Dodge DART PHOENIX 1960 Service Manual Download Page 457

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Summary of Contents for DART PHOENIX 1960

Page 1: ......

Page 3: ...ts The vehicle number is a code which tells the make of car 1st digit model of car 2nd digit year built 3rd digit assembly plant 4th digit and vehicle serial number last six digits Listed below is the...

Page 4: ...UJM Universal Joint Grease Medium Fibrous MEC Manifold Heat Control Valve Solvent SHL Sure Grip Hypoid Lubricant Part No 1879414 PSF Factory Recommended Power Steering Fluid CAPACITIES MODEL PD1 PD2 C...

Page 5: ...plete information pertaining to lubri ing pages To use the illustrations determine cation of the points indicated in the following a lubrication point number and refer to the illustrations is given in...

Page 6: ...LUBRICATION AND MAINTENANCE 13 14 f 24 60x1056 Fig 2 Lubricat on Points 225 Cubic Inch Engine MyMopar com...

Page 7: ...LUBRICATION AND MAINTENANCE 7 AIR CLEANER NOT SHOWN Fig 3 Lubrication Points 318 Cubic Inch Engine 13 14 60x1055 Fig 4 Lubr cat on Points 361 383 Cubic Inch Engine MyMopar com...

Page 8: ...DPO ML EO MEC MP MP PSF MP DPO TorqueFlite PowerFlite and TorqueFlite Six Transmissions Check Fluid Level Check Brake Fluid Level in Master Cylinder Reservoir ATF MFB EVERY 3 000 MILES Service Perfor...

Page 9: ...sions Maintenance Tune Up Drain Clean Oil Pan and Screen Adjust Complete EO ML ML MCL DCL WB ATF Brake Adjustment Brake Lining Headlight Aiming Service Perform all operations in 1 000 mile Engine Oil...

Page 10: ...Speedometer Cable Distributor Cam Front Wheel Bearings Repack and Adjust EVERY Service MP SHL UJL UJM MP ATF ML ML MCL DCL WB 23 000 MILES Type of Lubricant See Lubricant Key Perform all operations i...

Page 11: ...ock ed is usually designated by the letters MS MM or ML This API service classification system does not replace the SAE grade number of the oil which indicates the viscosity of the oil recommended For...

Page 12: ...distributor has one oil cup Fig 10 Add five to ten drops of ligth engine oil every 1 000 miles The cam wick and cam should be lubricated every 11 000 miles Put two or three drops of light engine oil o...

Page 13: ...are pre loaded and cannot be unloaded to reduce the restriction to lubricant flow At the time the grease is being applied turn the front wheels from side to side a number of times to help work the lub...

Page 14: ...full mark or slightly below never above F mark Add or remove Automatic Transmission Fluid Type A Suffix A as neces sary to obtain proper fluid level If it is necessary to check fluid level when transm...

Page 15: ...lean and repack with Fibrous Univer sal Joint Grease Medium every 21 000 miles Use 2 ounces of lubricant 17 REAR AXLE Fig 19 Drain and refill to bottom of filler hoi every 21 000 miles with Multi Purp...

Page 16: ...Wheel Bearing Lubrication Point 24 MANIFOLD HEAT CONTROL VALVE Every 1 000 miles or 30 days whichever occurs first apply a few drops of exhaust manifold heat control valve solvent Part Number 1879318...

Page 17: ...for any reason or new bearings are Note Rear wheel bearings require no lu installed In this case the bearings should be brication at any mileage or yearly intervals thoroughly cleaned and repacked be...

Page 18: ...speaker or a jumper wire connected to the rear seat speaker socket otherwise the receiver will not operate and damage to com ponents may result 1 Turn on the radio 2 Check to see if the tubes light up...

Page 19: ...of noise 6 RADIO IS NOISY WITH CAR STANDING STILL Eng ne Not Running 1 Tune in a local station and jar the side of the receiver case with the hand 2 Make sure that the connector plugs are firmly seate...

Page 20: ...is at fault substitute the test speaker tighten the attaching nuts finger tight only 4 If the reception is not corrected substitute tubes as outlined in Paragraph 1 or replace speaker SPEAKER GRILL IN...

Page 21: ...without removing radio from instrument panel MANUAL TUNING CONTROL DUMMY KNOB ANTENNA RECEPTACLE TONE CONTROL ANTENNA LEAD IN L RADIO ASSEMBLY RADIO MTG STUD ANTENNA COMPENSATOR ADJ AT 1000 KC RADIO M...

Page 22: ...ect battery 3 ANTENNA COMPENSATOR The antenna compensator receives its original ad justment at the time the set is manufactured however a final adjustment must be made so that the radio can be matched...

Page 23: ...trument panel MANUAL TUNING CONTROL ANTENNA RECEPTACLE TONE CONTROL ANTENNA LEAD IN SPKR CONTROL RADIO ASSEMBLY RADIO MTG STUD ANTENNA COMPENSATOR ADJ AT 1000 KC RADIO MTG BRACKET REAR SPKR RECEPTACLE...

Page 24: ...ECT TO ORANGE WIRE IN INSTRUMENT PANEL WIRING HARNESS FUSE AND A LEAD HOLDER CONNECT TO ACCESSORY TERMINAL BLOCK LOCATED ON LOWER FLANGE OF INSTRUMENT PANEL MANUAL TUNING BRACKET RADIO SUPPORT NUT WAS...

Page 25: ...g Range 540 to 1610 KC IF 262 5 KC _ _ PLATED PANEL WIRING LEGEND 1 B FILAMENT T AVC A LEAD 13 2V DC 8 o 2 m to E1 i4CI6 SPARI PLAT CAUTION A LEAD MUST BE CONNECTED TO POSITIVE H SJDE OF POWER SUPPLY...

Page 26: ...IS MEASUREO WITH VTVM ALL OTHER DC VOLTAGES MEASURED WITH A 20 000 OHMS VOLT METER B VOLTAGES SHOULD BE WITHIN 2O OF VALUES SHOWN C SENSITIVITIES ARE MEASURED AS FOLLOWS I USING A 40 UUF SERIES AND 4O...

Page 27: ...R SPEAKER RECEPT J U M P E R E3 ci8 S P l 1S P 1 REAR SPKR R 2O CONTROL 15 ILOT LIGHT C16 DIAG 63D562O61 0 TO I BOT f j P OP g ILS lot f PLATED PANEL WIRING LEGEND i f A FILAMENT T RF AVC r r IF CONV...

Page 28: ...OHMS VOLT METER 3 ALL AC VOLTAGES MEASURED WITH 1 000 OHMS VOLT METER 4 ALL VOLTAGES MEASURED WITH RESPECT TO CHASSIS 5 ALL VOLTAGES MEASURED WITH 13 2VOLTS INPUT WITH NEGATIVE GROUND DUMMY ANTENNA 4...

Page 29: ...aker Rotation between either position will allow TONE CONTROL CIVIL DEFENSE SYMBOLS 640 KC 1240 KC SPEAKER CONTROL S t l 10 12 14 l ON OFF VOLUME CONTROL STATION PUSHBUTTONS TUNING CONTROL PUSHBUTTON...

Page 30: ...and gas ket 3 Install lead in cable in fender splash shield and body opening 4 Plug in the antenna lead in cable in radio re ceptacle PRIMARY BATTERY POST MOUNTING BRACKET MOUNTING BOLT CONDENSER 57x4...

Page 31: ...ermostat stuck in closed position 5 Temperature control valve not closing properly cable needs adjusting 3 BLOWER MOTOR NOT OPERATING Possible Causes 1 Fuse blown 2 Faulty motor 3 Faulty electrical co...

Page 32: ...r Def Button Causes a major portion of the air to be forced against the windshield through air outlets on top of instrument panel for defrosting or defogging Hi Button causes major portion of air to b...

Page 33: ...sure to use new tinnerman clip when reassembling wheel to shaft 1 Install the blower motor and mounting plate to the heater housing Be sure the blower wheel is free and does not rub 2 Position the hou...

Page 34: ...ening to insure proper alignment 5 Connect the heater hoses at heater 6 Refill the cooling system 5 REAR WINDOW DEFROSTER The rear window defroster optional on all Models is located on and under the r...

Page 35: ...hen servicing the clock by remov ing the heater and transmission push button bezel from instrument panel before attempting the removal of the electric clock 1 REMOVING THE ELECTRIC CLOCK 1 Disconnect...

Page 36: ...e nor mal driving position 1 REMOVING THE REMOTE CONTROL MIRROR 1 Remove toggle lever assembly bezzel from the instrument panel 2 Remove the 2 screws attaching mirror to the fender 3 Remove mirror gas...

Page 37: ...TOOLS TORQUE REFERENCE TORSION BARS Par 10 14 15 8 16 16 12 17 1 9 7 Pag 6 6 6 6 6 8 9 4 10 10 6 11 3 4 3 18 11 13 12 1 6 2 2 7 SPECIFICATIONS MODELS STEERING AXIS INCLINATION CAMBER CASTER Manual Ste...

Page 38: ...aster Adjusting Short C 3710 Upper Control Arm Bushing Remover and Installer All Models DD 435 Turntables Wheel Aligning SP 3233A Adaptor Use with Tool C 3669 TORQUE REFERENCE BALL JOINTS IN CONTROL A...

Page 39: ...6 CAR PULLS TO ONE SIDE 1 Low or uneven tire pressure 2 Incorrect front end alignment 3 Upper control arm bent 4 Lower control arm bent 5 Shock absorber inoperative 6 Brake dragging 7 Check front car...

Page 40: ...eaned area of the ball joints Figs 1 and 2 SWIVEL BOLT TORSION BAR 60x100 Fig 3 Torsion Bar Adjustment Bolt 3 Carefully unlatch the measuring pins and guide them into contact with the cleaned surface...

Page 41: ...EC 5 POS 1 POS NEG 3 NEG 5 POS 1 POS NEC 4 NEG 5 2 POS 1 0 LEFT WHEEL INSTRUCTIONS Camber Positive Preferred A Adjust either the front or the rear cam bolt to obtain positive degree camber I CCT A l l...

Page 42: ...ince there is no adjustment for steering axis inclina tion the following test is used for determining if steer ing knuckles are bent or damaged 1 With front wheels on turn tables and gauge C 3409 atta...

Page 43: ...trut to 50 foot pounds 5 Install sway bar if so equipped 13 TORSION BARS The torsion bars are not interchangeable side for side The bars will be indicated as either right or left by art R or an L righ...

Page 44: ...8 and position the seal on the anchor so it indexes in the groove 6 Turn the torsion bar until the anchor cam is po sitioned approximately 120 degrees down from the frame 7 Engage front end of bar in...

Page 45: ...tud then position stud in steering knuckle Install washer and nut Tight en to 135 foot pounds and install cotter pin 4 Lubricate the ball joint using a good grade of heavy duty chassis lubricant 5 Rei...

Page 46: ...rely against lower stud Fig 9 Spread tool enough to place lower stud under pressure then strike steering knuckle sharply with a hammer to loosen stud Do not attempt to force stud out of knuckle with t...

Page 47: ...and engage with mounting bracket on lower control arm Install bolt washer and nut Tighten to 55 foot pounds 4 Position strut on lower arm install bolts wash ers and nuts Tighten to 100 foot pounds 5...

Page 48: ...ckle then install washer and nut Tighten nut to 100 foot pounds and install cotterpin 3 Install wheel and tire then remove jack 18 STEERING KNUCKLES Removal 1 Place a jack under the lower control arm...

Page 49: ...SE Assembly 11 9 Cleaning and Inspection 10 8 Disassembly 7 Installation in Carrier 14 Back Lash 14 Bearing Pre Load 15 Removal 6 GEAR TOOTH CONTACT PATTERN 17 15 GENERAL INFORMATION 6 3 PINION ASSEMB...

Page 50: ...Transmission 2 93 2 93 2 93 2 93 SPECIAL TOOLS Tool Number Tool Name C 292 F2 C 4O6 A C 4 1 3 C 452 C 485 C 496 C 499 C 637 C 685 C 745 C 758 D3 C 839 C 845 C 3005 C 3214 C 3281 C 3339 C 3565 C 3656...

Page 51: ...r in gears 5 LOSS OF LUBRICANT 1 Lubricant level too high 2 Clogged breather 3 Oil seals worn 4 Improper type lubricant SERVICE INFORMATION 6 GENERAL INFORMATION The rear axle assembly Figs 1 and 2 is...

Page 52: ...ner oil seals with puller Tool C 637 Fig 5 Remove the brake dust shield outer seal with Tool C 3565 Cleaning and Inspection 1 With mineral spirits or dry cleaning solvent clean the axle shafts bearing...

Page 53: ...tart measurement of end play with original shim packs after recording thickness of each Where either or both the axle shaft and bearing is replaced use shim 6X57 Fig 4 Removing Bearing from Axle Drive...

Page 54: ...drive cups in until tool bottoms on shim pack 12 Install new outer oil seal in brake support plate with Tool C 3565 with lip of seal toward center of car 13 Insert sleeve Tool C 745 in outer seal to...

Page 55: ...r bearing cone from the pinion shaft Fig 13 Remove pinion locating washer 13 The bearing cups can be removed from the car rier with a blunt brass drift and hammer Differential Case Disassembly 1 Secur...

Page 56: ...pening of the case Remove each pinion and thrust washer at that time 12 Remove the two differential side gears and thrust washers 10 CLEANING AND INSPECTION 1 Clean all parts in fast evaporating miner...

Page 57: ...4 Inspect pinion bearing shim pack for damaged or distorted shims Replace shims with correct ones during establishment of pinion bearing pre load 11 DIFFERENTIAL CASE ASSEMBLY 1 Install thrust washer...

Page 58: ...installed in carrier remove the main screw nut centralizing washer compression sleeve and the front pinion bearing 2 Install the pinion bearing spacer the larger bore of spacer next to the rear beari...

Page 59: ...bearing cup shoulders in the carrier and by the por tion of the pinion back of the rear bearing The thick ness of a pinion spacer washer suitable for the carrier can be determined by using Tool C 758...

Page 60: ...the pinion gear shaft These washers have a chamfer on one side The chamfer must face the pinion head 58x187 Fig 26 Pinion Oil Seal Installation 9 Position the rear bearing cone on the pinion shaft sma...

Page 61: ...lation read the marking on the end of the pinion 0 1 2 j 1 2 etc when the marking is add that amount to the thickness of the washer selected in 9 When the marking is subtract that amount Example With...

Page 62: ...ttern See Paragraph 17 Pinion Bearing Preload 1 With spacer and rear bearing installed on pin ion place tubular spacer and shims on pinion and hold the assembly in carrier 2 Install front bearing and...

Page 63: ...Install remaining adjuster lock lockwasher and attaching bolt Tighten lock retaining cap screws 15 to 20 foot pounds 17 GEAR TOOTH CONTACT PATTERN The gear tooth contact pattern Fig 30 will disclose w...

Page 64: ...oving the ring gear toward the pinion This would result in decreasing the backlash making it again nec essary to insert a thinner washer behind the pinion rear bearing 18 WELDING REAR AXLE HOUSING The...

Page 65: ...ng and carrier assembly with specified lubricant Refer to the Lubrication Group for axles equipped with Sure Grip differentials SURE GRIP DIFFERENTIAL CONTENTS Assembly Cleaning and Inspection Descrip...

Page 66: ...58x259 Fig 2 Sure Grip Differential Cross Sectional AXLE DRIVE GEAR AXLE DRIVE PINION AXLE SHAFT DIFFERENTIAL SIDE GEAR DIFFERENTIAL CASE AXLE SHAFT DIFFERENTIAL PINION 58x261 Fig 3 Power Flow Axle Sh...

Page 67: ...ial The lubricant should be changed every 20 000 miles CLUTCH PLATES SIDE GEAR RETAINER _ __ 58x720 Fig 7 Removing or Installing Clutch Plates 4 REMOVAL AND INSTALLATION WARNING Before raising a rear...

Page 68: ...ing out 58x724 Fig 11 Removing or Installing Side Gear from Differential Case SIDE GEAR RETAINER DIFFERENTIAL CASE CLUTCH PLATES 6 CLEANING AND INSPECTION Clean all parts thoroughly Inspect all parts...

Page 69: ...ttaching bolts Tighten lightly to seat cap on case Check the assembly for free turning of differential gears and both side gears If tight the side gear retainers may not be meshed through all clutch d...

Page 70: ...al Internal WIDTH THICKNESS CLEARANCE Internal Expanding With Automatic Transmission External Contracting With Manual Transmission Rear of Transmission 6 Manual Transmission 7 Automatic Transmission W...

Page 71: ...rear of the transmissions and op erate independently of the service brakes 1 SERVICING THE PARKING BRAKE External Band Type Removal and Installation 1 Remove adjusting nut guide bolt lock nuts ad juti...

Page 72: ...ng Type Hand Brake Assembled View 6OLT WASHER SUPPORT SPRING NUT _ WASHER NUT WASHER BRACKET SPRING 4 E R H NUT R VET BAND 1 s m SPRING X CLAMP LOCKWASHER SCREW SPACER BOLT CABLE LEVER PIN PIN P N PIN...

Page 73: ...ion Before adjusting brake be sure that free play between the anchor bracket on the center of the band and the sides of the brake support does not exceed 005 inch Otherwise band distortion may result...

Page 74: ...oe return spring up and over the right hand brake shoe pin then work the spring out of the assembly 7 Pry out the brake shoe retaining washer and remove outer guide 8 Slide each shoe out from under th...

Page 75: ...ing lever with the lever between the ball and the washer as shown in Figure 6 The cable must be installed so that the cable conduit is not pulled taut between any of the fastening points To provide fr...

Page 76: ...WHEEL CYLINDERS TESTING FOR FLUID CONTAMINATION SPECIAL TOOLS SPECIFICATIONS Par 13 11 15 4 3 7 5 9 10 2 6 1 14 8 12 Page 3 13 24 i Page 11 11 12 3 6 6 9 7 10 10 3 8 3 11 9 11 2 1 SPECIFICATIONS Type...

Page 77: ...t Nut Foot Po nds 35 55 20 20 20 Inch Pounds 200 50 SERVICE BRAKES SERVICE DIAGNOSIS 1 PEDAL GOES TO FLOOR Possible Causes 1 Fluid low in master cylinder 2 Excessively worn brake linings 3 Brake shoes...

Page 78: ...to the dust shield With the new design each brake shoe is lo cated on three platforms of the dust shield and guided by the three companion contact loops on the brake shoe as shown in Figure 3 The web...

Page 79: ...AND UNING SHOE RETAINER SHOE RETURN SPRING ADJUSTING CAM CONNECTING TUBE LOWER CYLINDER ASSEMBLY Fig 1 Total Contact Brakes Front Assembled View CYLINDER ASSEMBLY SHOE RETURN _ SPRINGS SHOE AND LININ...

Page 80: ...inserted between the spring and the brake shoe web to remove the shoe return spring DO NOT USE BRAKE SPRING PLIERS OR DAMAGE TO THE LINING WILL RESULT 4 Turn the brake shoe guide retainer turn then re...

