Dodge Monaco 1967 Service Manual Download Page 1

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Summary of Contents for Monaco 1967

Page 3: ...u In 1967 LBelvidere G 3 8 3 Cu In 6 N ewark H A 8 3 H P Cu In Windsor K 440 Cu In Std L 440 Cu In H P BODY NUMBER LOCATION The body number is stamped on a plate which is attached to the left front wheel house and will show trim code paint code body type and scheduledate Fig 2 TIRE PRESSURE A decal showing the recommended tire pressure is located on the body pillar at the rear of the left front do...

Page 4: ...INTRODUCTION 3 DODGE POLARA 4 DOOR SEDAN DODGE POLARA 500 CONVERTIBLE NP405 MyMopar com ...

Page 5: ...4 INTRODUCTION c I DODGE MONACO zyxwvut 500 2 DOOR HARDTOP DODGE MONACO 4 DOOR HARDTOP DODGE MONACO 4 DOOR STATION WAGON NP406 MyMopar com ...

Page 6: ...scribe lubrication and maintenance service on a time frequency as well as mileage interval basis Page HOOD LOCKS RELEASE MECHANISM AND SAFETY CATCH 19 HYDRAULIC BRAKE SYSTEM 6 LUBRICATION AND MAINTENANCE 3 m SERVICES MANIFOLD HEAT CONTROL VALVES 13 MATERIALS ADDED TO ENGINE OILS 9 PARKING BRAKE MECHANISM 7 PARTS REQUIRING NO LUBRICATION 23 PROPELLER SHAFT AND UNIVERSAL JOINTS 14 SPEEDOMETERCABLE 1...

Page 7: ...MML 36 000 miles whichever occurs first AMG 2 Clutch Bearing Sleeve Fork and Fork or Pivot If effort required to depress pedal MML is excessive or linkage is noisy lubricate cantact surfoces EO Floor Mounted Manual Transmission Con trols If necessary use light engine oil HL Shown on decal on body pillar leftside See Tires Group 22 for additional information Engine Coolant Check level and or anti f...

Page 8: ...ilter Rotate Tires Carburetor Air Cleaner Oil Bath CarburetorAir Cleaner Pa per Crankcase Ventilation System Carburetor Choke Shaft Oil Filler Pipe Breather Cap Distributor Transmission Rear Axle EverySecond Oil Change Service Interval X 9 13 12 10 x 1 9 14 1 3 11 14 12 8 16 5 Item Gear Linkage 15 5 Every 6 Months X X X Miles whichever occurs first When Necessary Service I I I X I X I 1 X X X I I ...

Page 9: ...d under the rear axle housing or under the front suspension lower control arms however a floor iack must never be used on any parts of the underbody CAUTION Do not attempt to raise one entire side of the vehicle by placing a jack midway between front and rear wheels This practice may result in perma nent damage to the body Bumper Jack The bumpers are designed to accept a bumper jack in an emergenc...

Page 10: ...faces of seals to permit thorough NK665A Fig 4 Steering LinkageLubrication inspection Replace damaged seals or joints immediately to prevent contamination of lubricant or failure of parts Lubricate ball joints if necessary When lubricating steering linkage ball joints use only the special long life chassis greases intended for this purpose Multi Mileage Lubricant Part Number 2525035 is a lubricant...

Page 11: ...erged in water such as on a boat launching ramp where water can enter the axle vent and contamination is suspected or evident replace the lubricant immediately to avoid early axle failure BRAKES The brakes on all models equipped with drum brakes except for some police cars and high perform ance models are equipped with a self adjusting mech anism which makes it unnecessary to perform major brake a...

Page 12: ...sted For adjusting procedure refer to Parking Brakes Group 5 CLUTCH LINKAGE Manual Transmission Clutch TorqueShaft Bearings Inspect clutch torque shaft bearings Fig 9 for wear and relubricate every 3 years or 36 000 miles whichever occurs first To perform this service refer to Clutch Group 6 After removing torque shaft Fig 8 F oot Operated ParkingBrake Lubrication assembly disassemble and thorough...

Page 13: ...eeze is therefore necessary to prevent coolant in the heater core from freezing in hot weather when the air conditioner is being operated on maximum cooling For complete information refer to Air Conditioning Group 24 When vehicle is operated in areas where protection from freezing is not required and vehicle is not equipped with Air Conditioning refill cooling system with clean water and add a hig...

Page 14: ...ils avail able through the Parts Division meet these require ments Oil ViscosityRecommendations Multigrades or above 32 F SAE 2OW 40 Where temperatures are consistently SAE 1OW 30 SAE 1OW 30 Suitable for year long operation in many parts of the U S may be used where temperatures occassionally drop as low as 10 F Recommendedwhere minimum tem SAE 5W 20 peratures are consistently below 10 F Single Gr...

Page 15: ...t is recommended that engine oil be changed every two months not to exceed 2 000 miles Replace filter every second oil change ENGINE OIL FILTER zyxwvut A l l engines are equipped with full flow throw away oil filters Fig 12 to provide efficient filtering of en gine oil for maximum engine protection The filter should be replaced every second oil change Since filters vary widely in quality it is rec...

Page 16: ... trips with prolonged idling it is recommended the sys tem be checked for operation with every oil change and serviced as required With engine idling remove ventilator valve assem bly from right hand cylinder head cover Fig 13 If valve is working freely a hissing noise will be heard as air passes through the valve and a strong vacuum should be felt when a finger is placed over the valve inlet If v...

Page 17: ...n Fuel System Group 14and Ignition System Group 8 respectively Taxi and Police Operuiion For this type of service the crankcase ventilation system should be serviced every oil change A sug gested practice for taxi and police operations is to maintain spare valves installing a clean valve every oil change Valves so removed can be cleaned by soak ing overnight in carburetor cleaner followed by dry i...

Page 18: ...ssured by application of a suitable solvent Such a solvent is available under Part Number 2525054 Manifold Heat Control Solvent Every engine oil change apply solvent to both ends of valve shaft where it rotates in bushings Fig 18 or 19 Apply solvent when manifold is COOL Allow solvent to soak a few minutes then work valve shaft back and forth until it moves freely CARBURETOR AIR CLEANER Paper Elem...

Page 19: ... This grade is suit able for all temperatures Reassemble cleaner and install on carburetor CARBURETOR CHOKE SHAFT Every six months apply Carburetor Cleaner Part Number 1643273 or equivalent to both ends of choke shaft where it passes through the air horn Fig 2 3 At same time move choke shaft back and forth until deposits are flushed out Run engine at idle to clean out excess cleaner from carbureto...

Page 20: ...8 cannot be relu bricated and must be replaced when seals are dam aged and leakage is evident Severe Service Requirements When the vehicle is operated under conditions classified as severe service as outlined below addi tional servicing is required a Police or taxicab use b Frequent towing of trailers Under this type of operation the universal joints should be inspected for leakage at seals every ...

Page 21: ...fect on rubber hoses Such a fluid is available under Part Number 2084329 Power Steering Fluid TRANSMISSION Manual Three Speed The lubricant installed in the transmission at the time of assembly is a high quality product and regu larly scheduled changes are not required for vehicles Fig 30 Power Steering Pump Reservoir whose operation is classified as normal service for passenger cars The fluid lev...

Page 22: ...lm of Multi Mileage Lubricant Part Number 2525035 or Automotive Multi Purpose NK561 Fig 32 Column Mounted Manual Transmission Gearshift Control Lubrication NK563 Fig 33 Floor Mounted Manual Transmission Gearshift Mechanism Lubrication Grease NLGI grade 2 to contact surfaces on levers Floor Mounted Manual Transmission Gearshift Mechanism If operation of the mechanism becomes difficult remove rubber...

Page 23: ...nd refill the transmission with the specified fluid adjust the bands and replace the filter initially after 36 000 miles or 3 years whichever occurs first and every 12 000 miles or 12 months thereafter whichever occurs first For transmission fluid draining and refilling serv ice filter replacement and band adjustment proce dures see TorqueFlite Transmission Group 21 FRONT WHEEL BEARINGS The condit...

Page 24: ...pening B post SPEEDOMETER CABLE To service a noisy speedometer cable it is first necessary to remove the Instrument Cluster See In strument Panels Group 8 Then disconnect housing at speedometer head Remove shaft and clean it thoroughly Apply a very thin film of speedometer cable lubricant on the shaft Such a lubricant is available under Part Number 1243632 Speedometer Cable Lubricant Wipe excess l...

Page 25: ...OOR UPPER REAR DOOR LOWER NK631 FRONT DOOR LOWER Fig 4l DOOr Hinge Lubrication All Models from water and ice Hood Hinge Lubrication Points All Models Apply Lubriplate sparingly to all pivot points and torsion bar contact areas Fig 40 Do not apply to torsion bar roller to cam surfaces Door Hinges All Models Fig 41 spring ends and contact areas On all hinges apply engine oil to hinge pin ends On low...

