust pipe branches to manifolds and to the exhaust extension 5 Connect steering linkage at idler arm asid at CGVER STRAIGHT EDGE FEELEP GAUGE pitman arm 6 Connect battery cable 7 Install drain plug and refifi crankcase OIL PUMP Removal Remove oil pump attaching bolts and remove pump and filter assembly from bottom side of enflie Assembly I Remove filter base and oil...

Page 265: ...ef valve spring has a free length of 2 0 32 to 2 19 64 inch and is red in color OuTER ROTOR INNER ROTOR PEELER yGAUGE KRIfl If the oil pressure is low inspect for worn bearings or look for other causes of possible loss of oil pressllre Installation When assembling the oil pump be sure to Use new oil seal rings between filter base and pump body 1 Install a new 0 ring seal on the pilot of oil pump b...

Page 266: ...ttle is free A clicking noise should be heard when the valve is shaken engine not running If the noise is heard the unit is functioning satisfactory and no further service is necessary If the valve does not click when shaken or if the paper is not sucked against fill pipe valve should be replaced and system retested Do not attempt to clean the valve On all engines the Mopar Ventilator Valve is ide...

Page 267: ..._______ VENT VALVE ASSEMBLY P V 8 ENGINES Fig 2 California Closed Crankcase Ventilation System 64X307D 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 inch drill through the passages to dislodge the solid particles Blow clean Use a ...

Page 268: ...Part No Insert Length Size Part No Part No Part No 20 5 16 18 s 16 7 16 14 13 1185 4 1185 5 1185 6 1185 7 1185 8 15 32 9 16 21 32 17 64 266 Q 332 X 332 29 64 453 33 64 516 4 CPB 5 CPB 6 CPB 7 CPB 8 CPB 528 4N 528 SN 5286N 528 7N 528 8N 1227 6 1227 6 1227 6 1227 16 1227 16 MyMopar com ...

Page 269: ...imits for taper and out of round Maximum Allowable Oversize Cylinder bores Tappet Bore Diameter Distributor Lower Drive Shaft Bushing press Ream to Shaft to Bushing Clearance CRANKSHAFT Type Bearings Journal Diameter 383 Cubic Inch 440 Cubic Inch Crank Pin Diameter Maximum Out of Round Permissible Number of Main Bearings Clearance Desired Bearings Installed l D Minus Maximum Clearance Allowable En...

Page 270: ...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 383 Cubic Inch 2 BBI Carburetor 130 59 59 13 26 2520 252 383 and 440 Cubic Inch 4 BBI Carburetor 18 58 66 14 32 252 260 TAPPETS Type Clearance in Cylinder Block Body Diameter Clearance Between Valve Stem and Rocker Arm Pad Oversize Avai...

Page 271: ...in Standard 005 020 040 Oversize Press Fit in Rod 1 0935 to 1 0937 3 555 to 3 575 00045 to 00075 0007 to 0012 Standard Only Toward Right Side of Engine 3 2 1 3 Piece Chrome Plated Rails with Stainless Steel Expander Spacer 0775 0780 025 013 025 015 055 0015 0030 0002 OOS 013 052 015 062 0015 004 0002 OOS 017 45 None 392 425 Nitrogen Treated Manganese Chromium Nickel Steel 160 371 to 372 Standard 0...

Page 272: ... Rotor Length Clearance Over Rotor Outer Inner Outer Rotor Clearance Tip Clearance Between Rotors When filter is replaced add 1 quart 2 Wedge Type 002 45 060 to 085 45 040 to 060 022 Rotor Full Pressure 4 5 Camshaft 45 to 65 lbs Full Flow 7 to 9 lbs 0015 inch or more 943 inch or less 2 469 inch or less 942 inch or less 004 inch or more 005 inch or more 012 inch or more 010 inch or more Stem to Gui...

Page 273: ...Rod Nut Cylinder Head Bolt Chain Case Cover Bolt Clutch Housing Bolt Crankshaft Rear Bearing Seal Retainer Crankshaft Vibration Damper Bolt Cylinder Head Cover Stud and Nut Distributor Clamp Nut Engine Front Mounting to Frame Bolt Engine Front Mounting to Block Nut Engine Front Mounting to Frame Stud Exhaust Manifold Nut Exhaust Pipe Flange Nut Exhaust Pipe Clamp Nut Exhaust Pipe Support Clamp Bol...

Page 274: ...porate a thermostatic heat control valve to direct the exhaust gases to a heat chamber beneath the carburetor mounting flange to help vaporize the fuel SERVICE DIAGNOSIS Possible Cause a Leaks at pipe joints b Burned or blown out muffler c Burned or rusted out exhaust pipe d Exhaust pipe leaking at manifold flange e Exhaust manifold cracked or broken f Leak between manifold and cylinder block a Ti...

Page 275: ...EAR VIEW IN CIRCLE A WASHER NUT VIEW IN CIRCLE B Newport 300 and New Yorker SUPPORT NK947A U NUT _ ____ SUPPORT PLATE CLAMP BOLT SCREW VIEW IN CIRCLE B BOLT CASKET PIPE CKET I PIPE PLATE ER VIEW IN CIRCLE A WASHER U BOLT SUPPORT NUT NN135A Fig 2 Exhaust System Dual Chrysler Newport 300 and New Yorker MyMopar com ...

Page 276: ...MUM CLEARANCE AS SHOWN BY ARROWS BOLT GASKET EXHAUST PIPE EXHAUST 11 3 FLANGE SUPPORT VIEW IN CIRCLE B TAIL BALL JOINT CONNECTION U BOLT NUT Fig 3 Exhaust System Single Imperial Sedan VIEW IN CIRCLE C WASHER NUT NN134 IN CIRCLE B Fig 4 Exhaust System Dual Imperial Convertible MyMopar com ...

Page 277: ... 2 Adjust support heights for proper alignment 3 Tighten U bolt nuts to 100 inch pounds 4 Tighten support clamp screws to 95 inch pounds 5 Align system at ball joint connection and tighten flange bolts to 20 foot pounds The inner sur faces of the flanges should be parallel to each other and perpendicular to the pipe axis 6 Adjust converter housing bracket so that it is flat against converter housi...

Page 278: ...ontrol valve Figs and II should be inspected periodically With en gine idling accelerate momentarily to wide open throt tIe The counterweight on Chrysler models should respond by moving counter clock aise approximately inch and return to its original position On Inipe na engines thc counterweight should move a similar distance in a clockwise direction If no movemcnt is obsen ed the shaft is bindin...

Page 279: ...t lnstahlation_ Chrysler Models U Be sure shaft retainer is in place on outer end of valve shaft 2 install counterweight and bumper en outer end of valve shaft The bumper should be located on the right hand side of the hub section of the counter weight and on the left hand side of the stop pin Fig to 3 Tighten clamp bolt to 50 inchpouuds with C 8SO Torque Wrench Test operation of valve for freedom...

Page 280: ...shaft fails to turn freely it will be necessary to hone the bushing to shaft size 3 Pull shaft out far enough to position the valve plate on the shaft then slide shaft into position n both bushings 4 Align hole in valve plate with hole in shaft and inscrt a drift into both holes to maintain correct posh tioning of valve plate as it is being welded to shaft SI Remove drift from valve plate and shaf...

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Page 327: ...i ble such as on an alignment pit or a platform hoist A two post hoist may be used where other means are not available The vehicle should be approximately level when taking angle measurements with any heavy items removed from the luggage compartment or passenger compartment The fuel tank should be full or the equivalent weight simulated CROSS AND ROLLER UNIVERSAL JOINTS SPECIFICATIONS GENERAL INFO...

Page 328: ...ASURING PROPELLER SHAFT ANGU LARITY FLANGE SEAL RETAPNER BUSH NO RETAINER 8 WASHa SEAL ER FRONT UNIVERSAL JOINTANGLE 1 Attach engthe adapter SP 5046 to gauge SP 5 Q 2 Position gauge or kit side of engine so that adapter pins contact flat surface of engine on pan flange adjacent to verticM wall of the oil pan flg 4 SHAFT _____RETAINFR JSMING ETAINER XSn A E TAINEP SEAL CROSS 0 RETAINER SLIDING V 7 ...

Page 329: ...s means that the angle is actually smaller than that specified and does not need correcting If bubble in spirit level Is found to be rearward of the acceptable range the angle is too large and must be corrected To reduce front un veNal joint angle install a flat shim between the transmission extension housing and rear engine mount Fig Ot Flat shims inch in thickness are required to move the bubble...

Page 330: ...o rear the nose of differentiat is too high so thick end of shim goes toward rear of car Fig 9 A 1 shim will move bubble in spirit level about 3 gradua tions forward or rearward depending on which way the thick end is installed Presently there are a number of makes of wedge type shims available commercially Always make sore shims you use are made of steel and are the same width as the springs on t...

Page 331: ...yoke from the transmission output shaft Fig 11 Be careful not to damage splines on output shaft or yoke Examine sliding yoke seal for evidence of leakage If no leak age is evident do not disturb the seal If necessary to replace the seal refer to Transmission Group 21 CAUTION It is important to protect the machined surface of the sliding yoke from damage after pro peller shaft has been removed Inst...

Page 332: ...l joint at the front end Fig 12 and constant velocity cross and roller universal joints at the center and rear end Figs 13 and 141 The shaft is supported by a ball bcaring and bracket located forward of the center joint The bracket height is non adjustabla Centering ball and socket arrangcmcnts are incor porated in the center and rear r onstant velocity joints tFigs 15 and 16 The centering balls b...

Page 333: ...nd washers Tighten nuts to 300 inch pound 2 Connect front uffiversal joiot to transmission output shaft yoke Install cross and roller hushing clamps bolts and washers Tighten bolts to 170 inch pounds NEP SOCFT YOKE SNAFF otiierwi5a support front end f pro prevent dan iging ce iter loint stud nuts and washers attaching rear c NTrlNG ASSEMBLY STAt t SSE vB L V Fig Id Rear Universal Joint Constant Ve...

Page 334: ... use a short length of pipe or a socket with an inside diameter of not less than 1 1 16 inch Clamp the joint with remover and receiver in a vise Fig 18 and press one of the rear yoke bearings approximately inch out of yoke 5 Securely clamp the exposed bearing in ise and drive yoke from bearing using a brass drift Fig 19 Apply only light blows on drift 6 UsIng same procedure press exposed end of cr...

Page 335: ...to bore at same time guiding cross into bearing Press bearing into yoke approxi mately 3 16 inch or far enough to install snap ring Install snap ring Reverse position of yoke and install bearing and snap ring in opposite bore in same manner 6 Place center yoke on cross installed in shaft yoke Install the two bearings and snap rings in yoke as previously described 7 Install cross assembly and two b...

Page 336: ...int Assembly Install snap rings 3 Position center yoke over cross in propeller shaft yoke Install two bearings in front bores of yoke Install snap rings 4 Apply film of Automotive Multi Purpose E P Grease NLGI grade 2 on centering stud 5 Install cross and center socket yoke as an as sembly in center yoke Guide centering ball on stud at same time engaging cross ends in yoke bores 6 Apply pressure t...

Page 337: ...ne DIAMETER INCHES Front Shaft Rear Shaft UNIVERSAL JOINTS Front Center Rear Cross and Roller Constant Velocity Constant Velocity TIGHTENING REFERENCE POUNDS FOOT INCH Front Transmission Flange Clamp Rear Pinion Flange Clamp Screw Rear Pinion Yoke Stud Nuts Center Bearing Bracket Bolt Nuts Pinion Bumper Plate Screw Rear Spring U Bolt Nuts Screw 35 45 170 170 300 200 26 59 40 81 2 25 3 00 MyMopar c...

Page 338: ... spring as neces sary SPRING NOISE SPRING BREAKAGE a Loose U bolts b Loose or worn shackle bushings c Worn or missing interliners a Loose U bolts b Shock absorber inoperative a Tighten U bolt nuts 45 foot pounds b Replace bushings Tighten shackle bolt nuts 35 foot pounds c Install new interliners a Replace spring Inspect U bolts for damage Tighten U bolt nuts 45 foot pounds b Replace spring and sh...

Page 339: ...ounds REAR SHOCK ABSORBER REPLACEMENT Removal 1 Remove nuts and washers from shock absorber upper mounting bolts and lower mounting studs Fig 3 2 Remove upper mounting bolt and shock ab sorber assembly 3 Inspect bushing for deterioration damage or wear Install new bushings if necessary Test and bleed shock absorber Installation 1 Position shock absorber on mounting studs and install remaining cupp...

Page 340: ...one should not be the reason for spring replacement PIVOT BUSHING REPLACEMENT Removal of old bushing and installation of new bushing is performed in one operation using Tool C 3709 Fig 4 1 On bolt SP 3178 position bearing washer SP 92 thrust bearing SP 332 bushing adaptor SP 3 179 flat side of adaptor next to washer spring leaf bush ing and remove adaptor SP 3 180 2 Insert bolt SP 3 178 through bu...

Page 341: ...sorbers 6 Remove vehicle floor stands and with the vehi cle weight on the wheels tighten pivot bolt to 125 foot pounds and shackle bolt nuts 35 foot pounds 7 Measure car curb height whenever a rear spring or shackle has been replaced SPECIFICATIONS REAR SPRINGS Type NUMBER OF LEAVES Std Heavy Duty Town and Country Standard Heavy Duty Police Taxi WIDTH inches LENGTH inches MOUNTING Front Rear Zinc ...

Page 342: ...eeis Possible Cause a Low or uneven tire pressure b Insufficient lubricant in the steering gear housing or in steering linkage c Steering gear shaft adjusted too tight d Front wheels out of line e Steering column misaligned a Incorrect tire pressure b Wheel bearings improperly adjusted Cc Dragging brakes d Improper caster and camber Ce Incorrect toe in f Grease dirt oil or brake fluid on brake lin...

Page 343: ...led by the worm thrust bearing adjuster which threads into the housing at the upper end of the wormshaft Worm Sewing Pre Lood I Disconnect steering gear arm from cross shaft with Tool 3646 Fig 3 2 Remove horn button or horn ring 3 Loosen cross shaft adjusting screw lock nut and back out adjusting screw approxilnateh two turns This wm relieve any friction load which may be present at closely meshed...

Page 344: ...g clamp at upper end of steering gear wormshaft 3 To provide sufficient clearance at coupling loosen column jacket to instrument panel clamp bolts sufficient to disengage tab on clamp from slot in column jacket Slide column assembly up far enough to disengage coupling from wonnshaft CAUTION Care is required to avoid scratching col umn jacket when sliding it up and dawn in damp assarm bI as It is n...

Page 345: ...in an arbor press insert Tool 0 3780 in lower end of housing FIg 7 and press both bearings through housIng The cross shaft cover as aefTibly Including a needle bearing or bushing Is serviced as an assembly 11 Remove wonnshaft oil seal from wormshafl bearing adjuster by inserting a blunt punch behind seal and tap alternately on each side of seal until seal is driven out of adjuster 12 Remove wormsh...

Page 346: ...adapter ring Press bearing into hoasing to inch below end of bore to provide space for oil seal 20 Install inner needle bearing by placing bearing on Tool 0 3333 Fig 9 Press bearing into inside end of housing bore flush with inside end of bore surface 21 Install wormshaft bearing nips position bear ing cup and spacer into adjuster nut and press them in place with Tool 0 3365 Figs 10 and 11 22 Tnst...