Page 81: ...uld show contact across the entire width extending from heel to toe Shoes showing contact on only one side should be examined and the cause determined If the web is bent discard the shoe The shoe shou...

Page 82: ...uld be in the same plane and within 010 inch for the platforms for each shoe Prevent lubricant from getting on the brake 5 INSTALLING THE BRAKE SHOES Whenever the brake shoes are removed from d s7shie...

Page 83: ...PLATES AND WHEEL CYLINDERS Should it become necessary to remove the front support plates and wheel cylinders due to damage or wear refer to Figure 13 then proceed as follows Removing the Front Suppor...

Page 84: ...llows Check the freeness of the adjusting cams and return spring links The adjusting cams should turn without binding 7 10 foot pounds Do not turn the ad justing cams unnecessarily A small move ment w...

Page 85: ...ch spring to the brake shoe refer to Figure 6 5 Install the brake shoe guide rod spring and re tainers 6 Install the wheel cylinder connecting tube be ing careful not to bend or distort 7 Turn the bra...

Page 86: ...g simple tests can be made 1 Place a small amount of drained brake fluid in a small clean clear glass bottle Separation of the fluid into two distinct layers will indicate mineral oil contamination 2...

Page 87: ...sed by more than 002 inch should be discarded and a new cylinder used Black stains on the cylinder wall are caused by the piston cups and will do no harm Use extreme care in cleaning master cylinder a...

Page 88: ...RAL INFORMATION 14 INSTALLING THE POWER BRAKE 9 23 LUBRICATION 11 23 PEDAL LINKAGE ADIUSTMENT ON THE BENCH 7 22 PEDAL TRIGGER ADJUSTMENT ON THE BENCH 8 23 POWER BRAKE PEDAL FREE PLAY ADJUSTMENT 2 16 R...

Page 89: ...Cause 1 Pedal trigger arm improperly adjusted 11 DELAY IN POWER Possible Causes 1 Weak or broken valve actuating spring 2 Weak or broken pedal return spring 12 LACK OF POWER ASSISTANCE WHEN COLD P sto...

Page 90: ...UUM VALVE AIR FILTER AIR VACUUM BELLOWS VACUUM VALVE SPRING 56 x 29 Fig 1 Bellows Type Power Brake Sectional View BOLTS 4 VALVE HOUSING O RING VACUUM VALVE SPRING OUTER MOUNTING COVER NUTS 4 STOP SEAL...

Page 91: ...the master cylinder piston applies pres sure to the brake fluid The trigger adjustment which must be made after pedal free play is adjusted determines how soon the power assist goes into action Free P...

Page 92: ...ightly compress bellows by hand for clearance when loosening set screw 6 Remove rubber stop seal washer 7 Lift valve operating rod out of unit remove and discard valve operation rod button seal as sho...

Page 93: ...move air valve spring from center of valve 17 Remove air filter and slide air valve out of housing as shown in Figure 11 To remove valve it may be necessary to use a hook formed from paper clip 18 Pla...

Page 94: ...bore of valve housing Cleaning and Inspection The bellows type power brake now has been dis assembled as much as necessary for cleaning and in spection 1 Clean all parts except bellows bearing and ai...

Page 95: ...as shown in Figure 17 7 Install vacuum valve spring in center of valve 8 Position guide over vacuum valve lining up bolt in guide with bolt holes in valve body SEAL UPS TOWARD BORE GU DE 56x542 FOLD U...

Page 96: ...r and inner mounting plate over spring being sure arrow stamped on plate is in line with arrow on edge of bellows 23 Compress return spring and fold bellows lip over edge of plate Be sure bellows fit...

Page 97: ...applied position when vacuum is applied to the unit During this operation the diaphragm should move throughout its full stroke with out hesitation Leakage Test To make a leakage test a vacuum source v...

Page 98: ...lever pin Align the scribed centerline of the gauge with the centerline of the pedal See Figure 23 Turn the ad justing screw until the outer curved surface of the trig ger arm rests exactly even with...

Page 99: ...is interchangeable with the Bellows Type Power Brake as a unit The power brake consists of three basic components air eleptical shaped power cylinder a vacuum piston and rod assembly an internal popp...

Page 100: ...er unit operation 3 Depress the brake pedal slowly and observe the vacuum gauge reading A vacuum gauge reading of one to 16 inches or more depending upon pressure applied to the pedal indicate that th...

Page 101: ...d must be made carefully to insure proper power brake performance and to prevent the possi bility of brake shoe drag See Figure 5 Pedal free play determines how far the pedal will travel before the ma...

Page 102: ...Insert a wooden block or wedge between the power lever and the bracket as shown in Figure 6 The use of a wedge or block will prevent damage to the ramp of the trigger arm 2 Scratch alignment marks acr...

Page 103: ...rake refer to Figure 7 then proceed as follows VALVE SPRING 57x185 Fig 11 Removing Valve Housing from Piston DIAPHRAGM SPRING DIAPHRAGM SPRING RETAINER PLATE J VALVE RETA NER PLATE 5 7 1 8 6 Fig 12 Di...

Page 104: ...ng Pliers Tool C 3229 remove the snap ring that retains the valve rod in the piston as shown in Figure 14 8 Slide the valve rod washer and spring off end of rod as shown in Figure 15 Slide the valve r...

Page 105: ...LEATHER PACKING RETAINER PLATE SPRING WICKING EXPANDER SPRING 57x194 TOOL 57x207 Fig 21 Piston Installed in Assembly Tool 4 If inspection reveals nicks or scratches on the piston rod valve seat on en...

Page 106: ...lace a new piston rod leather seal on the gasket with the raised shoulder up Slide spring over shoulder and seat against seal as shown in Figure 25 Center the seal and spring 8 Coat the bearing surfac...

Page 107: ...ibe marks in alignment install the attaching screws and tighten securely Install the bal ancing pin and diaphragm and slide vacuum hose over tube of housing 18 Slide a new O ring gasket over piston an...

Page 108: ...t for replacement of nylon bushings or trigger arm refer to figure 4 then proceed as follows 1 Remove the pedal return spring 2 Remove the master cylinder push rod retaining pin 3 Remove the pivot bol...

Page 109: ...n usually be brought within the desired radius by carefully bending the trigger arm until conformation has been obtained If the trigger however is out an excessive amount install a new pedal and trigg...

Page 110: ...quip 9 in B B 9 springs 9 in Auburn 3 springs 10 in B B 9 springs Borg and Beck 10 in Std lO in spec equip 10 in B B 9 springs lO in B B 9 springs 11 in B B 12 springs 361 cu in engine Single Plate Dr...

Page 111: ...7 Testing Fixture C 730 Pilot Studs C 860 Reamer C 869 Arbor C 870 Arbor C 3005 Torque Wrench C 3181 Bushing Installer C 3185 Bushing Remover C 3339 Dial Indicator DD 386 Pilot SERVICE DIAGNOSIS 1 CHA...

Page 112: ...elease lever causes the release bearing to shuffle on its sleeve 3 A metallic rattle or bumpy noise may be heard when the clutch disc damper is not function ing properly This noise is usually evident...

Page 113: ...has been removed 3 Hold the clutch disc pressure plate and cover in mounting position with the springs on the disc damper facing away from the flywheel Do not touch disc facing as clutch chatter may r...

Page 114: ...SEMBLY DISC ASSEMBLY PLATE STRUT NUT 55P1047 PLATE RETURN f SPRING ADJUSTING SCREW AND LOCK NUT RELEASE LEVER PIN RELEASE LEVER 55P1152 Fig 2 Borg and Beck 9 inch 6 Cyl nder upper Auburn 9 inch 6 Cyl...

Page 115: ...in pressure plate 8 Grasp the lever and eyebolt between the thumb and fingers as shown in Figure 5 so that inner end of lever and the upper end o eyebolt are close together Fig 4 Clutch Cover and Pre...

Page 116: ...nger Keep end of lever and eyebolt as close together as possible With the other hand grasp strut between thumb and first finger then insert in slot of pressure plate lug Drop strut slightly until it t...

Page 117: ...ring Washer Adjusting Screw 1 Punch Marks 45 x 83 F g 9 Disassembl ng Model 100131 4 Clutch in Fixture C 585 3 Install the cover support plate compression washer over the center screw so that it rests...

Page 118: ...hing allowing pilot to cut its own threads until a solid grip is obtained Insert puller screw and turn forcing bushing out of crankshaft NOTE Tool C 3185 may be used if Tool C 41 is not available Foll...

Page 119: ...the pivot balls and bush ings for signs of scoring or excessive wear Install new parts as required To assemble the torque shaft refer to Figure 11 then proceed as follows 1 Lubricate the pivot bushing...

Page 120: ...correction as follows To illustrate the recommended correction procedure assume that the total indicator reading is 016 inch in a direction which approximates 2 o clock on engine block Refer to Figure...

Page 121: ...ace runout tighten housing bolts to 50 foot pounds torque Install transmission as outlined in Transmission group 16 STEAM CLEANING PRECAUTIONS The clutch housing being ventilated steam vapor condenses...

Page 122: ...inch Tubular 318 Cu Inch Eng Pressure Vent 21 Qts 20 Qts 14 PSI Centrifugal Ball Bearings Pellet 177 182 202 4 Std 7 A C 18 inch Tubular 361 383 Cu Inch Eng Pressure Vent 17 Qts 16 Qts 14 PSI Ball Be...

Page 123: ...head bolts 5 Cracked valve port 6 Sand holes or porous condition cylinder block 7 Crack in cylinder block at valve chamber 3 OVERFLOW LOSS Possible Causes 1 Refer to Causes listed in Paragraph below...

Page 124: ...ore power available to the wheels and eliminating the fan noise encountered at higher engine speeds Engine Overheating If the fan drive operates below its minimum design speed excessive engine heating...

Page 125: ...pressure cap in water and apply cap to end of adapter 6 Working the plunger as shown in Figure 4 bring pressure to 14 pounds on the gauge 7 If pressure cap fails to hold pressure within a range of 12...

Page 126: ...mum protection temper ature of 15 F Testing 1 Using kit Tool C 3499 proceed as follows 2 Wipe radiator filler neck sealing seat clean It must be free of dirt and devoid of deep scratches or nicks 3 Fo...

Page 127: ...ssion fluid Also the transmission fluid may enter the cooling system Both the cooling system and the transmission should be checked in case the cooler is leaking Testing Oil Cooler 1 Disconnect both o...

Page 128: ...pe seal from the pump body using Tool C 3753 5 On V 8 engines support body on front face fan hub end and apply pressure to rear end of shaft to press out shaft and bearing assembly through front o f p...

Page 129: ...eat face Exert sufficient pressure against tool to obtain a highly polished seat Do not use a motor to obtain seat turn the tool by hand and in a clockwise direction 4 On V 8 engines install a new sea...

Page 130: ...SUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE 1 Check belt tension and belt condition 2 If belt is excessively glazed or worn replace and tighten as specified 2 BELT SQUEAKS WHEN ACCELERATING ENGIN...

Page 131: ...which belt tensions can be properly established 7 BELT DEFLECTION METHOD All belts can also be tightened by measuring the deflec tion of the belt at the mid point between two pulleys un der a five pou...

Page 132: ...OTOR 1 WINDSHIELD WIPERS 43 WIRING DIAGRAMS 59 i Par Page ASSEMBLING THE STARTER 11 6 BRUSH AND SPRING REPLACEMENT 6 4 BUSHING REPLACEMENT 10 6 CLEANING THE STARTER 5 4 DISASSEMBLING THE STARTER 4 4 F...

Page 133: ...AILS TO OPERATE Possible Causes 1 Weak battery or dead cell in battery 2 Ignition switch defective 3 Loose or corroded battery cable terminals 4 Open circuit wire between ignition starter switch and i...

Page 134: ...NSULATED BRUSHES SCREW 3 BRUSH PLATE BRUSHES GROUNDED INSULATOR BRUSH SPRINGS BUSHING END HEAD WASHERS BUSHING PINION HOUSING ROLL PIN BENDIX DRIVE PLATE BUSHING THRUST WASHER THROUGH BOLTS 9 o t 55 A...

Page 135: ...er 100 ampere scale and carbon pile rheostat in series with battery positive post and starter terminal Connect voltmeter 15 volt scale across starter Rotate carbon pile to full resistance po sition Co...

Page 136: ...e place grounded armature Testing Commutator Run out Refacing and Undercutting Place armature in pair of V blocks and check run out with dial indicator Check both shaft and commu tator A bent shaft re...

Page 137: ...s brushes While holding armature against the brush es with slight pressure push brushes up and allow them to rest on edges of commutator When all brushes are seated on commutator slide armature and pi...

Page 138: ...n Engine Distributor Make Model Centrifugal Advance Degrees and RPM Degrees and RPM Vacuum Advance Degrees at inches of vacuum Contact Gap Dwell Angle Condenser Capacity Arm Tension Spring Rotation Ti...

Page 139: ...e IBP 4003N 0 350 to 550 0 to 2 550 2 to 4 750 6 5 to 8 5 2400 0 7 6 to 8 8 6 8 to 9 8 13 12 to 14 8 17 014 to 019 27 to 32 25 to 285 mfd 17 to 21 5 oz Clockwise 10 BTC A42 035 PD1 Hi Performance 383...

Page 140: ...ist of two separate circuits The battery ammeter ignition switch primary winding of the ignition coil distributor contacts and condenser vehicle frame and the primary wiring make up the low voltage pr...

Page 141: ...on connect tach dwell red lead to distributor terminal of coil and black lead to a good ground 4 Turn ignition switch ON Observe dwell meter reading Meter pointer should be well within black bar marke...

Page 142: ...fied be tween idle speed and 1500 r p m probable wear in the distributor shaft bushings or breaker plate is indicated Remove distributor for complete inspection and testing on a distributor tester Dwe...

Page 143: ...USH ROTOR SCREW LOCK WASHER CONDENSER CUP WASHER GOVERNOR WEIGHT SPRING SET GOVERNOR WEIGHTS SPACER SHAFT 58x271 A SPRING CLIP AND BRACKET SCREW AND WASHER SCREW AND WASHER PIN Fig 2 Eight Cylinder Di...

Page 144: ...PRING CUP AND BRACKET SHAFT THRUST WASHERS BUSHING TERMINAL INSULATION BUSHING CAM OILER SPACER COUNTERWEIGHTS 56x70B BASE ASSEMBLY BUSHING WASHER RIVET SPRING CLIP AND BRACKET WASHER LOCKWASHER SCREW...

Page 145: ...etal around the base off spring and should not be removed 6 cyl inder 3 Remove hairpin clip and washer attaching the vacuum control unit to the breaker plate advance arm Remove the two screws and lock...

Page 146: ...arbor press and use Driver Tool C 3041 to remove the upper and lower bushings from the bottom of housing as shown in Figure 9 16 Soak the new bushings in S A E 10 engine oil for approximately 15 minu...

Page 147: ...nspect all bearing surfaces and pivot pins for roughness binding or excessive looseness Inspect dis tributor points for evidence of burning or pitting 4 Install spacer 5 Slide cam and yoke on distribu...

Page 148: ...Install a new contact set the sleeve at one end of the adjustable bracket fits over and pivots on the upper breaker plate mounting pin the contact insulator also retains the terminal screw head 3 Alig...

Page 149: ...lace the diaphragm housing assembly Vacuum Advance Curve Perform operations 1 through 5 under Automatic Advance Curve and proceed as follows 1 Turn tester vacuum pump ON Adjust vacuum pump regulator t...

Page 150: ...15 IGNITION COIL The ignition coil is designed to operate with an ex ternal ballast resistor When testing the coil for output include the resistor in tests Check the coil for external leaks and arcing...

Page 151: ...or ground in generator to reg ulator wiring 4 NOISY GENERATOR Possible Causes 1 Misaligned belt or pulley or loose pulley 2 Brushes seating improperly 3 Worn bushing or bearing 4 High insulation betwe...

Page 152: ...1 7 1 2 to 1 3 3 8 to 4 3 2 9 to 3 4 FIELD COIL DRAW amps at 10 volts MOTORING DRAW amps at 10 volts OUT PUT TEST at 70 F Amps Partial Volts Generator rpm max Amps Total Volts Generator rpm max 1 2 to...

Page 153: ...5 minute run at rated current Maximum Setting 15 04 Minimum Setting 14 42 CURRENT LIMITING REGULATOR Armature Air Gap 048 to 052 048 to 052 048 to 052 Contacts closed with high limit gauge installed C...

Page 154: ...rned to No 1 po sition the ammeter circuit is direct all lead resistors being shunted out Also the field jumper circuit is automatically closed for uncontrolled generator output in No 1 position 5 Sta...

Page 155: ...nob to number 1 position 2 Turn voltmeter selector switch to 4 volt position When using the 4 volt scale the zero correc tor must be reset so that the meter pointer reads on zero at the left of the sc...

Page 156: ...e removed from the vehicle for furth er tests service and adjustment 1 Disconnect the battery wire from the battery terminal of the regulator and connect negative lead of test ammeter to the battery w...

Page 157: ...become discharged If the cur rent regulator setting is not within the specified limits or is unstable or erratic the regulator should be re moved from the vehicle for further tests service and adjust...

Page 158: ...e air gap loosen the bracket screws and raise or lower the contact point bracket until the desired clearance is obtained Be sure these screws are tight ened securely after adjustments are made When th...

Page 159: ...ators so equipped remove commuta tor cover band disconnect armature terminal field lead from insulated brush holder 2 Remove the commutator and head bearing cov er screws cover gasket bearing retainer...

Page 160: ...ULATOR SCREW AND WASHER NUT WASHER WASHER WASHER INSULATOR POLE PIECE BOLT HEAD SCREW WASHER GENERATORS IF FELT RETAINER BEARING SPACER SCREW ANDWASHER GASKET R E T A I N E R S C R E W U P SO EQUIPPED...

Page 161: ...ove field coils from field frame at this time 13 CLEANING AND INSPECTION When cleaning generator parts do not im merse armature field frame and field assem bly or bearing felts in cleaning solution Ne...

Page 162: ...it indicates that either terminal post or brush holder is grounded 6 Remove terminal post and retest brush holder If lamp still lights brush holder is grounded Replace defective parts It is necessary...

Page 163: ...and carbon dust from the generator Generators that have the brush holders riveted to the commutator end head should have the brush spring tension checked with the commutator end head and brushes insta...

Page 164: ...lease brushes and make sure they are properly aligned on commutator Connect armature lead wire to insulated brush holder 17 Position end frame and bushing assembly and install through bolts 18 Install...

Page 165: ...lator setting 3 Circuit breaker points stuck 4 Short in charging circuit 3 BATTERY WILL NOT TAKE A CHARGE 5 Battery terminals corroded 1 Low electrolyte level 6 Faulty stop light switch 2 Internal sho...

Page 166: ...a reading with eye on level with liquid in barrel Do not tilt hydrometer The reading of the hydrometer will vary with the tem perature of the electrolyte An ordinary dairy type thermometer may be use...

Page 167: ...d high rate discharge tester used to check battery before discarding battery as unsuitable for use 4 HIGH RATE DISCHARGE TEST Battery Capacity Satisfactory capacity tests can be made only when battery...