Page 26: ... Deck Lid Latch Lubrication AllModels TORSION BAR TORSION BAR NP179 Fig 44 Deck Lid Hinge Lubrication All Models areas and to remote control return spring Fig 45 Tail GateHinge All Station WagonModels areas Fig 46 both sides Apply engine oil sparingly to hinge pin pivot Tail Gate Hinge Torsion Bar and Check Arm Lubrication All Station WagonModels Apply Automotive Multi Purpose Lubricant NLGI grade...

Page 27: ...h manual and automatic transmis sions apply a thin film of the prescribed lubricant CONTACT AREAS v QUARTER PANEL NP183 Fig 47 Fuel Tank Access boor Hinge Spring and Pin Lubrication Ail Station Wagon Models on the accelerator shaft where it turns in the bracket pig 48 On models with automatic transmission also apply a thin f i l m of the same lubricant to the pivot ends on both upper and lower tra...

Page 28: ...not only because lubricants will cause rubber to fail but also will destroy their necessary friction characteristics The following parts should not be lubricated Accelerator PedalPivot zyx A l l Rubber Bushings Alternator Bearings Automatic Transmisson Controls and Linkage Carburetor A i r Cleaner Paper Element Type Clutch Pedal Push Rod Ends Clutch Release Bearing Drive Belts Fan Belt Idler Pulle...

Page 29: ...wheel set to the desired speed move the button to the Auto position and release The button will spring back to ON position and the panel light will illuminate When the vehicle speed indicated on the edge of the thumb wheel is reached a reaction pressure will be felt in the accelerator pedal The Auto Pilot is now in automatic control No further control of the accelerator pedal is required The Auto ...

Page 30: ... b Noisy speedometer head assembly c Short circuit in wiring drive mecha a nism or switches SERVICE PROCEDURES __ Fig 1 Accelerator Linkage Adjustment Adjust brake switch Adjust or repair as necessary See Electrical Tests See Electrical Tests Adjust or repair as necessary See Electrical Tests Adjust brake switch to specification Align the cables Replace if necessary Lubricate the cables Adjust the...

Page 31: ...st lamp lead to good ground and the other lead first to terminal number 2 black wire and then to terminal number 3 If lamp fails to light on number 2 terminal test for open circuit in black wire between auto pilot and ignition circuit If test lamp fails to light when number 3 terminal is touched test for open circuit in light blue wire circuit from auto pilot to control switch If panel lamp on aut...

Page 32: ... from falling down the cable 3 Loosen and remove spring wire clip on dust shield 4 pull control cable free from the drive mecha nism 5 Disconnect accelerator linkage from exterior arm on drive unit 6 Remove bolts and nuts securing drive mecha nism to mounting brackets and remove drive mecha nism leaving brackets in vehicle lnstallation 1 Position drive mechanism on mounting brackets and install mo...

Page 33: ...fresh air either through or past the heater core The amount of blend is determined by the setting of the temperature lever on the instrument panel Direction of the blended air is controlled by the Heat Defrost lever on the instrument panel The blower switch determines the speed of the Page Heater Core 7 Heater Doors 7 Heater Installation 7 Heater Removal 6 Rear Window Defogger 7 blower motor and t...

Page 34: ... beyond edge of cable retaining clips 3 Install control assembly on instrument panel 4 Place top control lever in center or Heat position and connect heater defroster cable left cable to heater defroster door of heater assembly while holding door in extreme clockwise position 5 Connect fresh air cable center cable to heater shut off door on heater assembly while holding door in extreme clockwisepo...

Page 35: ...fill cooling system 13 Start engine operate heater and bleed air vacuum hoses rotat with 1 studs Fig 2 Heater Hose Connections from heater system HEATER CORE Removal 1 Remove heater as outlined in Heater Removal Remove heater cover plate Remove screws that mount heater core to rassembly and remove core Pllafion mounting screws Position core into heater assembly and install 2 Install heater cover p...

Page 36: ... the radio dial two matching wheels serve as a tone con trol The manufacturers of the radios and reverberators make repair service available through their author ized service depots If a schematic wiring diagram is desired it should be obtained from the manufacturer of the particular unit Fader Control This control is used only when the vehicle is equipped with a rear seat speaker F u l l upward p...

Page 37: ...ce type wires in the high tension circuit of the ignition system complete the interference suppression If radio noises are evident be sure the capacitor lead wires are making good contact on their respec tive terminals and are securely mounted Faulty or deteriorated spark plug wires should be replaced Antenna Trimming All radios are trimmed at the factory and should require no further trimmer adju...

Page 38: ... of antenna Fig 5 Index upper adapter locating pins in two 3 16 holes in fender Lubricate cap nut threads and tighten with Tool 2 3977 Fig 2 6 Insert antenna lead through 3 4 hole in floor P A D NllT IlPPFP GASKET SPACER Fig 3 Antenna Cable Rouling pan and snap grommet in place Route antenna lead over fresh air duct This can be done by disconnecting alligator clip on hose pushing hose to right and...

Page 39: ... ash receiver 7 Install center bezel on instrument panel with 8 Install heater or air conditioning control 9 Connect battery ground cable and test opera five retaining screws knob s tion of radio SPEAKERS Front Speaker Removal 1 Remove radio See Radio Removal 2 Open glove box door remove four door hinge retaining screws and remove door assembly 3 Two speaker mounting screw access holes are provide...

Page 40: ...half of glove box and glove box door assembly 3 Install radio See RadioInstallation Rear Seat Speaker Removal 1 Remove spare tire 2 Disconnect speaker leads 3 Remove the four sheet metal screws holding speaker to shelf panel lnstallation four mounting screws 1 Position speaker under shelf panel and install 2 Connect speaker leads 3 Install sparetire and test operation of speaker MyMopar com ...

Page 41: ...ct front wheel alignment or vehicle stability plugs Service replacement ball joints are equipped with a Knock Off type lubrication fitting After lubrication knock off that portion of the fitting over which the lubrication gun was installed A ball check is installed in the remaining portion of the fitting to prevent for eign materialsfrom passing through The tie rod end seals are serviced separatel...

Page 42: ...Steeringgear low on lubricant Steeringgear not adjusted properly Idler arm binding i Free up idler arm wheel alignment g Fill steering gear to the correct level h Adjust steering gear Worn or loose front wheel bearings Incorrect steering gear adjustment Loose steeringgear to frame mounting c Tighten steeringgear to frame bolts bolts Worn tie rod ends a Adjust or replace wheel bearings as b Adjusti...

Page 43: ...t steer ing axis inclination and toe out on turns The latter two are valuable in determining if parts are bent or damaged particularly when the camber and caster adjustments cannot be brought within the recom mended specifications Do not attempt to modify any suspension or steer All adjustments should be made in the following a Front suspension height b Caster and Camber c Toe in d Steering Axis I...

Page 44: ... vehicle has the recommended tire pressures full tank of fuel no passenger load and is on a level floor or alignment rack To obtain accurate readings vehicle should be jounced in following manner just prior to taking each measurement Height Caster Camber and Toe Grasp bumpers at center rear bumper first and jounce up and down several times Always release bumpers on the down cycle after jouncing bo...

Page 45: ...bound underno Load zyxwvut 2 TORSION BAR PLUG 1 1 h SEAL L RING NK377 SUSPENSION AND STttKING LINKAGE 2 5 3 Release all load from torsion bar Fig 3 by turning anchor adjusting bolt counterclockwise 4 Slide rear anchor balloon seal off of rear anchor and remove lock ring from anchor 5 Using Tool C 3728 remove torsion bar Fig 4 from its anchors It is advisable to place Tool C 3728 toward rear of tor...

Page 46: ...ition steering knuckle arm on steering knuckle and install mounting bolts and nuts finger tight only 3 Install upper ball joint stud in steering knuckle and tighten ball joint stud nut 100 foot pounds and install cotter pin 4 Tighten steering knuckle upper bolt nuts 55 foot pounds Tighten lower bolt nuts 80 foot pounds and install cotter pin 5 Place a load on torsion bar by turning adjusting bolt ...

Page 47: ...rviced separately If replacement is necessary in stall a new sway bar assembly 3 Remove sway bar link insulators from frame bracket If insulators are worn or deteriorated in stall new insulators as required lnstallation 1 Dip sway bar link insulators in water and install in hole in frame bracket using a twisting motion When installed properly groove in insulator will index with opening in frame br...

Page 48: ...arbor press with torsion bar hex opening up and with a support under outer edge of control arm Fig 11 5 Place a brass drift into hex opening and press pivot shaft out of control arm Fig 11 The bushing inner shell will remain on shaft and outer shell will remain in anchor 6 Remove rubber portion of bushing from control arm shaft Cutoff if necessary 7 Cut bushing inner shell from pivot shaft 8 Remov...