Page 347: ...ing gear housing rig 4 The cross shaft and sector teeth should be coated with steering gear lubricant before installing cross shaft in housing 40 Make certain some lash exists between cross shaft sector teeth and bali nut rack Install and tighten cover bolts to 25 foot pounds GEAR INSTALLATION to loot where column coupling will clear end of wormshaft to permit installation of steering gear Make su...

Page 348: ... the bench or without removing steering gear from vehicle CAUTION When replacing oil seal in vehicle clean the exposed portion of cross shaft to help prolong oil seal life Use Tool C 3880 to service cross shaft seal The tool consists of adapter SP 3056 half rings SP 1932 and nut SP 3610 1 Slide threaded adapter over end of cross shaft and install nut portion of tool on shaft Fig 13 Maintain pressu...

Page 349: ...r from the steering gear through a return hose SERVICE DIAGNOSIS a Inflate tires to recommended pres sures ID See Fluid Level Power Steering Pump Cc See Group 7 Cooling d See Front Wheel Alignment Front Suspension Group 2 Ce Perform the Pump Pressure and Flow Tests f Repair and lubricate as necessary g Adjust or repair as follows 1 See Gear Shaft Adjustment 2 Remove steering gear repair as necessa...

Page 350: ...ring gear unit 8 Rough or catchy worm in the piston assembly a Tires not properly inflated b Improper wheel alignment c Valve body out of adjustment Cd Valve lever damaged Ce Column support spanner nut loose f Coupling not centered 7 Remove steering gear disassemble completely clean in a clean solvent inspect and make repairs as nec essa ry 8 Replace worm and piston assembly See Gear Reconditionin...

Page 351: ... adjustment 3 Coupling loose on the worm shaft 4 Worm and piston assembly Cc Metallic clatter or tapping noise Cd Knocking condition at the bracket stop when the engine is running Ce Loose pump belt SERVICE PROCEDURE a Noisy pump make pressure test and repair as necessary Damaged hydrau lic lines or interference of the hoses with components attached to the fender shield Air in system work steering...

Page 352: ...SHAFT RALANONO RING RIGHT TURN REACTION RING rn TURN REACION RING CYLINDER HEAD 64 I7 edges of valve The sharp edge is vitally isnportant to operation of this valve 7 Clean valve bodies and valve piston thoroughly in clean solvent Blow out all passages with com pressed air Lubricate pistons and bores with power steering fluid 0 Install steering spool valve In valve body so valve lever hole is alig...

Page 353: ...art and stop the engine several times tap ping the valve body up or down as required until there is no movement of the steering wheel when the engine is both started or stopped 21 The valve is now centered Tighten the two screwa attaching valve body to housing to 200 inch pounds Gear Shaft Oil Seal Replace The gear shaft oil seal may be replaced kthoat removing the steering gear from the vehicle 1...

Page 354: ...he steering arm by prying with a lever or striking with a hammer as serious steering gear internal darner may result i Disconnect pressure and return hoses at steer ing gear Fasten ends of hoses above oil level in pump reservoir B Drive out roll pin in flexible coupling 7 Remove the four nuts and washers connecting master cylinder to brake booster and move master cylinder towards engine 8 On cars ...

Page 355: ...mshaft to Full left turn position for CIii sler models or full right turn position for Imper ial models to compress power train parts Remove power train retaining nut i4th Tool 3634 Fig 11 Remove housing head tang washer 0 While holding power train finnly compressed pry on piston teeth with a screw driver using gear 628 shaft as a fulcrum and remove complete power train It is irnportant that the c...

Page 356: ...SHER SNAP RING RETAINER SEAL SEARING FICU5ING 0 RING SHAFT SCRSW a 0 II II NUT NUT HEAD RING VALVE ASS EM BLY RACE SPRING BEARING PACE RI F G BEARING RACE AND SPACER SERVICED IN MATCHED SEIS RING SPRIN WASHER NUT SEAL SEAL PING N fI2I40 Fig 13 Steering Geor Dijossembled View Chrysler Models MyMopar com ...

Page 357: ...ASHER NUT 06 VALVE ASSEMBLY HEAD RING RAC E BEARING SPRING INC BEARING RACE ING SPRNG WASHER HOUSING SEAL RING SHAFT 5CR WASHER O RING RING RING NUT NOT RING 0 PING RING NUT SEAL SEAL RING 64 y2i B Fig T45teeri g Gear Disassembled Vlew inip riel Modeis MyMopar com ...

Page 358: ...aft oil seal is to be replaced perform the operation with the housiag head assem bled in the steering gear housing 12 Remove large 0 ring from groove in housing F rrIi4sA Fig I 6 Ren ovlng Reaction Seal from Worm Shaft Support head 13 Remove reaction seal from groove In face of housing head tth air pressure directed into ferrule chamber flg IS 14 Inspect all grooves for burrs Make sure pas sage fr...

Page 359: ... itton ring into place In piston groove then place piston and ring assembly in Tool C3878 with lower part of piston and ring resting on and of tool Fig 20 b Press down on piston to seat ring in piston groove forcing open ends of ring out for ease of lock ing the ring 28 Place piston assembly in a vertical position wormshaft up in a vise equipped with soft jaws 29 Inspect cylinder head ferrule oil ...

Page 360: ...ylinder head ferrule This will alIgn the valve pivot lever hole in the center bear ing race with the valve pivot lever hole in center bearing spacer assembly The saiali 0 rln for the ferrule groove should not be installed until after upper reaction spring and spacer have been installed 38 Install upper reaction ring on center race and spacer with flange down against spacer 39 Install upper reactio...

Page 361: ...lve lever hole in center bearing race and spacer exactly with the valve lever hole in the gear housing Turn the housing head by tapping on a reinforcing rib with hammer and drift Use Tool C 3640 to maintain alignment Fig 24 The aligning tool should not be removed until the spanner nut is securely tightened 54 Install housing head tang washer to index with groove in housing Install spanner nut and ...

Page 362: ...er direction attempt to return the unit to center by ap plying a torque wrench at steering gear sbaft Hold wormshaft until cross shaft torftue builds up to 50 foot pounds Release wormshaft and maintain a con stant steady pull at 2 rpm on the gear shaft II cross shaft torque does not drop to 20 foot Founds maxi mum as the unit passes through center check for too much interior drag binding valve lev...

Page 363: ...rews finger tight CAUTION While the stoe ing column is not rigidly attached to the instrument panel use extreme care to prevent any misalignment ol the column from the true column position which would result in damage to the flexible coupling dlst and horn ground 6 After positioning steering column assembly so that flexible coupling disc assumes an unstressed axial position and top of steering col...

Page 364: ...See Pump Flow Test Service flow control valve as necessary b Adjust belt See Cooling System Group 7 c Inspect and correct fluid level d Perform Pump Flow Test and ser vice as necessary NO ASSIST NO ASSIST WHEN PARKING ONLY a Pump seizure b Broken slipper spring Cs c Flow control bore plug ring not in place d Flow control valve sticking a Wrong Pressure relief valve b Broken 0 ring on flow control ...

Page 365: ...ace a thermome ter with a range of 200W in oil 4 Install tachometer and operate engine 500 RPM Inspect and correct lump fluid level if necessary 51 Expel all air from unit by turning steering wheel to full right turn and back to full left turn several times and recheck oil level To assist in heating pump oil slowly close pressure gauge valve until gauge reads 400 psi and open valve fully when oil ...

Page 366: ...ssure line reads 850 psi without fully closing valve The Jow gauge in return line should read a minimum or io psi A value of less than 10 psi indicates a sticking flow control valve a leaking pressure relief valve or a badly worn pump When removing test equipment reinstall pressure and return hoses in same position they were in before removal PUMP REMOVAL ii Lnosen pump lower mounting and locking ...

Page 367: ...aft Fig 7 0 Install new pump ring and reservoir gasket Lubricatc 0 ring before installation 101 Install reservoir and pump brackets Tighten screws to 16 foot pounds 11 Install pump and adjust belt as outilned under Cooling Group DISCHARGE FITTING FERRULE REPLACEMENT 1 Remove pump from engine FLOW cONrR0L VALVE 2 Clamp pump in vise upside down to prevent chips from falling into pump 9 25 TOOL SeAL ...

Page 368: ...635675A of the bore It may be necessary to lightly rap valve and repeat above operation if it is stuck in position H dirt chips etc are round on valve or within valve borc entire pump should be disassembled washed out and rebuill If valve bore is badly scored replace pump body 14 Seat control valve sprcng in spring pocket 5 Remove any burrs on valve with crocus cloth but DO NOT round off edges of ...

Page 369: ... press shaft rotor and insert out of housing I Fig 12 5 Broken edges or deep scoring of rotor and slippers will require pump body replacement Do not mistake two machined notches on inside surface of cam Insert for scoring I Ot Smooth off burrs on pulley end onlyi of pump shaft to prevenl seal damage on installation Clean all parts thoroughly with solvent Cleanliness is essential throughout pump as...

Page 370: ...The silpp r ends may hang up in cam insert ports during installation Rotate shaft while inutalling to prevent this occurence 14 Remove flat washer Make sure slipper springs are in place by rotating shaft and looking through end of each slipper 151 lubricate rotor assembly and rotate to make sure slippers do not bind 16 Replace shaft seal See Oil Seal Replace nenrI and O ring seal on front insert L...

Page 371: ... utilize an oil cooler mounted on the left side of the radiator sup port in front of the air conditioning condenser Fig 1 The oil return hose from the steering gear returns the oil to the pump through the cooler To replace or service the cooler remove the return hose at the pump and drain the oil out of the cooler Next remove the hose clamps and hoses from the cooler and the cooler support retaini...

Page 372: ... 11 in lbs Pull through high spot POWER STEERING GEAR Type Ratio Wheel Turns Stop to Stop Cross Shaft Bearings Worm Shaft Thrust Bearing Pre Load Cross Shaft Adjustment Fluid Capacity of Hydraulic System Type of Fluid Constant Control Full Time Power 15 7 to 1 3 2 Needle Bearings and 1 Direct Bearing on Gray Iron Cover 16 24 Ozs Tighten Adjusting Screw to 2 turn past Zero Back Lash Center of High ...

Page 373: ...r Shaft Adjusting Screw Lock Nut Gear Shaft Cover Nut Pump Inlet Fitting Steering Arm Nut POUNDS FOOT INCH Steering Column Support Nut Steering Shaft Coupling Bolts Valve Body Attaching Bolts Valve Body End Plug Steering Wheel Nut POUNDS FOOT INCH 12 25 24 200 200 POWER STEERING PUMP Pump Inlet Fitting Pump to Bracket Bolts 96 pump FOOT POUNDS FOOT POUNDS 30 1 2 pump 35 30 Reservoir to Pump Body B...

Page 374: ...n Installation Transmission Removal 4 specifications 2 steering Column and Gearsllift 3 TighteningRetsrerice Page 4 a 4 11 4 69 11 rear end of the mainshaft is supported by the sliding yoke and hushing in the extension housing The speedometer drive gear is integral with the mainshaft lMPORTANT All transmission have the sliding spline type outpid shaft Whenever th propeller shaft front slidins yoke...

Page 375: ...is adjustment correctly To check this start engine with clutch disengagod then release the clutch slowly 2 Inspect fore and aft movement of shift levers in he steering column if movement at outer end of levers exceeds 1 16 inch loosen the two upper bush ing screws Fig 2 and rotate bushing downward until all free play of levers has been removed Re tighten bushing screws securely 3 Install a wedge o...

Page 376: ...properly adjusted should allow pedal to return to ahout one inch from the floor SPEEDOMETER PINION Removal and Installation Rear axle gear ratio and tire size determines pmlon gear size requirements Refer to Speedometer Pinion Chart for pinton usage I Remove bolt and retainer securing speedometer pinion adapter in the extension housing Fig 5 2 Vith cable housing connected carefully work adapter an...

Page 377: ...ension housing and on TTTarnshaft splines Connect propeller shaft to rear axle pinion shaft yoke SERVICE OUT OF VEHICLE TRANSMISSION REMOVAL 1 Drain lubricant from thatransmission 12 Disconnect propeller shaft at rear universal joint Carefully pull shaft yoke out of tbe transmission extension housing CAUTION Re careful not to scratch or nick ground surface on sliding split yoke during removal aid ...

Page 378: ... A I A kiN C SNAP AING OIL SLINGER CASE SNAP PING DRIVE PINION I OLLLj TEAT PJGS TAPERED FIN C P0MM F I POLLEE EFAP NCs THRUST WAS HER THRUST PLATE AOl F VI t H r LEVER WASHER NUT WASH ER LOC K Wt SH ER PjSHNc LKwASNEE CPGPMET GASKET PAWL I XI I IS ION I SEAL BOLT AND WASHER I N r LIA IN LW YORE IDLER f EAA BEARING THRuST WASHER SHAFT LEVtR I DETENT BALL STOP RING r Pt UG p BUSHING 0LF F I WS A TA...

Page 379: ...ch main drive pinion bearing rctainer then slide retainer off the pinion Discard gasket and drive seal out of the retainer using a suitable drift 12 Grasp pinion shaft and pull assembly out of ease slightly the slide synchronizer front inner stop ring from the short splines on pinion as pinion assem SEAL STOP RINGS NN92 OIL SLINGER N ORIV PrNION Fig Z Drlye Pinion Asemby KP172b bly is being remove...

Page 380: ...should be from Fig 17 Removing or installing Moinshoft 0045 to 028 inch This measurement will determine if new thrust washers are to he installed at rea s_ sembtyL i21 Using countershaft bearing arbor Toot C 3834 driver countershaft toward rear of case until smEill key can be removed from countershaft Drive countershaft remaining way out of the case keeping arbor tight against end or countershaft ...

Page 381: ...for flat spots or hrinel ling Inspect all bearing roller spacers for signs of wear or galling Install new parts as required Gears Inspect gear teeth oni synchronizer clutch gears and stop rings If there is evidence of chipping or exces sively worn teeth install new parts at reassembly Be sure clutcI sleeve slides easily on the clutch gear inspect countershaft gear and all sliding gear teeth for ch...

Page 382: ...h keyway aligned with recess in ease drive shaft forward inserting key hefore keyway is ob scored Continue driving shaft forward until key seats in recesS Gearshift Mechonism To install gearshift mechanism refer to Fig 19 then proceed as follows 1 Place new shift lever shaft seals centered in their bores in the case Using Tool 1 3768 drive hoth seals into the case until tool bottoms 2 Install seal...

Page 383: ...snap ring Drive Pinion 1 Slide oil slinger if removed over pinion shaft and down against the gear Fig 13 2 Slide bearing over pinion groove away from gear end then using an arbor press 3 Secure bearing and washer with selected thick ness snap ring Four snap rings are available to elimi nate end play same thickness as clutch gear and mainshaft snap rings Be sure snap ring is properly seated If the ...

Page 384: ...of front tarn versal joint yoke refer to Lubrication and Mainte nance Group 0 Carefully guide front universal 5W ii C RETAINING r cppws 131 joint yoke into extension housing and on mainshaft splines Connect propeller shaft to the rear axle pin on shaft yoke t Road test vehicle making sure transmission shifts smoothly and operates quietly I 0 If the shift linkage requires adjustment refer to Page 2...

Page 385: ...ver Fig 25 0 Remove three Inwer support cup to jacket attaching screws Fig 20 and remove the cup I Remove nylon thrnst washer low and reverse lever and the spaccr 8 Remove two lower shift tube bushing retaining screws at slotted holes in the jacket 9 Slide shift tube with 2nd and direct lever nylon bushing spring and spring retainer out of the jacket Fig 27 NOTE The shift tube with 2nd nd direct l...