Page 168: ...tive terminal The battery can be damaged beyond repair if the following precautions are not met The battery electrolyte temperature must NEVER exceed 125 degrees Fahrenheit If this temperature is reac...

Page 169: ...mper wire from B to H terminal If horns operate relay is defective If horns faiLto operate difficulty is in wire to the horns in the horns or wire to horn relay B terminal 2 ADJUSTING Horns A and Pry...

Page 170: ...ACEMENT SERVICE DIAGNOSIS SPECIAL TOOLS Par Page 3 1 4 2 5 41 40 42 41 40 42 39 39 SPECIAL TOOLS C 3674 Headlight Aimer Kit SERVICE DIAGNOSIS CONDITIONS POSSIBLE CAUSES 1 LIGHTS DO NOT BURN Possible C...

Page 171: ...ght which illuminates the side of the road ditches etc 1 AIMING THE HEADLIGHTS Pre Aiming Instructions 1 Check dimmer swich for faulty operation 2 Check high beam indicator indicates that high beam is...

Page 172: ...ot 3 Mount the second aimer on the other outboard headlight in the same manner 4 On each aimer set pointer to numeral 2 on the DOWN side of the DOWN UP scale 5 On each aimer position the pointer of th...

Page 173: ...ECKING AIMER FOR CALIBRATION 1 Using a carpenter known accuracy locate window or smooth surface 2 Set DOWN UP pointer on DOWN 2 or stone mason level of a true vertical plate glass 59 x 428 Fig 6 Check...

Page 174: ...d Undercutter SP 839 Blade SERVICE DIAGNOSIS CONDITIONS POSSIBLE CAUSES 1 WIPER OPERATES SLOWLY Possible Causes 1 High resistance in brush to commutator contact or carbon deposits in slots Check armat...

Page 175: ...points GENERAL INFORMATION The constant control wiper motor shown in Figure 1 is connected to the wiper switch and from the wiper switch B terminal to the Ace accessory terminal of the ignition start...

Page 176: ...tor with links far enough towards the left so that right hand link will clear glove compartment opening in instrument panel and remove Fig 2 Removing Windshield Wiper Motor and Link Assembly Typical a...

Page 177: ...or 000 sandpaper to remove burred edges CAUTION Be sure the commutator is clean and free from oil or grease A dirty greasy commutator will cause a high resistance and greatly impair the efficiency of...

Page 178: ...black wire to the yellow and blue wire Motor should park 13 ASSEMBLING THE WIPER MOTOR Make sure the gear box is full of long fibre grease Correct indexing of the contact plate constant speed motor o...

Page 179: ...position by moving the cam adjustment lever which projects from the switch cover 5 Connect wires at wiper motor 6 Install glove compartment and compartment door ELECTRIC WINDOW LIFTS CONTENTS Par Pag...

Page 180: ...5 WINDOW IS OPERATED IN WRONG DIRECTION BY MASTER SWITCH OR INDIVIDUAL DOOR SWITCH Possible Cause 1 Lead wires are not connected to proper term inals GENERAL INFORMATION A master switch group on the...

Page 181: ...52 REMOVING THE FLEXIBLE CABLES 4 53 REMOVING THE FRONT SEAT AND ADJUSTER 2 52 REMOVING THE POWER SEAT MOTOR 6 53 REMOVING THE SLAVE UNIT 10 55 SERVICE DIAGNOSIS 50 SERVICE DIAGNOSIS CONDITIONS POSSIB...

Page 182: ...de from base 5 Remove rivet F and replace with 5 16 18 x bolt 1 as shown to retain proper position To reassemble reverse the above sequence In re assembly a frayed drive cable may occur Such a cable m...

Page 183: ...horizontal movement CAUTION The wire harness should be clip ped securely so wires will not be pinched when track is in the extreme forward position The right and left tracks are each replaced as an as...

Page 184: ...bly to the left guide bracket 7 Remove drive assembly with tubes from left slave unit as shown in Figure 4 8 Remove flexible cables from tubes 5 INSTALLING THE FLEXIBLE CABLES 1 Place the three left c...

Page 185: ...IL SPRINGS COIL COVER RUBBER COUPLING COIL COIL GROUND WIRE 58x749 INSULATING WASHER Fig 6 Solenoid and Coil Exploded View COIL PLATE COIL GROUND WIRE INSULATING WASHER PLATE SCREW HORIZONTAL RISER CA...

Page 186: ...e solenoid springs and position the solenoids over the springs 7 Fasten the solenoids to the drive unit 8 Install the drive unit Refer to Paragraph 4 Re moval and installation of Flexible Cables 10 RE...

Page 187: ...NDUCTOR DISC TERMINAL INSULATOR Fig 1 Tank Unit ELECTRICAL CONDUCTING SPRING X O Fig 2 Temperature Sender Unit Tank Unit A float is hinged to allow the float to raise or lower dependent on the fuel le...

Page 188: ...f the coolant Fig 5 Operation at Low Temperature TEMPERATURE UNIT OPERATION WITH HIGH TEMPERATURE RESISTANCE WHEN HOT WATER TEMPERATURE UNIT Fig 6 Operation at High Temperature Any change in the coola...

Page 189: ...instrument panel fuel gauge move the test sending unit to the empty po sition and turn on the ignition The gauge should indi cate empty Move the float to the full position and the gauge should indicat...

Page 190: ...at it is faulty Always disconnect the battery before attempting to remove a unit from the instrument panel NEVER GROUND the tank or engine sending unit terminal or wire The panel gauge will be damaged...

Page 191: ...GAUGE SENDING UNIT GROMMET M 2 LEFT ROOF RAIL LIGHT MALE TO BODY WIRING L M 2 O LEFT REAR DOOR AUTOMATIC SWITCH LEFT TAIL STOP AND TURN SIGNAL LIGHT POCKET PANEL LIGHT WIRING CONVERTIBLE COUPE L 7 RIG...

Page 192: ...14 14 16 14 16 14 14 14 14 14 4 DOOR SUB H T 4 DOOR H T 12 14 14 14 14 14 12 14 12 14 4 DOOR H T CV CPE CL SED 12 14 14 14 14 14 12 14 12 14 COLOR GRAY LT GREEN BROWN LT GREEN VIOLET BLACK RED LT GRE...

Page 193: ...3__ _i 1 RIGHT REAR q U CIGAR L I G H T E R 3 d H LEFT REAR d UC 1 G A LIGHTER LEFT FRONT DOOR LOCK SWITCH 5 p UNLOCK X 3 2 B f O F E D CIRCUITS 5YM A l A 1 A X 2 X 3 X 32 32B X 3 3 X 34 X 35 X 36 3...

Page 194: ...R 18 DK BLUE 18 RED I 1 h T a 18 l IB I 8 8 8 18 18 18 18 18 l l 16 18 12 18 18 12 l 16 16 18 18 18 16 J 8 8 8 8 B 8 4 4 4 0 2 8 6 8 6 16 6 18 WHITE BLACK RED PINK WHITE TAN LT GREEN BROWN DK GREEN TA...

Page 195: ...ON 7 DIAGNOSIS 1 6 ENGINE REPLACEMENT 13 9 PISTONS 26 19 Pins 27 20 ROCKER ARMS AND SHAFT 15 13 SPECIFICATIONS 1 TIMING CHAIN COVER SEAL 21 16 TIMING SPROCKETS AND CHAIN 20 15 TOOLS 4 TORQUE REFERENCE...

Page 196: ...am Length Center to Center 6 697 to 6 701 Weight Less Bearing Shells 26 8 oz Bearings Steel Backed Babbitt Diameter and Length 2 1870 x 1 015 Diametral Clearance Desired 0005 to 0015 Maximum Allowable...

Page 197: ...on Oil Control RING SIDE CLEARANCE Compression Upper Intermediate O VALVES Intake Material Head Diameter Length to gage dim Line Stem Diameter Stem to Guide Clearance Maximum Allowable Before Recondit...

Page 198: ...haust Valve Seat Angle 45 Seat Width finished 040 to 060 Cylinder Head Gasket Compressed thickness 022 ENGINE LUBRICATION Pump Type Rotary Full Pressure Capacity qts 4 Pump Drive Camshaft Operating Pr...

Page 199: ...ase Cover Bolt Torque Converter Housing Bolt Converter Brace to Aluminum Housing Converter Brace to Engine Block Clutch Housing Bolt Crankshaft Rear Bearing Seal Retainer Cylinder Head Cover Bolt Dist...

Page 200: ...ean or too rich 3 Incorrect carburetor float setting 4 Faulty starter solenoid 3 ENGINE STALLS Possible Causes 1 Idle Speed set too low 2 Idle mixture too lean or too rich 3 Improper choke adjustment...

Page 201: ...ly 4 Excessive bearing clearance 5 Loose flywheel or torque converter 6 Excessive end play 7 Crankshaft journals out of round 8 Sprung crankshaft 11 EXCESSIVE OIL CONSUMPTION Possible Causes 1 Oil lea...

Page 202: ...8 ENGINE OX355 3OX35 4 Fig 1 Engine Assembly MyMopar com...

Page 203: ...from cylinder head cover 5 Disconnect the fuel lines carburetor linkage and wiring to engine 6 Disconnect the exhaust pipe at the manifold 7 Raise the car on hoist 8 Drain the converter housing and th...

Page 204: ...ter cable and gear shift rods 11 Install clutch torque shaft brake cables and rods 12 Install oil cooler lines and transmission filler tube 13 Lower the car 14 Tighten front engine mount bolts to 85 f...

Page 205: ...exhaust pipe at exhaust manifold flange 9 Remove the intake and exhaust manifold and carburetor as an assembly 10 Remove the outlet vent tube and cylinder head cover 11 Remove the rocker arms and sha...

Page 206: ...f conical washers against manifolds Tighten nuts to 10 foot pounds 10 Tighten 3 bolts holding the intake manifold to the exhaust manifold to 15 foot pounds 11 Connect the heater hose and by pass hose...

Page 207: ...he rocker shaft bolts Install long bolt at rear of engine Tighten to 30 foot pounds 4 Adjust tappets 16 VALVES AND VALVE SPRINGS Valves are arranged in line in the cylinder head and operate in guides...

Page 208: ...maining margin after the valves are refaced Fig 11 Valves with less than 4 inch margin should be discarded 3 When refacing the valve seats it is important that the correct size valve guide pilot be us...

Page 209: ...TIMING 1 Rotate the crankshaft until 6 exhaust valve is closing and 6 intake valve is opening Install dial in dicator so that the indicator pointer contacts the valve spring retainer on 1 intake valve...

Page 210: ...en with edge of a chain link apply torque in the reverse direction 30 foot pounds cylinder head installed or 11 64 INCH 60x146 CHAIN CASE COVER m m PULLER BLOCKS TOOL LIP OF SEAL RETAINER 60x160 J Jf...

Page 211: ...al installing plate into the new seal with protective recess toward lip of seal retainer Fig 20 INSTALLING PLATE TOOL SEAL RETAINER CHAIN CASE COVER 4 Install the flat washer and nut on puller screw h...

Page 212: ...and insert the camshaft in the cylin der block Fig 25 NOTE Whenever an engine is rebuilt and a new camshaft and or new tappets are in stalled one quart of factory recommended oil additive should be ad...

Page 213: ...type of boring equipment is used boring operation should be closely coordinated with the fitting of pistons and rings in order that specified clearance may be maintained The cylinder bores should be c...

Page 214: ...30 Tool Arrangement for Removing Piston Pin down to insure positioning rings squarely in the cylin der wall 2 Insert the feeler stock in gap Fig 29 The ring gap should be between 010 to 020 inch This...

Page 215: ...in screw to hold assembly together Place assembly on a press Fig 34 10 Press in the piston pin until piston pin bottoms on the pilot properly positioning the pin in the con necting rod 11 Remove the t...

Page 216: ...expander gap toward the right side of the engine Turn the oil ring gap toward the left side of the engine 3 Immerse the piston head and rings in clean engine oil Slide the ring compressor Tool C 385...

Page 217: ...me Remove upper bearing by inserting Tool C 3059 Fig 38 into the oil hole on crankshaft 3 Slowly rotate crankshaft clockwise forcing out upper bearing 32 CHECKING THE MAIN BEARING CLEARANCE Shim Stock...

Page 218: ...that protrudes above the cap Fig 40 4 install the two side seals in grooves in seal retainer 5 When installing seal retainer tighten screws to 30 foot pounds 318 CUBIC INCH ENGINE CONTENTS Par Page CA...

Page 219: ...ng Order 1 8 4 3 6 5 7 2 CYLINDER NUMBERING from driver s seat front to rear Left Bank 1 3 5 7 Right Bank 2 4 6 8 ENGINE LUBRICATION Pump Type Rotary Full Pressure Crankcase Capacity qts 5 When filter...

Page 220: ...t of Round Maximum Allowable Taper Center Bearing Run Out Total Indicator Reading when supported at front and rear main bearing CRANKSHAFT ROD JOURNALS Diameter Maximum Allowable Out of Round Maximum...

Page 221: ...earance upper intermediate lower TAPPETS Type Body Diameter Clearance in Block Service Tappets Available in Standard and 001 008 030 O S Operating Clearance hot VALVES Intake Head Diameter Length to c...

Page 222: ...fication VALVE TIMING 2 Barrel 4 Barrel Intake Opens BTC 17 13 Intake Closes ABC 47 55 Exhaust Opens BBC 55 51 Exhaust Closes ATC 9 17 Valve Overlaps 26 30 CYLINDER HEAD Valve Seat Run Out Maximum 002...

Page 223: ...t carburetor float setting 12 Faulty fuel pump 13 Vapor lock Check to see that heat shield is in place 14 Faulty ignition cables 2 ENGINE STALLS 1 Idle speed set too low 2 Idle mixture tool lean or to...

Page 224: ...diluted oil 4 Misaligned connecting rods 5 Excessive bearing clearance 6 Crankpin journals out of round 9 MAIN BEARING NOISE 1 Low oil pressure 2 Insufficient oil supply 3 Thin or diluted oil 4 Loose...

Page 225: ...ission 12 Attach crane or other suitable lifting tool to intake manifold fixture Remove support fixture Re move engine from car Mount engine on repair stand 13 INSTALLING OF ENGINE IN CAR 1 Attach eng...

Page 226: ...ation A check of the accuracy of the timing marks at the front of the engine can be made before the left cylinder head is installed The valve timing can be checked after the engine has been run 1 Moun...

Page 227: ...R WASHER SHAFT W GEAR RETAINER SPRING TAPPET PLATE SPACER SPROCKET ECCENTRIC CHAIN CREW WASHER KEY SPROCKET CRANKSHAFT BEARING BY PASS SLEEVE CAP WASHER SCREW CAP WASHER SCREW BEARING STRAINER Fig 3 E...

Page 228: ...n one complete turn Adjust the dial indicator to zero Rotate the crank shaft clockwise normal running direction until the valve has lifted 033 inches for 2 bbl camshaft 024 inches for 4 bbl camshaft T...

Page 229: ...ceed 1 1 6 inch If space is greater than 1 l f inch a n inch spring spacer should be in stalled next to the cylinder head 2 To check installed valve stem length hold the valve on its seat and place ga...

Page 230: ...f the chain is necessary remove the crankshaft oil slinger and the camshaft sprocket bolt Slide both sprockets and the chain off as an assembly Installing Timing Chain When installing the timing chain...

Page 231: ...l be found under CYLINDER BLOCK Installing Camshaft 1 Lubricate the cam lobes and bearing journals before inserting the camshaft 2 Install Tool C 3509 with tongue back of distri butor drive gear Fig 7...

Page 232: ...ion THRUST BEARING LOWER H M 59x55 F g 13 Uppe nd Lower Main Bearings CAP SEAL LONG C A P SEAL SHORT OIL SEAL LOWER DOWEL OIL DRAIN HOLE BEARING SHELL F g 14 Rear Main Bearing Cap and Seals Crankshaft...

Page 233: ...f round and taper Micrometer measure ment for size is to be taken half way down the bore and crosswise to the engine Cylinder walls not requiring reboring should be resurfaced with Tool C 3501 using 2...

Page 234: ...de as the large chamfer on large end of connecting rod Assemble pistons and rods to be used in the right cyl inder bank 2 4 6 8 with Front and indent opposite the large chamfer in the connecting rod P...

Page 235: ...s CONTENTS 361 383 CUBIC INCH ENGINE CAMSHAFT Installation Removal CAMSHAFT BEARINGS CONNECTING RODS CONNECTING ROD BEARINGS CRANKSHAFT CRANKSHAFT BEARINGS CYLINDER BLOCK CYLINDER HEAD DIAGNOSIS DISTR...

Page 236: ...Compression Ratio 10 0 to 1 Compression Pressure at 150 rpm plugs removed Wide Open Throttle 150 to 180 psi Maximum Variation Between Cylinders any one engine 30 psi Firing Order 1 8 4 3 6 5 7 2 CYLI...

Page 237: ...5 TIMING CHAIN Adjustment Number of Links Pitch Width TAPPETS Type Clearance in Block Body Diameter Clearance Between Valve Stem and Rocker Arm Pad PISTONS Type Material Land Clearance diametral Clear...

Page 238: ...0030 Intermediate 0015 to 0030 O 0010 to 0030 VALVES Intake Material Silicon Chromium Steel Head Diameter 1 95 Length to center of valve face 4 79 Stem Diameter 372 to 373 Stem to Guide Clearance 001...

Page 239: ...leeves C 3028 Tappet Bore Reamer C 3033 Engine Front End Puller Kit C 3052 Distributor Drive Shaft Bushing Puller C 3054 Spark Plug Socket C 3059 Main Bearing Upper Shell Remover and Replacer C 3068 T...

Page 240: ...ut Fan Belt Idler Pulley Bracket Bolt Flywheel Housing to Cylinder Block Bolt Flywheel Housing Cover Bolt Fuel Pump Attaching Bolt Generator Mounting Nut Generator Adjusting Strap Bolt Generator Adjus...

Page 241: ...k plug wires for brittle cracked or frayed insulation Inspect small lead wires for tightness or damaged insulation 5 Check for excessive play in distributor vacuum advance plate bearing Install a new...

Page 242: ...48 ENGINE 59x54 fig 2 Front End Sectional View 58x135 Fig 3 Side Sectional View MyMopar com...

Page 243: ...62 61 7 8 9 io li 12 13 14 40 37 36 35 34 33 32 31 30 52 51 50 49 48 47 46 45 O 59x52 Fig 4 Complete Engine External Parts Exploded View MyMopar com...

Page 244: ...G GEARAND SHAFT SPROCKET CHAIN CAMSHAFT BOLT OIL SEAL SERVICED IN PACKAGE CRANKSHAFT SPROCKET OIL SLINGER RETAINER SCREW CAP S C R E W SCREW SCREW CAP SERVICED IN ROD NUT CAP 59x53 A Fig 5 Complete En...

Page 245: ...t ing bolts 4 INSTALLING THE ENGINE ASSEMBLY 1 Attach the engine lifting fixture Tool C 3466 to carburetor flange studs on the intake manifold 2 Attach the chain hoist to fixture eyebolt 3 Remove the...