Page 49: ... 9 Adjust front wheel alignment as necessary LOWER BALL JOINTS ON MODELS EQUIPPED WITH DISC BRAKES RE FER TO GROUP 5 FOR BRAKE DISC REMOVAL AND INSTALLATION PROCEDURES Inspection 1 Raise the front of the vehicle at the outer most portion of the control arm This will unseat the ball joint stud 2 With the weight of the vehicle on the control arm measure the axial travel of the ball joint hous ing ar...

Page 50: ...sing Tool 2 3964 remove stud 4 Remove nuts lockwashers cams and cam bolts attaching upper control arm and bushing Fig 12 to support brackets Lift control arm up and away from support 5 Remove ball joint using Tool C 3560 Fig 13 6 Assemble Tool C 3962over control arm bushing The sealwill come off asball joint is removed and press bushing out of arm Fig 1 4 Assembly When installing new bushings be s...

Page 51: ...that ball joint threads engage those of control arm squarely Balloontype seals should always be replaced oncethey have been removed 1 Screw ball joint squarely into control arm as far aspossible by hand 2 Using Tool 2 3560 tighten ball joint until it bot toms on housing Tighten to a minimum of 125 foot pounds If ball joint cannot be torqued to 125 foot pounds inspect threads on ball joint and also...

Page 52: ...am Bolt Nut 65 Idler Arm Stud Nut at Mounting Bracket 45 at Center Link 40 Shock Absorbers Front U pper 25 Lower 55 REFERENCE Foot Inch Pounds Steering Knuckleto Brake Support Bolt Nuts Upper 55 Lower 80 Strut Front Bushing Nut 40 Strut To ControlArm Nuts 100 Sway Bar Cushion HousingNuts 30 Tie Rod Clamp Bolt Nuts to Steering Knuckle Arms Wheel Mounting 65 100 Link Nuts 15 40 Tie Rod Stud Nuts MyM...

Page 53: ... on the pressure face of gear teeth or in the bore are caused by instantan eous fusing of the mating surfaces Scored gears should be replaced Fill rear axle to required capacity with proper lubricant See Specification section b Replace scored gears Inspect all gears and bearings for possible dam age Clean out and refill axle to re quired capacity with proper lubricant See Lubrication section c Rep...

Page 54: ...icient ring gear to pinion clear e Readjust ring gear and pinion back ance lash and check gears for possible scoring ter nut LOSS OF LUBRICANT with proper lubricant OVERHEATING OF UNIT REAR AXLE ASSEMBLY 8 RING GEAR INDEX Axle Shafts and Bearings Axle Shaft End Play Differental and Carrier Removal Differential and Carrier Installation DifferentiaI Case Drive Gear and Pinion Backlash Gear Tooth Con...

Page 55: ...ove retainer nuts the right shaft with threaded adjuster in retainer plate will have a lock under one of the studs that should be removed at this time 3 Removeparking brake strut 4 Attach axle shaft remover Tool C 3971 Fig 3 to axle shaft flange and remove axle shaft Remove brake assembly and foam gaskets BLOCKS BEARING ADAPTER drum REMOVING SP 5020 NK360 SLEEVE RING BLOCK NK59A SP 5041 HOLDING SP...

Page 56: ...r bearings is an unsafe practice because heat is fed into the axle shaft bearing journal and thereby weak ens this area 1 Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut deep grooves into retaining collar at 90 intervals Fig 6 This w i l l enlarge bore of collar and permit it to be driven off of axle shaft 2 Remove bearing roller retainer flange by cut ...

Page 57: ... cone using Tool C 3971 Fig 3 Tighten bolts of tool alternately until cone is removed Fig 1 2 8 Remove seal in bearing retainer plate and re place with new seal Assembly 1 Install retainer plate and seal assembly on axle shaft 2 Lubricate wheel bearings with Automotive Multi Purpose Grease NLGI grade 2 3 Install a new axle shaft bearing cup cone and collar on shaft using Tool C 3971 Fig 13 and tig...

Page 58: ...et to seat right wheel bearing cup against adjuster and rotate axle shaft several revolu tions sothat a true end play reading is indicated 3 Remove one retainer plate nut install adjuster lock If tab on lock does not mate with notch in ad juster turn adjuster slightly until it does Install nut and tighten 30 35foot pounds 4 Recheck axle shaft end play If it is not within the tolerance of 013 023in...

Page 59: ...ase at point of maximum runout The marking of differential case will be very useful later in checking differential case runout Total indicator reading should be no more than 005inch If runout exceeds 005 inch the differential case may be dam aged and a second reading will be required after drive gear has been removed This operation is cov Fig I Removing Companion Flange ered during Differential Di...

Page 60: ...earing cap bolts down lightly and screw in both adjusters with spanner wrench Tool C 406A 5 Tighten cap bolts and adjusters sufficiently to prevent any side play in bearings 6 Attach a dial indicator Tool C430 or Tool C 3339 to carrier flange so pointer or indicator squarely contacts drive gear surface of differential case flange between outer edge flange and drive gear bolt holes Fig 1 9 7 Rotate...

Page 61: ...t case for cracks or other visible damage which 1 Clean all parts in a fast evaporating mineral might render it unfit for further service spirits or a dry cleaning solvent and with the excep 4 Inspect differential pinion shaft for excessive tion of bearings dry with compressed air wear in contact area of differential pinions Shaft 2 Inspect differential bearing cones cups and should be smooth and ...

Page 62: ...RICATE ALL PARTS BEFORE ASSEMBLY WITH LUBRICANT AS SPECIFIED IN LUBRICA TION GROUP zyxwv 0 1 Install thrust washers on Merential side gears and position gears in case 2 Place thrust washers on both differential pin ions and through large window of differential case mesh the pinion gears with the side gears having pinions exactly 180 degrees opposite each other 3 Rotate side gears 90 degrees to ali...

Page 63: ...ar depth of mesh is determined by the loca tion of the bearing cup shoulders in the carrier and by the portion of the pinion in back of the rear bear ing The thickness of the rear pinion bearing mount ing shim suitable for the carrier can be determined by using Tool C 758 D4 PINION BEARING PRELOAD WITH BEARING SPACER Small Stem Pinion Bearing Preload 1 With tool installed in carrier remove main sc...

Page 64: ...al bearing caps and attaching bolts on carrier pedestals and in sert a piece of 002 inch shim stock between arbor and each cap Tighten cap bolts to 10 foot pounds 3 Select a rear pinion bearing mounting shim which will fit between cross arbor and gauge block This fit must be snug but not too tight similar to the pull of a feeler gauge Fig 29 This shim is then used in determining the correct thickn...

Page 65: ...le spacer SP 2921 to main section of tool followed by spacer SP 1730 Install rear pinion bearing cone over spacer SP 1730 and against spacer SP 2921 Fig 30 2 Insert assembly into carrier and install front pinion bearing cone over tool shaft and in its proper position in bearing cup Install tool spacer tool thrust washer and tool nut on shaft 3 With nose of carrier up place flange holding Tool C 32...

Page 66: ...increments from 014 026 inch 17 Remove tool with shim pack bearing cone pinion mounting shim and spacer from carrier and tool 18 With stem of pinion facing up install correct shim on pinion stem Shims are chamfered on one side and must be installed on the pinion stem with chamferedsidetoward pinion head 19 Position rear bearing cone on pinion stem small side away from pinion head Make certain that...

Page 67: ...and correct bearing preload obtained remove the drive pinion flange Install the oil seal with Tool 3980 Install the KP zyxwvutsrq 20 h L Fig 3I Adjusting Differential rings pinion flange washer and nut and tighten the nut to 240 foot pounds lnstallation of Differential and Ring Gear in Carrier 1 Holding differential and ring gear assembly with bearing cups on respective bearing cones care fully in...

Page 68: ... contact Fig 33 will result Notice that the cor rect contact pattern is well centered on both drive and coast sides of the teeth When tooth contact pat terns are obtained by hand they are apt to be rather small Under the actual operating load however the contact area increases If improper tooth contact is evident the pinion must be readjusted by either increasing or decreasing DRIVE COAST CORRECT ...

Page 69: ...odels SURE GRIP DIFFERENTIAL IDENTlFICATION Identification of sure grip type differential assem bly can be made by lifting the rear wheels off the Page Lubrication 21 Sure Grip Differential 19 Sure Grip Differential Identification 17 ground and turning them If they both turn in the same direction the vehicle is equipped with a Sure Grip Differential Another means of identification is a metal tag r...

Page 70: ...y circulates the lubricant and brings it to operating temperature 5 Stop vehicle and remove drain and or fill plug and using a suction gun remove as much of the old lubricant as possible 6 Reinstall drain plug on axle so equipped Refill axle to proper level with new Sure Grip Lubricant Fig 3 Power Flow Axle Shafts Turning a Same Speed P a r t Number 2585318 or equivalent Reinstall fill plug and ti...