Page 386: ...t rests against the 2nd and 3rd speed shift lever 8 Install low and reverse lever Then install the nylon washer centering it over end of the shift tube ici Install lower support cup in the jacket F ig 26 while holding pressure against cup to overcome selec tor spring load start the three support cup retaining screws and tighten t0 30 inch pounds 10 Loosely enter lower bushing retaining screws thro...

Page 387: ...ll pin 3i Loosely fasten steering column jacket to in strument panel bracket with clamp and the two at tarhing screws Re sure tab on clamp is entered in locating slot in the column lacket 41 Thc steering shaft coupling must he centered at midpoint of its travel Move coltiniri assembly up or down in 1 nstrunient panel bracket so dimension be tveen tnp of coupling and center of gauge hole IFig 31 is...

Page 388: ...luminum Thread Repair Band Adjustments Console Gearshifts I N D EX Extension Housing and Bearing Extension Housing Yoke Seal Governor Hydraulic Control Pressure Tests Hydraulic Control Pressure Adjustments 31 Lubrication 41 Neutral Starting Switch 32 Parking Lock Components 38 Speedometer Pinion 37 Steering Column and Gearshift Page 44 43 45 40 41 32 37 46 43 33 Page 25 15 15 25 26 MyMopar com ...

Page 389: ...rtant functions to perform In a general way the components of any automatic control system may be grouped into the following basic groups The pressure supply system the pressure regulat ing valves the flow control valves and the clutches and band servos Taking each of these basic groups or systems in turn the control system may be described as follows pump housing Pressure Supply System The torque...

Page 390: ...E PLATE OIL FILTER NVALVE RODY SUN GEAR DRFVINO SMELL PARKING LOCK A5SEMRLY ENGINE CRANKSHAFT TURBINE IMPEL LR STATOR Oft REAR PLANETARY GEAR SET a LOW AND REVERSE RAND OVERRUNNING CLUTCH GOVERNOR IMPERIAL MODELS RE ARING OUTPUT SHAFT a a a a a 0 C In 1 r I fll ar RUSHING NNII7 Fig I TorquoFIfre FronsrWsson and Converse MyMopar com ...

Page 391: ...TORQUE CONVERTER TORQUEFLITE TRANSMISSION 21 11 ENGERE RUNNING TO LyE rOQUE CONVERTER Park Hydtaullc Circuits NN34 CONTROL SVSTEJt Il NEUTRAL ENOINE RcJNNJNO NN3S Neotral HydraulicCircuits MyMopar com ...

Page 392: ...21 18 TRANSMISSION TORaIJEFLITE CONTROL StSTEJd IN DRIVE SRfAKAWAYI HALF TIIROTTLC I________ I Drit e Dreakaway Hydraulic Circuits MyMopar com ...

Page 393: ...TORQUEFLITE TRANSMISSION 21 19 KU I DROUE CONVERTER I REAR CLUTCH II CONrEOL SYSTEM PM DRIVE SECOND hALF THROTTLE N37 I OIL PRESSURES II IT T5 TOTS Orive Seond Hydraulic Circuits MyMopar com ...

Page 394: ...FLITE I SEAQ CLUICH Ij______ ri FRONT CLUTCH UIiI _ ACCUMULrOR oL PRESSURES V U E ST PI LVOITSTITS S TO CONTROL SflTSM SN DRIVE DIRECTE RD fl SVTVC H TDROUE CONVERTER TO OUT OIL F ITR Drive Direct Hydraulic Clrtuits MyMopar com ...

Page 395: ...SION 21 21 SERVO IUCgDOWN r TO LUE FU P IT CONTROL SYSTEM IN DRIVE IOCIDOWN AT 50 M P K TORQUE CONVERTER OIL PRESSURES LINE LVRII STITR _______iI ____________________ OUFVTfR II A L 1 T p1 Dtlve Kickdown Hydrolic Circuits MyMopar com ...

Page 396: ...RQUEFLITE SO SERVO L II CSS r CLIITCI I 1 1 J ACC L M I IL TOE II flJ O L PEESSUREL 5 53 CONTROL SYTTE 4 IN MANUAL SECOND CLOSED THROTTLE NH4U rCVQUE CONVE RTE SO LU6 ii Selector Lever Secand Hydruulic Circuits MyMopar com ...

Page 397: ...TORQUEFLLTE TRANSMISSION 21 23 I I II II LIJ NN4 Selector Lever LDw HydraulicCircuits MyMopar com ...

Page 398: ...21 24 TRANSMISSION TORQUEFLITE REAR CLUTCH TCRCIIE CONVERTER FRONT CLUTCH 4 OIL E LTER P U PRI F1 OIL PRESSURES CONTROL SYSTEJR IN REVERSE NN4 RD SERVO TJUV EUVVR Reverse HydraulicCircuits MyMopar com ...

Page 399: ...on is controlled by a lever type gearshift incorporated within the steering column The control has six selector lever positions P park H reverse N neutral D drive 2 second and 1 low Some vehicles are equipped with a lever type console gearshift which has the same selector lever positions The parking lock is applied by moving the selector lever past a gate to the P position CAUTION Never apply the ...

Page 400: ...use the transmission receives lubrica low position should be selected on upgrades which tion only when the engine is running it is good prac requires heavy throttle for 1 4 mile or more Lower tice to always tow a disabled vehicle with a rear end ratios reduces the possibility of overheating the pickup or remove the propeller shaft SERVICE DIAGNOSIS The transmission should not be removed nor disass...

Page 401: ...ure tests to determine cause and correct as required f Governor malfunction f Inspect the governor and repair as required g Accumulator sticking broken rings or g Inspect the accumulator for sticking spring broken rings or spring Repair as required h Clutches or servos sticking or not h Remove the valve body assembly and operating perform the air pressure tests Repair as required i Kickdown servo ...

Page 402: ...rvo for sticking broken seal rings binding linkage or faulty band lining Repair as required j Disassemble the transmission and re pair the overrunning clutch as required SHIFTS ERRATIC a Low fluid level b Aerated fluid c Incorrect throttle linkage adjustment Cd Incorrect gearshift control linkage adjustment e Hydraulic pressures too high or low f Governor sticking g Oil filter clogged h Valve body...

Page 403: ...ssemble and inspect clutch Re pair or replace as required 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 Replace parts as required d Perform the hydraulic pressure tests and adjust to specifications e Adjust the low reverse band f Perform pressure tests to determine cause and c...

Page 404: ... adjustment Cd Valve body malfunction or leakage e Front clutch or rear servo sticking or not operating f Low reverse servo band or linkage malfunction g Worn or faulty front clutch b Perform the hydraulic pressure tests and adjust to specifications c Adjust the low reverse band d Perform pressure tests to determine cause and correct as required e Remove the valve body assembly and perform air pre...

Page 405: ...a Drain the fluid to the correct level Cb Inspect and clean breather vent opening in oil pump housing Cc Replace the oil filter d Inspect for air leakage into oil pump suction passage TRANSMISSION OVERHEATS a Low fluid level Cb Kickdown band adjustment too tight c Low reverse band adjustment too tight Cd Faulty cooling system e Cracked or restricted oil cooler line or fitting f Faulty oil pump g I...

Page 406: ... part will be ti9htened to the same torque LUBRICATION The transmission fluid and filter should provide satisfactory lubrication and protection to the auto matic transmission and no change is recommended in vehicles used in normal service Regularly scheduled fluid and filter changes therefore will not be re quired except when the operation of the vehicle is classified as severe Fluid Level Inspect...

Page 407: ...nkage rod from lever at lower end of steering column 3 Remove heat shield from lower end of steering column Drive roll pin out of the steering shaft to upper joint coupling 4 Disconnect turn signal and horn wires IDSHLNO NN4o 5 Depress horn ring or horn ring ornament and rotate turn counterclockwise to remove Discon nect horn wire at horn sitch Remove three screws and insulators then remove horn r...

Page 408: ...from inside bearing housing to separate it from shift lever gate Slide gate out of the column jacket If necessary tap column bearing out of bearing housing GARSH FT I1OUSNG 8 Rotate gearshift housing to align opening with the lock screw FIg 10 Remove lock screw with an alien wrench then carefully pull gearshift tube out of column jacket If necessary remove shift lever cross over spring load pans F...

Page 409: ...With gearshift housing in NEUTRAL position insert gearshift lever Support gear shift housing Fig 8 while driving shift lever roll pin into place 10 Position turn signal svj h in bearing housing install snitch retainer plate and secure with three screws 11 Place gearshift lever in NEIYI RAL position and snap back up amp sndteh operating lever on lug RETAINER provided on gearshift tube slide washer ...

Page 410: ...o align pointer correctly then tighten clip screw 7 Attach finish plate to bottom of instrument panel Align and attach floor plate to toe board Install turn signal lever 8 With master splines in steering wheel hub and steering shaft aligned place steering wheel on the steering shaft Install retaining nut and washer tight en nut to 24 foot pounds 9 Install horn switch parts previously removed from ...

Page 411: ...pper rod to the unit and connect back up lamp switch wires 2 Lower console down over shift lever insert dial lamp in its housing and connect all electrical connec tions 3 Position console over floor brackets and install retaining screws and bolts Install upper finish plate 4 Install gearshift handle and spring secure handle to lever with set screw Fig IS With lever in NEUTRAL install knob by threa...

Page 412: ...tighten band adjusting screw to 47 to 50 inch pounds If adapter C 37115 is not used tighten adjusting screw to 72 inch pounds 4 Back off adjusting screw 3 turns Hold adjust ing screw in this position and tighten lock nut to as foot pounds 5 Reinstall oil pan using a new gasket Tighten oil pan bolts to 150 inch pounds 6 Fill transmission th Automatic Transmission Fluid AQ ATF Suffix Keferto page 32...

Page 413: ...ck at idle Tighten cable clamp nut 4 11 Route cable so it does not interfere with car buretor rod 15 or upper belicrank 8 throughout NK 335 Ii full throttle linkage travel 12 Connect choke rod 3 or remove blocking fixture Manual Transmission Fig 21 Chrysler Models with 383 or 440 Cu In Eng 1 Apply a thin film of multi purpose grease on both ends of accelerator shaft 1 where it turns in the bracket...

Page 414: ...rom carburetor lever 8 F Back off ferrule 3 inch This provides inch cable slack at idle Tighten cable clamp 41 nut 101 Route cable so that it does not interfere with transmission rod throughout it 5 full travel 110 Connect choke rod 12 or remove blocking fixture HYDRAULIC CONTROL PRESSURE TESTS Line Pressure and Front Servo Release Pressure Line pressure and front servo release pressure tests must...

Page 415: ... or occur too early in relation to eMcle speeds In which case the throttle linkage should be adjusted before throttle pressure setting is adjusted Refer to age 42 GOVERNOR PRESSURE CHART VEHICLE SPEED TO AXLE RATIOS PRESSURE Newport SOD New Yorker Imperial LtMlTS 2 76 1 3 23 1 3 23 2 93 i PSI 19 22 17 19 17 19 19 22 IS 42 51 36 44 36 44 43 51 50 70 78 61 OS 61 68 71 78 75 The governor pressure sho...

Page 416: ...sur ad justment is made with spflng fully compressed and valve bottomed in the valve body 16 Remove tool and tighten stop screw lock nut securely 510 SCREW MNYS AIR PRESSURE TESTS A NO DRIVE condition might einst even With TOOL correct fluid pressure because of inoperative clutches KECKOOWN or bands The inoperative units clutches bands and VALVE servos can he located through a series of tests by s...

Page 417: ... Install adapter in pinion housing with pinion range numbers aligned with 0 o clock position Fig 29 6 Install retainer and bolt aith retainer tangs in adaptec positioning slots Tap adapter firmly into the extension housing and tighten Tetamer bolt to 100 inch pounds SPEEDOMETER PINION CHART TO RQU EFLITE A727 B OUTPUT SHAFT DRIVE GEAR 13 TEETH Axle Ratios Number of Pinion Tire Size Gear Teeth and ...

Page 418: ...This position the parking lock control rod rearward so it can be dissagaged or engaged with the parking lock sprag SI Remove two screws plate and gasket from bot tom of extension housing mounting pad Spread large snap ring from output shaft bearing th Tool C 3301 Fig 33 With snap ring spread as far as possible carefully tap extension housing off output shaft bear ing Carefully pull extension housi...

Page 419: ...f governor body lift out governor weight assembly 41 Remove snap ring from inside governor weight remove inner weight and spring from outer weight Figure 36 shows a disassembled view of the governor assembly SI Remove snap ring from behind governor body then slide body and support assembly off the output shaft If necessary remove four bolts and separate governor from the support CIecnIn9 and Inspe...

Page 420: ...Ing parking lock rod to the valve body manual ever 5 Place a drain pan under transmission then re move the ten hex head valve body to tnnsmission case bolts Hold valve body in position while removing the bolts 8 While lowering valve body out of transmission case disconnect parking lock rod from the lever To remove parking lock rod pull it forward out of the case if necessary rotate propeller shaft...

Page 421: ...ffset so these parts will be installed in original posi tion This maintains balance of the engine and con verter 6 Rotate engine with Remote Control Switch to locate two converter to drive plate bolts at 5 and 7 o cloclC positions Remove the two bolts rotate en gine with switch and remove the other two bolts Do not rotate converter or drive plat by prying with a screw driver or similar tool as the...

Page 422: ... to the gear teeth Place a few drops of water on face of gear at intervals during heating process Wben gear is hot enough to just boil the water installation of the gear on torque converter can be made t After ring gear is expanded by heating place the gear in position on converter front cover Tap gear on cover evenly with a plastic or rawhide mallet until front face of gear is even with scribed l...

Page 423: ...all a new seat place the seal in opening of the pump housing lip side facing inward Using Tool C 3860 drive the seal into housing until tmñ bottoms Fig 43 DISASSEMBLY__SUB ASSEMBLY REMOVAL Prior to removing transmission sub assembhes plug all openings and thoroughly clean exterior of the uoit preferably by steam Cleanliness through entire disas sembly and assembly cannot be over emi phasized When ...

Page 424: ...se disconnect parking lock rod from the lever Accumulator Piston and Spring I Lift spring off accumulator piston and withdraw piston from the case Extension Noosing and Output Shaft Bearing Before removing extension housing pull park a lock rod forward out of the case Rotate propeller shaft if necessary to align parking gear and spng to permit knob on end of control rod to pass the sprag I Remove ...

Page 425: ...eful not to lose thrust washer locat 4 between rear end of input shaft and forward end of ootpot shaft Planetary Gear Assemblies Sun Gear and Driving Shell 1 While supporting output shaft and driving shell carefully slide assembly forward and out through the case CAUTION Be very careful not to damage ground surfeces on output shalt during removal Rear Band and Low Reverse Drum I Remove low reverse...

Page 426: ... gear as RFOULA1O VALVE 5RING T C ONTROL VALW SPRI NC V LINE PRESSURE ADJUSTME NT MANUAL VER ASSY NN8O sembly If bushings are found worn or scored they should be replaced as outlined in the following recon ditioning procedures The bushing replacement tools listed by SP numbers are part of Tool Kit C 8887 NOTE The bushing in the oil pump has ben re located In the pump housing thus requiring a new i...