Page 246: ...kage 3 Coat the new gaskets with number 1122893 sealer Install the gaskets and cylinder heads 4 Install cylinder head bolts Starting at top center tighten all cylinder head bolts to 70 foot pounds tor...

Page 247: ...ped arrow on rocker shaft must be on top and the arrow must point to ward the push rod side of the rocker arm This is necessary to provide proper lubrica tion to the rocker assemblies The two wide bra...

Page 248: ...s are available in 005 015 and 030 inch oversizes Reamers to accom modate the oversize valve stem are as follows Reamer Tool C 3433 379 to 380 inch Reamer Tool C 3427 404 to 405 inch 8 Slowly turn rea...

Page 249: ...test a spring first deter mine the length at which the spring is to be tested As an example the compressed length of the spring to be tested is l15 32 inches Turn the table of Tool C 647 until surfac...

Page 250: ...ng and or rocker arm to vibrate or feel rough in operation NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case none may be dampened by applying side t...

Page 251: ...valve from seating install a new tappet assembly Testing Fill a pan with clean kerosene 2 Remove cap from plunger and completely sub merge the tappet in an upright position 3 Allow tappet to fill wit...

Page 252: ...e chain cover and gasket 5 Slide the crankshaft oil slinger off end of crank shaft 6 Remove the camshaft sprocket attaching bolt 7 Remove timing chain with crankshaft and cam shaft sprockets Installat...

Page 253: ...LER SCREW TOOL REMOVING AND INSTALLING PLATE TOOL SLEEVE TOOL CHAIN CASE COVER INSTALLING PLATE TOOL SEAL ASSEMBLY PULLER SCREW TOOL CHAIN CASE COVER 58x154 Fig 28 Pcs t on ng Installer Plate on New S...

Page 254: ...G MARK VIBRATION DAMPER TOOL DRIVE GEAR CAMSHAFT FUEL PUMP ECCENTRIC CAMSHAFT LOCATING DOWEL O XIO Fig 32 Camshaft and Sprocket Assembly Disassembled View Rearward camshaft thrust is taken by the rear...

Page 255: ...installed one quart of factory rec ARM TOOL DISTRIBUTOR DRIVE GEAR CAMSHAFT Fig 36 Camshaft Holding Tool C 35O9 ommended oil additive should be added to the engine oil to aid in break in The oil mixt...

Page 256: ...Position bearing in the tool Install horse shoe lock and by reversing removal procedure carefully drive bearing shell into place as shown in Figure 38 3 Install remaining shells in like manner NOTE In...

Page 257: ...pansion under normal operating conditions Under operating temperatures expansion forces the pin bosses away from each other thus causing the piston to assume a more nearly round shape It is important...

Page 258: ...on at 70 F Piston pins are PRESS MAIN SCREW TOOL PISTON ANVIL TOOL SPRING TOOL PILOT TOOL PISTON PISTON PIN MAIN SCREW TOOL GUIDE SMALL TOOL 58xl96B GUIDE LARGE TOOL Fig 43 lnstall ng Piston Pin using...

Page 259: ...que the piston pin and connecting rod inter ference is satisfactory the tool may be removed 58x169 Fig 46 Showing Location of External Engine numbering pad 55x162 Fig 47 Showing Location of Internal L...

Page 260: ...od over the crankshaft jour nal as shown in Figure 48 6 Tap piston down in the cylinder bore using the handle of a hammer At the same time guide connect ing rod into position on crankshaft journal 7 T...

Page 261: ...umber 3 main bearing 6 Fit the remaining bearings in same manner Only one main bearing should be selective ly fitted while all other main bearing caps are properly torqued It is permissible to use one...

Page 262: ...oot pounds torque 28 FRONT ENGINE MOUNTS Removal 1 Disconnect throttle linkage at transmission and at carburetor BOLT ENGINE REAR SUPPORT INSULATOR LOCKWASHER l3 NUT WASHER NUT LOCKWASHER BACKING PLAT...

Page 263: ...Plug 35 Oil Pump Attaching Bolt 8 Cylinder 35 6 Cylinder 200 inch pounds Oil Pump Cover Bolt 8 Cylinder 10 6 Cylinder 130 inch pounds CONTENTS 361 383 CUBIC INCH ENGINE Par Page OIL FILTER 3 4 OIL PA...

Page 264: ...d rotor type oil pump and a full flow oil filter Oil is forced by the oil pump to a series of oil passages in the engine as shown in Figure 1 1 OIL PAN Removal 1 Disconnect battery cable 2 Raise car o...

Page 265: ...l outlet vent pipe 5 Connect steering linkage at idler arm and at steering arm 6 Connect battery cable 7 Install drain plug and refill crankcase COVER STRAIGHT EDGE FEELER GAUGE 2 OIL PUMP Removal Rem...

Page 266: ...the plunger is scored replace the plunger 12 The spring should conform to specifications on chart If for any reason the spring has to be replaced the same color spring should be used 13 An exception i...

Page 267: ...y l inch by attaching support fixture and disconnecting front engine mounts 6 Block engine and remove support fixture 7 Remove oil pan attaching bolts 8 Lower the rear of the pan turning it sideways t...

Page 268: ...SSUtf UOMT OMT 0 OAU Y ROCKER SHAFT BRACKET O i l FtOWS TO ONLY ONf BRACKET ON EACH HIAO BRACKET i SECOND FROM REAR ON RIGHT HEAD MACK T 1 SECOND FROM FRONT ON LEFT HIAD f A SAOf TO CAMSMM1 SfA UA HG...

Page 269: ...more than 004 inch can be inserted between rotors and straight edge install a new pump body and or rotors 10 The mating face of the oil pump should be smooth If the cover is scratched or grooved it sh...

Page 270: ...o the rear Do not turn oil pick up out of position Installation 1 Install the oil pan Fig 1 Tighten bolts to 15 foot pounds 2 Lower the engine 3 Install left side support connecting converter housing...

Page 271: ...TOR DIAMETER 60x136 5 Slide outer rotor and inner rotor into pump body and place a straightedge across the face between the bolt holes Fig 6 6 If a feeler gauge of more than 004 inch can be inserted b...

Page 272: ...HART Color Free Length Loaded Length Compression Pounds Gray Lt 2 Red Std 2 i 4 Brown Hvy 2 2 3 64 1 64 4 11 85 to 12 85 I4 85 to 15 85 I7 9O to 18 90 OUTER ROTOR INNER ROTOR V 60x139 J Fig 8 Measurin...

Page 273: ...to Exhaust Manifold Bolts Manifold to Cylinder Head Nuts Foot Pounds 20 30 40 10 15 30 15 10 SERVICE DIAGNOSIS 1 EXCESSIVE EXHAUST NOISE OR VIBRATION 1 Check for interference of exhaust pipe muffler o...

Page 274: ...ifold SERVICE INFORMATION 6 CYLINDER ENGINE DESCRIPTION The intake manifold Fig 1 consists of six long curved tubes which supply fuel and air to each individ ual cylinder from a single throat downdraf...

Page 275: ...s to a heat chamber in the intake manifold and preheat the fuel air mixture Thus the fuel is vaporized to a greater degree before entering into the combustion chambers providing quicker warm up When t...

Page 276: ...PIPE 60x847 NUT PLAINWASHER SUPPORT j BOLT y l1 I C L A M P LOCKWASHER P I P E SUPPORT PIPE Fig 4 Exhaust System High Performance SUPPORT PLAINWASHER LOCKWA HER NUT U BOLT NUT LOCKWASHER PLAINWASHER...

Page 277: ...t manifolds Tighten nuts to 40 foot pounds 3 Install generator on right exhaust manifold and adjust belt tension 4 Connect spark plug cables at spark plugs 9 EXHAUST PIPES MUFFLERS AND TAIL PIPES Figs...

Page 278: ...and stop from end of shaft exposing the thermo static coil 2 Unhook coil from pin and remove by prying out of valve shaft slot 3 If valve shaft is frozen in manifold apply mani fold heat control valve...

Page 279: ...he frame alignment Diagonal measurements should be taken when straightening the frame Measure the distance between the points connected by line A in Figure 2 This distance should agree within inch wit...

Page 280: ...he fender to body post bolts 10 Remove the bolts attaching the front end sheet metal to the stub frame yokes Fig 7 11 Disconnect the radiator yoke from the frame 12 With an assistant raise the fenders...

Page 281: ...he frame and engine assembly under the body 2 Install the body to frame bolts and tighten se curely 3 Raise the car and connect the exhaust pipe to the muffler and the propeller shaft to the transmiss...

Page 282: ...dy to Frame Alignment checks should be per formed whenever the vehicle has been in an accident or if the front end sheet metal cannot be properly aligned When checking body to frame alignment as shown...

Page 283: ...and a fuel gauge sending unit In operation the fuel pump draws fuel from the tank and forces it to the filter and carburetor The carbu retor meters the fuel into the air stream drawn into the engine...

Page 284: ...t level 5 Automatic choke not operating properly 6 Incorrect fuel pump pressure 3 POOR PERFORMANCE MIXTURE TOO RICH Possible Causes 1 Restricted air cleaner 2 Excessive fuel pump pressure 3 High float...

Page 285: ...el 21 Detonation or pre ignition BBS SERIES CARBURETOR CONTENTS Par Automatic Choke well type Carburetor Adjustments Accelerator Pump Bowl Vent Adjustment Choke Unloader wide open kick Fast Idle Cam I...

Page 286: ...gh speed system When the engine is under a heavy load suddenly accelerated or operated at very high engine speeds the step up system supplies additional fuel through the diffuser bar discharge port Fu...

Page 287: ...E ER AM VER DASH POT ACCELERATOR PUMP PLUNGER ROD CHOKE PISTON HOUSING ACCELERATOR PUMP ROCKER ARM MAIN BODY THROTTLE BODY IDLE MIXTURE ADJUSTING SCREW ACCELERATOR PUMP OPERATOR ROD REPAIR STAND ACCEL...

Page 288: ...am which pro vides the necessary increased idle speed during the warm up period SERVICE INFORMATION PROCEDURES 1 SERVICING THE CARBURETOR Often the carburetor is blamed for a great variety of trouble...

Page 289: ...ol T109 59T remove the accelator pump jet as shown in Figure 9 14 Unscrew and remove the idle mixture adjusting screw and spring AIR HORN V ACCELERATOR PUMP ROCKER ARM BOWL VENT VALVE PUMP SPRING ACCE...

Page 290: ...mains Never clean jets with a wire drill or other mechanical means because the orifices may become enlarged making the mixture too rich for proper performance 4 INSPECTION AND REASSEMBLY Throttle Body...

Page 291: ...plunger and press lightly on the plunger shaft to expel air from the pump passage 10 Using a small clean brass rod hold the dis charge check ball down firmly on its seat Again raise the plunger and p...

Page 292: ...h pump rocker arm Refer to Figure 4 20 Place a new gasket on the main body then in stall air horn by tilting air horn as shown in Figure 3 in order to engage fast idle link with fast idle cam After en...

Page 293: ...der to obtain correct bowl vent clearance CALIBRATION SETTING DO NOT CHANGE COVER THERMOSTATIC COIL SPRING INDEX NOTCH 60x93 Fig 18 Well Type Automatic Choke Unit Idle Speed Adjustment Curb Idle The i...

Page 294: ...n Metering Jet Standard 053 054 One Step Lean 052 053 Two Steps Lean 051 052 Power Jet 2 56 2 56 ADJUSTMENTS Idle Mixture Both Screws l turns open l turns open Idle Speed rpm 500 500 with air conditio...

Page 295: ...PLUGS IDLE MIXTURE ADJUSTING SCREW THROTTLE BODY SCREWS PUMP ROD SCREW THROTTLE SHAFT AND LEVER ROCKER ARM AIR HORN SCREW AIR HORN CHOKE LEVER NUT LOCKWASHER IDLE ROD VACUUM POWER PISTON POWER BY PAS...

Page 296: ...LE VALVE AND SEAT ASSEMBLY IDLE MIXTURE ADJUSTING SCREWS 2 REPAIR STAND DUST WASHER THERMOSTATIC COIL SPRING BOWL VENT TUBE AIR HORN CHOKE VALVE MAIN BODY FAST IDLE LEVER FAST IDLE ROD FAST IDLE CAM W...

Page 297: ...uch case NEW parts be installed 2 DISASSEMBLING THE CARBURETOR To disassemble the carburetor for cleaning or over haul refer to Figures 1 or 2 depending on model of carburetor then proceed as follows...

Page 298: ...arburetor main body and drop out the accelerator pump inlet check ball IDLE TUBE IDLE PASSAGES DISTRIBUTOR TUBE CONNECTION FITTING VACUUM Do not attempt to remove the high speed bleeders located in th...

Page 299: ...IN METERING JET 54x425 Fig 11 Removing or Installing Main Metering Jets are formed in the jet during removal will not damage the jet 20 Unscrew and remove the idle mixture adjusting screws and springs...

Page 300: ...sible from the top of the throttle body when valves are installed The notch cut in the edge of the throttle valves should be centered over idle discharge port See Figure 12 6 Slide the valves in posit...

Page 301: ...rottle body on the invert ed main body using a new gasket Install screws and lockwashers then tighten securely Fig 17 Installing Discharge Check Ball 5 Invert the carburetor and place on repair block...

Page 302: ...der lip of boss to keep fulcrum pin in position TOOL 2lNCH FLOAT OAT LIP 57x120 Fig 20 Bending Float Lip FLOAT UP HELD AGAINST FUEL INLET NEEDLE Fig 19 Checking Float Setting Checking Float Height y U...

Page 303: ...djustment turn the idle speed adjusting screw out far enough to clear the throttle lever tang when the throttle valves are closed 2 Hold the throttle valves in closed position then turn the fast idle...

Page 304: ...040 VACUUM PISTON PISTON LEVER EAR BEND AS REQUIRED Fig 27 Vacuum Kick Adjustment 57x158B paper clip or a piece of 040 inch diameter wire into the shape shown in Figure 27 Insert the bent end into the...

Page 305: ...1 With the throttle valves held closed and idle speed screw backed out it should be possible to insert a 2 inch drill shank between the bowl vent valve and the air horn 2 If an adjustment is to be ma...

Page 306: ...040 to 063 ADJUSTMENTS Idle Mixture Both Screws to Turns Open Idle Speed rpm 500 with car cooling rpm 550 Fast Idle Speed rpm 1375 to 1425 Fast Idle Speed Cam Index choke blade opening Drill 3 Turns...

Page 307: ...itions of operation Fuel enters the car buretor at the fuel inlet flowing through the float cham ber as shown in Figures 1 and 2 When the fuel reaches a given level the float shuts off the supply of f...

Page 308: ...ed air bleeders as shown in Figure 3 This mixture of air and fuel is then discharged from the tips of the main discharge nozzles into the air stream through the auxili ary venturi The main body and ma...

Page 309: ...rst stage valve closes cutting off the supply of fuel through the upper hole The Accelerating System To insure a smooth uninterrupted flow of power for acceleration additional fuel must be metered int...

Page 310: ...opens is governed by the pressure of air against the offset choke valve as shown in Figure 8 The heat from the manifold gradually decreases the tension of the thermostatic coil spring until the sprin...

Page 311: ...CELERATOR PUMP ROD FAST IDLE CAM IDLE MIXTURE ADJUSTING SCREWS 2 THROTTLE LEVER BOWL VENT VALVE MAIN BODY IDLE MIXTURE ADJUSTING SCREWS 2 VACUUM PASSAGE DISTRIBUTOR CHOKE VALVE FAST IDLE LEVER AIR HOR...

Page 312: ...ure 3 3 Remove the hairpin clip that holds the fast idle rod in the fast idle cam Disengage rod from cam then rotate rod to disengage from choke lever as shown in Figure 4 4 Remove the three short air...

Page 313: ...r horn This assembly is staked in the air horn and care should be used at removal Discard air horn gasket 8 Remove the screws that hold the choke valve and the choke piston link bracket to the choke s...

Page 314: ...nable However there are other commercial solvents such as Metal clene which may be used with satisfactory results IMPORTANT If the commercial solvent or cleaner recom mends the use of water as a rinse...

Page 315: ...ody Exploded View against the stop The idle speed adjusting screw must be backed off when seating the valves in the following operation 6 Slide the valves down into position with the notches in the va...

Page 316: ...position Install attaching screws and tighten securely Refer to Figure 8 Again depress the accelerator plunger A clear straight stream should emit from each jet orifice If the streams are not identica...

Page 317: ...ugh to hinder smooth operation in stall a new piston assembly Vacuum Kick Adjustment 7 Insert a 59 drill in the top groove of the vacuum piston as shown in Figure 20 Apply light closing pres sure agai...

Page 318: ...e open and then open and close the throttle valves Failure to obtain full throttle operation indicates improper assembly or adjustment of the choke mechanism 4 With the throttle valves held in the ope...

Page 319: ...5 shows the component parts of the control unit along with the number stamped on the crown of the cover When installing the well type choke unit make cer tain that the coil housing does not contact th...

Page 320: ...emove long screw from side away from fuel bowl and on opposite side and assemble short screw Checking Float Setting or Fuel Level through main body flange Securely tighten Remove on the vehicle remain...

Page 321: ...VENTURI Primary P fe Secondary W MAIN METERING JET R1971A R2O52A Standard 22R 40 60 22R 40 61 1 Size Lean 22R 40 59 22R 40 60 2 Sizes Lean 22R 40 58 22R 40 59 ADJUSTMENTS Idle Mixture 1 Full Turn Ope...

Page 322: ...LEVER FAST IDLE ADJUSTING SCREW MANIFOLD CHOKE ROD CONNECTION FAST IDLE CAM 60X38 F g 1 Carburetor Assembly R2O52A and R1971A CARBURETOR PART NO LOCATION FLOAT LEVEL ADJUSTMENT LOCK SCREW FLOAT LEVEL...

Page 323: ...ich is located on the primary fuel bowl The pump is actuated from a cam on the primary throttle An override spring on the pump operating lever prolongs the discharge of fuel for smoother acceleration...

Page 324: ...hoke Rod 25 Choke Rod 26 Retainer Choke Rod 27 Seal Choke Rod 28 Throttle Body Screws 29 Lockwashers Throttle Body Screws 30 Main Body 31 Throttle Body 32 Gasket Main to Throttle Body 33 Screw Bowl Ve...

Page 325: ...d that in such cases NEW parts be installed 4 Always use a complete repair kit when over hauling the carburetor Using the code number stamped on the air horn adjacent to the fuel inlet refer to the pa...

Page 326: ...e 8 Re move the float baffle 13 Remove the float adjusting lockscrew and gas ket see Figure 9 14 Remove the needle valve and seat assembly by turning float adjusting nut Lift out needle valve assembly...

Page 327: ...cam assembly and spring from the end of the primary shaft Slide shaft out of body 30 Remove the pump cam only from the pri mary shaft assembly 31 Remove the secondary shaft lever Slide shaft out of bo...