Page 71: ... I KR719 Fig Removing or Installing Differential Case Cap SURE GRIP DIFFERENTIAL Removal Follow the same procedure outlined under removal and installation of the conventional rear axle differen tial Disassembly 1 Remove axle drive gear Measure runout of the drive gear mounting flange Replace both case halves if runout exceeds 003inch 2 Before disassembling case halves place scribe marks on each ha...

Page 72: ...d if they are worn or distorted If either case half is worn it w i l lbe necessary to replace both halves ASSEMBLING THE DIFFERENTIAL 1 Position clutch plates and discs in their proper 2 Place side gears in their retainers Insert splines 3 Place aligning pin through one axle shaft thrust location in each half of the case Fig 1 5 of retainers through the splines of clutch discs AFT SPACER KR722 Fig...

Page 73: ...de gear and clutch plates in exact alignment during the tightening procedure move axle shafts back and forth as bolts are being tightened After assembly slight misalign ments of the splines can be corrected by moving axle shafts back and forth until free Remove axle shafts Since the sure grip clutches are preloaded by the dished plates and discs clearance should not exist between the pinion shafts...

Page 74: ...aring Preload 30 Rear Axle Assembly Removal 23 Rear Axle Assembly Installation 32 Using Pinion Depth Gauge Tool DD 1244 the rear pinion bearing cup and the carrier casting Drive pinion bearing preload is maintained by using different thicknesses of shim packs between the drive pinion bearing shoulder and front pinion bearing cone The Sure Grip differential case is used exclusively in both axle ass...

Page 75: ... at front of rear springs 2 Block brake pedal in the up position using a wooden block 3 Remove rear wheels 4 Disconnect hydraulic brake lines at wheel cyl inders and cap fittings to prevent loss of brake fluid 5 Disconnect parking brake cables To maintain proper drive line balance when reas sembling make scribe marks on the propeller shaft universal joint and the pinion flange before removal 6 Dis...

Page 76: ...ater NN1021 Fig 3 Bearing Cap Identification NN1022 Fig Spreading Rear Axle Housing 6 Check the clearance between the differential bearing cap and bearing cup by trying to insert a piece of 003 inch feeler stock between them A 003 inch feeler should not enter between the bearing cap and cup A clearance of more than 003 inch could be caused by bearing cup having turned in carrier caus ing excessive...

Page 77: ...asket front pinion bearing cone and preload shim pack Record the thickness of the shimsin case they should be lost 16 Position the carrier and tube assembly on an arbor press then press out the drive pinion stem and rear bearing cone assembly 17 With the aid of a brass drift and hammer drive NN1024 Fig 6 Measuring Differential Case Drive Gear Mounting Flange Face Runout out the front and rear pini...

Page 78: ...NTIAL The Sure Grip Differential used in the 9 1 4 and 8 3 4 axle assemblies are similar in appearance but differ in size The service procedures appear FLAT PLATE FLAT DISC DISHED DISC SIDE GE AR RING FLAT 6LATE DISHED PLATE ND126B Fig 8 Arrangement of Plates and Discs 9 114 Differential in the SureGrip Differential section of this group Figure 8 shows the proper clutch plate and disc arrangement ...

Page 79: ...number must be positively identified before continuing with the assembly pro cedure Midway between the two sets of figures de scribed above are numbers and letters These numbers and letters are etched for manufacturing purposes only but as one of these numbers may be 0 it might be confused with the number needed for assembly procedure A rule to follow would be to first examine the shaft end for a ...

Page 80: ...029 Fig 15 Determining Pinion Depth Setting 8 Install the step plate clamp assembly on the carrier housing Position step plate over pinion and tighten step plate screw against step plate Make sure the four step plate feet are squarely positioned on the pinion 9 Adjust the micrometer so it is directly over and at a 90 degree angle to the step plate Screw the micrometer down until the anvil contacts...

Page 81: ...9 1 4 axle in axle housing differential bearing seats Center the arbor so that an approximate equal distance is main tained at both ends Correctly position differential bearing caps and insert bolts and tighten to 10 foot pounds 9 Using a feeler gauge select the proper thick ness of shims that will snugly fit between arbor and gauge block This fit must be snug but not too tight similar to the pull...

Page 82: ...IVE GEAR AND PINION BACKLASH 1 With drive pinion and bearings installed and bearing preload set install differential case and ring gear assembly with their respective bearing cups In stall bearing caps in their positions align identifica tion marks and tighten cap bolts finger tight Refer to the measurement taken previously in step 7 of Installation Differentialcase and Ring Gear This reading take...

Page 83: ...ompare the patterns on the drive teeth with those in Fig 20 to determine if all adjust ments have been properly made Correct Adjustment Proper Tooth Contact With all the adjustments properly made correct tooth contact Fig 20 will result Notice that the correct contact pattern is well centered on both drive and coast sides of the teeth When tooth contact pat terns are obained by hand they are apt t...

Page 84: ...ts and tighten nuts to 45 foot pounds and install shock absorbers on spring plate studs 5 Connect parking brake cables 6 Connect hydraulic brake lines at wheel cyl inders and bleed brakes install brake drums and adjust brakes 7 Install rear universal joint of propeller shaft in same position as removed match scribe marks on propeller shaft universal joint and pinion flange Tighten universal joint ...

Page 85: ...e and ring gear backface End Play 005 012 DIFFERENTlAL Sure Grip WHEEL BEARINGS Type Taper Roller Adjustment Threaded Adjusting Nut Lubrication Automotive Multi Purpose Grease NLGl grade 2 LUBRICATI0N Capacity 5112 Pts 4 112 Imperial Type Sure Grip differentials use only the special multi purpose gear lubricant intended for use in limited slip differentials Such a lubricant is avail able under Par...

Page 86: ...PEDAL a Air in hydraulic system a Fill master cylinder and bleed hy b Improper brake fluid low boiling b Drain flush and refill with brake fluid c Excessively worn or cracked brake c Replace all faulty brake drums d Broken pedal pivot bushing d Replace nylon pivot bushing a Contaminatedlining a Replace contaminated brake lining b Frontend out of alignment b Align front end c Incorrect brake adjust...

Page 87: ...e drum b Loose support plate b Tighten support plate bolts to proper c Bent support plate c Replace support plate d Distorted brake shoes d Replace brake shoes e Machine grooves in contact face of e Grind or replace brake drum f Contaminatedbrake lining f Replace either front or rear or all BRAKES DO NOT SELF a Adjuster screw frozen in thread a Clean and free up all thread areas ADJUST b Adjuster ...

Page 88: ...aster cylinder to prevent any dirt from fall ing into the master cylinder reservoir when the cover is removed Using the one man bleeder tank C 3406 with adaptor provides a convenient means of keeping the master cylinder full while pressurizing the hydraulic system for bleeding Complete bleeding of the dual master cylinder is important See Bleeding the Mas ter Cylinder of this section Manual bleedi...

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Page 90: ...justing lever away from star adjust ing wheel Care should be taken not to bend adjusting lever 3 Insert Tool C 3784 into brake adjusting hole and engage notches of brake adjusting star wheel Release brake adjustment by prying up with adjust ing tool 4 Remove wheel cover grease cap cotter pin lock adjusting nut outer wheel bearing and remove wheel and drum assembly from spindle to expose Removing t...

Page 91: ...ver Remove cable cable guide Fig 3 Removing or InstallingBrake Shoe Return Springs Left Front and anchor plate 4 Disconnect lever spring from lever and disen gage from shoe web Remove spring and lever 5 Remove primary and secondary brake shoe as semblies and adjusting star wheel from support In stall wheel cylinder clamps ToolC 416 to hold pistons in cylinders Removing the Rear Brake Shoes 1 With ...

Page 92: ... be replaced Shoes having sufficient lining but lack of contact at toe and heel should be measured for proper grind Clean the support using a suitable solvent then inspect for burrs Remove if necessary Clean and lubricate threads of the adjusting screws then inspect for pulled or stripped threads GRINDING RECOMMENDATIONS Brake Shoe Lining New lining should be meas ured and ground 060 to 080 maximu...

Page 93: ... lever to back side of secondary shoe Fig 9 3 Place secondary and a primary shoe in their Fig 9 lndalling Brake Shoes Lett Rear relative position on a work bench 4 Lubricate threads of adjusting screw and install it between primary and secondary shoes with star wheel next to secondary shoe The star adjusting wheels are stamped R right side and L left side and indicate their location on vehicle 5 O...

Page 94: ...e lining d Rachet or pedal mechanism worn d Replace pedal assembly SERVICE PROCEDURES ADJUSTING THE PARKING BRAKES The service brakes must be properly adjusted be fore adjusting the parking brake 1 Release parking brake lever and loosen cable ad justing nut to insure cable is slack Fig 1 Before looseningcable adiusting nut clean threads with wire brushand lubricate with grease 2 Tighten cable adju...

Page 95: ...rking brake cable bracket and install retaining clip ent size slot for corresponding cable and fitting REMOVING THE FRONT PARKING BRAKE CABLE 1 Disengage front parking brake cable from 2 Disengage cable from guide clip 3 Using a screw driver force cable housing and attaching clip out of body crossmember 4 Fold back left front edge of floor mat and re move rubber cable cover from floor pan 5 Depres...