Page 427: ... 4 Slide regulator valve out of valve body Slide torque converter control valve out of valve body 5 Remove I transfer late retaining screws Carefully lift transfer plate and steel separator plate assembly off the valve body 6 Invert transfer plate assembly and remove the stiffener plate Remove remaining screws securing separator plate to the transfer plate and carefully lift off the separator p at...

Page 428: ...g straightedge Tool C 3335 inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Make sure all meter ing holes in the steel plate are open Ushig a pen hght inspect bores ii the valve body for scores scratches pits and irregularities Inspect all valve springs or distortion and collapsed coils Inspect all valves and plugs for burn nicks and sc...

Page 429: ...ition valve body assembly on the repair stand 11 Place the six steel balls iii valve body cham bers with large ball in the large chamber mg 03 12 Position transfer plate assembly on the valve body Install the 7 retaining screws starting at cen ter and working outward tighten screws to 28 inch pounds 13 Install the torque converter valve and regu lator valve Fig 55 14 Position the torque converter ...

Page 430: ...embly 1 Position sprag and spring in the housmg and insert the shaft Fig 37 Make sure square 1u on sprag is toward parking gear and spring is positioned so it moves sprag away from the gear 1 Install reaction plug and pin assembly in the housing and secure with snap plug GOVERNOR AND SUPPORT Disassembly 1 Remove large snap ring from weight end of governor body and lift out the weight assembly 2 Re...

Page 431: ...nd face of the rotors Clearance limits are from 001 to 0025 inch Also with a feeler gauge measLLre rotor tip clearance between inner and outer rotor teeth Clearance limits are from 005 to Oil inch Pump Bushing Replacement II Place pump housing on a clean smooth surface with the rotor cavity dowil 2 Place removing head Tool SP 3550 in the bush lag and install handle Tool SP 3549 in the removing hea...

Page 432: ...tion vent baffle over the vent opening Install retaining bolts and tighten to 150 inch pounds 3 Place a new oil seal in opening of pmnp housing lip of seal facing inward using Tool C 3g0 drive seal into housing nntil tool bottoms FRONT CLUTCH Disassembly Figure 63 shows a disassembled view of the front clutch assembly 1 Using a screw driver remove large snap ring that secures pressure plate in the...

Page 433: ...p sa atches light scratches v4ll not interfere with sealing of neoprene rings Inspect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus doth Inspect seal grooves for nicks and burrs Inspect neoprene seals for deteri oration wear and hardness and the piston springs retainer and snap ring for distortion Front Clutch Retainer Bushing ...

Page 434: ... seat snap ring in the 1mb groove Remove compressor toot 4 Lubricate all clutch plates instali one steel plate followed by a lined plate until ali plates are instalied Install pressure plate and snap ring Make sure Snap ring is properly seated oj With front clutch complete assembled insert a fader gauge between pressure plate and snap ring Fig 67 The clearance should be 024 to 123 inch If not inst...

Page 435: ...shing Replacement 1 Clamp input shaft in a vise with soft jaws being careful not to clamp on seal ring lands or journals 2 Assemble remover Tool SP 3630 cup Tool SP 3633 and hex nut Tool SP liOI 3 With cup held firmly against clutch piston re tainer thread remover into bushing as far as possible by hand Fig 0O 4 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage thr...

Page 436: ...ly 1 Remove thrust washer from forward end of the output shaft Fig 73 2 Remove selective snap ring from forward end of output shaft then slide front plimetary assembly off the shaft 3 Slide front airnulus gear off the planetary gear set Fig 73 Remove thrust washer from rear side of the planetary gear set 4 Slide sun gear driving shell and rear plane tar assembly off the output shaft 16 Uft sun gea...

Page 437: ...arefully work front planetary and annulus gear assembly on the output shaft meshing planetary pinions with the sun gear teeth 7 With all components properly positioned install selective snap ring on front end of the output shaft Re measure end play of the assembly The clearance can be adjustS by the use of various thickness snap rings Snip ring are aveilable in 041 052 OS5 S59 and 062 066 Inch tt ...

Page 438: ...ool to seat cam into the case Make sure cam is firmly bottomed then install cam retaining Se screw Stake case around set screw to prevent it coming loose 7 Remove cam installing tool Install and tighten support retaining screws to 140 inch pounds Stake case around the cam in six places with a hlunt chisel Fig 77 KWKDOWN SERVO AND BAND Inspection Figure 78 shows a disassembled view of the kick down...

Page 439: ... do not assemble free ly investigate cause and correct the trouble before proceeding with assembly procedures Mways use new gaskets during assembly operations IMPORTANT Use only Automatic Transmission Fluid AO ATF Suffix A to lubricate transmission ports during assembly Overrunning Clutch 1 With transmission case in an uptight position insert clutci race Inside the cam Install overrunning clutch r...

Page 440: ...plines are fully engaged on the rear clutch splines 5 Align rear clutch plate inner splines grasp in put shaft and lower the two clutch assemblies into the transmission case 6 Carefully work clutch assemblies in a circular LEVER kAPr ANCHOR motion to engage rear clutch splines over splines of the front anulus gear Make sure front clutch drive lugs are fully engaged in slots in the driving shell Fr...

Page 441: ...dy Assembly and Accun ulator Piston l Clean mating surfaces and inspect for burrs on both the transmission case and valve body steel plate 2 Install accumulator piston in transmission case and place piston spring on the accumulator piston 3 Insert parking lock rod through opening in rear of case with knob positioned against the reaction plug and sprag Move front end of rod toward cen ter of transm...

Page 442: ...the other two drive plate to converter bolts Tighten bolts to 270 inch pounds 11 Install crosamember and tighten attaching bolts securely Lower transmission so extension hous lug Is aligned and rests on rear mount Install bolts and tighten to 35 foot pounds 12 Install gearshift torque shaft and connect gear shift rod to the transmission lever Console Shift Align gearshift torque shaft lower bracke...

Page 443: ...123 inch 037 to 060 inch SNAP SPRINGS Front and Rear Clutches Rear Snap Ring Selective Output Shaft Forward End THRUST WASHERS Reaction Shaft Support to Front Clutch Retainer Selective Output Shaft to Input Shaft Sun Gear Driving Shell Thrust Plate Steel Rear Planetary Gear to Driving Shell Front Planetary Gear to Annulus Gear Support Front Annulus Gear Support to Driving Shell Front Clutch Retain...

Page 444: ...Bolt Output Shaft Support Bolt Overrunning Clutch Cam Set Screw FOOT INCH 100 Pressure Test Take off Plug Reaction Shaft Support to Oil Pump Bolt 150 Reverse Band Adjusting Screw Lock Nut 150 Speedometer Drive Clamp Screw 150 Transmission to Engine Bolt Valve Body Screw 150 Valve Body to Transmission 140 Case Bolt 40 U Joint Yoke Bolt Imperial 100 100 POUNDS 29 25 30 POUNDS FOOT INCH 75 150 35 100...

Page 445: ...uirement of the vehicle For continuous operation at MAXIMUM LOAD CAPACI TV see Vehicle Load and Tire Pressure Charl or other heavy duty cjerations tional oversize and or heavy service B ply rating tires are available Refer to Page 2 Page Page 3 WHEELS 5 BALANCING 4 5 BEARING ADJUSTMENT 4 INSTALLATION with Disc Brakes 4 3 without Disc Brakes 4 3 LUBRICATION OF BEARINGS 3 3 REMOVAL with Disc Brakes ...

Page 446: ...IAL EXCEPT COI 4VERTIBLE 22 22 26 28 IMPERIAL CONVERTIBLE 24 24 28 30 1 Cold Inflation pressures must not exceed 32 PSI for 4 ply rating normal Do not reduce pressure of warm tires 2 Over sized tires use the same pressure as standard tires 3 Trailer towing pockages provide oversize or heavy service tires be increased 4 PSI front and rear and 40 PSI for 8 ply rating tires Pressure build up during d...

Page 447: ...quence Fig 3 lire life will be pro longed Rotate tires at eve second oil change REPAIRING LEAKS Leaks between the tire and wheel require the re moval of the lire Leaks in the tire can often be re paired without removing the tire Always follow the equipment manufacturers recommendations Tools used for dismounting and mounting tires must be smooth free from sharp edges or projections which could dam...

Page 448: ...pindle and apply a light coating of wheel bearing lubricant over the polished sarfaces 6 Install wheel tire and drum assembly on spindle 7 Install outer bearing cone thrust washer and adustingnut installation with Disc Brakes Perform steps I through 7 in same manner for those vehicles equipped with Disc Brakes Adjustment I Tighten wheel bearing adjusting nut to 90 inch pounds while roialing wheel ...

Page 449: ...d not exceed 080 inch Rotating tire on wheel nay reduce runout or it may be necessary to take dial indicator measurements of the wheel itself in order to determine which unit has the excessive runout Since the exterior surfaces of the wheel rim may have paint runs or bubbles scratches or othcr imperfections it is better to dial indicate the protected areas A and B Fig 7 Under no circumstances 5hou...

Page 450: ...5 ft lbs Bearing Nut Torque Wheel Spinning 90 in lbs 90 in lbs 90 in lbs 90 in lbs TIRES Type Tubeless Size Sedans 8 25 14 8 55 14 8 55 14 9 15 15 With 440 Cu In Engine and Air Cond 8 55 14 Convertibles 8 25 14 8 55 14 9 15 15 With 440 Cu In Engine and Air Cond 8 55 14 Station Wagon All 9 00 14 DISC BRAKES Sedans and Convertibles 8 15 15 With Air Cond 383 Cu In or Air Cond 440 Cu In Engine 8 45 15...

Page 451: ...ure and the body as sembly An integral fore structure assembly extending forward of the front passenger compartment is bolted to the Unibody with ten body bolts Eight of these lie in a fore and aft position and two in a transverse position MAINTENANCE AND CARE APPEARANCE DRAIN HOLES LUBRICATION INDEX Glove Compartment 4 Headliners 4 Kick Pad Panels Luggage Compartment 2 Package Shelves 2 Sealers L...

Page 452: ...staining matter so the correct cleaning agent may be used General Instructions Use a piece of clean cotton cheesecloth approximately 3 x 3 Squeeze most of the liquid from the fabric and it is less likely to leave a ring Wipe the soiled fabric very lightly with a lift ing motion Always work from the outside toward the center of the spot Turn the cheesecloth over as soon as one side becomes stained ...

Page 453: ...inking On nap type lay down nap usually left to right Do not stop when washing a headliner Complete the entire operation using the same solution Starting in the left rear corner clean only one or two sections at a time Thoroughly work suds into the cloth with a natural spongs Use circular or short back and forth strokes to remove all the dirt The amount of dirt determines the effort needed When he...

Page 454: ...h edges Fill any visible cracks with sealer Use a step application procedure in filling deep cracks After sealer has thoroughly dried sand lightly with 400 grade sandpaper until the surface is smooth Apply the desired shade of color to the repaired area POLISHING Acrylic Finishes To retain the new car look of the car exterior surface the acrylic finish should be polished at least twice a year to r...

Page 455: ...bjects from the glass by chlipping Do not use putty knives razor blades steel wool or any other metal object to remove deposits from the glass DRAIN HOLES The drain holes in the bottom of the cowl plenum chamber doors and floor sills rocker panels should be inspected regularly to insure drainage Road tars mud and similar other foreign matters should be re moved immediately Should bare metal be exp...

Page 456: ...Rests Glass Convertible Adjustments Regulators Replacement Run Channel Hardtop Adjustments Regulators Replacement Run Channel Chrysler Sedan Front 24 Imperial 31 Adjustments Regulators Replacement Run and Channel 24 25 25 28 31 32 32 33 Vent Wing Sedan Rear 25 28 31 35 Adjustments Regulators Replacement Runs 28 29 28 29 35 36 35 36 Stationary Glass Handles Inside 44 16 44 16 Outside 21 21 Hinge Lo...

Page 457: ... 47 47 48 47 49 46 46 45 49 46 49 Weatherstrips and Seals SHEET METAL DOORS EXTERIOR MOULDINGS COWL PANELS GRILLE PANEL OUTER Removal 1 Remove windshield wiper arm and blade as semblies 2 Remove windshield lower moulding 3 Remove cowl grille attaching screws center cap on Imperial Figs 1 and 2 and grille material Inspect plenum chamber inner seams using a mirror and light to make sure all seams ar...

Page 458: ...d seal assembly 7 Inspect seal for damage side Installation 1 Install spring nut to bottom of fresh air door housing if removed 2 Position seal in line with outer edge of housing flange Fig 5 3 Position fresh air door on cowl side panel and align attaching holes 4 Install attaching screws and tighten progres sively 5 Insert actuator cable assembly through hole in door frame flange and install coil...

Page 459: ...e outside edge of hood then tighten bolts securely Lower hood and inspect fit Hood Projects Beyond Front of Fender If hood projects beyond front fender arid fender to door spacing is close the fender can be shifted for ward to correct this condition Hood Side Contour Does Not Follow Fender When the side contour of the hood does not follow curve of the fender the hood should be reshaped 1 Insert a ...

Page 460: ...r from hood hinge 3 Remove hood assembly 4 Remove torsion bars from center support and remove bars from end reinforcements 5 Lubricate torsion bar rollers and install on hinges 6 Install and align hood HINGE REPLACEMENT CHRYSLER MODELS 1 Disengage torsion bar roller from hood hinge Fig 12 2 Scribe hinge location on hood and remove hinge to hood screws 3 Support hood at hinge area 4 Remove the cowl...

Page 461: ... fender to door spacing is too close the fender can be shifted slightly forward 1 Loosen screws attaching front fender to cowl side panel and move fender forward 2 When spacing between door and fender is cor rect and hood is even with front end of fender tight en fender to cowl screws securely Fender Too Far Forward at Door Loosen fender to cowl attaching screws pressure to forward section of fend...

Page 462: ... VIEW IN CIRCLE SHIELD N INNER OUTER SUPPORT 300 EXTENSION 15 it is first necessary to remove the bumper and fender assembly The wheelhouse at the front end is at tached between the frame and radiator yoke When installing the wheelhouse make sure it is correctly aligned before tightening the screws RADIATOR CORE SUPPORT REPLACEMENT Removal OUTER SUPPORT 1 Drain radiator and remove hoses from radia...

Page 463: ...nd light wires to the core sup port with the plastic straps 5 Install the radiator and hoses FiU cooling sys tem and inspect for leaks OUTER BRACE CROSSMEMBER PAD BRACE VIEW B B VIEW ARROW A BUMPER BRACE PAD AIR SHIELD AND CROSS BAR Refer to Fig 16 for the air shield and cross bar attaching points FRONT BUMPER Refer to Figs 17 ing points BUMPERS and 18 for front bumper attach REAR BUMPER Refer to ...

Page 464: ...cast metal DOORS The service procedures for internal door compo nents do not include obvious operations such as re moving door or quarter panel trim panels testing operation of windows or inspecting glass fit after ad justments or replacement have been performed ALIGNMENT FRONT DOOR Up and Down Up or down adjustment of the door can be made at the front pifiar or in the door itself Figs 25 and 26 1...

Page 465: ... attaching bolts and raise or lower door to desired position Lowering end of door moves lower part of door forward when in closed position 7 Tighten attaching bolts 8 Open and close door several times and inspect clearance around all door edges 9 Repeat steps 4 5 6 and 7 until door is centered in door opening 10 Adjust the door lock striker In and Out 1 With door in a full open position place a wo...