Page 328: ...sembly on shaft 11 Bring outer end of spring up over lever 12 Locate secondary throttle shaft stop lever with hooked end on lever and install spring on shaft with straight end extending downward betwe...

Page 329: ...tall choke connector rod seal 19 Install choke connector rod 20 Adjust idle air adjusting screw as shown in Figure 16 Seat the screw lightly then back off one turn use screwdriver 5 CARBURETOR ADJUSTM...

Page 330: ...aded Adjustment wide open kick 60X54 jj j Fig 21 Bending the Fast Idle Cam Lever ADJUST CLEARANCE BY BENDING HERE lever to the underside of the throttle body as shown 2 This measurement should be 1 an...

Page 331: ...hten securely Check the fuel level in the secondary bowl in the same manner CAUTION It is suggested that suitable precaution be taken by placing a shop towel or a container under the bowl to catch any...

Page 332: ...ransmission THROTTLE BORE Primary V Secondary 7 r MAIN VENTURI Primary 1 6 Secondary l 6 LOW SPEED JET Primary 65 O35 ADJUSTMENTS Accelerator Pump Setting top of plunger to airhorn V 6 Choke Unloader...

Page 333: ...loat systems two low speed systems primary side only two high speed systems one accelerator pump system and one automatic choke control system SERVICE INFORMATION PROCEDURES 1 SERVICING THE CARBURETOR...

Page 334: ...ER THROTTLE OPERATING ROD PRIMARY THROTTLE SHAFT DOG DISTRIBUTOR VACUUM FITTING PRIMARY THROTTLE SHAFT ARM INNER 58x276 A CHOKE VALVE CHOKE SHAFT LEVER CHOKE PISTON CYLINDER PLUG ACCELERATOR PUMP ARM...

Page 335: ...move the two needle valves from their respec tive seats after marking the one on the pump side for identification Using a wide blade screw driver remove the needle valve seats Be sure each needle valv...

Page 336: ...6 Invert the main and throttle body casting then remove the accelerator pump intake check ball plug Using Tool T109 59 screw driver bit remove the check ball seat as shown in Figure 7 Again invert th...

Page 337: ...ani cal means because1 the orifices may become enlarged making the mixture too rich for proper performance SECONDARY VALVE THICK PRIMARY VALVE T H I N 3 4 F g 9 Throttle Valve Identification 4 INSPECT...

Page 338: ...either one is diverted or restricted a new accelerator pump jet housing should be in stalled After test pour the gasoline from the carburetor bowl and remove pump plunger Assembling the Air Horn 1 Sli...

Page 339: ...g screws and tight en securely The two long screws should be installed in the holes that are located at the air cleaner mount ing surface The 1 inch screw at the front and the 1 inch at the rear 5 Sli...

Page 340: ...st idle adjusting screw BEND THROTTLE CONNECTOR AT THIS ANGLE THROTTLE VALVcS SEATED IN BORES IDLE SPEED SCREW BACKED OFF 58x292 Fig 16 Checking Accelerator Pump Travel Choke Unloader Adjustment With...

Page 341: ...e been made reinstall carbure tor or engine using a new gasket It is suggested that the carburetor bowl be filled with clean gasoline This will help prevent dirt that is trap ped in the fuel system fr...

Page 342: ...n Before indexing the choke piston be sure the ignition system and timing are at the required specifications that the manifold heat control valves are operating properly this is very important for nor...

Page 343: ...ning or overhaul set the throttle linkage as outlined under the Ram Manifold Section FUEL PUMP CONTENTS Cleaning Fuel Pump Parts Disassembling the Fuel Pump General Information Reassembling the Fuel P...

Page 344: ...in Figure 3 is used on the 361 cubic inch engine when equipped with the Stromberg WWC 3 series dual carburetor is also used on the 383 cubic inch V 8 engine The fuel pumps are driven by an eccentric...

Page 345: ...from 5 to 7 p s i on Models M 26O8S and M 2611S The pressure should remain constant or return to zero very very slowly when the engine is stopped An instant drop to zero indicates a leaky outlet valv...

Page 346: ...t fitting while the line is disconnected 1 Start the engine or turn over with starting motor 2 There should be a noticeable vacuum present not alternated by blowback 3 If blowback is present the inlet...

Page 347: ...assemble the fuel pump refer to Figures 1 2 3 or 4 then proceed as follows 1 Place the airdome diaphragm in position on the valve body with inlet passage hole over passage 2 Align the scribe marks on...

Page 348: ...under kick up in floor pan is open If this is not done a collapsed fuel tank will result The fuel tank on all models except the suburban has a 20 gallon capacity The suburban tank capacity is 22 gall...

Page 349: ...1 Drain the tank then disconnect the fuel line and the wire lead to the gauge unit 2 Disconnect vent tube at hose connection at lead ing edge of tank 3 Remove the nuts that hold the ends of the fuel...

Page 350: ...om sleeve and 0 ring from filler tube 6 Slide the tank down and out from under quarter panel Reach up under quarter panel and disengage the hold down strap from the bracket if strap is to be re placed...

Page 351: ...mixture from each carburetor flows into a chamber directly under the carburetor then passes through the long individual intake branches to the opposite cylinder bank The right hand carburetor supplies...

Page 352: ...coil wire 7 Disconnect the throttle linkage at both carbur etors and the bell crank to the accelerator shaft 8 Loosen the clamps that attach the equalizer tube couplings to the manifolds and to the e...

Page 353: ...ht 4 Slide a new gasket between the left hand ex haust manifold elbow and the lower chamber of the intake manifold Install attaching bolts finger tight 5 Slide a new gasket between the left hand ex ha...

Page 354: ...cting car performance can be encountered such as loss of RIGHT BANK CARBURETOR ROD BELL CRANK 3 16 x3 PIN WELDING ROD ADJUSTING LINK D LOCKING BOLT AND NUT ADJUSTING LINK LOCKING BOLT AND NUT TOP VIEW...

Page 355: ...h a spirit protractor 4 After correct measurement has been obtained reconnect rod Remove pin from accelerator shaft bracket Setting the Bellcrank To set the bellcrank refer to Figure 3 then proceed as...

Page 356: ...2 4 1 5 6 Page 75 75 74 75 74 75 75 SPECIAL TOOLS 1 Piece of 6 inch Welding or Drill Rod SERVICE INFORMATION PROCEDURES I SETTING THE THROTTLE LINKAGE All V 8 Except Ram Manifold As mentioned previou...

Page 357: ...follows 1 Unsnap the accelerator pedal to shaft rod 2 Turn the threaded end of the rod either in or out until a measurement of 114 degrees is obtained be tween the floor of car and the flat face of t...

Page 358: ...ntly when driving under severe conditions such as in dusty areas NOTE INSULATOR TO BE ASSEMBLED TO CARB LINKAGE BEFORE INSULATOR INSTALLING SHAFT INTO INSULATOR CLIP O RFIirDAM1 J r BEL LCRANK TQ THRO...

Page 359: ...N AND OPERATION 3 DIAGNOSIS 1 2 DRIVE LINE ANGULARITY 4 4 PROPELLER SHAFT 5 A Removal Installation SPECIFICATIONS PROPELLER SHAFT Type Tubular 118 inch wheelbase Length Centerline trunnion and yoke be...

Page 360: ...12 Improper drive line angularity 13 Rear springs not matched 14 Undercoating on shaft 2 UNIVERSAL JOINT NOISE Possible Causes 1 Lack of lubrication 2 Worn universal joint 3 Propeller shaft flange nut...

Page 361: ...n Universal Joint PROPELLER SHAFT 5 4 x 4 9 PROPELLER SHAFT ROLLER AND BUSHING ASSEMBLY ROLLER AND BUSHING ASSEMBLY RETAINER ROLLER DUST SEAL DUST SEAL RETAINER CROSS ASSEMBLY BUSHING RETAINER ROLLER...

Page 362: ...Recheck angularity 5 Place the protractor on the underside of the propeller shaft and record the angularity Fig 5 6 Add the readings of the carrier housing and the propeller shaft They should total ap...

Page 363: ...e race ways in the body for roughness or wear If either part is to be replaced use the correct tool see Tool Speci fications on hydraulic press to press the pin out of end of the shaft Cleaning and In...

Page 364: ...urfaces should be smooth free from pits and ripples If dust seal retainers are damaged replace assembly 3 Examine roller bearings in bushings Bearings that have operated on a worn cross assembly shoul...

Page 365: ...PRINGS MODEL TYPE NO OF LEAVES Sedans Hardtops Convertibles Station Wagons W DTH inches LENGTH inches SHACKLE HANGER PD 5 5 6 57 Side L PD2 PD3 Semi Elliptic 5 5 5 6 57 Silent Block 4 4 2 50 55 Rubber...

Page 366: ...ds No lubrication of any kind should be used on rubber bushings Front suspension heights may be affected if the rear spring height varies more than inch one side as compared with the other side To che...

Page 367: ...the pivot bolt out of the spring 6 Remove the spring U bolts and spring Installation 1 Position the springs in their respective front hang ers and install the pivot bolts and nuts ringer tight Only 2...

Page 368: ...e interliner makes contact is clean and smooth 2 Insert the interliner between the spring leafs Fig 7 until the prongs of the metal fasteners are aligned with the holes 3 Pry the prong end of the fast...

Page 369: ...shing and install the new bushing Remove Tool after the new and remover adapter SP 3180 bushing has been correctly positioned SHOCK ABSORBERS CONTENTS GENERAL INFORMATION SHOCK ABSORBERS Front Rear Te...

Page 370: ...roperly the groove in the bushing will index with the opening in the frame 2 Install the steel sleeve in the bushing 3 Using Tool C 3553 press the bushing into the shock absorber eye until it is cente...

Page 371: ...CE GENERAL SPECIFICATIONS MODELS TYPE Worm and Three Tooth Roller RATIO 20 4 to I GEAR SHAFT BEARINGS 2 Needle Roller Bearings WORM SHAFT BEARINGS Tapered Roller HIGH POINT wheels straight ahead Notch...

Page 372: ...9 Bent suspension parts 4 WHEEL TRAMP Excessive Vertical Motion of Wheels 1 Incorrect tire pressure 2 Improper balance of wheels tires and brake drums 3 Loose tie rod ends of steering connections 4 W...

Page 373: ...crew against the gear shaft will pull steering arm from the gear shaft 11 Disconnect the hydraulic brake line at the master cylinder and brake tee and remove the line 12 Slide the steering gear jacket...

Page 374: ...ms in the event a bind or excessive end play occurs Shims are available in 003 006 and 011 inch 4 Install the gear shaft 5 Before installing the cover turn the adjusting screw all the way out 6 Place...

Page 375: ...er SP 3056 with nut of tool while turning the adapter SP 3056 forcing it into the seal until it engages the metal lip of the seal 7 Slide retainer of Tool C 3350 over adapter en gage the grooves in th...

Page 376: ...urning 5 Reinstall steering gear arm 11 REMOVAL AND REPLACEMENT OF THE IDLER ARM Fig 4 1 Place the front wheels in the straight ahead position 2 Remove cotter pin and nut and separate center link and...

Page 377: ...the nut lock on nut with one pair of slots in line with cotter pin hole 3 Back off the adjusting nut l slots Cotter pin hole will be covered 4 Remove lock and re position it so the cotter pin can be i...

Page 378: ...S 9 TORQUE REFERENCE 8 SPECIFICATIONS Ratio 16 to 1 Fluid Capacity of Power Steering System 2 qts Type of Fluid Use only Part Number 2084329 Power Steering Fluid Maximum Pump Pressure 850 to 950 psi M...

Page 379: ...linkage needs lubrication 8 Power steering pump output low See Paragraph 11 Pressure Check A Steering Gear Malfunction 1 Gear shaft adjustment too tight See Paragraph 12 2 Pressure control valve stuck...

Page 380: ...n or worn ring on worm piston 3 Piston end plug loose 4 Reaction seal missing 7 LACK OF ASSIST Both Directions 1 Pump belt slipping 2 Pump output low 3 Broken or worn ring on worm piston 4 Piston end...

Page 381: ...FRAME SIDE RAIL STEERING SHAFT FLEXIBLE COUPLING COLUMN JACKET SUPPORT WORM SHAFT BALANCING RING LEFT TURN REACTION RING CENTER THRUST BEARING RACE RIGHT TURN REACTION RING CYLINDER HEAD WORM SHAFT R...

Page 382: ...es which the steering linkage and wheels transmit to the steering gear cross shaft Instead the wormshaft is drawn out of the piston a very small amount a few thousandths of an inch TO RESERVOIR CROSS...

Page 383: ...earing race to its neutral position The driver feels this force on the reaction rings shown in Figures 5 and 6 as a force proportional to operating oil pressure It causes the driver to exert a steerin...

Page 384: ...tions are tight and that shut off valve is fully opened C5 Start the engine and operate at idle speed 500 RPM 6 With the engine operating at idle 500 RPM and oil temperature between 150 degrees F and...

Page 385: ...ion and tighten lock nut to 50 foot pounds torque to main tain this setting 13 REMOVING POWER STEERING GEAR UNIT 1 Disconnect battery ground cable 2 Remove steering wheel ornament by removing the scre...

Page 386: ...teering gear housing pow er train housing in a clockwise motion towards cowl panel until the gear shaft end of housing and shaft will clear the A frame of front suspension Then tilt en tire gear assem...

Page 387: ...F g 13 Removing or Installing Gear Shaft Cover Nut SPANNER NUT 58x38 Fig 14 Removing Steering Column Support Nut housing Rotate the shaft 180 and allow the ends of the teeth to rest on the housing 7 T...

Page 388: ...wer thrust bearing and lower thrust bearing race thick 8 Remove lower reaction ring and reaction spring 9 Remove cylinder head assembly The worm and piston assembly is furnished as a complete assembly...

Page 389: ...e cylinder head oil seal back up ring and retainer if removed Make sure retainer is seated in groove 3 Install the lower reaction seal in the cylinder head groove The small O ring for the ferrule groo...

Page 390: ...ssembly must be removed from the gear shaft the 51 needles will fall out of the cover If any needles 51 become lost it will be necessary to replace the cover and bearing as an assembly Use wheel bear...

Page 391: ...h soft jaws 2 Slide cylinder head assembly ferrule up on worm shaft check worm shaft seal ring making sure gap is closed to avoid damaging the ring as cylinder head moves against piston flange 3 Lubri...

Page 392: ...G RING RING RETAINER O RING SEAL SEAL WASHER NUT COUPLING LEVER SPRING SPRING PLUNGER SPRING BODY PIN PLUG GASKET PISTON HOUSING ISCREW O RING O RING ADAPTER GASKET m m 2 NUT VALVE ASSEMBLY SUPPORT W...

Page 393: ...ed 7 Install center bearing spacer assembly over center bearing race and engage dowel pin of spacer in slot of race and slot of spacer entered over cylinder head ferrule This will align valve lever ho...

Page 394: ...bring steering gear to normal operating temperature 4 Expel all air from the unit by turning worm shaft several times to the right and then to the left 5 Refill reservoir before proceeding with the f...

Page 395: ...ll a new ring if old ring will not fully seat in the groove Install the spacer wash er spring and tapered spacer on top of the snap ring 4 Assemble the horn ground strap into the lower end of the jack...

Page 396: ...AGNOSIS DISASSEMBLY INSPECTION INSTALLATION OPERATION REMOVAL SPECIFICATIONS TOOLS TORQUE REFERENCE Par Page 10 9 6 1 8 9 11 6 7 28 28 26 26 27 28 29 26 26 25 26 25 SPECIFICATIONS Type Maximum Pump Pr...

Page 397: ...the spring loaded slippers in the pump rotor are in contact with the eccentric inside diameter of the housing As the rotor revolves the slip pers force the oil from the inlet side of the pump to the...

Page 398: ...t from turning and turn screw inward tc remove the pulley Fig 2 6 Remove relief valve assembly and gasket Fig FLOW CONTROL VALVE PLUG AND SNAP RING X 58x224 O RING RELIEF VALVE ASSEMBLY 58x280 GASKET...

Page 399: ...g bore 3 Install new oil seal with lip of seal toward pump Use Tool C 3640 to drive seal flush with insert Fig 7 4 Install pressure relief valve and gasket as sembly 5 Remove front bracket Support pum...

Page 400: ...ND SERVOS BANDS Adjustments Kickdown Low Reverse Inspection Installation Kickdown Low Reverse Removal Kickdown Low Reverse CLUTCHES CLUTCH FRONT Assembly Checking End Clearance After Assembly Before D...

Page 401: ...le Compensated 26 KICKDOWN PISTON SERVICING IN CAR 29 28 NEUTRAL STARTER SWITCH 15 23 Servicing in Car 24 27 OIL LEAKS 13 22 OIL PAN Removal Unit out of Vehicle 37 33 OIL PAN AND GASKET Installation 1...

Page 402: ...DY Inspection Includes Valves Installation Removal SERVICE DIAGNOSIS CHART SERVICE DIAGNOSIS EXPLANATION SERVOS Low Reverse Installation Removal Kickdown Installation Removal SHIFT PATTERN SUMMARY CHA...

Page 403: ...Front Clutch Automatic Three Speed with Torque Converter n l2 HiPerf 18 pts Automatic Transmission 21 pts with l2 Converter Fluid Type A Suffix A Water 2 45 to 1 1 45 to 1 1 00 to 1 2 20 to 1 Gear Ro...

Page 404: ...C 811 Wrench C 32O3A Jack C 3276 Pilots C 3280 Stand C 3281 Wrench C 3283 Pilots C 3288 Pilots C 3292 Gauge C 3293 Gauge C 3301 Pliers C 3339 Set Dial Indicator C 3355 Straightedge C 3380 C 3461 C 348...

Page 405: ...Output Shaft Support to Case 25 Propeller Flange Nut 175 Reaction Shaft to Case 25 Rear Clutch Pressure Tap 120 Pump Housing to Support 120 Oil Pressure Tap 180 Suction Pressure Tap 180 Servo Apply Pr...

Page 406: ...or V Rear Pump a Front Pump Drive Sleeve b Regulator Valve Body Gasket Surface c Front Clutch d Rear Clutch e Planetary Gear Set f Overrunning Clutch g Manual Valve Lever Shift Abnormalities Response...

Page 407: ...ST PLUG LINE PR TAKE OFF PLUG GOVERNOR PRESSURE TAKE OFF PLUG NEUTRAL STARTER SWITCH 60x35 KICKDOWN BAND ADJUSTING SCREW Fig 1 Transmission Case Left Side which improved performance elimination of slu...

Page 408: ...check proceed as follows Refer to Figs 1 2 and 3 CAUTION Compressed air supply must be free of all dirt and mois ture 1 Raise the vehicle on a hoist drain the transmis sion fluid and remove the transm...

Page 409: ...CKDOWN ANNULUS GEAR OUTPUT SHAFT SUPPORT REAR OIL PUMP EXTENSION GOVERNOR ASSEMBLY SPEEDOMETER PINION M P o OUTPUT SHAFT ASSEMBLY OUTPUT SHAFT DRIVE HOUSING REAR CLUTCH PISTON REAR CLUTCH ASSEMBLY FRO...