Page 96: ...ont outlet tube from the master cylinder is connected to the hydraulic system safety switch Figs 8 and 9 and thence to the rear brakes The rear outlet tube from the master cylinder is also Page Installing Master Cylinder 14 Master Cylinder Removal 11 Reassembling Master Cylinder 12 Testing Hydraulic System Safety Switch 15 Testing Master Cylinder 14 connected to the safety switch and the front bra...

Page 97: ...eats PISTON RETAINER RESIDUAL PRESSURE VALVE AND SPRING f b RESIDUAL U A L PRESSUR PRESSURE VALVE VALVE SPRING Fig 3 Removing or InstallingResidualPressure Valves and Springs solvent and dry with compressed air Wash the cylin der bore with clean brake fluid and inspect for scoring or pitting Master cylinder bore walls that have light scratches or show signs of corrosion can usually be cleaned with...

Page 98: ...ings i n outlet Ports and install tube seats firmly When the BLEEDING THE MASTER CYLINDER Before installing the master cylinder on vehicle it must be bled on the bench as follows 1 Clamp master cylinder in a vise and attach bleeding tubes Tool C 4029 Fig 7 If vehicle is equipped with disc brakes be sure residual pressure valve is on end of tube in large capacity reservoir This keeps brake fluid fr...

Page 99: ...l be necessary to pump up the brakes rapidly and then hold the pedal down Have an observer watch the fluid in the rear reservoir while the pedal is raised A disturbance in the fluid indicates that the compen sating port is open HYDRAULIC SYSTEM SAFETY SWITCH The hydraulic system safety switch Figs 8 and 9 FROM MASTER CYLINDER PORT STAMPED IF SWITCH BODYzy 0 PISTON SEAL 0 RING SEAL 0 RING BR SWITCH...

Page 100: ...e extreme care in cleaning wheel cylinder after reconditioning Remove all dust or grit by flushing the cylinder with alcohol wipe dry with a clean lint less cloth and clean a second time with alcohol Dry the wheel cylinder with air pressure then flush with clean brake fluid Be sure bleeder screw port and the bleeder screw are clean and open Wheel cylinder bores or pistons that are badly scored or ...

Page 101: ...olts and tighten securely 17to 20 foot pounds 2 Connect brake tube to wheel cylinder and tighten to 95 inch pounds rear wheels or connect brake hose to wheel cylinder front wheels and tighten to 25 foot pounds before connecting brake hose to frame bracket Should hose be connected to wheel cylinder last the tightening of hose into wheel cylinder will twist hose which can result in suspen sion or ti...

Page 102: ...bling the Power Brake 20 Installing the Power Brake 23 Cleaning and Inspection 20 Removing the Power Brake 18 GENERAL INFORMATION The Midland Ross power brake Fig 1 is located on the engine side of the dash panel The front cover of the Power Brake Unit supports the master cylinder The power brake derives its power from the intake manifold vacuum and atmospheric pressure It does not require a vacuu...

Page 103: ... power brake and master cylinder from vehicle and place on a service bench for further dis assembly DISASSEMBLING THE POWER BRAKE To disassemble the power brake unit for repair or overhaul Fig 2 proceed as follows 1 Remove four nuts that attach master cylinder to power brake unit Remove master cylinder 2 Remove air filter cover assembly from power brake unit separate cover and retainer then remove...

Page 104: ...k and zyxwvuts 0 ring from diaphragm 16 Using snap ring pliers remove retainer that holds plunger to control hub Fig 12 Separate con trol hub and plunger assembly Fig 1 3 It may be clamp band Separate front and rear covers from rear housing bellows Fig 7 r l L l t K L U V t K INER Fig Filter Retainer and Cover Assembly Fig 4 Scribe Marks on Front Cover ClampBand and Rear Cover necessary to file an...

Page 105: ...ring pitting dents or nicks small imperfections can be smoothed out using crocus cloth Replace all parts that are badly scored nicked or damaged At reassembly coat all rubber parts including the diaphragm with silicone grease Dow Corning 33 IAPHRAGM POWER PISTOh Fig 8 Removing or Installing Bellow8 PUSH ROD ASSEMBLY I RUBBER 1 SEGMENTS CONTROL HUB NN I 3 POWER PISTON DIAPHRAGM ASSEMBLY Fig 9 Push ...

Page 106: ...LUNGER NN16 SNAP RING PLIERS Fig 12 Removing or Installing Plunger Retainer Fig 13 Control Housing and Plunger Assembly 16 8 Install lever assembly in control hub with rubber segments toward control hub Be sure the levers are evenly spaced within the control hub THIS IS IMPORTANT 9 Slide reaction cone over push rod Fig lo then install retainer Install two plastic guides on push rod Install push ro...

Page 107: ...is being tightened Tighten to 10 inch pounds Min 16 Install rubber boot to input push rod and as semble plastic retainer to end of rod Insert rod into plunger so that retainer engages groove in plunger Install lip of boot in groove of rear seal POWER PISTON ASSEMBLY 17 Position air filter in plastic filter cover then snap cover and filter on metal hub with filter between Fig 3 18 Assemble cover fi...

Page 108: ...m suspended type which utilizes engine intake manifold vacuum and atmospheric pres sure for its power This type of units does not require a vacuum reservoir The Bendix Power Brake Unit can be identified by the twist lock method of attaching the housing and cover together The basic elements of the vacuum unit are as fol lows A mechanically actuated control valve integral with CONNECTOR CLAMP 2 the ...

Page 109: ...and washers and remove master cylinder from power brake INSTALLING THE POWER BRAKE 1 Install master cylinder on power brake 2 Insert brake link through brake support and 3 Install attaching bolt and nut through power 4 Attach vacuum hose to check valve 5 Attach brake lines to master cylinder 6 Fill and bleed master cylinder and bleed brakes 7 Inspect adjustment of stop light switch CAUTION Do not ...

Page 110: ...ake unit and master cylinder as sembly from brake support bracket 6 Remove four master cylinder attaching nuts and washers and remove master cylinder from power brake INSTALLING THE POWER BRAKE BUDD DISC BRAKES INDEX GENERAL INFORMATION 1 Install master cylinder on power brake 2 Insert brake push rod through brake support 3 Install push rod attaching bolt and nut through 4 Attach vacuum hose to ch...

Page 111: ... acts as a heat insulator Inserted between the pistons and the disc is the segmented lining and shoe assembly which are held in position by the brake shoe anti rattle spring Fig 2 Operdon As the brake pedal is depressed the hydraulic pressure exerted in the system loads the pistons clamping the disc between the brake shoe pads with equal and opposite force When the brake pedal is released the hydr...

Page 112: ...st wheel bearing to specified g Damaged caliper piston seal h Power brake malfunction a Excessive lateral runout of braking a Check disc for lateral runout with dial b Excessive thickness variation of brak b Check disc for thickness variation c Excessive front bearing clearance c Readjust wheel bearings to specfied torque d Rear brake drums out of round d Regrind rear drums and check for out of ro...

Page 113: ...ly posi time and if condition persists check tioned following causes Leak in system or caliper b Check for leak and repair as required Damaged piston seal in one or more c Disassemble caliper and replace pis of cylinders Air in hydraulic system or improper d Bleed system bleeding procedure Bleeder screw open e Close bleeder screw and bleed entire system Leak past primary cup in master cyl f Recond...

Page 114: ...ads and turn knob on tool until pistons are fully compressed Fig 4 Remove to bench for disassembly DISASSEMBLING THE CALIPER To disassemble the caliper Fig 5 proceed as fol lows 1 Drain caliper then place caliper assembly in a vise Remove piston compression Tool C 3992 and four bolts that hold two halves of caliper together 2 Separate halves and remove two crossover seals 3 Using a small screwdriv...

Page 115: ...in cleaning the caliper after honing Remove all dust and grit by flushing the cali per with alcohol wipe dry with a clean lintless cloth andthen clean a second time in the same manner h SCREWDRNERa I ASSEMBLING THE CALIPER To reassemble the disc brake caliper Fig 5 pro ceed as follows 1 Clamp caliperhousing in a vise and coat cylin der bores with 55 Dow Corning Pneumatic Silicone Grease or equival...

Page 116: ...posi tion by retainer and that retainer is fully seated in grooveover boot Fig 12 7 Install remaining pistons in same manner then test pistons for smooth operation in their bores by depressing with fingers 8 Lightly clamp outer caliper half in vise and in stall new crossover passage seals in position in recess of caliper mating surface Wsf BOOT GROOVE PISTON SEAL P NN365 Fig IO Removing Piston Sea...

Page 117: ...p wheel hub in a vise with disc attaching 2 Remove bolts that attach disc to hub 3 Lift disc from hub to remove 4 Remove damaged stud using an arbor press 5 Install new stud in position and press into place that balancewill be assured at reassembly bolts facing up installing the Braking Disc onthe Hub After stud had been installed wipe hub and disc mating surfaces to remove any loose foreign mater...