Page 466: ...door around door hinge plate 2 Loosen upper hinge attaching bolts 3 Grasp front edge of door at the hinge and push door in or pull out to the desired position 4 Tighten hinge attaching bolts Adjust one hinge at a time to prevent door from dropping in door ROTOR AND STRIKER The door strikers Fig 29 are attached to the pil lars through oversize holes permitting movement of the striker up and down an...

Page 467: ...rear door inner hardware installed sup port door on a padded jack and position door on hinges 2 Install attaching bolts finger tight 3 Align hinges with scribe marks 4 Tighten attaching screws and test door for alignment 5 Install door interior trim and hardware On vehicles with electric window lift insert wiring HANDLE NNo 10 NN605 into the door and attach wiring to motor and control switch prior...

Page 468: ...tcheon washer handles and arm WATERSHIELDS Refer to Figures 37 and 38 for the sealing area and applications of the watershields The lower edge of the shield must be inserted into the slots in the bot tom of the inner panels DOOR 1 ORNAMENTT 1 VIEW B B NNO2O FASTENER k 1 SECTION VIEW VIEW ARROW A ARROW C BUTTON VIEW ARROW B LIGHT SOCKET tj _ TERMINALS FRONT DOOR LOCK ASSEMBLY Remote Control Manual ...

Page 469: ... Removal 1 Disconnect handle to lock link Figs 39 to 42 from lock by pulling link outward at lock 2 Disconnect locking lever rod front door only from the lock assembly control REMOTE CONTROL NN625 WATERIEjr CEMENT INIRLE Z TAPE ______ ______ NN659 Fig 38 Door Watershields Imperial Fig 40 Front Door Locking Mechanism Imperial OUTER HANDLE LOCKING ROD REMOTE CONTROL LINK LIP N LINK RETAINER t Fig 4I...

Page 470: ... from cylinder 3 Remove retainer from cylinder body on Chrys ler models or screw from handle base on Imperial models Remove cylinder Installation 1 Position cylinder in door and install retainer on cylinder body 2 Connect the cylinder link to the cylinder arm and to clip on lock lever 4 door models 3 On 2 door Chrysler models Fig 44 connect cylinder link to cylinder position link bracket on door f...

Page 471: ...st volt age at the red feed wire terminal of the relay Con nect one lead of voltmeter to buss bar connecting two relays and the other voltmeter lead to a good ground Fig 47 With no load voltage should be 12 6 volts and when locks are activated voltage should be 9 4 volts A lower voltage reading indicates a shorted so lenoid and a higher voltage reading indicates an open circuit To determine which ...

Page 472: ...rom door Installation 1 Install handle into door opening Engage link from handle to lock 2 Attach retaining nuts and test operation of the handle Rear Door Removal 1 With door open and glass in up position remove retainer from link at handle connector 2 Depress outside handle release button Chrysler Models and remove link from handle connector DOOR LOCK FRONT KEY LOCK SWITCH X 32 LOCK FEED FRONT D...

Page 473: ...ork weatherstrip from index points to a point midway between them Avoid puckering or stretching of weatherstrip Hardtop ConvertibleModels Fig 54 Front Door 1 Apply a inch bead of cement on weatherstrip as illustrated 2 Position the moulded end of weatherstrip and attach with fasteners 3 Index and install weatherstrip on door using fasteners as a locating point and working from hinge pillar side of...

Page 474: ...t frame door glass and quarter glass The glass up stop must be adjusted so the fully raised glass just curls the outer lip of weatherstrip against the inner lip When the up stop roof rail weatherstrip and glass are properly adjusted the outer lip of weatherstrip will seal along the top edge of the glass and the inner lip of weatherstrip will seal along the upper inside edge of glass NN227 WEATHERS...

Page 475: ...nt wing assembly 1 Open door and lower window approximately halfway 2 Adjust glass run retainer screw at bottom so glass moves in run freely 3 Run window down so top of glass is even or slightly below belt line of door outer panel 4 On manually operated windows position stop on regulator place against stop on regulator sector 5 On electrically operated windows reach through major access hole and p...

Page 476: ...ng assembly and install cotter pin at lower end of division channel 3 Lubricate sliding surfaces of lift bracket 4 With regulator in fully down position install vent wing and door glass assembly into door and position vent wing pivot swivel assembly into vent wing regulator 5 Position regulator arm roller into glass lift bracket and move glass rearward into glass run channel 6 Install vent wing at...

Page 477: ...test bulb should light If the bulb does not light and the wire continuity has been estab lished replace the circuit breaker Switch Slide a thin blade behind the switch housing front and back to depress retaining clips and pull switch out from trim panel Carefully separate the multiple terminal block from the switch body Connect one lead of a test light to the black wire terminal and touch the othe...

Page 478: ...T GREEN X32F I I LIGHT GREEN X32G IS LIGHT GREEN 103 14 ORANGE X33A 14 ORANGE X33B 14 ORANGE X33C 14 ORANGE X33D X33E X33F 14 14 16 ORANGE ORANGE ORANGE X34 14 PINK X34A 14 PINK X348 14 PINK X34C X34D 14 14 PINK PINK X34E 14 PINK X34P 16 PINK X35 IS ORANGE X35A X35B 16 18 ORANGE ORANGE X35C 16 ORANGE X3SD 16 ORANGE X35E IS ORANGE X35F IS ORANGE X36 16 X36At IS PINK PINK FRONT OF VEHICLE FOR SWITCH...

Page 479: ...oximately Vs inch below door frame 2 Adjust regulator pivot bracket Fig 67 so gap between top of glass and door frame is the same along the entire length To raise front of glass lower front oi pivot bracket and to lower front of glass raise front of pivot bracket 3 On manually operated regulators run window down so top of glass is even or slightly below belt line REGULATOR STOP DOWN BRACKET NK903 ...

Page 480: ... of run HARDTOP CONVERTIBLE Chrysler Models Front Door Glass Adjustments Refer to Figure 72 for adjusting points of the vent wing and door glass assembly 1 Open door and run window approximately 2 3 way up 2 Adjust upper attachment of rear run channel so window is centered between inner and outer belt weatherstrips 3 Close door and loosen vent wing belt line screws Run window completely up and tig...

Page 481: ...glass and remove bracket and gasket Installation 1 Position lift bracket and gasket on glass and install plastic rivet 2 Assemble door glass and frame to vent wing RIVET N 898 A division bar 3 Lubricate slide area of lift bracket guide 4 With regulator in down position install door glass and vent wing assembly into door and position vent wing pivot swivel into regulator assembly 5 Position glass l...

Page 482: ... with the A post and also make a good weather seal at the roof rail weather seal 2 Loosen forward attaching screws and division bar adjusting stud locking nut and washer Fig 77 3 Run glass to the down position and move vent wing fore or aft to for correct alignment with the A post 4 Holding vent frame in position tighten two forward adjusting screws 5 To move top of vent frame inboard turn divi si...

Page 483: ...l lower adusting screw lock nut and washer 4 Adjust vent wing and door glass Door Gloss Replacement RemQVOI Ii Run door glass to down position and remove stop brackets Fig 78 12 Remove spring nuts from regulator studs and removc studs from glass lower frame rollers Fig 01 IS Raise glass up and out of run channels I 4 Remove rollers from glass lower frame Installation 1 Install rollers iii roller t...

Page 484: ...eatherstrip and front of glass flush with top of front door glass 2 Adjust front track lower attachment Fig 85 so NK1068 front of glass is aligned with rear of front door glass at roof rail Turn adjusting sleeve nut counterclock wise to move glass inboard and clockwise to move glass outboard 3 Adjust pivot bracket so front edge of glass is parallel to rear edge of front door glass 4 Move front tra...

Page 485: ...tuds into rollers and install spring nuts 6 Lower glass install down stop and adjust glass Regulator Assembly Manual and Electric The regulators are attached to the door inner panel by screw and washer assemblies Fig 87 Spring nuts attach the regulator arm studs to the door glass lower frame and roller assembly Lubricate tooth contact area approximately inch wide along entire length of area on out...

Page 486: ...ss Rear Door Glass Imperial Adjustments Fig 90 1 Loosen lock nut of both upper guide track adjusters 2 Raise door glass approximately three fourths of way up 3 Turn upper track attachment nut until rear of PARALLEL ADJUSTMENT STABILIZER IN AND OUT 64 x 589 IN AND OUT FORE AND AFT CENTER SUPPORT IN AND OUT IN AND OUT FORE AND AFT glass touches belt line weatherstrip lightly at door outside panel si...

Page 487: ...in door panel Installation 1 Insert stabilizer into door and insert stud on inner stabilizer into attaching hole in door inner panel Fig 93 2 Install nut and washers on stud Do not tighten 3 Position outer stabilizer to attaching hole in outside panel support and install screw and washer assembly securely 4 Position bracket on inner stabilizer to front of bracket on inside panel and install screw ...

Page 488: ...l and adjust the door glass QUARTER PANELS GARNISH MOULDINGS The garnish mouldings Fig 95 should be held in position when tightening to assure satisfactory align ment Do not over tighten the mounting screws or the moulding will become damaged by metal stretching 9 LERTIBIT SECTION A A NN6I9 VIEW IN DIRECTION OF ARROW 7 6 WINDOW SEDAN NN114 Fig 97 Quarter Trim Panels 4 Door Chrysler FASTENER MANUAL...

Page 489: ...top of glass fully against roof rail weatherstrip and front of window flush with top of front door window 3 Adjust upper front track attachment so front of window is aligned with rear of front door window at belt line Turn sleeve nut clockwise to move window in and counterclockwise to move window out 4 Adjust lower front track attachment so front of window is aligned with rear of front door window...

Page 490: ...ect front and rear track roller assemblies for damage or excessive wear 2 Apply lubricant to regulator arm roller slots track slide roller slot and bracket and roller assembly slot in glass lower frame 3 Position window assembly into quarter panel engaging track roller assemblies 4 Insert regulator arm rollers in glass lower frame slots and position regulator arm studs into rollers securing in pla...

Page 491: ...ket and roller assembly to bottom of track and slide roller up track and insert into slot on glass lower frame 5 Insert track upper stud into slot at belt line and install nut and washers 6 Position brace on inside panel attaching holes and install screw and washer assemblies 7 Insert lower stud on track through hole in brace Install nut and washers and adjust glass REAR TRACK ASSEMBLY Removal 1 R...

Page 492: ...ust lower stabilizer attachment in or out as necessary 11 On manually operated windows position stop on regulator plate against stop on regulator sector On electrically operated windows adjust down stop against bumper 12 Adjust center support inboard against inside panel GLASS REPLACEMENT Removal 1 Remove spring nuts from regulator arm studs Fig 110 and studs from rollers 2 Remove rollers from gla...

Page 493: ...D OUT Stabilizer Channel The quarter glass stabilizer channel assembly is at tached to the quarter inner panel at the upper end and to the side sill outer panel and reinforcement at the lower end Fig 113 The adjusting stud at the upper end of the stabilizer allows in and out move ment to position the top edge of the glass against the belt line weatherstrip The attachment at the lower end permits i...

Page 494: ...r assemblies Fig 116 2 Support window assembly and remove regulator arm studs from rollers 3 Remove screw and washer assemblies attaching regulator mounting bracket to front support and body lock pillar mounting reinforcement 4 Remove regulator arm from pivot channel 5 Remove regulator assembly Installation 1 Apply lubricant to tooth contact area of regu lator approximately half inch wide along en...

Page 495: ...and nut loosely 7 Position outer stabilizer on outer support run window of the way down and install attaching screw and washer assembly securely 8 Adjust quarter window STATIONARY QUARTER WINDOW FOUR DOOR SEDAN Removal 1 Remove garnish mouldings at quarter window 2 Remove screws attaching front retainer Fig 119 to window opening and remove retainer 3 Remove screws attaching top and rear retainer t...

Page 496: ...r surface of side rail support and install re taining screws 5 Position wheelhouse belt bar retainer to belt bar and install retaining screws Fig 121 6 Position rear pillar upper retainer on end of belt bar retainer and rear pillar Install retaining screws 7 Position body lock upper front pillar retainer on end of belt bar retainer and pillar Install retainer screws 8 Install garnish mouldings 9 P...

Page 497: ...r face bar TRIM PANEL The tail gate trim panel is attached screws Clean all foreign material from area of the trim panel before installing LOCK with metal the seating To replace the lock assembly Fig 125 remove trim panel and raise glass The lock assembly is re tained on the tail gate by screws accessible at ends of tail gate Lock Cylinder To replace the lock cylinder it is first necessary to remo...

Page 498: ...ass and tighten two top screws 5 Tighten lower nut on bottom of lower run Run glass up to approximately inch below Adjust regulator so top of glass is parallel to AND OUT AND OUT AND OUT NK944 channels 6 glass run 7 glass run To raise or lower left or right side of glass raise or lower regulator on that side REPLACEMENT Removal 1 Remove retainers Fig 129 from ends of regu lator arm studs 2 Remove ...

Page 499: ...ass in lowered position should start to rise If glass oper ates during these tests but fails to operate when the control switch lever is moved to UP or DOWN position the switch is at fault Jf glass fails to operate during these tests perform the wire harness tests Wire HarnessFig 132 Disconnect wire harness connector at motor Con nect one wire of a test light to brown and the other to a good body ...

Page 500: ...inge on torsion bar and insert torsion bar into tail gate 8 Position hinge to tail gate and install mounting screws Tighten screws 30 foot pounds 4 Install bearing and bearing retainer on torsion bar Fig 135 Tighten retainer nut 95 inch pounds 5 Position clamp over end of torsion bar and from outside end of tail gate install attaching screws Tighten to 200 inch pounds 6 Install tail gate trim pane...

Page 501: ...lar SCREW 4 Position roof rear header tail gate glass run re tainer on seal and install retaining screws Upper Run and Pillar Run Removal 1 Remove upper run from run retainer a press fit into retainer Fig 139 2 Remove screw attaching pillar run to upper end of tail gate lower opening weatherstrip 3 Remove three screws attaching pillar run and retainer to pillar and remove run and retainer as sembl...

Page 502: ...eel U shaped clip attached from with in the body Vacuum Actuated Lock Release The vacuum actuated deck lid lock release system Fig 142 consists of a vacuum tank mounted on the rear of the engine a push button control switch in the glove box and a vacuum actuated diaphragm assembly connected to the lock Vacuum is supplied to the system from the intake manifold Rubber hoses are used to connect the c...

Page 503: ...e when removing torsion bar as it is under a load 2 Unwind torsion bar 3 Unhook torsion bar from support bracket 4 Push torsion bar out of roller in hinge arm and remove torsion bar from hinge support Installation 1 Install torsion bar insert bar into hinge support 2 Insert end of torsion bar into roller in hinge arm 3 Hook torsion bar into support bracket 4 Wind torsion bar and insert end of bar ...

Page 504: ...BODY AND FRAME 23 53 Fig 746 Exterior Mouldings 300 New Yorker NN838 Fig 747 Exterior Mouldings Imperial MyMopar com ...

Page 505: ...e Form Retainer 6 Plastic or Metal Retainer w Stud Nut 7s Screw Sheet Metal Thread 7m Screw Machine Thread 8 Die Cast or Aluminum Stud w Thread Cutting Nut 9 Driven Stud w Machine Nut 10 Die Cast or Aluminum Stud w Barrel Clip 11 Plastic or Metal Retainer w Screw 12 Metal Retainer w Pinch Leg Snap Over 13 Retainer w Barbs For Pinch Weld Applica END PIECE AWMINUM STAMPING N N 143 Fig 748 Exterior M...