Page 410: ...prings Check cam roller ramps for being worn g Manual Valve Lever A loose or badly worn manual valve lever cam should be replaced If loose it may be silver soldered only so as not to re quire high tem...

Page 411: ...mph 3 2 second position provides driving character istics similar to D drive except that the transmission will remain in second until the wide open throttle 2 3 upshift speed is attained as indicated...

Page 412: ...ns with either heavy loads or when pulling trailers the 2 second or 1 low position should be selected on upgrades which require heavy throttle for mile or more Lower ratios reduces the possibility of...

Page 413: ...low in D Drive Position 2nd Speed and 2 Second Position 2nd Speed 56x690 FRONT AND REAR CLUTCHES APPLIED DRIVE POSITION DIRECT DRIVE Fig 8 Power Flow in D Drive Position Direct FRONT CLUTCH APPLIED LO...

Page 414: ...own planet pinion shafts to rotate the kickdown plant pinion carrier The carrier which is splined to the output shaft drive housing rotates at a slower speed than the annulus gear thus providing a gea...

Page 415: ...operation The engine and transmission should be warmed up to operating temper ature A short drive approximately five to ten miles with frequent stops and starts will produce normal operating temperat...

Page 416: ...low reverse servo piston is moved hydraulically to apply the low reverse band through the low reverse band lever strut and anchor The results are To hold the carrier of the front planetary gear set s...

Page 417: ...or shaft transmits this force to the governor valve Oil is allowed to flow from the line pressure port to the governor pressure port building up pres sure in the governor circuit and against the valve...

Page 418: ...s are applied When the R reverse button is pushed in the man ual valve shuts off line pressure to the secondary re action area of the regulator valve and routes line pres sure at 225 psi 260 psi on Ra...

Page 419: ...ecessary that whenever the forces of governor pressure and throttle pressure act on the shift valve to cause an upshift the valve must snap from one posi tion to the other without hesitating or huntin...

Page 420: ...on moves on This back up pressure is greatest on low speed kickdowns when the kickdown piston applies rapidly and is sufficient to hold the clutch applied until the kickdown band is applied At this ti...

Page 421: ...ft control cable seal ring and housing gasket Governor line lubrication rear clutch apply and throt tle compensated pressure check plugs in transmis sion case or support pressure test holes Neutral st...

Page 422: ...CORRECT 58 X 16 F g 14 Lever Alignment an additional to turn Should the test light still fail to light and the seating surfaces have been cleaned to obtain a good ground it is recommended that the fol...

Page 423: ...s tor que This will be a true torque of 70 75 inch pounds which should be used if the torque wrench C 3380 is used without the adapter C 3583 as may be done if adjustment is made with the transmission...

Page 424: ...All line pressure adjustments should fall within the limits specified in the table shown for all other push button positions If line pressure cannot be satisfactorily adjusted check Service Diagnosis...

Page 425: ...necessary to fabricate a tool to be used as a gauge to properly reset throttle valve lever stop screw Use a piece of drill rod or other similar stock approximately 6 or inch in diameter Cut it off ver...

Page 426: ...on and hold it firmly engaged until the cable attachment oper ation is completed 2 Back the adjustment wheel off on the cable housing counter clockwise until only two or three threads are showing behi...

Page 427: ...emove oil pan 2 Disconnect throttle linkage and remove throttle valve lever and washer 3 Remove manual control lever to cable adapter tud nut 4 Remove oil strainer and transfer plate bolts and lower v...

Page 428: ...6 Install valve body assembly and oil pan 30 OUTPUT SHAFT REAR OIL SEAL Removal TOOL 60x30 Fig 24 Removing Output Shaft Rear Bearing Oil Seal 1 Disconnect front universal joint 2 Apply hand brake or u...

Page 429: ...ION 60x29 TOOL Fig 26 Removing Output Shaft Rear Bushing REAR EXTENSION 60x28 Fig 27 Installing Output Shaft Rear Bushing to support plate and install guide studs Tool C 3283 and then remove the balan...

Page 430: ...ernor valve which may be sticking in housing or travel restricted by chips or other foreign matter If inspection reveals necessity for further governor servicing then remove governor support locating...

Page 431: ...y turning output shaft Both weights should fall freely in body 6 Install transmission extension DISASSEMBLY INSPECTION AND ASSEMBLY OF COMPONENT PARTS 34 REMOVAL OF TRANSMISSION FROM VEHICLE 1 Disconn...

Page 432: ...ion until the kerosene drained out is clear To complete the flushing procedure rotate the converter with the drain plug removed This will re move any residual solvent and trapped dirt Reinstall the dr...

Page 433: ...and take indicator reading This clearance should be from 020 to 050 If clearance exceeds the specified limit particular attention should be paid to the condition of the input shaft thrust washer when...

Page 434: ...NG REMOVAL 1 Using a small screw driver remove the governor valve shaft snap ring from the weight assembly end as shown in Figure 36 2 Remove governor valve shaft and valve Fig ure 37 3 Using pliers T...

Page 435: ...INER AND INPUT SHAFT ASSEMBLIES Keep unit centered as much as possible and remove 56x614 A 56x615A Fig 42 Removal of Unit No 2 from transmission case as shown in Figure 43 Use ex treme care when remov...

Page 436: ...levers KICKDOWN BAND STRUT KICKDOWN BAND ADJUSTING SCREW 56x619 A Fig 46 Removal and Installation of Kickdown Band 50 LOW REVERSE SERVO REMOVAL 1 Install Tool C 3529 or C 3289 modified and depress th...

Page 437: ...transmission case by tapping housing lightly with a soft hammer Figure 51 Using dye mark pump gears in rela tion to face of oil pump housing for reassem bly purposes DO NOT SCRIBE TOOL SNAP RING 5 x62...

Page 438: ...TER REACTION SHAFT REMOVAL Refer to Inspection of torque Converter Reaction Shaft Paragraph 49 If inspection reveals it is neces sary to remove torque converter reaction shaft pro ceed in the followin...

Page 439: ...ts for pulled threads or foreign material in threads This is very important in obtaining proper band adjustments 59 TRANSMISSION EXTENSION HOUSING INSPECTION Inspect extension for cracks in casting an...

Page 440: ...or support seal rings with Automatic Transmission Fluid Type A Suf fix A and install on the governor support Make sure rings are free to rotate in grooves 2 Position governor body and support and inst...

Page 441: ...g and housing for any cracks and internal driving lugs for excessive wear or brinnel ling Housing and output shaft are serviced as an as sembly Inspect interlocking seal rings L M on output shaft K fo...

Page 442: ...ON Inspect for worn cracked or broken gear teeth 71 UNIT NO 1 OUTPUT SHAFT KICKDOWN PLANET PINION CARRIER AND INTERMEDIATE SHAFT ASSEMBLIES ASSEMBLY To aid in the assembly of Unit No 1 use the propell...

Page 443: ...screw drivers inserted between clutch and intermediate support remove rear clutch retainer N GEAR 56x637 Fig 66 Removal and Installation of Sun Gear Reverse Planet Pinion Carrier and Overrunning Clutc...

Page 444: ...by com pressing the spring too far 5 Remove piston return spring retainer snap ring with parallel jawed snap ring pliers Tool C 3301 6 Release compressor carefully Tool C 3575 and remove clutch retur...

Page 445: ...riving disc Repeat this procedure until all discs and plates have been installed The number of discs and plates vary ac cording to the engine and transmission equip ment The rear clutch pistons are of...

Page 446: ...r hub 6 While holding the two assemblies together re move Tool C 3527 Lubricate bearing surface on re verse sun gear and install intermediate support and planet pinion carrier assembly 7 Lubricate the...

Page 447: ...retainer K for distortion breakage and cracks 6 Inspect levers L cushion spring N and cushion spring washer M for wear distortion or evi dence of scoring 7 Inspect piston Q and piston retainer R Re m...

Page 448: ...wear 89 REVERSE SERVO PISTON ASSEMBLY INSPECTION FIG 76 Inspect lever contacting surface on plug L for ex cessive wear Remove and inspect reverse servo piston seal ring Z neoprene for deterioration a...

Page 449: ...otor bore metal portion of seal down use driver Tool C 3278 and drive seal until tool bottoms on face of housing as shown in Figure 77 Inspect drive sleeve seal ring con tacting surface in housing for...

Page 450: ...ghly cleaned and inspected the valves should be reinstalled in body Fig 56 Place assembly on a clean surface and cover with a paper towel lint free until ready for installation Inspect regulator valve...

Page 451: ...Improper tightening of these bolts may cause pump gears to bind 3 Lubricate front pump drive sleeve With a slight rotating back and forth motion install sleeve smooth bearing surface first being sure...

Page 452: ...pon disassembly by rotating band ends over center support in transmission case as shown in Figure 46 Use extreme care when in stalling bands to prevent damage to lining on edges of transmission case 2...

Page 453: ...ve force when install ing this unit so as to prevent damage to clutch discs in rear clutch A drift may be used to assist in alignment of intermediate locating holes 4 Install the intermediate support...

Page 454: ...56x611 A Fig 86 Removal and Installation of Rear Oil Pump Pinion GOVERNOR AND REAR OIL PUMP HOUSING ASSEMBLIES Fig 87 Removal and Installation of Governor and Rear Oil Pump Housing Assemblies initely...

Page 455: ...r and pry clutch forward by carefully inserting screwdriver between the front and rear clutch 2 Remove screwdriver and with point of dial in dicator contacting edge of front clutch retainer set in dic...

Page 456: ...ch end clearance 112 BAND ADJUSTMENTS Since both band assemblies have been removed it is very important that the hand brake drum is turned in a clockwise and counter clockwise direction to cen ter ban...

Page 457: ...guide studs and install the two trans mission case to housing screws and lockwashers in right side then draw the four down evenly and tighten to specifications 6 Place crossmember into position and in...

Page 458: ...throttle valve cover plate S throttle valve T throttle valve spring U kickdown valve V and detent W For general cleaning purposes it is not usually nec essary to disassemble and remove the manual valv...

Page 459: ...fi it will require readjustment with a special service tool Refer to Paragraph of this manual for adjustment procedure Inspect the manual and throttle valve operating lev Relay Valve Side of Body F 1...

Page 460: ...30 inch pounds torque 9 Turn valve body over and refer to Fig 96 In stall shuttle valve I small end first into valve body and install snap ring J Snap ring should be replaced if it does not fit secur...

Page 461: ...incorporates a heavier spring along with a lighter outer weight GOVERNOR PRESSURE CHART Ram Manifold Cars Only Push Button Position Rear Wheels Engine RPM Governor Pressure Free to Turn Free to Turn...

Page 462: ...CRANK ACCELERATOR SHAFT TO THROTTLESHAFT LEVER ROD ANTI STALL UNIT DLE POSITION ACCELERATOR PEDAL TO SHAFT ROD 3 16 xlO PIN WELDING ROD ACCELERATOR SHAFT BRACKET ACCELERATOR PEDAL ACCELERATOR PEDAL T...

Page 463: ...64 TRANSMISSION MyMopar com...

Page 464: ...12 82 Throttle Linkage Adjustments 14 83 OPERATING OF TRANSMISSION 2 69 OPERATING INSTRUCTIONS 5 78 POWER FLOW 3 69 RECONDITION SUB ASSEMBLIES 29 94 Accumulator Piston and Spring 31 98 Extension Hous...

Page 465: ...h Discs 3 GEAR RATIOS 1 Low 2 45 to 1 2 Second 1 45 to 1 D Drive 1 to 1 R Reverse 2 20 to 1 N Neutral FRONT REAR PUMPS Type Gear Rotary End Clearance 001 to 0025 inch DRIVE TRAIN END PLAY 024 to 062 i...

Page 466: ...Clutch Piston Spring C 3762 Aligning Sleeve Rear Oil Pump Cover C 3763 Gauge Throttle Pressure Setting C 3768 Protector Output Shaft Oil Seal C 3790 Adapter Transmission Band Adjuster Use with C 3380...

Page 467: ...a Front Pump b Front Clutch c Rear Clutch d Planetary Gear Sets e Overrunning Clutch f Converter Harsh N to D or N to R Shift Abnormalities Delayed Nto D Runaway on Upshift and 3 2 K D Harsh Upshift...

Page 468: ...front clutch by a driving shell which is splined to the sun gear and to the front clutch retainer The hydraulic system consists of a front and rear pump and a single valve body which con tains all of...

Page 469: ...RONT OIL PUMP OUTPUT SHAFT EXTENSION HOUSING REAR OIL PUMP PLANETARY OVERRUNNING CLUTCH CONTROL VALVE BODY FRONT CLUTCH BAND 0 I L STRAINER Kickdown SUN GEAR DRIVING SHELL SUN GEAR INPUT SHAFT ENGINE...

Page 470: ...2 45 to 1 DISENGAGED ENGAGED RELEASED APPLIED OVER RUNS R REVERSE 2 20 to 1 ENGAGED DISENGAGED RELEASED APPLIED OVER RUNS Drive In D drive position the front and rear clutches are engaged while front...

Page 471: ...INPUT SHAFT OUTPUT SHAFT REAR CLUTCH ENGAGED Fig 2 Power Flow in D Drive Position Direct KICKDOWN BAND APPLIED 5OX82S INPUT SHAFT OUTPUT SHAFT REAR CLUTCH ENGAGED SOK83O Fig 3 Power Flow n D Drive Pos...

Page 472: ...ockwise With the rear plane tary cage held stationary the sun gear rotating clock wise rotates rear planet pinions counterclockwise which turns the rear annulus gear splined to output shaft in the rev...

Page 473: ...GED INPUT SHAFT LOW REVERSE BAND APPLIED Fig 5 Power Flow in Reverse Position OUTPUT SHAFT OX83Z INPUT SHAFT OX833 REAR CLUTCH ENGAGED OUTPUT SHAFT OVERRUNNING CLUTCH HOLDING Fig 6 Power Flow in D Dri...

Page 474: ...reverse operation Rear Pump The rear pump smaller than the front pump and driven by the output shaft furnishes all of the oil required by the transmission in normal driving at all vehicle speeds abov...

Page 475: ...O REAR CLUTCH GOVERNOR PLUG GOVERNOR PLUG TORQUE CONVERTER CONTROL VALVE TORQUE L CONVERTER REVERSE BLOCKER VALVE TO LUBRICATION GOVERNOR REAR _ V A L V E PUMP PUMP CHECK VALVES Fig 7 Hydraulic Contro...

Page 476: ...Oil is allowed to flow from the line pressure port to the governor pressure port building up pressure in the governor circuit and against the valve reaction area sufficient to balance the centrifugal...

Page 477: ...may be made approximately 60 mph from drive to second and approximately 30 mph from drive or second to breakaway The throttle pres sure actuated kickdown detent plug on the stem of the kickdown valve...

Page 478: ...Do not depress 1 low or 2 second buttons above 70 mph as immediate downshift into second gear will result The transmission will not however shift into low gear if vehicle speed is above the 3 1 kickdo...

Page 479: ...screws holding the cable bracket to the control housing Installation 1 Insert end of cable on actuator and reassemble hairpin clip Place cable bracket on control unit and install screws securely 2 Ca...

Page 480: ...may occur wide open throttle stall operation should be avoided 9 LUBRICATION For lubrication requirements of the TorqueFlite Six Transmission refer to Lubrication Group of this man ual 10 FLUID LEAKS...

Page 481: ...threads of the switch Fig 10 then screw switch into trans mission case a few turns 5 Connect one lead of a test lamp to battery cur rent and the other lead to the switch terminal Screw switch into tr...

Page 482: ...smission with Automatic Transmission transmission throttle control lever forward until it stops Fluid Refer to Lubrication Group in this manual Then tighten lock nut A securely NOTE INSULATOR TO BE AS...

Page 483: ...in the clutches place the finger tips on clutch housing and again apply air pressure Move ment of the piston can be felt as the clutch is applied Kickdown Servo Direct air pressure into the kickdown...

Page 484: ...ly Pressure 1 Connect a 0 300 psi pressure gauge Tool C 3293 to apply pressure take off point at rear servo Fig 14 2 With transmission control in R reverse posi tion and the engine speed set at 1600 r...

Page 485: ...nsion housing Install grease shield retainer spring with opening of spring toward brake shoe adjusting nut Make sure spring is properly seated in groove 4 Slide the brake shoe return spring behind the...

Page 486: ...Fig 25 Governor and Weight Snap Rings housing See Paragraph 19 Installation Steps 1 through 4 2 Using a new gasket carefully slide the housing into place Install the retaining bolts and washers tighte...

Page 487: ...overnor housing and install snap ring 4 Place the governor valve on valve shaft insert the assembly into housing and through the governor weights Install the shaft retaining snap ring Install the exte...

Page 488: ...cur rent and the other lead to the switch terminal Screw switch into transmission case until the lamp lights then tighten switch an additional to turn NOTE The switch must be tight enough to prevent o...

Page 489: ...C clamp to edge of bell housing to hold converter in place during removal of transmission 20 Remove the bell housing retaining bolts Care fully work the transmission rearward off the engine block dow...

Page 490: ...ling of parts must be exercised to avoid nicks or burrs Oil Pan 1 Place transmission assembly in repair stand Tool C 3750 2 Unscrew oil pan bolts and remove oil pan and gasket Valve Body Assembly 1 Un...

Page 491: ...e front band adjuster remove the band strut and slide the band out of the case 2 Slide the front clutch assembly out of the case Input Shaft and Rear Clutch 1 Grasp the input shaft and slide input sha...

Page 492: ...E SPRING REGULATOR VALVE SPRING SPRING RETAINER BRACKET LINE PRESSURE ADJUSTING SCREW ASSEMBLY CABLE ADAPTER STUD HOLE THROTTLE LEVER SHAFT Fig 32 Removing or Installing Oil Screen Fig 33 Spring Brack...

Page 493: ...ck Valve Disassembled View 60x368 ONE LARGE STEEL BALL FIVE SMALL STEEL BALLS 60x370 FRONT PUMP CHECK VALVE Fig 35 Front Pump Check Valve and Steel Ball Locations E CLIP THROTTLE LEVER AND SHAFT DETEN...

Page 494: ...G REGULATOR VALVE END PLATE SHIFT VALVE END PLATE Fig 39 Valve Body Shift Valve Side Exploded View Tip up the valve body to allow the shuttle valve throttle plug spring shuttle valve and the shift val...

Page 495: ...ovement in the transfer plate Install stiffener plate and tighten retaining screws to 25 inch pounds torque 2 Turn transfer plate over and install reverse blocker valve spring and valve Rotate valve u...

Page 496: ...shing into place with the tool Make sure oil hole of bushing aligns with slot in the bushing 4 Install cup on the tool followed by the nut While holding the screw from turning tighten the tool nut to...

Page 497: ...ant Inspect machined surfaces on oil pump body and reaction shaft support for nicks and burrs Inspect oil pump rotors for scoring or pitting With rotors cleaned and installed in pump body place straig...

Page 498: ...nstalling Front Clutch Spring Retainer Snap Ring and remove snap ring then slowly release tool until spring retainer is free of the hub Remove the tool retainer and spring 3 Invert clutch retainer ass...