Page 118: ...e tandem master cylinder Fig 1 1 and 1 8 inch bore is of the compensating type with the reservoirs cast integrally The master cylinder con sists of a front and rear piston in tandem two out lets with 1containing a residual pressure valve and spring rearbrake line outlet only Fig 3 The front outlet tube from the master cylinder i s connected to the hydraulic system safety switch Figs 8 or 9 and the...

Page 119: ...res that have deep scratches or scoring may be honed providing the diameter of the bore is not increased more than 002 inch If master cylinder bore does not clean up at 002 inch when honed the master cylinder should be discarded and a new master cylinder in stalled If master cylinder pistons are badly scored or corroded replace them with new ones The piston cups and seals should be replaced when r...

Page 120: ...ston assemblies into bore Carefully work lips of cups into bore then seat piston assemblies Fig 6 3 Holding pistons in seated position install pis ton retaining screw and gasket Tighten securely Fig 6 4 Install residual pressure valve and spring Fig 3 in front brake outlet then install tube seats firmly When the bleeding tubes are attached the tube seats will be positioned correctly BLEEDING THE M...

Page 121: ...brake tubes and tighten to 150 inch pounds 4 Bleed brakes at wheel cylinders using regular procedure being sure fluid level is maintained See Bleeding Brake System TESTING MASTER CYLINDER Be sure that the master cylinder compensates at both ports This can be done by applying the pedal lightly with the engine running power brakes and observing for a gyser of fluid squirting up in the FROM MASTER CY...

Page 122: ...ch To test the service brake warning system raise the car on a hoist and open a wheel cylinder bleeder while a helper depresses the brake pedal and observes the warning light If the light fails to light inspect for a burned out bulb disconnected socket a broken or disconnected wire at the switch If the bulb is not burned out and the wire continuity is proven re place the brake warning switch in th...

Page 123: ...11 87 11 89 Inside 7 23 7 25 Disc Runout Max Allowable 005 Disc Surface Finish 30 60 Micro Inches Disc Thickness 8725 8775 Disc Mounting To Hub 5 Bolts Type 0rganic Lining Thickness 1 2 Nom Width 2 3 16 Length 53 16 Braking Area Per Shoe Approx 10 Sq Inches Maximum Wear Limit Not lessthan 1 32 at any point BRAKING DISC HUB Type Malleable Cast Iron Piston Bore Diameter 1 1 8 Maximum AIIowable After...

Page 124: ...83 cubic inch engines with 2 and 4 barrel carburetors use a 10 1 2 inch clutch Models with the 440 cubic inch engine use an 11 inch clutch as standard size I Clutch Pedal and Bracket The clutch pedal is connected to the torque shaft through a vertically positioned rod Fig 2 A non adjustable over center spring is provided between the pedal and the pedal bracket to allow easy clutch pedal operation ...

Page 125: ...d for the clutch is the pedal linkage adjustment to provide the prescribed clutch pedal free play This is the pedal movement required to close the clearance between the release bearing and the clutch release levers when releasing the clutch The adjustment is necessary to restore pedal freeplay reduced by normal clutch wear Improper operation or excessive wear may impair the clutch function to a po...

Page 126: ...aning and lnspection 1 Use compressed air to clean dust out of clutch housing Inspect for oil leakage through engine rear main bearing oil seal and transmission drive pinion seal If leakage is noted it should be corrected at this time 2 Friction face of flywheel should have a uni CAUTION Handle clutch and disc carefully to avoid contaminatingthe friction surfaces RETURN SPRING RETAINING SPRING CLU...

Page 127: ...in 015 inch The cover should be a snug fit on pressure plate lugs If clutch assembly does not meet these require ments it should be replaced 11 Examine condition of clutch release bearing CAUTION The clutch release bearing is a prelubri cated sealed thrust bearing and should not be im mersed in solvent The bearing should turn freely when held in the hands under light thrust load with no evidence o...

Page 128: ...lutch fork has a riveted flat retaining spring that is engaged in a hole in the pivot The clutch re lease fork pivot is an L shaped bracket bolted in side the clutch housing 5 Remove fork from clutch housing lnstallation 1 Apply Multi Mileage Lubricant Part Number 2525035 or Automotive Multi Purpose Grease NLGI grade 2 to edge of pivot hole Fig 4 2 Lubricate bearing contact areas at end of clutch ...

Page 129: ...lay page 2 TORQUE SHAFT AND BEARINGS Removal from torque shaft lever Fig 3 1 Remove pedal rod spring washer and pedal rod 2 Remove clutch fork return spring Fig 3 3 Remove spring washer and clutch release fork 4 Remove torque shaft ball stud nut and washer 5 Unscrew torque shaft ball stud from clutch rod from torque shaft lever Fig 3 at frame end of torque shaft housing lnsfallation 1 Install new ...

Page 130: ...1736348 and 036 through 052 use 021 dowel No 1736353 8 To install dowels remove clutch housing and old dowels from rear face of engine block 9 Install both dowels with slots parallel and aligned in direction to correct bore runout Slot in dicates direction of maximum dowel eccentricity Both dowels must be inserted into engine block up to off set shoulder 10 Install clutch housing to engine block b...

Page 131: ...Spring Color No Paint Pedal Free Play at fork end Std 318 cu in CLUTCH DISC 5 Black 5 Red CLUTCH COVER 5132 POLARA MONACO CLUTCH Make Borg Beck Model 1647 Type Dry Disc Model Application Polara Monaco Usage with Engine Size Std 383cu in Facing Material Woven Asbestos Outsde Diameter 10 1 2 Thickness 125 Disc Springs number 10 Spring Color 5 Green 5 Tan Pressure Springs number 12 Spring Color 6 Whi...

Page 132: ... sure adequate anti freeze and corrosion protection In areas where anti freeze is not required MOPAR rust inhibitor or equivalent must be added to the water coolant for normal corrosion protection Air condi tioned cars require year round protection with permanent type anti freeze with a minimum of 15 F protection for summer operation and addi tional anti freeze in the winter according to the pre v...

Page 133: ... hose d Reposition hose clamps or replace the hose Check radiator outlets for dents or out of rounds e Faulty thermostat f Water pump impeller broken or loose f Replace the water pump impeller as g Restricted radiator core water pas g Flush the radiator thoroughly or rod h Restrictedengine water jacket h Flush the engine cooling system thor oughly a Blocked radiator air passages a Blow out the rad...

Page 134: ...red ley a Broken cord in belt b Belts not matched A C a Belt too loose b Belts not matched A C c Misaligned pulleys a Replace belt b Install matched belts a Adjust belt tension b Install matched belts c Align accessories SERVICE PROCEDURES FAN There are no repairs to be made to fan If fan is bent or damaged it should be replaced Removal Loosenfan belt Remove four fan attaching screws 1 If equipped...

Page 135: ...corrected with test unit WATER PUMP Removal 1 Drain the cooling system Remove upper half P NK48UA Fig 2 Torque Control Fun Drive NP541 w Fig 3 Thermul Control Fun Drive 318 Cubic Inch Engine of fan shroud if so equipped or set one piece shroud back on engine 2 Loosen power steering pump idler pulley and alternator Removeallbelts 3 Remove fan spacer or fluid drive and pulley CAUTION To prevent sili...

Page 136: ...8 Cubiclnch Engines Inspect the seal surface of the impeller hub to be sure it is free of nicks burrs scratches and rust If necessary remove these blemishes using crocus cloth on a flat plate 1 Apply a thin coat of Perfect Seal or equivalent to seal pocket in pump body 2 With pump housing supported at hub end use a 1 1 4 inch 12 point socket to apply pressure against outer lip of seal retainer and...

Page 137: ...ocket to apply pressure against outer lip of seal retainer and press seal as sembly into the body until retainer lip is against the pump body 3 With slinger ring in position on long end of pump shaft approximately 1 8 inch from bearing assembly start shaft and bearing assembly into fan hub end of pump body bore 4 Use a 2 inch length of 1 1 2inch O D pipe and support pump body at seal end With Tool...

Page 138: ...cooler in the tank 8 Attach bottom tank to radiator using soft sol der 9 Install radiator as described in Paragraph Radiator 10 Fill cooling system and test for leaks If the transmission operates properly after repair ing the leak drain the transmission and torque con verter while hot remove the transmission oil pan and inspect for sludge rust dirty or plugged inlet filter If none of these conditi...

Page 139: ... gauge can be inserted into valve opening the feeler gauge should pass freely into the valve opening at a water temperature of 177 to 184OF If outside of this range replace thermostat 4 Continue heating water to approximately 200 F The thermostat valve should be fully open at this temperature If it is not replace thermostat installation 1 Using a new gasket position thermostat so pellet end is tow...