Page 506: ...d nuts CONSOLE The consoles Fig 3 are attached to welded brack ets on the floor pan tunnel with screws and bolts To loosen the rear mountings raise the carpet lower 55 55 Page 64 65 66 64 66 67 63 60 61 62 edges to expose the screw and bolt All other attach ing screws are accessible from within the console FLOOR COVERING Scuff Plates The scuff plates and extensions Fig 4 are retained to the floor ...

Page 507: ...iners and support wire from rear listing wire Fig 6 7 Remove all foreign material and cement from windshield header area and rear window opening VIEW A USED WITH COLUMN NN408 areas 8 Remove listing wires from headlining and insert in comparable listing of new liner Installation 1 Trim excess listing material even with edges of headlining 2 Locate centerline of lining and at front and rear ends cut...

Page 508: ...ires into roof side rail retainers following same cautions as in step 5 7 When cement at windshield header area be comes tacky start at centerline area of windshield and position headlining to cemented area 8 Using a duU putty knife secure liner on barbs at header area do not install material at top of wind shield posts making sure there are no wrinkles and B B NN145 MyMopar com ...

Page 509: ...stall rear seat cushion and coat hooks 16 Locate dome light opening and cut out suf ficient material for correct lighting Install dome lamp bezel and lense HARD BOARD LINING Retainer Moulding Replacement The individual hard board headlining sections are held in position with semi flexible type plastic mould ing Fig 7 forced over the retainer sections of the roof bows Starting at either outer end r...

Page 510: ...ldings on bow retainers and caps over ends 5 Install any garnish mouldings removed NIC 049fr GLOVE BOX Removal Chrysler I Remove glove box door and disconnect deck lid vacuum switch lines at switch 2 Remove screws attaching glove box to instru ment panel Fig 8 and remove glove box assembly 3 Remove glove box map drawer and housing Fig 8 4 Remove screws attaching upper glove box half to lower half ...

Page 511: ... lid remote switch to glove box 4 Remove glove box assembly from opening Installation Imperial 1 Fold new glove box along scored lines and staple overlapped areas 12 places Fig 12 2 Punch out material from glove box side for in stallation of deck lid remote switch 3 Position glove box in instrument panel opening and install attaching screws except at remote switch area 4 Insert remote switch into ...

Page 512: ...which are attached to mounting brackets welded to the rear floor pan Town and Country Second Seat Back Removal 1 Remove screws attaching second seat back to hinge assemblies Fig 17 2 Release catch from seat back and remove scat back assembly Installation 1 Position second seat back on hinge assemblies bolts To remove from under the plates to the floor pan Fig 14 Front Seat Attachment 2 Install hin...

Page 513: ...at back cushion is retained to seat back panel Fig 19 with screws Installation 1 Position seat back cushion on seat back panel and install retainer screws 2 Position seat back and support panel assembly on hinge links and install retaining screws SCREW Cushion NN846 Removal 1 The third seat STRAPS SCREW Fig Il Second Seat Back Fig IS Rear Seat Attachment N N 183 Fig lB Second Seat Cushion HEATER C...

Page 514: ...i RELEASE HANDLE RETAINER RING NN844 Fig 2I Reclining Seat Mechanism Imperial 4 Door Hardtop 9 With seat back in upright position compress adjusting clip to free release spring press release handle down as far as possible 10 Insert a 060 inch shim between the cam and adjuster washer and pull release lever down until cam presses shim against adjuster washer 11 Release adjusting clip and remove shim...

Page 515: ...ment with 6 hog rings front 2 Spring pad to the 2nd vertical bar of center elements with 2 hog rings front 3 Spring pad to top rim with 6 hog rings 3 each side equally spaced 4 Spring pad and cover pad to the 10th bar of each intermediate element with 11 hog rings rear 5 Spring pad and cover pad to the 8th bar of each center element with 3 hog rings rear 6 Cover to each slot in frame assembly with...

Page 516: ...gs rear Front Seat Back Two Door Chrysler Fig 24 1 Spring pad to listing and trim brace with 5 hog rings equally spaced top 2 Spring pad to 3rd turn of 1 and 5 coils of each row with 8 hog rings 4 each side Twist burlap extension and attach firmly to suitable coil turn with 2 hog rings 1 each side 3 Spring pad to 3rd turn of each coil in bottom row with 5 hog rings 4 Foundation board to brace X wi...

Page 517: ...ith 8 hog rings to the vertical bolster wires 8 Cover listing with 3 hog rings to the horizontal bolster wires 9 Cover with 4 hog rings to spring retainer slots front 10 Cover with 10 hog rings to trim wires 5 each side 11 Cover with 8 hog rings to spring retainer slots bottom 12 Listing reinforcement with 2 hog rings to trim wires 1 each side 13 Cover welt with 2 hog rings to bottom spring retain...

Page 518: ...ront 5 Cover to each slot in 3 rim with 12 hog rings 6 each side 6 Cover to 3rd loop of each element with 12 hog rings rear 7 Silencer to the 4th loop of every other element with 7 hog rings rear 8 Silencer to the 2nd bar of the 1st 3rd and 5th element with 5 hog rings front 2nd Seat Back Fig 3 1 Spring pad to trim brace wire with 11 hog rings equally spaced top 2 Spring pad to top rim with 8 hog ...

Page 519: ...exible cables The control switch is on the left side of front seal and is wired through a relay to a U ampere circuit breaker located above the left cowl The wire power to the Power is breaker Six wires go to the switch One used for power two for motor field current which also actuates the relay NN panel from the bulkhead disconnect supplies circuit breaker supplied to the relay from the circuit N...

Page 520: ...is faulty and should be replaced Relay Using a test prod on a jumper wire connect the jumper from the red feed in wire to either the green or black wire terminal on tho relay Motor should run If motor doesn t run replace the relay Front Seat and Adjuster Removal Disconnect battery ground cable 2 Remove four mounting screws which hold front seat to adjustcr and tilt compicte seat back assembly forw...

Page 521: ... slide Install washer and cotter pin Rear Jack Removal The seat track assembly must be removcd from the vehicle separated and mounted in a vise Fasten a 10 inch C clamp from the base to the upper slide just tight enough to keep in in place Fig 35 0 not over tighten Drive the roll pin out of slide assembly and remove the 4 jack mounting screws from under the base Slowly loosen and remove the C clam...

Page 522: ...aft Motor FIg 36 Removal 1 Remove two screws that hold left side of front seat to seat adjuster 2 Prop up left side of seat cushion approximately six inches 3 Remove two nuts that attach motor to drive unit 4 Remove motor and rubber r oupling from drive unit 5 Disconnect motor wires from relay Installation 1 Connect motor wires to relay Assembly 1 Install clutch lever and shaft Make sure lever s p...

Page 523: ...R SEAT COVER C STATION WAGON 2 DOOR BENCH BUCKET SEAT VIEW CIRCLE Z RETRACrABLE VIEW CIRCLE X FRONT SEAT BELT I VIEW CIRCLE Y Fig 38 Seat Belt Applications Seat Belts Refer to Figure 38 for methods of seat belt at NN557 tachment MyMopar com ...

Page 524: ...on outside exert hand pressure on glass at one of upper corners to force glass and weatherstrip off of fence and seal Page WINDSHIELD 72 7 Lift glass and weatherstrip up and out of open ing to clear the windshield wiper pivots 8 Inspect polyethylene seal on windshield opening for damage 9 Inspect fence area for burrs or misalignment and correct as necessary 10 If original weatherstrip is to be rei...

Page 525: ...ing flange of windshield opening Installation Chrysler 1 Apply sealer on each lip of glass groove in weatherstrip and position glass in weatherstrip 2 Insert a twine starting at top center of weath erstrip into fence groove portion of weatherstrip across top and down both sides Fig 4 3 With an assistant position glass and weather strip on windshield opening 4 With pressure being applied against gl...

Page 526: ... 7 Remove all cement and sealers from weather strip and fence 8 Inspect fence area for high spots bends and correct alignment 9 Inspect moulding retainers and if satisfactory install sealer around area where retainer is connected to sheet metal 10 Inspect seam joints between roof panel and fence for proper sealing Installation 1 Apply a continuous bead of sealer to fence groove area of weatherstri...

Page 527: ...ar window Seals and Seaters When replacing polyethylene seal Fig 9 it is nec essary that fence area is free of all cement sealers and other foreign material Inspect fence areas for burrs and misalignment 1 Apply a inch bead of sealer across bottom of rear window opening and up both sides to lower edge of upper corners Fig 9 2 Position one polyethylene seal to window open ing fence at lower section...

Page 528: ...outside enter car and seat weatherstrip on fence by pulling twine Fig 10 downward and toward center of glass 6 Seat glass in weatherstrip using hand pressure 7 Apply a inch bead of sealer Fig 10 across full width and up sides to lower portion of weather strip and fence at top corners 8 Remove all excess sealer and cement from glass 9 Place the Imperial deck opening upper panel and seals Fig 8 into...

Page 529: ...ont hinge only a Adjust by moving serrated adjustment plate up or down to hold side rails in their correct relationship to window frame Adjust both sides to same height to maintain parallelism of side rails Imperial Only a Adjust power link fore or aft across serrated plate Adjustment is in direc tion of movement desired Chrysler Models adjust power cylinder mount ing bracket assembly a Adjust fol...

Page 530: ...material folds are outboard of the bows or slop the folding mechanism approximately two feet from the stacked position and push the top material and stay pads out from between the bows Lower the top completely Fasten the top boot over the compartment snapping it at the sidos and rear To Raise Top Unsnap the top boot at the sides and rear and fold into the storage compartment Turn the top control s...

Page 531: ...dd shims at the body mounting near the front and rear of the door In some instances add shims on the right side of the car and remove them on the left side or vice versa The important thing how ever to keep in mind is that shimming of the body as illustrated changes the fitting of the top header at the windshield frame Door and Glass Alignment Before making any top adjustments doors vent wings and...

Page 532: ...so adjust able lo Chrysler Models the front hinge set screw iF ig is accessible frnpti the homwnni surface of Lhe front rail and center rail directly below the hinge Very little adjustment is possible at the hinge The set screw is also used as a mean s of eliFr iluislin g noise at the front hinge by progressively tightening until the noise disppcars On Imperial Models the front h nge set scres is ...

Page 533: ...structure mounting supports unless the top assembly has been removed for servicing or replacement of linkage parts When this is done be sure both sides are adjusted to provide identical travel of the piston rods The power links are part of the folding top frame which when loosened permit fore or aft movement It is important that the links on both sides be in the same position rearward otherwise it...

Page 534: ...Mners and rnouldings ELECTRICAL TESTS Circuit Oyeoker Disconnect the wire harness connector at the motor Uig Ui and connect one wire of a test light to bros wire and the other to a good body ground Position the i r t rurtient panel swilch in the position The bulb should light Repeat this Test with the yellow wire but position the switrh in the DOWN position It the bulb fails to light cil her time ...

Page 535: ...er to liner attaching edges 6 Install an even coat of cement to bottom edge of liner attaching edges 7 Position new well liner in well and press attach ing surfaces to cemented surfaces 8 Slit liner 2 places on rear seat back support for tension cables and attach tension cables 9 Apply polyethylene seals to belt areas on quar ter outside panels and to deck upper panel over in stalled well liner 10...

Page 536: ...ly before installing the weatherstrips and seals Raise the glass until top edge curls the outer lip of the weatherstrip inward just enough to contact the inner lip Adjust up stops to limit further upward travel of glass TOP MATERIAL QUARTER PANEL VIEW IN DIRECTION OF ARROW V WEATHERSTRIP COVER REPLACEMENT Removal Use care not to damage the top material if the WINDSHIELD UPPER CORNER FRAME NK969 VI...

Page 537: ...nd rear window areas 8 Remove screws from ends of moulding on rear boss Fig 18 9 Remove screws attaching moulding retainer to roof bow and remove retainer 10 Using a sharp pointed tool remove staples and tacks at rear bow 11 Remove staples and tacks one tack used on each side at binding areas attaching top cover to rear bow 12 Unsnap top boot and lay it over rear seat back 13 Unzip rear window and...

Page 538: ... front end of cover is in alignment with center line on header and press cover on header 9 At backlight area align end of window curtain TENSION CABLE AND BRACKET RAIL FRONT RAIV SCREW VIEW IN CIRCLE B Fig 20 Cover Tension Cables NK972 with mark on masking tape and install retaining screw 10 Align end of top cover with alignment mark on masking tape Position backlight moulding retainer over cover ...

Page 539: ...l to lap over 31 Position locking flaps at front outer edge of cover Fig 19 between roof rail retainers and rail Install retaining screws and weatherstrips 32 Apply cement across top cover tacking area making sure each tack is completely covered Use care not to allow cement outside of tacking strip area 33 Apply cement between outer edge of cover and header Press cover firmly down on header 34 Pos...

Page 540: ...re Tire Compartment IMPERIAL MODELS 94 93 91 Floor Pan Front Cowl and Floor Pan 95 Center Top Panel and Dash Panel 95 Plugs Rubber Dash Panel Top 95 Rear and Lower Panel Pillars Front Lock and Drain Trough Quarter Panels Inside Deck Opening Lower Panel Upper Panel Drain Troughs Floor Pan Center 97 96 95 96 Outside Front 95 Roof Extension Rail Rear Plugs Rubber Side Sills 95 96 Side Sills Front End...

Page 541: ...IED BE FEATHERED AS SHOWN Jj SEAL BEYOND HOLE APPLICATION OP SEALING PUB HOLD GUH NOZZLE IN DIRECTION DO NOT MOLD GUN NOZZLE IN DIRECTION OF ARROW IN ORDER TO EPPECTIVELY OP ARROW SEALER APPLIED AS SHOWN SEAL METAL JOINTS IS INEFFECTIVE METAL THICKNESS 2 METAL THICKNESS APPLICATION OF SEALER WHERE SEAL IS REQUIRED BETWEEN WELDED PANELS NY1446 A post blue carpenter s chalk applied to the weath erst...

Page 542: ...____________________________________________ LOWER PILLAR AND PAN OUTER PANEL A VIEW A 8 SEALER SEALER VIEW B SEALER TAIL GATE OPENING AREA j VIEW A A B VIEW A VIEW B NN309 Fig 4 Wheelhouse and Tall Gate Opening Chrysler MyMopar com ...

Page 543: ...AND FRAME 23 89 SEALER SEALER SEALER VIEW A VIEW CIRCLE D 4 DOOR SEDAN AND NT 4 DOOR SEDAN FWD 4 DOOR HT CENTER PILLAR 2 DOOR HT AND CONVERTIBLE NN31B Fig 5 Lock Pillars and Drain Trough Chrysler MyMopar com ...

Page 544: ...SCREWS SEAMS AND OPENINGS IDE SILL SEALER 1 2 BALL SEALER PILLAR Fig 6_Cowl Dash Panel_Moor Pan and Side Sill Chrysler NNSO8 OR SEALER SEALER VIEW DIRECTION ARROW C YLT i DIRECTION ARROWB NN604 Fig 1 Deck Opening Seams Chrysler MyMopar com ...

Page 545: ...DY AND FRAME 23 91 VIEW ARROW X VIEW ARROW Y VIEW ARROW A Fig 8 Quarter Outside Panel and Roof Extension Chrysler NN316 VIEW ARROW A NN312 Fig 9 Wheelhouse and Spare Tire Compartment Chrysler MyMopar com ...