Page 499: ...in bottom of retainer 3 Place spring on piston hub and position spring retainer and snap ring on spring Compress spring with Tool C 3575 Fig 46 and seat snap ring in the hub groove Remove compressor t...

Page 500: ...properly seated in the piston grooves TOOL FEELER GAUGE SNAP RING Fig 49 Removing or Installing Rear Clutch Spring Retaining Snap Ring SELECTIVE SNAP RING 60 x 183 Fig 50 Checking Rear Clutch Plate Cl...

Page 501: ...nicks or burrs and remove with a sharp edged stone Make sure all oil passages in the shaft are open and clean Check bushings in sun gear for wear or scores re place sun gear assembly if ushings are d...

Page 502: ...eck band lining for wear and bond of lining to the band If lining is worn so grooves are not visible at the ends or any portion of the band replace the band Inspect band for distorting or cracked ends...

Page 503: ...se install the short strut then connect the long lever and strut to the band Screw in band adjuster just enough to hold struts in place Kickdown Servo 1 Carefully push servo piston into case bore In s...

Page 504: ...pring fully com pressed and the valve bottomed in the valve body 6 Remove the tool and tighten the stop screw lock nut securely SERVICING OPERATIONS WITH TRANSMISSION IN VEHICLE Various transmission s...

Page 505: ...then tighten the cover bolts evenly to 14 16 foot pounds torque PILOT STUDS 60x375 TOOL ALIGNMENT HOLES VERTICAL 60x393 Fig 56 Aligning Front Pump Rotors Fig 55 Installing Front Pump and Reaction Shaf...

Page 506: ...C CONTROL 2 114 Direct Clutch 114 Governor 114 Line 114 Lubrication 114 Throttle 114 TRANSMISSION Assembling 8 128 Disassembly 7 119 Inspection 7 119 Installation 10 138 Removal 6 118 VALVE BODY and T...

Page 507: ...to 064 O72 to 074 O82 to 084 058 to 060 062 to 064 078 to 080 082 to 084 086 to 088 lf this selection of snap rings fails to provide minimum clearance use kickdown sun gear snap ring 058 060 C 452 Pul...

Page 508: ...Nut 20 Oil Pan Filler Tube Nut 40 Output Shaft Support Bolt 25 Output Shaft Support Pipe Plug 120 Rear Oil Pump Housing Bolt 180 Regulator Valve Spring Retainer 50 Reverse Band Lever Adjusting Bolt N...

Page 509: ...lts Mating Surfaces S Speedometer Pinion T Governor U Rear Pump a Front Pump Drive Sleeve b Reg Valve Body Gasket Surfaces c Converter Housing d Direct Clutch e Planetary Gear Set f Seal Rings Shift A...

Page 510: ...bearing and or unseated snap ring Snap rings are available in two sizes N Torque converter housing cooling air passages Check for dirt mud or other foreign material on screens or torque converter cool...

Page 511: ...direct the flow of oil in the unit thus multiplying engine torque The stator is mounted on an over running clutch which permits it to rotate only in the direction of impeller and turbine rotation The...

Page 512: ...o drive the engine by power transmitted from the rear wheels How fo Drive the Car 1 When starting in extremely cold weather allow the engine to warm up while in N neutral position If the engine is col...

Page 513: ...With the rear wheels free to turn accelerate the engine slowly until an upshift occurs During the upshift the pressure gauge attached to the kickdown servo will dwell twice but should show a very rapi...

Page 514: ...bolt 4 Remove the control housing stud nuts that are now accessible and remove control and cable from rear of instrument panel 5 Remove hairpin securing control cable to ac tuator and the screws holdi...

Page 515: ...e adjustment lock nuts on both the carburetor rod and the transmission throttle rod 3 Insert a 6 rod or drill bit in the hole and open slot of the accelerator shaft bracket end into the elon gated hol...

Page 516: ...SSURE ADJUSTING SCREW WRENCH C 3279A LOW PRESSUR GAGE C 3292 Fig 5 Adjusting Throttle Pressure Typical Fig 6 Adjusting the Reverse Band Typical ored pencil on the corner of the adjusting screw square...

Page 517: ...oads connected to battery current and terminal of the switch screw switch into transmission case until test light lights then turn switch an addi tional to turn Do not exceed 75 ft lbs torque Excessiv...

Page 518: ...INSPECTION 1 Remove the front oil pump drive sleeve and in spect Check the drive lugs and machined surfaces for STAND TOOL 56x170 Fig 9 Transmission Inverted in Repair Stand 53 6iL Fig 10 Checking Tra...

Page 519: ...aring oil seal and remove if necessary by using puller Tool C 748 Remove any burrs from counter bore of extension hous ing 3 Remove the seven transmission extension to case screws and lockwashers 4 In...

Page 520: ...MARY OUTER WEIGHT INTERMEDIATE WEIGHT SPRING SECONDARY INNER WEIGHT SNAP RING 56x26 OUTPUT SHAFT SUPPORT REAR OIL PUMP HOUSING GOVERNOR BODY SUPPORT GOVERNOR BODY GOVERNOR SUPPORT PISTON RINGS 53x14 F...

Page 521: ...thrust washer from direct clutch piston Fig 20 Removing or Installing Reverse Band retainer assembly if not removed with gear train Inspect for cracks burrs and wear 3 Because the diameter of the dir...

Page 522: ...ar for pitted cracked and broken teeth Remove the small tabbed thrust washer and inspect for cracks burrs and wear 5 Remove kickdown planet pinion carrier assem 57x42 Fig 24 Removing or Installing Inp...

Page 523: ...band lining has become excessively worn Inspect reverse planet pinion carrier assembly in same manner as kick down planet pinion carrier assembly Inspect all oil passages in output shaft support for o...

Page 524: ...g contacting areas on retainer for grooving Inspect the band contacting sur face for deep scores and burns especially if the kick down band lining is worn to the point where the steel band has been co...

Page 525: ...e housing to loosen Pull oil pump housing assem bly and gears from the transmission case Figure 31 Using dye mark front side of gears Do not use scribe marks 5 Remove oil pump gear from front oil pump...

Page 526: ...ct servo bore for scoring Light scores may be TOOL REVERSE SERVO ASSY RETAINER SNAP RING 53x4O Fig 33 Removal and Installation of Reverse Servo Assembly Retainer Snap Ring TORQUE CONVERTER REACTION SH...

Page 527: ...torque conver ter reaction shaft into transmission case so that holes in shaft align with bolt holes in case Install Tool C 3297 or Tool C 3531 4 Place two front oil pump to transmission case screws c...

Page 528: ...using metal portion of seal down Using driver Tool C 3278 bottom seal into housing as shown in Figure 37 2 Coat new front oil pump housing seal neo prene with transmission fluid and install on housing...

Page 529: ...e close to zero as possible Make sure snap ring seats properly Snap rings are avail able in the following two thicknesses 058 to 060 inch and 062 to 064 inch 10 Place fiber thrust washer select fit se...

Page 530: ...C 3283 in rear of trans mission case Position new output shaft support gasket over guide studs and against case 2 Insert input shaft planet pinion carrier housing output shaft support and output shaft...

Page 531: ...e governor housing when plac ing the rear extension housing over the output shaft and onto the guide studs 5 Position housing by tapping with soft hammer Remove guide studs and install the seven trans...

Page 532: ...ct clearance Assemble as previously instructed Adjustment of Bands Bench Kickdown Front Band 1 Using a inch open end wrench loosen the locknut 2 Check the reeness of the adjusting screw in the transmi...

Page 533: ...spring from cam and throttle operating lever 7 Compressing the throttle valve operating lever assembly against throttle valve spring as shown in Figure 46 rotate the throttle valve operating assembly...

Page 534: ...therwise damaged parts must be replaced Using straightedge Tool C 3335 check all mating sur faces for distortion Inspect fores in valve body for score marks pits and irregularities Inspect all springs...

Page 535: ...r in direct alignment with the control cable adapter clip Refer to Figure 50 At the same time align the shoulder on the manual valve lever with the sleeve bore in the valve body so that the detent bal...

Page 536: ...ump check valve springs Make sure pump check valves enter transfer plate otherwise the valve body plate will be damaged when assembly is drawn down onto valve body 24 Keep sufficient pressure on trans...

Page 537: ...on case to con verter housing bolts and lockwashers but do not tight en Remove guide studs and install the two upper trans mission case to converter housing bolts and lockwash ers Draw all bolts down...

Page 538: ...nstall torque converter and housing as follows 3 Position torque converter unit on crankshaft flange Using wrench Tool C 589 tighten stud nuts to specifications Before installing torque converter hous...

Page 539: ...th and remove all nicks where metal is raised weld ing splatter etc as these will cause noisy starter operation Reinstall torque converter and housing Refer to Paragraph 1 3 TORQUE CONVERTER HUB RUNOU...

Page 540: ...e Runout or TorqueFlite transmission is removed to correct leakage at the front pump oil seal or front pump failure also whenever an en gine replacement is made 1 Mount Tool C 3461 shown in Figure 4 i...

Page 541: ...ons will be for one direction only but it is possible that the housing bore may be out in two directions In the latter case it may be necessary to use the next higher step dowels adjust ing these dowe...

Page 542: ...Rotate converter 3 If the total indicator reading is greater than 008 note the amount of the total indicator reading and the location of the lowest indicator reading i e the point where the indicator...

Page 543: ...144 TRANSMISSION MyMopar com...

Page 544: ...s 20 000 Miles GEARS Type Helical TOLERANCES Second Speed Gear End Play OO3 OO8 Countershaft End Play OO4 OI2 Synchronizer Clutch Gear Snap Ring Thickness O86 O88 O89 O9l O92 O94 O95 O97 Pinion Bearin...

Page 545: ...l rods Discon nect parking brake control cable CAUTION Remove speedometer cable pinion comes out with cable with hand so that housing is not crushed 3 Remove the back up light switch leads if so equip...

Page 546: ...ER ASSY CLUTCH GEAR SYNCHRONIZER STOP RING INNER ASSY SYNCHRONIZER STOP OUTER RING 4 5 0 7 4 Fig 4 Synchronizer Assembly Exploded View drive pinion bearing on the pinion shaft using snap ring pliers R...

Page 547: ...transmission The de tent balls are spring loaded as the shaft is being with drawn the ball will drop to the bottom of the case 22 Remove the interlock sleeve spring pin and both balls from the case R...

Page 548: ...he second ball is to stick the ball in the tool recess by means of grease then use the tool to position the ball on the detent spring 5 Install Tool C 3767 then depress the interlock ball using Tool C...

Page 549: ...snap ring is properly seated If the large snap ring around the bearing was removed install at this time 10 Place the pinion shaft in a vise with soft jaws then install the 14 rollers using grease to...

Page 550: ...ng bolts and tighten to 50 foot pounds Attach crossmember to rear support 5 Using a pointed drift align the crossmember bolt holes with frame holes then install attaching bolts Tighten to 50 foot poun...

Page 551: ...152 TRANSMISSION MyMopar com...

Page 552: ...ical TOLERANCES Countershaft end play OO4 OI2 Second Speed Gear end play OO3 OI4 Countershaft Thrust Washers thickness 062 Main Drive Pinion Bearing Snap Rings thickness 086 103 Intermediate Bearing S...

Page 553: ...than the conventional pin type The reverse idler gear is bushing mounted SERVICE INFORMATION PROCEDURES Should it become necessary to remove the transmis sion from the vehicle for overhaul or the ins...

Page 554: ...ns mission This precaution will avoid damaging the clutch disc 8 Lower the transmission and remove from under vehicle 9 Remove the rear motor support and crossmem ber then mount the transmission in re...

Page 555: ...ing pliers remove the speedom eter drive gear snap rings then slide the gear and lock ball from the mainshaft 23 Remove the inner snap ring from the inter mediate bearing using snap ring pliers then s...

Page 556: ...gear bear ing bore and the needle bearings using clean grease Install 20 needle bearings a spacer washer and then 20 needle bearings and a spacer washer in each end of the countershaft gear The greas...

Page 557: ...34 Grease a new gearshift housing gasket and position against the case Install housing being care ful to guide the shift forks into their respective levers Install attaching bolts and tighten to 20 fo...

Page 558: ...ynchronizer Pin Length 1 570 1 580 Synchronizer Clutch Gear Snap Ring Thickness 086 to 088 089 to 091 092 to 094 095 to 097 Mainshaft Rear Bearing Snap Ring Thicknesses 086 to 088 091 to 093 Countersh...

Page 559: ...ousing bore or face out of alignment 3 Adjustment of gearshift rods 4 Linkage interference 3 TRANSMISSION NOISES Possible Causes For Backlash Noise 1 Excessive end play in the cluster gear 2 Loose syn...

Page 560: ...P LIGHT SWITCH MOUNTING HOLE HOUSING INTERLOCK INTERLOCK SLEEVE S BAIL SPRING LOW AND REVERSE GEARSHIFT LEVER SECOND AND DIRECT GEARSHIFT LEVER RETAINING PIN LOW AND REVERSE 57x163 RETAINING Fig 1 Gea...

Page 561: ...to Paragraph 3 Pointed ends of clutch teeth must retain their original contour to allow proper synchronization Check end play of second speed gear More than 008 inch end play may result in noise Exce...

Page 562: ...on clutch gear Check the pins of the inner and outer synchronizer stop ring assembly for straight ness and looseness Replace stop ring if pins are bent or loose Replace countershaft cluster gear if a...

Page 563: ...haft 57x170 Fig 10 Installing Reverse Idler Gear of either wood or metal by turning and cut ting the stock to a length of 1 0625 inches and a diameter of 750 inch inch dowel stock should prove satisfa...

Page 564: ...he to 5 e inch nut from synchronizer clutch gear sleeve and in ner stop ring if not done so previously Guide drive pinion shaft through front of case en gaging synchronizer outer stop ring with clutch...

Page 565: ...ion 7 Position gasket on transmission case to gearshift housing mating surface and install gearshift housing by engaging shift fork ends with their respective operating lever shafts Tighten gearshift...

Page 566: ...GEARSHIFT HOUSING LOW AND REVERSE CONTROL ROD SECOND AND HIGH OPERATING LEVER SECOND AND HIGH SHIFT LEVER LOW AND EVERSE OPERATING LEVER SECOND A N D HIGH CONTROL ROD LUBRICATION FITTING TUBE LEVER P...

Page 567: ...mbly is also a possibility because of in TUBE L VER LOCK SPRINO TUBE LEVER LOCK PIN TUBE SUPPORT TUBE LEVER PIN ROUND TU ASSEMBLY TUBE LEVER LOCK BUSHING UNDER SPRING TUB LEVER ASSEMBLY LOW AND REVERS...

Page 568: ...gearshift linkage completely assembled and adjusted in a vehicle should be checked for binding Ordinarily binding results from one of the following causes a Floor seal interference b Column jacket tw...

Page 569: ...2 8 2 2 1 1 2 8 10 STATION WAGON PASSENGER CAR MODELS 2 SEATS 3 SEATS 118W B 122 W B WHEELS Type Steel Disc Steel Disc Rim Drop Center Safety Wheel Drop Center Safety Wheel Size 14 x 5 14 x 6 14 x 5...

Page 570: ...be inspected regularly to find and remove all puncturing objects After the object has been removed the hole in the tire should immediately be sealed by installing a repair plug Refer to Paragraph 7 SE...

Page 571: ...ire Removing valve core is quickest way 2 Place wheel and tire over base of Tool C 715 or C 3455 then insert pry arm on the tire directly next to the rim of wheel 3 Exert sufficient pressure on the To...

Page 572: ...is im perative to coat the tire beads with a mild solution of soapy water 1 or 2 This will enable the tire beads to slip easily over the contours of the rim Do not use rubber lubricant Installing Tub...

Page 573: ...tire bead mark the leaky spot on both the rim and tire with crayon then dismount Several conditions can cause leaks at this point They are as follows Rusty Rim Remove the rust with a scraper and finis...

Page 574: ...er of the hole 3 Roll the small end of the plug into the eye of the needle from the end of the plug as shown in Figure 9 4 Dip plug and needle end in the repair cement and immediately insert into the...

Page 575: ...Install spreaders Trim the inside end of plug flush with the liner Next buff the liner approximately 1 inch around the puncture Be sure and leave the plug in the hole as this will serve to keep moist...

Page 576: ...of the recom mended tire pressure 9 REMOVING PROTECTIVE COATING FROM WHITE SIDEWALL TIRES All white sidewall tires are protected with a water soluble coating over the sidewalls Each tire has print ed...

Page 577: ...d dynamically A wheel and tire assembly correctly balanced should run smoothly at all speeds on its axis of rotation through the centerline of the wheel See Figure 17 If wheel and tire weight is uneve...

Page 578: ...irregular wheel movement and cause uneven tire wear Mechanical inspection repair and alignment to gether with wheel and tire balancing will usually dis close and correct the causes of uneven tire wea...

Page 579: ...es traction skid resistance and breaking efficiency increases the possibility of cuts and bruises and lowers the resistance of the fabric to injuries 13 FRONT WHEEL BEARINGS Front wheel bearing lubric...

Page 580: ...wheel 2 Position nut lock on nut with one pair of slota In line with colter pin hole Cl9 shown in Figuto 25 Flg 2 S Adjusf i Sl Front Wheel Bear 3 Baclc off the lock and adjU t1nq nut l n slol8 Cotter...

Page 581: ...emblies Removal 23 29 Door Ventilator Assembly 14 20 Fender Alignment 7 13 Fender Replacement 6 12 Fender Splash Shield Replacement 8 14 Front Door Glass 12 18 Front Door Remote Control Assembly 16 21...

Page 582: ...lease Assembly 38 39 Seat Pivot Assembly 39 39 Seat Back Assembly 40 39 Nylon RoUers 41 39 Arm Rest Hinge Assembly 42 39 Arm Rest Hinge Nylon Bearings Replacement 43 39 Arm Rest Assembly 44 40 Front D...

Page 583: ...d 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 trans verse position The fore structure with box section si...

Page 584: ...BODY FORE STRUCTURE ASSEMBLY UNDER BODY OUTER RAILS UNDER BODY FLOOR PAN 60x1275 Fig 2 Under Body Construction T 6OxV276 Fig 3 Frame to Under Body Alignment 118 W B MyMopar com...

Page 585: ...floor pan side rails or brackets may cause ruptures of the welds or cracks in the bent part Whenever heat is used to facilitate repair the part or area should never be heated more than a dull red Che...

Page 586: ...2 REPLACEMENT OF BODY PANELS SUB ASSEMBLIES With proper equipment an experienced body repair man can repair a damaged area in a body panel by one of three methods 1 External or surface damage than can...

Page 587: ...k the engagement of the door latch with the striker plate If the door raises as the latch passes over the plate the plate is too high and must be lowered The striker plate shown in Figure 7 can be mov...

Page 588: ...d and the door fits snugly against the weath erstrip Be sure the top surface of the striker plate is parallel with the bottom face of the door latch The striker plate is properly positioned when the d...