Page 140: ...rly established The Torque Method and The Belt Deflection Method If the specified tensions are not maintained belt slippage may cause engine overheating lack of power steering assist loss in air conditioning capacity reduced Fig 12 Pressure Testing Cooling System If the needle continues to fluctuate it indicates a leak on the bank still in operation If the needle ceases to fluctuate the leak is in...

Page 141: ... is not possible to use the torque wrench because of clearance use an ex tension Belt Deflecfion Method All belts can also be adjusted by measuring the deflection of the belt at the mid point between two pulleys under a five pound push or pull A small spring scale can be used to establish the five pound load See Figure 13 for correct location at which to measure deflection This method should be us...

Page 142: ...N A 16 17 A C CA P 3 Speed Manual N A N A N A N A N A N A N A N A N A N A N A N A 16 17 7 Automatic 1W 4 Speed Manual 4 661 only Automatic lvt 4 Speed Manual Automatic 1V res 18 7 2 1 4 Thermal None 67 4 661 only Yes 18 Xh 1 4 Thermal None 67 Trailer Tow Automatic 15 18 7 2 95 Solid 1 24 4 38Il 10 Trailer Tow Automatic 18 l 2342 1 4 Thermal None 3 67 6 With A C With or Without C A P CSpeed Manual ...

Page 143: ...be used TORQUE METHOD TORQUE FT LBS TO BE APPLIED TO COMPONENTS New Belt 383 318 440 1116 118 1116 1116 1116 118 118 118 114 Engine Used Beltt Displacement 383 Cubic Inches 318 440 POWER STEERING ALTERNATOR Solid Bracket 55 50 Self Tightening 45 With A C Single Belt 40 Dual Belt 35 Without AC 40 9K LJ AIC IDLER BRACKET 45 FAN IDLER 50 25 40 40 New Belt 383 318 440 85 90 45 55 50 40 55 60 35 zy 60 ...

Page 144: ... light min eral grease or petrolatum after tightening 12 If electrolyte level is low fill to recommended level with mineral free water SPECIFIC GRAVITY TEST A hydrometer Tool 40 Bis used to measure specific gravity of electrolyte in battery cells This gives an indication of how much unused sulphuric acid re mains in the solution A hydrometer should be graduated to read from 1 160 to 1 320 in gradu...

Page 145: ...harged relatively new battery has a specific gravity reading of 1 260 plus 015 minus 005 all batteries for use in temperature climates lest Conclusions a Battery specific gravity is less than 1 220 bat tery should be recharged Make a high rate discharge test for capacity If battery cells test O K recharge and adjust gravity of all cells uniformly Test voltage regulator setting Thoroughly test the ...

Page 146: ... Do C tion and a safe stateof charge C If all cells vary LESS than five scale divisions on the TOP scale but if any of the cells test in the RED section of the BO ITOM scale the battery is in good condition but is in a low state of charge Rechargeat once to avoid a starting failure D If ANY cell readings are in the RECHARGE AND RETEST section of the TOP SCALE and the balance of the readings are wi...

Page 147: ...ld read 9 5volts or more which will indicate that the battery has good output capacity 6 After the 15 second test turn Battery Starter Tester control knob to the OFF position If the voltage in the High Rate Discharge Test was under 9 5volt the battery should be test charged to determine whether the battery can be satisfactorily charged Charging the Battery Three Minute Charge Test Fig 5 This test ...

Page 148: ... When batteries are being charged an ex plosive gas mixture forms beneath the cover of each cell Do not smoke near batteries on charge or which have recently been charged Do not break live circuits at the terminals of the batteries on charge A spark will occur where the live circuit is broken Keep all open flames away from the battery Slow Charging Batteries Many discharged batteries can be brough...

Page 149: ...ing 13 Assembling the Starter 14 Brushes and Springs Replacement 13 Cleaning the Starter Parts 12 Disassembly 10 General Information 6 Bushings Replacement 13 Field Coils Replacement 13 Field Coils Testing 13 Page Ground Circuit Test 9 Insulated Circuit Test 9 Installing the Starter 17 Removing the Starter 10 Resistance and Current Draw Testing 9 Service Diagnosis 6 Specifications 68 Testing the S...

Page 150: ...t for open circuit wire between starter relay solenoid terminal and solenoid terminal post Faultysolenoid switch or connections b Test for loose terminal connections between solenoid and starter field Solenoidswitch contacts corroded c Test and replace solenoid if neces sary Broken lead or a loose soldered con d Test and redace solenoid if neces nection inside solenoid switch brush holder plate Ba...

Page 151: ...C 0 T 8 5 k 5 I L MyMopar com ...

Page 152: ...m solenoid connector and connect to the following points repeating test at each connection Starter terminal of solenoid battery terminal of solenoid battery cable terminal at sole noid starter relay and cable clamp at the battery B A small change will occur each time a normal portion of the circuit is removed from test A def inite change in the voltmeter reading indicates that the last part elimin...

Page 153: ...xture only DO NOT clamp 2 Remove two through bolts and starter end head assembly 3 Carefully pull armature up and out of gear housing and starter frame and field assembly Re move steel and fiber thrust washer The wire of shunt field coil is soldered to the brush terminal One set of brushes are connected to this terminal The other pair of brushes is attached to the series field coils by means of a ...

Page 154: ...revent it from springing away after removal 18 Release retainer ring at front of pinion shaft Fig 9 Do not spread retainer ring any greater than out BRUSH HOLDER INSULATOR PLATE SCREW Fig 5 Removing or InstallingBrush Holder Plate Screw ID RELAY STUD SOLENOID LEAD CONTACT WASH VAPOR BARRIER SOLENOID COIL WASHER Fig 6 Solenoid Assembly Fig 7 Removing Dust Cover side diameter of pinion shaft otherwi...

Page 155: ...e factory and solvent will wash lubricant from the clutch 3 The starter clutch outer housing and pinion gear may be cleaned with a cloth moistened with cleaning solvent and wiped dry with a clean dry cloth 4 Unsolder solenoid lead wires from solenoid terminal relay stud 5 Clean all corrosion from solenoid assembly washers sleeve and retainer and inside of solenoid moving core Fig 1 2 remove clutch...

Page 156: ...ods If lamp lights it indicates a grounded armature Replace grounded armature Testing Commutator Run Out Refacing and Undercutting Place armature in pair of V blocks and measure runout with dial indicator Measure both shaft and commutator A bent shaft requires replacement of armature When commutator runout exceeds 003 inch commutator should be refaced Remove only a sufficient amount of metal to pr...

Page 157: ...l 1 Position shifter fork in drive housing and install shifting fork retainer pin One tip of pin should be straight other tip should be bent at a 15 degree angle away from the housing The fork and retainer pin should operate freely after bending tip of pin 2 Install solenoid moving core and engage shifting fork Fig 1 2 3 Enter pinion shaft into drive housing and install friction washer and drive g...

Page 158: ...he washer 1 1 Install solenoid contact plunger assembly into solenoid and reform double wires to allow for proper entry of terminal stud into brush holder with the double wires curved around the contactor CAUTION The contactor must not touch the double wires when solenoid is energized after assembly is completed Fig 6 Make sure contact spring is positioned on the shaft of the solenoid contact plun...

Page 159: ...e tightly around brush terminal post as shown in Figure 22 and solder securely with a high temperature resin core solder and resin flux 15 Carefully enter solenoid coil and brush plate assembly into bore of gear housing and position brush plate assembly into starter gear housing Align tongue of ground terminal with notch in brush holder Fig 23 16 After the brush holder is bottomed in housing insta...

Page 160: ...sition starter end head assembly and install starter frame lockwashers and through bolts Tighten through bolts securely 23 Clean area at the joint between brush holder plate to field frame and gear housing mating joint apply a bead of brush plate sealer Part No 2421847 around the four sides of the joint Fig 26 CAUTION Sealer must be flowed continuously to avoid gaps After the bead has been flowed ...

Page 161: ...alternator are the rotor stator rectifiers the end shields and the drive pulley See Fig 2 SERVICE DIAGNOSIS Condition Possible Cause Correction ALTERNATOR FAILS TO a Blown fusible wire in voltage regula a Locate and correct cause of the fuse CHARGE No Output tor blowing Install new fuse wire Solder both ends of new fusible wire se cureIy b Alternator drive belt loose b Adjust drive beltto Specific...

Page 162: ...red d Interference between rotor fan and d Remove and disassemble alternator stator leads or rectifiers Correct interferenceas required e Rotor or rotor fan damaged e Remove and disassemble alternator Install new rotor f Open or shorted rectifier f Remove and disassemble alternator Test rectifiers Install new rectifiers as required g Open or shortedwinding in stator g Remove and disassemble altern...

Page 163: ...ttery cable Battery Post Adapter BY PASS SWITCH must be open for all charging system tests It is closed only for starting the engine Field CircuitResistance Test Fig 4 ignition ballast resistor 1 Disconnect slip on connector from either end of 2 Turn ignition switch on 3 With vehicle doors closed and all accessories turned off observe Voltmeter reading Voltage should not exceed 55 volt A reading i...