Page 546: ...BODY AND FRAME VIEW DIRECTION ARROW 8 Fig JO Floor Pan and Side Sill Area Chrysler VIEW DIRECTION ARROW B NN307 SEALER VIEW DIRECTION ARROW C SEALER SEALER NN603 Fig Il Deck Drain Trough Chrysler MyMopar com ...

Page 547: ...ONT PAN Fig 12 Floor Pan Plugs Chrysler CENTER PAN NN41o SEALER DRAIN TROUGH SEALER VIEW ARROW 9 VIEW CIRCLE A NN311 Fig 14 Wheelhouse Outer Opening and Inner Panels Chrysler Fig 13 Tail Light and Deck Drain Trough Chrysler MyMopar com ...

Page 548: ...INT VIEW ARROW B VIEW ARROW B NN314 Fig 19 Rear Roof Rail Areas Chrysler 4 DOOR NN6O2 VIEW ARROW B Fig IS Inside Quarter Panels Chrysler TROUGH JOINT EALER SEALER Fig 16 Deck Opening Upper Panel Seams Chrysler NNÔOJ VIEW CIRCLE Y NN587 VIEW DIRECTION VIEW CIRCLE A ARROW B Fig 17 Convertible Wheelhouse and Belt Bar Fig 20 Wheelhouse Opening Flanges Chrysler MyMopar com ...

Page 549: ...gs Imperial NN593 NN590 Fig 22 Floor Pan and Cowl Area Imperial VIEW DIRECTION ARROW D VIEW DIRECTION ARROW A Fig 25 Dash and Cowl Top Panels Imperial NN599 VIEW DIRECTION ARROW B NN59B VIEW CIRCLE C Fig 23 Drain Trough Area Imperial Fig 26 Outside Quarter Panel and Pillars Imperial MyMopar com ...

Page 550: ...VIEW CIRCLE B SEALER VIEW DIRECTION ARROW C SEDAN HARDTOP VIEW DIRECTION ARROW B FRONT OF CAR CONVERTIBLE Fig 27 Deck Opening Upper Panel Imperial VIEW DIRECTION ARROW C 2 DOOR SEALEI C VIEW CIRCLE A 4 DOOR NN594 Fig 28 Floor Pan and Side Sills Imperial MyMopar com ...

Page 551: ...BODY AND FRAME 23 97 NN595 z SEALER a VIEWARROW Z Fig 29 Deck Opening Lower Panel Imperial MyMopar com ...

Page 552: ...Remove sealer from drain trough windshield and rear window reveals roof and panel extensions Remove retainers from drain trough and roof areas Installation Imperial Models 1 Locate and mark centerline of roof panel and vinyl cover at front and rear ends Mark moulding clip hole locations on masking paper to aid in installa tion 2 Apply a thin film of cement to center four inches of roof panel and v...

Page 553: ...all sealing screws 15 per side and remove clamps 16 Trim cover along drain trough using the in board face of drain trough as a guide Fig 6 17 Apply a bead of sealer in drain trough sealing the edge of retainer and cover 18 Apply inch balls of sealer to studs of roof panel extension medallion and install medallion 19 Install moulding retainers and mouldings 20 Inspect cover for air bubbles 21 Remov...

Page 554: ...xposed Fig 4 VIEW IN DIRECTION OF ARROW Y 16 Sealer along edge of fabric outboard of re tainer to drain trough and also around and under roof on top of exposed edge of material from roof to upper inside corner of C pillar 17 Apply bead of sealer to edge of fabric and blend upward to form a seal covering staples and edge of fabric at rear window area 18 Apply a bead of exposed sealer covering the f...

Page 555: ...d fibre tool Fig 3 10 Starting at the top center secure cover to windshield reveal using staples spaced 1 inches apart maximum or tacks spaced inch apart Fig 4 11 Position cover to the roof panel extension mak ing certain all wrinkles are removed 12 Starting at the top center secure cover to rear window reveal using staples spaced 1 inch apart maximum or tacks spaced inch apart Fig 4 13 Trim fabri...

Page 556: ...stallations locate and drill index hole for front pillar moulding upper locating boss Fig 5 24 Apply a bead of sealer to edge of cover and blend upward to form a seal over staples and edge of cover Extend sealer across trimmed edge of cover on the A post Fig 5 25 Locate and punch holes in cover at the roof extension belt line 26 Trim cover on a line inch below the belt line moulding holes and curv...

Page 557: ...gh steps 19 20 21 and 22 2 Door Models 11 install windshield and roof mouldings 12 Inspect cover for air bubbles 13 Remove masking tape and masking paper AIR BUBBLE REMOVAL 1 Place strips of masking tape over the surface of the bubble 2 Using a No 19 hypodermic needle and suitable syringe insert 3M Vinyl Trim Adhesive No 8064 or equivalent into the bubble area Extreme care must be used to avoid de...

Page 558: ... coat and clear coat will extend beyond the edges of the overlay for good adhesion and sealing Tack off all dust and dirt particles from the sanded areas Mask the areas next to the sanded area to prevent overspray of the bond coat application from depositing on the painted sur faces Bonding Coat Application Apply the bonding coat by spray to all areas Fig 1 that have been sanded and also around th...

Page 559: ...for blisters of trapped air or water and work these out with the squeegee Install the other half of the transfer film in the same manner Inspect the transfer carefully for trapped air or water Blisters of this type should be punctured with a razor blade and squeegeed firmly or pressed down with the thumb to remove excess water or air and to seat the transfer to the bond coat firmly Minute in spect...

Page 560: ...uld be taken when straightening frame Measure distance between points connected by line A Fig 3 Chrysler models or any diagonal Figs 1 and 2 Imperial Models This distance should agree within inch with distance between points con nected by line B or comparable diagonal on oppo site side The diagonals Fig 4 represent only one of the few that may be checked Care should be taken to make sure that any ...

Page 561: ...ing bent frame parts A badly distorted frame can in most cases be replaced more economical ly than by attempting repairs FRAME PLACEMENT Chrysler Models The forestructure stub frame is attached to the body at ten locations four at brackets extending 64 x 678A Fig 2 Frame Dimensions Imperial Convertible MyMopar com ...

Page 562: ... between engine and dash panel I4i Remove bolts attaching I 00d torsion bar brack ets to cmvi and wheelhouse IFig 5 Remove brake line al roaster cylinder and pow er brake hose fros brake unit Disconnect throttle linkage and steering gear at the flexible coupling 171 Disconnect windshield washer tube at cowl con riection 8 lIaise vehicle on a hoist ar l remove propeller shaft exhaust pipe at muffle...

Page 563: ...placed transfer serviceable parts to new frame Installation I position forestructnre assembly under body guide tops of fenders past wind shield moulding and align frame attechiri bolt hole 2 Install bode to frame bolts and nuts and tighten to 75 foot pounds 3 With both front doors open install fender to A post attaching nuts and tighten securely 141 Install A post filler plate I Install floor siii...

Page 564: ...boot Position 2 in front of forward face of rear crossmembe r of stub frame Fig II Re work N 2 gauge as shown in Fig 12 and assemble into new hole F Fig 13 rai The rear frame gauge is suspended from Center line of rear iFring pivot bolt IThe attached rod eve and or adapter sleeve fits over outboard hex of bolt or nut I Fig 14 4 Place the checking bars over No 2 and No 8 gauges and the short bars o...

Page 565: ...mpare the matching measurements of both sides of the vehicle All dimensions must be measured at the welded joints of the body to insure uniform meas urements 60 97 60 98 STATION WAGON 5 32 STATION WAGON NK1 168 A Wheelbase Distance Below Body 0 Line 3 07 Letter D Hole Centerline of Lower Control Arm inner Pivot Shaft 1 4 forward of Nut washer 6 36 Letter F Hole Bottom edge of Torsion Bar Clear anc...

Page 566: ...N 111 SPOT REPAIR 112 small amount of retarder and applied as a final coat to increase flow and lustre of lacquer type finishes PRIMING The function of a primer is to form a bond between the surface and the succeeding product PUTTYING A glazing putty is used for filling in tions which are too deep to be taken facer coats It may be applied either the last coat of surfacer REDUCERS Reducers are mixt...

Page 567: ...y 2 Remove silicone polish wax or any other sur face contamination with wax and grease remover A chemically clean surface allows for effective sanding and assures adhesion of the undercoats and finish color 3 Sand the old finish This operation removes sur face deterioration feathers out scratches nicks stone bruises or any other minor imperfections Water sand with 360 grit paper or its equivalent ...

Page 568: ...on can be described as A closed pattern that appears lighter with fine metal lic dispersion An open pattern that appears richer with the metallic flakes less noticeable A closed pattern is best matched by reducing the DDL color 150 with DTL 135 Acrylic Thinner or equivalent adjusting the air pressure at the gun to 35 lbs and applying medium wet coats An open pattern is achieved by lowering the air...

Page 569: ...mpericI InstaIIotions Operation of the doors and damper which direct air Two types of original equipment air comlitloiler flow through the combination heater and air condi tions arc available The first option is a combination tionar unit is by means of vacuum diaphragm units air conditioning and heating unit It is a dash mounted called vauirTi actuators he vacuum source is the unit operated by pus...

Page 570: ...ter flow through the heater core The bypass door will be closed sending all air through the core The bypass door linkage can be adjusted The distribution duct damper is also operated by a vacuum actuator Its function is to control the per centage of air directed to the instrument pane outlet grilles and spot cooler and the percentage of air de livered through the central floor outlet deflector In ...

Page 571: ...24 3 NK141Ô NK1417 Fig 3 Air Flow Maximum Cooling EVAPORATOR FRESH AR DOOR OPEN SPOT HEATER CORE REAR VIEW OF SWITCH TO VACUUM SOURCE DEFLECTOR FRESH AIR COOLING LOWER OUTLET Fig 4 Air Flow Fresh Air Cooling MyMopar com ...

Page 572: ... DOWN FRESH AIR DOOR OPEN SPOT BY PASS DOOR CLOSED SOURCE DEFLECTOR DOWN DOWN LOWER OUTLET DEFROSTINJG Fig 5 Air Flow Defrosting CORE BY PASS DOOR CLOSED REAR VIEW OF SWITCH NK1418 NI 1419 up TO VACUUM SOURCE LOWER OUTLET HEATING Fig 6 Air Flow Heating MyMopar com ...

Page 573: ...air With the Defrost button in most of the air is discharged through the instrument panel outlet grilles with the Heat button in most of the air is discharged through the floor level outlet The driver can adjust the air distribution control to change the position of the distribution duct damper only when the Defrost button is pushed in ELECTRICAL CONTROLS AND CIRCUITS On all air conditioning syste...

Page 574: ...celerator 4 At higher speeds shift the transmission to D Drive position 5 When hauling a trailer and with the air condi tioning system in operation it may he necessary to turn the air conditioner Off for awhile when over heating conditions are encountered Also driving at reduced highway speeds will help the engine to run cooler Highwayand Light Traffic Operation As soon as the vehicle cools down a...

Page 575: ... of a rotary two speed switch Push Buttons__control the source and route of circulating air Off turns off systemt Max A C Imaximum air condition ingi A C rest air air con di ion ing Heat for heater use only Oct shield defroster Temperature Control Slide Lever Maintains any desired temperature by sliding tine ever right or left when operating either the heater or air ninditioncr Fan Switch Permits ...

Page 576: ...4 FRESH AIR THRU COWL VENT C fl fl C Ci 2 HEATER DEFROSTER FRESH AIR DOOR CLOSED HEATER DOOR POSITION AIR INLET OPEN Fig 9 Air Conditioning Controls Of F Position REAR VIEW OF SWITCH C C EVAPORATOR C C C IHEATER CORE HEATER DOOR POSITION 3 OPEN REAR VIEW OF SWITCH Fig JO Air Flow Maximum Cooling MyMopar com ...

Page 577: ...AIR THRU COWL VENT nVn0n HEATER CORE DEFROSTER HEATER 1 DOOR 2 POSITION 3 HEATER DOOR POSITIONS Fig Il Air Flow Fresh Air Cooling REAR VIEW OF SWITCH FRESH AIR THRU COWL VENT FRESH AIR DOOR 1 2 3 RECIRCULATING AIR INLET CLOSED REAR VIEW OF SWITCH NK 1426 Fig 12 Air Flow Heating MyMopar com ...

Page 578: ...igh Hi far right 4 Adjust the four cooling outlet vanes to direct cooled air to the desired area to suit occupants wishes Normal Cooling Cooling with Fresh Air When the desired amount of cooling is obtained with the Max Cool you can continue cooling with fresh outside air for added comfort by pushing the Fr Cool button and adjusting the fan switch to change fan blower speed If less cooling is desi...

Page 579: ...IGHT GREEN C2 18 DARK BLUE C4A 16 BROWN C5A 16 DARK GREEN C5B 16 DARK GREEN C6A 16 LIGHT GREEN C 16 TAN C8 16 DARK GREEN C9 16 BROWN ClO 16 LIGHT GREEN C20 16 BROWN C22 16 DARK GREEN C24 14 BLACK AIR CONDITIONING AND BLOWER SWITCH C24 CIRCLE INDICATES WIRING SPLICE GROUND 22 HIGH CLUTCH FEED C4A FUSE BLOCK NK7O2C Fig 74 Electrical Control Circuits MyMopar com ...

Page 580: ...nits The inspections tests and adjustments should be used to locate the cause of a malfunction The inspections and tests in this manual have been arranged in a logical sequence that has proved to be the surest and shortest route to accurate diagnosis Tt is recommended that they be followed and performed in the order in which they are presented OPERATION OF ALL CONTROLS Imperial Operating controls ...

Page 581: ... was re moved at the start of tAils test to minimize pressure in the vehicle cooling system A continuous flow of water indicates that the valve is not closing properly This may be caused by an improperly adjusted con trol cable or a faulty valve Readjust the control cable or replace the valve as necessary and retest RADIATOR CAP The 1906 air conditioned vehicles must he equipped with a radiator ca...

Page 582: ...cting the heater outlet hose at the upper side of the heater If the temperature control valve does not close completely reposition the control cable housing in the retaining clip so that the valve does close completely If the valve cannot be closed completely by adjust ment replace the water valve and retest the adjust ment RADIATOR CAP The 1966 air conidtioned vehicles must be equipped with a rad...

Page 583: ...or Inlet Gauge is mounted at the right side of the manifold set This mounting is for conven ience only There are no passages between this gauge DISCHARGE LINE DISCHARGE SUCTION LI SUCTION SERVICE PORT SERVICE PORT ADAPTER and the gauge manifold The compressor inlet gauge is calibrated to register 0 to 30 of vacuum and 0 to 150 psi This gauge and evaporator suction gauge must he accurately calibrat...

Page 584: ...ows 1 Open the suction gauge adapters make sure below the discharge air from the gauge valve momentarily TEMPERATURE PRESSURE RELATIONSHIP CHART FOR REFRIGERANT 12 Temp F Press PSI Temp F Press PSI Temp F Press PSI Temp F Press PSI Temp F Press PSI 0 2 4 6 8 9 1 10 1 11 2 12 3 13 4 35 36 37 38 39 32 5 33 4 34 3 35 1 36 0 60 61 62 63 64 57 7 58 9 60 0 61 3 62 5 85 86 87 88 89 91 7 93 2 94 8 96 4 98...

Page 585: ... pressure at 225 to 250 psi add refrigerant gas through the suction side of the system until foam is cleared from sight glass then add exactly one half 2 pound of refrigerant TEST 3 TESTING THE SYSTEM FOR LEAKS The Leak Detector Torch Tool C 3569 is a propane gas burning torch used to locate a leak in any part of the refrigeration system Refrigerant gas drawn into the sampling or snifter tube will...