Page 589: ...the attaching bolts Rear Bumper Bar and Bracket Replacement Refer to Figure 12 and proceed as follows 1 Remove the rear bumper bar to body frame bracket attaching bolts and remove bumper bar assem bly...

Page 590: ...sized holes which will allow the lockplate to be shifted slightly in any direction The striker stud is threaded in the lock plate and is secured by a locknut see Figure 14 To adjust the striker to len...

Page 591: ...hood until the attaching nuts have have been tightened Unequal Spacing Between Rear of Hood and Fenders To correct this condition adjust as follows 1 Loosen the four hinge to hood attaching bolts on...

Page 592: ...en tighten locknut Do not adjust the striker too short as difficulty will be experi enced when closing the hood Hood Side Contour Does Not Follow Fender When the side contour of the hood does not foll...

Page 593: ...shown in Figure 19 Remove the screwdriver and tighten fender bolt Bottom Rear Edge of Fender Lower than Sill Panel Install the bumper jack with extension between the radiator support and the fire wall...

Page 594: ...er back to close the gap then retighten the attach ing bolts Fender too Far Forward at Upper Door Opening Loosen the fender to cowl attaching bolts Apply pres sure to the forward section of the fender...

Page 595: ...panel will have to be replaced The repair of a damaged quarter panel can be handled the same as it always has been on any other body panel When a section of the rear fender or quarter pan el has been...

Page 596: ...so as to hold lid in position while removing last two bolts This will keep lid from sliding down and damaging rear deck 3 Remove last two bolts and lift deck lid up and away from rear of car When ins...

Page 597: ...Contour Insert large end of Tool C 3011 in opening of under side of lid hooking exposed end of Tool under rear quarter panel as shown in Figure 28 Pull out on rear end of deck lid to decrease contour...

Page 598: ...LLATION 1 Remove the door inside hardware trim panel and garnish moulding Fig 30 2 Lower the glass and pull the glass run channel free at the top Fig 31 3 Pull the glass run channel up until the upper...

Page 599: ...34 Removing or Installing Rear Door Glass Install trim panel door hardware and garnish mould ing After installation of the glass is completed adjust the glass channel and the divisional bar so that wi...

Page 600: ...ator assem bly Fig 36 4 Install ventilator assembly and tighten attach ing screws 5 Adjust anchor screw for proper operation of ven tilator and seal 6 Install trim panel door hardware and garnish moul...

Page 601: ...ushion and seat back 2 Use Tool C 3448 to remove regulator handle 3 Remove trim panel and shower curtain 4 Use regulator handle to raise the glass high enough to reach through the access hole to remov...

Page 602: ...P 60x1330 Fig 42 W ndsh eld Weatherstrip ation 5 Replace shower curtain trim panel inside hard ware and garnish moulding The front track can be adjusted fore and aft to the rear or inward and outward...

Page 603: ...ght ened and the opening clearances can be checked as follows 1 Remove windshield weatherstrip 2 Install the glass in the opening with six pieces of four inch weatherstrip as shown in Figure 45 This i...

Page 604: ...n this section 5 Align and install the upper windshield chrome moulding over the top of windshield make sure to Fig 48 Locking Windshield Glass in Weatherstrip exert sufficient pressure on center of m...

Page 605: ...the moulding against weatherstrip then press rear edge down over header 3 Install screws to hold in position then rap light ly with a rubber hammer to seat Be sure cap is evenly spaced across header 4...

Page 606: ...he glass as shown in Figure 55 Make sure the glass is properly seated by tapping 57P152 Fig 55 lnstall ng Rear Window Glass into Weatherstrip Typical the glass with palm of hand Do not use a rubber ma...

Page 607: ...ed with key and also the remote control handle on front doors On rear doors check also with the lock locking control knob Check if one or the other of the two releasing systems does not unlock door 2...

Page 608: ...le adjustment 2 Bend lock lever 3 Lock levers bent and over riding one another This is an obsolete lock and must be replaced Front Door Lock Locks Automatically When Door is Closed This may be result...

Page 609: ...lock inside handle and rear door lock locking knob To remove the lock inside handle on all cars remove the nut in the center of the handle hub and pull handle off the square shaft On models where the...

Page 610: ...the clip at the bottom bracket and that the top clip hooks into the slot provided After this channel is secure push the felt channel down the edge of the glass into the metal channel Be sure it goes...

Page 611: ...Side Are Unlocked 1 Door hose lines connected improperly to tees in side cowl One Door Operates The Opposite From The Other Doors 1 Hose connected improperly to tee in side cowl 2 Hoses connected impr...

Page 612: ...side door lock if on rear door window regulator handle inside door handle and arm rest Finally reinstall the garnish moulding 27 VACUUM DISTRIBUTOR VALVE Removal Disconnect the large hose leading from...

Page 613: ...lve must first be installed under the instrument panel by slipping it over the fitting on the vacuum distributor valve Then slip the hose through the grommet in the fire wall and install the other end...

Page 614: ...MOULDING MOULDING GLASS MEDALLION MOULDING INSERT PANEL MOULDING HANDLE CYLINDER AND KEYS PLATE SKIRT MOULDING BAR MOULDING GLASS AND FRAME MOULDING DEFLECTOR COVER WHEEL S 3 NAME PLATE DOOR CYLINDER...

Page 615: ...the car remove the 4 nuts attaching the seat base to the floor pan Remove seat and base as sembly UP AND DOWN TILT SIX ADJUSTMENTS FRONT TO REAR STATIONARY SUPPORT PLATE 2 WAY SEAT TRACK ADJUSTING BO...

Page 616: ...e door is opened and back to straight ahead position when door is closed is accomplished by an actuating cable concealed under the floor carpet One end of the cable is attached to the door at the lowe...

Page 617: ...I I I LT 5 3 RIGHT SIDE SHOWN 6OX 9O CO MyMopar com...

Page 618: ...38 BODY Fig 61 Swivel Seat Assembly MyMopar com...

Page 619: ...ers on their mountings 3 Install the seat assembly as described in Par agraph 35 38 PIVOT BEARING REPLACEMENT When replacing the nylon bearing on the pivot as sembly it is necessary to remove the seat...

Page 620: ...ter ne of the new location of the cable is above the center line of the bottom door hinge attaching bolt holes The hole in the pillar should be vertically located exactly in the center of the cutaway...

Page 621: ...stabilizer horizontally forward and retighten 2 screws securely or hammer ramp down only as last resort 9 Seat return spring stretched or broken replace 48 SEAT DOES NOT LATCH WHEN SWUNG MANUALLY INT...

Page 622: ...nstall it in position in the new headlining ROOF RAIL _ gf _ ROOF RAIL BOW RETAINER SOCKETS HEADLINING BOWS v This procedure assures correct installation of the bows Before installing the bows in the...

Page 623: ...of the headlining After listings are cut start at the front and trim the headlining so that only to 1 inch of material hangs Fig 68 Trimming Excess Material at Wind Cord down below the rear window ope...

Page 624: ...val is the same except the head lining runs from side to side and it is only necessary to remove the garnish mouldings when the front or rear section of the headilning is being replaced CONVERTIBLE CO...

Page 625: ...ear control link care should be taken to adjust both sides equally to maintain parallelism between header panel and windshield frame Before making this adjustment loosen top header at windshield to re...

Page 626: ...system an elec tric motor a pump and reservoir assembly and a double throw rotary switch The wiring and motor are protected by a separate circuit breaker as shown in Figure 74 The pump is a two direct...

Page 627: ...ch is defective and should be replaced Repeat this test at green wire terminal moving top control lever to left If test lamp lights in both cases but the pump motor fails to operate replace the pump m...

Page 628: ...ed by two torsion bars to aid in raising and lowering The 3 seat subur ban is equipped with an electric window which is op tional on the other models The electric window is con trolled by a switch on...

Page 629: ...ing screws on the hinge pivot pin Fig 80 7 Connect wires to control switch and install the trim panel 8 Operate tail gate window and check for align ment 57 TAIL GATE GLASS Removal 1 Lower tail gate g...

Page 630: ...wl vent and windshield opening Clean the seamed area thoroughly and apply Heavy Sealing Putty or Body Seam Sealer Be sure to apply the sealer over the hood hinge bracket and along the seam to the rear...

Page 631: ...rames Be sure the door and window frame fits the door opening and body contour Leaks around the door weatherstrip may be detected by water test blue carpenters chalk or the use of trace powder and tes...

Page 632: ...bracket at the door frame and at the junction of the division bar and door frame The first and most important requirement to obtain a good water tight seal between the door window frames and the roof...

Page 633: ...by loosening the weatherstrip at the joint and applying sealer to the en tire seam at the inside of the trough and then recement the weatherstrip Seal all openings and joint seams on the inside of the...

Page 634: ...n upholstery stains can be removed as follows Candy Chocolate or Ice Cream Stains Scrape off as much of the staining matter as possible with a dull knife Clean with a one half of 1 solution of a laund...

Page 635: ...tton cheese cloth dipped in a sudsy solution of a non alka line detergent in water If the vinyl plastic trim still does not clean up a clean brush with many fairly stiff bristles should be used in pla...

Page 636: ...perating the Air Conditioning Unit 1 3 Performance Temperature Chart front unit only 27 Performance Temperature Chart front unit Dual 28 Performance Temperature Chart roof unit Dual 29 Piston and Conn...

Page 637: ...Front of Radiator Cylindrical Steel Container Engine Compartment Refrigerant 12 2 to 27 8 25 8 to 3 Dash Panel Centrifugal Dash Panel 250 to 265 cubic feet of air per minute at high speed Approx 14 1...

Page 638: ...onjunction with the front unit only the front unit will be described in detail 1 OPERATING THE AIR CONDITIONING UNIT Selection of the degree of air conditioning desired is by means of push buttons con...

Page 639: ...door is open 75 of the air is bypassed around the heater core and the remaining 25 flows through the heater core The temperature control valve is mechani cally controlled by the temperature control le...

Page 640: ...tral deflector The defroster door should be fully open for defrosting and heating and should be closed for all other push button positions The door is operated by the vacuum actuator that controls the...

Page 641: ...PER OUTLET V TO VACUUM SOURCE DEFLECTOR UP MAXIMUM COOLING LOWER OUTLET Fig 4 Air Flow Maximum Cooling 60x312 FRESH AIR DOOR OPEN EVAPORATOR HEATER CORE n n S BY PASS DOOR OPEN REAR VIEW OF SWITCH REC...

Page 642: ...regulates the temperature control valve which controls water cir culation through the heater core Since the defroster outlet door is closed no air can be discharged through the defroster outlet at th...

Page 643: ...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...

Page 644: ...d position Because of the fixed line resistor in the low speed circuit the primary power feed to the blower motor is through the medium or the high speed circuit depending on the temperature control l...

Page 645: ...opening of the fresh air door Fresh Cool operation will be the most desirable operating position except for extremely hot or humid weather or starting with a hot car as previously out lined If less c...

Page 646: ...he system A complete under standing of the over all operation of the new system will help you use the new test procedures to isolate and correct malfunctions The Compressor pulls heat laden refrigeran...

Page 647: ...tor Valve to complete the cycle The foregoing is a very general explanation of the refrigeration cycle of the new system 8 DESCRIPTION AND OPERATION OF THE COMPONENTS The Compressor The compressor sho...

Page 648: ...the valve off its seat The open valve allows vapor to enter the com pressor inlet The compressor performs its normal pres surizing function The Compressor Inlet Service Port located on the compressor...

Page 649: ...ing forward slowly the fan action draws air through the condenser to accelerate heat dissipa tion The only function of the condenser is to get rid of the heat in the compressed refrigerant vapor re ce...

Page 650: ...pillary tube is a thermal bulb that fits into a well on the suction mani fold The thermal bulb senses the temperature of the suction manifold refrigerant gas The area above the diaphragm including the...

Page 651: ...ng heat from the coils It also absorbs heat from the air passing over the coils and the liquid refrigerant changes to a gas This process continues the entire length of the evaporator coils un til shor...

Page 652: ...the service port When the adapter is installed at the port and tightened the stem of the valve in the service port is depressed opening the service port valve Discharge Pressure Gauge at the center of...

Page 653: ...nning Install the gauge set manifold For identification of test hose connections at service ports see Figure 20 After tightening all three service port adapters make sure that the needle valve located...

Page 654: ...159 3 161 5 163 8 166 1 168 4 170 7 173 1 175 4 177 8 182 2 182 6 185 1 187 6 190 1 If the temperature control valve does not close com pletely reposition the control cable housing in the re taining...

Page 655: ...gn matter Clean if necessary Any obstructions to the free flow of air across the condenser will decrease heat dissipation from con denser decrease the efficiency of the condenser and in turn decrease...

Page 656: ...5 to 250 psi and check the sight glass for foam There should be no foam If sight glass is clear remove air restriction from the condenser and allow the discharge pressure to return to normal 60x274 If...

Page 657: ...he fresh air door moves to its fully closed position Defroster Outlet Door Linkage A turnbuckle adjustment is provided in the linkage between the floor outlet deflector and the defroster outlet door S...

Page 658: ...shown in Fig ure 30 Start the test by pushing the H or heat button The vacuum tester gauge needle will drop until the actu ator has operated and then will return to 8 inches Note how much the vacuum...

Page 659: ...ant bearing on the temperature of the air deliv ered to the car s interior This is true of all air condi tioning systems whether in home office or car It is important to understand the effect humidity...

Page 660: ...fan in front of the condenser in order to keep the pressure down to these limits Determination of System Performance Observe and record both the Inlet Dry Bulb Tem perature and Inlet Wet Bulb Temperat...

Page 661: ...ed by the thermometer at the right hand grille outlet Determine the maximum allowable discharge air temperature for the prevailing Dry and Wet bulb temperatures from the Roof Unit Performance Tem pera...

Page 662: ...8 58 58 59 59 59 60 60 61 62 62 62 63 63 63 64 64 64 65 65 66 66 71 56 56 56 56 56 56 56 57 57 57 58 58 58 58 58 59 59 59 60 60 60 60 61 62 62 63 63 63 64 64 64 64 65 65 66 66 72 56 57 57 57 57 57 57...

Page 663: ...89 Z9 o o u O r o 4 o CO o 3 o 5 8 5 o U o U 8 CO u 8 00 U 8 00 8 CO U IV U rv U rv U IV U o o s U rv CO CO CN o 69 69 89 Z9 U O r o r o CO o 3 o z 2 2 o U O u O U O U O U 8 CO U CO 00 U 00 U 00 U CO...

Page 664: ...61 61 62 62 62 62 63 63 63 63 64 64 64 65 65 66 67 67 67 68 68 68 69 69 69 70 70 71 71 71 61 61 61 61 61 61 61 62 62 62 63 63 63 63 63 64 64 64 65 65 65 65 66 67 67 68 68 68 69 69 69 69 70 70 71 71 7...

Page 665: ...ure gauge The pressure registered at the compressor inlet gauge will increase quite rap idly Both suction gauges should again stabilize at a pressure of 31 psi or slightly higher within a few min utes...

Page 666: ...ty Test the compressor must be disconnected from the rest of the system That means the system must be discharged l Place the manifold discharge hose into an ex haust ventilation system or to the outsi...

Page 667: ...ACHOMETER USED MUST BE ACCURATE Compressor capacity test results are dependent upon controlling engine speed at exactly 500 RPM Test Pressures and Results 1 Start the engine and adjust speed to exactl...

Page 668: ...ves or a frac tured head gasket Such a leak would allow refriger ant gas used in the expansion valve test to leak from the discharge side of the compressor back into the suction side of the compressor...

Page 669: ...rant manifold valve fully counterclockwise to allow refrigerant vapor to flow to the gauge set manifold 3 Adjust the right hand gauge set manifold valve to maintain exactly 70 psi on the discharge gau...

Page 670: ...t heat the refrigerant container with a blow torch or any other means that would raise tem perature and pressure above this temperature Do not weld or steam clean on or near the system components or r...

Page 671: ...rant dispensing mani fold the gauge set manifold and test hoses should be kept clean and dry The special refrigeration oil supplied for the system is as clean and dry as it is possible to make it Only...

Page 672: ...G REPLACEMENT PACKAGE 25 CYLINDER BLOCK WITH CRANKSHAFT SUPPORT BUSHING NOT SERVICED 2 19 21 1 THROUGH 17 SERVICED INDIVIDUALLY 18 THROUGH 24 SERVICED IN PACKAGES 24 16 Fig 44 Compressor Assembly Expl...

Page 673: ...CAUTION The system must be completely discharged before attempting to perform any disassembly or repair services to the com pressor Cleanliness is extremely important The work area must be clean and...

Page 674: ...se care to remove all shreds of old gasket from plate block and head surfaces Clean attaching stud holes in block If valve plate or cylinder head is dam aged replace using a complete compressor valve...

Page 675: ...wered on case as shown in Figure 48 6 Tighten sump bolts finger tight to prevent spring misalignment then tighten to 15 19 foot pounds 7 Refill with new refrigerant oil after compressor is installed o...

Page 676: ...he bearing housing is rotated after f the housing seal contacts the carbon seal 8 Install bolts and tighten to 10 13 foot pounds 26 CRANKSHAFT AND BALL BEARING Removing the Crankshaft and Ball Bearing...

Page 677: ...in series with a fully charged 12 volt battery and the insulated brush lead The current draw at 12 volts should be 2 4 to 2 8 am peres CAUTION Do not attempt to remove the electromagnet coal from the...

Page 678: ...rubber grommet from the evaporator engine side housing Carefully pull the thermal bulb and thermal bulb wedg ing shims from the well located inside the evaporator housing as shown in Figure 54 Install...

Page 679: ...p before installation on the car to form a complete unitized evaporator assembly The unitized evaporator assembly must be removed and installed as a complete assembly as shown in Figure 56 Removing th...

Page 680: ...ses and actuator rods from each vacuum unit Remove hoses from their at taching clips 4 Disconnect the distribution duct damper control cable 5 Remove temperature control valve capillary from the engin...

Page 681: ...ant 12 provide a complete recharge for these dual installations If the bulk tank method of charging is used an ac curate scale must be used to insure charging with the proper amount of refrigerant Sin...

Page 682: ...COOL button pushed in blower on high and the car hood up On dual installations both blowers must be on high speed during the charging operation If necessary block the condenser to maintain a dis char...

Page 683: ...a flame color varying from yellowish green to bright green A large leak will produce a brilliant blue flame 1 Open the torch valve until you hear a faint hiss of escaping gas Light the test torch and...

Page 684: ...te quickly upon ex posure to the atmosphere When installing a drier have all tools and supplies ready for quick reassembly to avoid keeping the system open any longer than necessary 40 EVACUATING THE...

Page 685: ...old connected to the compressor Charge the system with the proper amount of Refrigerant 12 Failure to pull at least 26 inches of vacuum indicates a leak in the refrigeration system or a defective vacu...

Page 686: ...unds 3 Turn the three refrigerant manifold valves com pletely clockwise to puncture the cans and close the manifold valves 4 Turn the refrigerant manifold valves counter clockwise to open them 5 Momen...

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Dodge DART PHOENIX 1960, Service Manual

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