Page 586: ...nt Level T ES I 2 Re felt adding ref rigcrn n t where cause of low level is not known the system should he tested for leaks ss iiiiIl g no culcs are prescnt or that leaks have been corrected wilhout discharging the system pro ce ed with partial charge Install and r onnect the gauge set naniloLd valves in Fig 20 ii Close huth gauge set manifold valves Open gauge set jua t lo d needle valve 12 Con n...

Page 587: ...l protective caps at the service ports TEST 5 OVER ALL PERFORMANCE TEST Humidity the amount of moisture in the air has an important bearing on the temperature of the air delivered to the vehicle s interior This is true of all air conditioned systems whether in the home office or vehicle It is important to understand the effect humidity has on the performance of the system When humidity is high the...

Page 588: ... unit off by pushing the OFF button Next connect a jumper from the positive terminal of the battery to the compressor so that the refrigeration part of the entire system can be operated without air flow through the front unit Open the windows adjust engine speed to 800 rpm and close the hood Turn the trunk unit blower motor switch to high speed position Place the motor driven psychrometer Tool C 3...

Page 589: ...reas it may be necessa to put an electric fan in front of the condenser in order to keep the pressure down to these limits Observe and record both the Inlet Dry Bulb Tempersture and mint vel Bulb Temperature as registered on the psychrometer Observe and record tbe Discharge Air Tempera ture registered by the thermometer at the right hand grille outlet From the approximate Roof Unit Performance Tem...

Page 590: ...58 58 59 60 61 61 62 63 64 65 65 66 67 68 69 69 70 71 72 91 55 55 55 55 55 55 55 55 55 55 56 56 56 57 57 58 58 59 60 1 61 62 63 64 65 66 66 67 68 69 70 70 71 72 73 92 55 55 55 55 56 56 56 56 56 56 56 56 57 57 58 58 59 59 60 61 62 62 63 64 65 66 66 67 68 69 70 70 71 72 73 93 T 56 56 56 56 56 56 56 56 56 57 57 57 58 58 59 59 60 61 57575757575757575757575758585960606161626363646566666768697070717273 ...

Page 591: ...1 71 72 73 74 9 57 57 57 57 57 57 57 57 57 57 58 58 58 59 59 60 60 61 62 63 63 64 65 66 67 68 68 69 70 71 72 72 73 74 75 92 57 57 57 57 58 58 58 58 58 58 58 58 59 59 60 60 61 61 62 63 64 64 65 66 67 68 68 69 70 71 72 72 73 74 75 93 58 58 58 SB 58 58 58 58 58 59 59 59 60 60 61 61 62 63 63 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 94 59 59 59 59 59 59 59 59 59 59 59 59 60 60 61 62 62 63 63 64 65 ...

Page 592: ...52 52 53 53 53 54 54 55 55 56 57 58 58 59 60 61 62 63 63 64 65 66 67 67 68 69 70 92 52 52 52 52 53 53 53 53 53 53 53 53 54 54 55 55 56 56 57 58 59 59 60 61 62 63 63 64 65 66 67 67 68 6970 93 53 53 53 53 53 53 53 53 53 54 54 54 55 55 56 56 57 58 58 59 60 60 61 62 63 63 64 65 66 67 67 68 69 70 94 54 54 54 54 54 54 54 54 54 54 54 54 55 55 56 57 57 58 58 59 60 60 61 62 63 63 64 65 66 67 67 68 69 70 95...

Page 593: ... 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 U 77 78 79 80 81 82 T 83 84 85 86 87 88 89 90 44 45 46 47 48 49 50 51 52 52 52 53 53 54 54 55 55 55 56 58 59 60 61 61 62 64 66 68 69 70 71 72 73 DISCHARGE AIR DRY BULB TEMPERATURE INLET AIR DRY BULB TEMPERATURE MUST BE BETWEEN 75 AND 1 10SF NK1343A Fig 26 Performance Temperature Cha fl Front Unit of Dual System ROOF UNIT OF DUAL INLET AIR W...

Page 594: ...the point where it just about balances the internal gas pressure in the bellows The EPR valve is actually operating as a modulating valve 3 When fluctuation at the compressor inlet gauge NY 206A stops and the pressure registered drops steadily the EPH valve is maintaining minimum suction line pres sure Allow pressure registered at the compressor in let gauge to drop to 17 psi or lower then read th...

Page 595: ...t the vapor will still absorb lone heat before it leaves the evaporator This wili create over superheatad condition whore the temperature will be very high in relation to pressure If the compressor capacity is low it is because the refrigerant vapor is leaking internally usually past the reed valves or a blow ri gasket l liis will be indi cated by low discharge pressure With the refrigerant being ...

Page 596: ...ch is very important when making this test Discharge The System When making the Compressor Capacity Test the compressor must be disconnected from the rest of the syste That means the systcm must be discharged lii Lead the manifold discharge hose into an ex haust ventflation system or to the outside of the build ing so the service area will not be filled with refriger ant vapor Zi Fully open the ma...

Page 597: ...g orifice in the test cap The pressure registered at the discharge gauge should build up to at least the minimu n PSI shown in the chart 13 The load on the compressor may affect engine speed to exact R P M shown in the chart The dis charge pressure should build up to the minimum PSI COMPRESSOR CAPACITY CHART Engine Cu In Model Displacement Compressor Type Engine RPM Minimum PSI Chrysler 383 RV Z 5...

Page 598: ...st hose to the suction service port using the special adapter to keep the sucthon service valve open 4 Connect the dischaTge test hose t0 the discharge service port using a special adapter to hold this Sen ice valve open 5 Connect one end of the long test hose to the center of the gauge manifold the other end to the refrigerant dispcnsing manifold 6 Close two of the dispensing manifold valves turn...

Page 599: ...sure reg istered at the discharge gauge is maintained at exact ly 75 psi Minimum Flaw Test Thermal Bulb At 22 F I Close the right gauge valve to reduce pressure on the expansion valve This will accelerate movement of the valve toward the minimum flow position 2 Insert the thermal bulb in the container of ice and water Use sufficient ice to insure a water tem perature of 32 F This will cause the ex...

Page 600: ...that it tends to freeze anything it contacts For this reason ex treme care must be taken to prevent any liquid re frigerant from contacting the skin and especially the eyes Always wear safety goggles Tool C 3355 when serv icing the refrigeration part of the air conditioning system Keep a bottle of sterile mineral oil and a weak solution of boric acid handy when working on the refrigeration system ...

Page 601: ...ons to seat squarely and to be tightened evenly to the proper torque Fit tings which are not oiled with refrigerant oil are al most sure to leak Fig 37 The use of proper wrenches when making connec tion is very important Improper wrenches or im proper use of wrenches can damage the fittings Al ways use two wrenches when loosening or tightening tube fittings to prevcnt distorting of lines and com p...

Page 602: ...for the engine cooling system Summer protection to 15 F will provide adequate inhibitors for protection of engine cooling system against corrosion In the springtime after the winter s operation with the cooling system protected with permanent type antifreeze for the temperatures of the area it is sug gested the system be drained and flushed out with water When draining flushing and refilling have ...

Page 603: ...ight seat Hold the assemblcd tcster in a vertical position with the radiator cap downward as shown in Figure 38 Stroke the tester pump plunger until the gauge di cates the prcssurc cap is relicving pressure It must relieve at a presstJ re between I to 16 psi If within these specifications reinstall on the radiator These test specifications are for caps tested at average altitudes In high altitudes...

Page 604: ...st set to obtain exactly 8 inches of vacuilni with a finger blocking the prod on the end ol the test hose Fig 41 It is absolutely essential that lie bleed valve be adjusted so the vacuum gauge pointer will return to exadfly 8 inches when the prod is covered by a finger othenvise a false reading will be obtained when the control circuit is tested CAUTION Alternately release and reblock the hose pro...

Page 605: ...ty hose or actuator If the vacuum drop occurs at numbers S or 7 holes first check the tee connectors under the instrument panel that tie numbers 5 and 7 hoses to the bypass door and deflector hoses if the tee connections are all right inspect the hose connections to the actuator involved Then test whether the actuator or hose is at fault use the test hose an the actuator involved iFig 45 A leak in...

Page 606: ...uum with a finger blocking the prod on the end of the test hose tFig 48 is absolutely essental hat the b eed valve be adjusted so the vac uLim gauge pointer will return to exactly 8 inches when the prod is covered by a finger Otherwise a false reading will he obtained when l he control circuit is tested CAUTION Alternately release and reblock the hose prod several times Make sur the bleed yaks is ...

Page 607: ...the hose connections to the actuator in volved Thcn test whether P he actuator or hose is at fault use the test hose on the actuator ii volved flg I leak in a hose may he detected with the leak tester by running the fingers along the hose and wak l ng the vacuum gauge reading A faulty spot may he cut out and the hose spliced using inch 00 copper tubing A vacuum drop in excess of inch below the 8 i...

Page 608: ...ssembly I II Remove small snap ring from drive hub with Tool C 3128 or equivalent I On Warner Plate l ype install the drive hub puller Tool C 3Th7 aligning the three pins of the Tool in Ihe three holes in the hub and shoe assembly Tighten the hex head bolt down until drive hub is removed froni the bearing IFig 54I Ii On Pitts Electro Loc install a bold il x 2 4 inch into rear of hub and while hold...

Page 609: ...ng System Service parts are available so that the compressor can be repaired in the field Figure 57 is a disassembled iew of the compressor with the nomenclature of the parts Some parts are serviced individually and some are serviced in pack ages which include two or InUre service parts Refer to the parts book for this information CAUTION The refrigerant oil used In the compressor is carried throu...

Page 610: ...g Tool C 3822 by rotating the valve counterclockwise slightly Fig 58 CAUTION bo not handle the EPR Valve more than necessary The valve should be Inspected esternelly and wiped clean with a lint free cloth Place the valve in a plastic bag until ready to be installed Installation II Install new ring on the ErR Valvo I2 l Lubricate 0 ring with refrigerant oil and in stall E R Va I VU in the compresso...

Page 611: ...t from plate block and head surfaces Glean attaching stud holes in the hlock if the valve plate or cylinder head is damaged replace using a complete compressor valve plate replacement package CAUTION Do not touch or p the reed valve Installation I the valve plate and the cylinder head must he assembled with the reed assembly as shown in Fig lIre 60 121 Dip gaskets ir clean refrigerant oil Do Not S...

Page 612: ...ousing seal bolts 12 Remove bearing housing from the crankcase using two screwdrivers inserted in the slots provided to pry the housing from the case Fig Ia 3 Remove crankshaft hearing housing gas seal seat plate from the bearing housing This is part of 1 the gas seal replacement package and must be repl ac ed whcn the gas seal assemhly is replaced 4E Remove gas seal from the crankshaft Installati...

Page 613: ...ore the crankahelt removal 4 Remove crankshaft and thrust washer front crankcase 3 Use a small arbor press to remove the Crank shaft ball hearing Make sure the bearing is properly supported before pressing the bearing from the shaft Inspection Clean and inspect all the parts Replace the ques tionable parts as required If the crankshaft ball bear ing is in good condition and clean protect it agains...

Page 614: ...bber grommet from the evaporator engine side housing Carefully pu1i the thermal bulb IFig 67 and the thermal bulb wedging shims from the well located inside he evaporator housing Installation Clean the thermal bulb well wedging shinis and thermal bulb before installing the expansIon valve The valve will not function properly unless there is a good thermal contact between the bulb and its well Clea...

Page 615: ... heater core and cover assembly from the evaporator engine side housing Remove the temperature control valve capillary from its well in the engine side housing 2 Discharge the refrigerant from the system and disconnect the expansion valve and the suction line Cap all refrigerant lines to prevent entrance of dirt and moisture 3 Disconnect the recirculating door actuator rod from the recirculating d...

Page 616: ...ulation blanket to assist in removal of the trunk unit coil ponents 3 Release the four clamps on the flexible ducts Jig 71 and remove the ducts from the evaporator i4 Disconnect electrical connections and drains C M P OpENED 64 777 5 Disconnect the suction and discharge lines Cap all refrigerant lines to prevent dirt and moisture from entering the system 61 Remove the mounting bracket to flange bo...

Page 617: ...e is correct the outlet door will he fully closed adjust the linkage as necessary Fig 73i 3 Position the housing on the dash panel making sure the large niounting plate to dash panel gasket is properly positioned to insure a good seal Install the three attaching screws CAUTIOM There is a spacer at each attaching screw Be sure those spacers are installed between the distribution duct and the dash p...

Page 618: ...te cover attached to the evaporator case forward 0f tha instrument panel Figs 75 and 76 I Disconnect the cable at the battery drain the cooling system Fe riiove the air cleaner and disconnect thc heater hoses 121 RemOve the distribution housing Fig 75 glove box and the heater core inlet outlet tube assembly Fig 77 3 Remove the fresh air recirculating air inlet hose 14 Disconnect the floor air actu...

Page 619: ...itch operating arm to have 020 to 060 inch operating clearance betveen the operating arm and the actuator rod Fig 81 71 Install the vacuum hoses to the flonr air actu al r and the fresh air recirculating actuator hose with red stripe to the rod side and install the fresh air rectrculating door housing Connect the floor air actuator rod to the linkage with the retainer clip 8 Install the fresh air ...

Page 620: ...d the expan iUFI valve to the evaporator fittings Use two wrenches to revent rotation and twisting of the lines 0i Install heater as described in Paragraph Heater After the evaporator and boater assembliee are installed in the vehicle it will be noassa ry to sweep the system test for leaks and charge the system with the proper amount of refrigerant It Is recommended that the operation of all contr...

Page 621: ... the other end of this hose into an exhaust ventilation system outlet or to the outside of the building 2 Open the gauge set manifold needle valve and close both of the gauge set manifold gauge valves 3 With the vehicle windows open and hood up operate the engine as shown in the following chart Model Engine Engine R P M Imperial 8 Cyl 800 Chrysler 8 Cyl 1300 4 Imperial installation push in Fresh C...

Page 622: ...he flame Small leaks will produce a green color and large leaks a bright blue color If leaks are observed at the tube fittings tighten the connection using the proper flare wrenches and retest If the flame remains bright yellow when the tester is removed from a possible leak point insufficient air is being drawn in through the sampling tube or the reaction plate is dirty REMOVE SWEEP TEST CHARGE I...

Page 623: ... insure charging with the proper amount of relrig r nt The special refrigerant dispensing manifold per mits charging three full cans of refrigerant at one time 1966 REFRIGEAANT CHARGE MODEL Single Dual Imperial 3 lbs 14 or 04 lbs 2 oz 4 lbs 14 or to 5 lbs 2 oz Chrysler 2 lbs Ia oz to 3 lbs 2 or 3 lbs 1402 to 4 lbs loz Keep the refrigerant mainfold valves capped when not Ira use Keep supply of extr...

Page 624: ...engine and adjust the speed as follows lal Charge the system through the suction side of the system by slowly opening the Ieft hand gauge set manifold valve Adjust the valve as necessary so the charging pressure does not exceed 50 pSi Maintain the temperature of the water in the pan by adding warm water as necessary Ib When all three cans of refrigerant are com pletely empty close the gauge set ma...

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Chrysler Imperial 300 1965, Service Manual

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Summary of Contents for Imperial 300 1965

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