Page 164: ...Battery Post Adapter 11 Rotate tester Control Knob to LOAD position untilVoltmeter reads 6volts 12 Rotate tester Field Control to DIRECT position and adjust tester Control Knob until Voltmeter reads exactly 15volts 13 Observe test ammeter Ammeter now indicates maximum output of alternator Current output should be within limits shown in Specification Current output should be within 5 amperes of rat...

Page 165: ...10 amps observe voltmeter reading Voltmeter now indicates amount of voltage loss across ground circuit Voltage loss should not exceed 3volt 4 Rotate tester Field Control to the OPEN posi tion VOLTAGE REGULATOR CHRYSLER BUILT lator frame by a screw Fig 9 The upper contact bracket is connected to the IGN terminal by a fusi The only function of the regulator is to limit the output voltage The voltage...

Page 166: ... tension and opens the upper contacts The arma ture contacts at this time do not touch either the upper or lower stationary contacts Field current now flows through the regulator IGN terminal through the two parallel resistors through the FLD termi nal and through the rotor field to ground The two resistors in series with the field circuit reduce field current and rotor field strength with a corre...

Page 167: ...ster Voltmeter to battery negative terminal 7 Rotate Tester Field Control to the DIRECT posi tion 8 With engine operating at 1250 RPM rotate tester Control Knob clockwise until Ammeter reads exactly 15amperes 9 Rotate tester Field Control from DIRECT posi tion to OPEN position and then back to DIRECT posi tion to cycle the system 10 Observe test voltmeter Voltmeter now indi cates setting of the vo...

Page 168: ...vity in the summer with a minimum water requirement not more than an ounce of water per cell per one thou sand miles Fig 12 Adjusting Spring Tension Voltage Regulator Fusible Wire Replacement 1 Cut fuse wire above solder connection at the base and unwind wire at top bracket CAUTION If an attempt is made to unrolder the old fuse the very small wire from voltage coil may be damaged 2 Tin end of fuse...

Page 169: ... and test lamp should be dim Make sure air gap is checked with stationary con tact bracket attaching screw fully tightened VOLTAGE REGULATOR ESSEX GENERAL INFORMATION The only function of the regulator is to limit the output voltage The voltage regulator accomplishes this by controlling the flow of current in the rotor field coil and in effect controls the strength of the rotor magnetic field The ...

Page 170: ...s opening and closing the lower contacts This alternately puts in and takes out resistance in the field circuit and in effect limits the alternator output voltage When the electrical load requirements are low and the engine speed is high the alternator output voltage tends to increase The battery line voltage now slight ly increased causes the regulator voltage coil mag netic force to pull the gro...

Page 171: ... DIRECTposition Upon completion of test reduce engine speed to idle stop engine and disconnect all test leads and adaptors Be sure that all vehicle s cables and wiring connections are secure before restarting engine CAUTION Be sure the negative post of battery is always connected to ground Incorrect battery polari ty may result in wiring harness damage and may damage alternator rectifiers Do not g...

Page 172: ...low 2 volt increase air gap by bendingfixed contact bracket UP NN338A Fig 19 Bending Stationary Contact Arm a Connect a small dry cell test lamp in series with the IGN and FLD terminal of the voltage regu lator b Insert a 032 inch wire gauge between regulator armature and core of voltage coil next to stop pin on the armature Fig 20 and press down on the arma ture until armature contacts wire gauge...

Page 173: ...tic insulator and screw Screw is a special size and must not be substituted 5 Install insulated brush holder terminal insu lated washer shake proof washer and screw If the parts were not assembled in this order or if wrong screw was used this could be the cause of the ground condition DISASSEMBLING THE ALTERNATOR To prevent possible damage to brush assemblies they should be removed before proceedi...

Page 174: ...retest The read ing of the good rectifiers will now be within satisfac tory range When one rectifier is open it will read approximate ly one ampere and two good rectifiers will read with TEST PROD NEGATIVE CASE NK106 T OENDHOUSING Fig 25 Testing Negative Rectifiers in satisfactory range Negative Case Rectifier Fig 25 a Connect test lead clip to rectifier end housing b Touch exposed connection of e...

Page 175: ...ctifier leads from stator leads Do not blow solder off with air fine particles of y NK112 I NK113 Fig 29 Testing Stator Windings for Continutty solder can short other rectifiers f Test stator for grounds using a 110 volt test lamp Fig 28 Use wood slats to insulate the stator from rectifier shield Contact one prod of test lamp to stator pole frame and contact the other prod to each of the three sta...

Page 176: ...er to separate rotor from end shield The new bearing is lubricated with a predeter Fig 32 Disengaging Bearing Retainer from End Shield TOOL RETAINER ND112 Fig 33 Removing Bearingfrom Rotor She mined amount of special lubricant and does not re quire additional lubrication 9 The drive end ball bearing is an interference fit with the rotor shaft Remove bearing with puller Tool C 3615or C 3934and adap...

Page 177: ...failures REPLACING SLIP RINGS Slip rings that are damaged can be replaced as a Remove rotor plastic grease retainer follows F NP365 C I Fig 36 Solder Points Slip Ring Installed OLD SLIP RING CUT wtin cnmi ND526 Fig SI Cvtting Old Slip Rings b Unwind field coil leads from slip ring lugs Fig c Use a chisel to cut through the copper of both d Break the plastic insulator and remove the old e Clean awa...

Page 178: ...ed n If rotor is not grounded and field circuit is continuous lightly clean slip rings surface with 00 sandpaper 0 Position grease retainer on rotor shaft and press retainer on shaft with installer Tool C 3921 Fig 41 The plastic retainer is properly positioned when the inner bore of the installer tool bottoms on the rotor shaft zyxw 4 NP368 d Fig 40 Soldering FieldCoil Leads ASSEMBLING THE ALTERNA...

Page 179: ...ol 2 3925 so that notches in the support tool will clear the raised sec Fig 44 Installing Rectifier EndShieldBearing tion of the heat sink and press the bearing into posi tion with Tool SP 3381 Fig 44 New bearings are prelubricated additional lubrlca tion is not required 7 Insert drive end bearing in drive end shield and install bearing retainer plate to hold bearing in place 8 Position bearing an...

Page 180: ...nnect battery ground cable 24 Start and operate engine and observe alter 25 Test current output and adjust regulator nator operation voltage setting if necessary IGNITION SYSTEM 8 CYLINDER INDEX Page Assembling the Distributor 43 Ballast Resistor 46 Contact Arm Spring Tension Testing 43 Distributor Contact Dwell 40 Distributor Contacts 44 Distributor Disassembly 41 Distributor Lubrication 45 Distr...

Page 181: ... on the cable and nipple until cables are properly seated in the cap towers Use the same procedure to install cable in coil tower Fig 2 Use the following procedure when removing the I I _ I Secondary Circuit Inspection Check high tension cable connections for good con tact at the coil and distributor cap towers and at the spark plugs Terminals should be fully seated The nipples and spark plug cove...

Page 182: ...stance is less check for a loose connec tion at the tower or for a faulty coil Inspect coil tower for cracks carbon tracking or oil leaks DISTRIBUTOR RESISTANCE TEST This test indicates the resistance of the ignition primary circuit from the distributor side of the coil through the points and the distributor ground Exces sive resistance in this portion of the ignition system will prevent the coil ...

Page 183: ...han 2 degrees from initial reading between idle speed and 1500 RPM probable wear in the distributor shaft bushings or contact plate bearing and pivot pin is indicated Re move distributor for complete inspection and testing on a distributor tester Dwell variation at speeds above 1500 does not necessarily indicate distributor wear Dwell and gap of the contacts must both be within their specified lim...

Page 184: ...plunger on indicator dial Be sure rub bing block of contact arm is on highest point of the cam lobe during this test If plunger movement ex ND326 ceeds 006 inch replace bushings and or distributor shaft see Distributor Disassembly DISTRIBUTOR DISASSEMBLY Fig 5 1 Remove distributor rotor The distributor cap clamp springs on Chrysler built distributors are held in place by peened metal around the op...

Page 185: ...09C COLLAR PIN Fig 5 Distributor fDisauembled View Chrysler Built SPRING NB156A Fig Removing or Installing CamFelt Wick Fig I Removing Distributor Housing Upper Bushing the tap tighten tool nut to remove bushing Invert housingand removelowerbushingin same manner PRESS RAM TOOL DRIVER ITOOL ADAPTER Fig 8 Installing Distributor Housing Upper Bushing MyMopar com ...

Page 186: ...nside diameter is 4995 inch ASSEMBLING THE DISTRIBUTOR 1 Test operation of governor weights and inspect weight springs for distortion Lubricate governor weights 2 Inspect all bearing surfaces and pivot pins for roughness binding or excessive looseness 3 Install cam spacer chamfered end down on dis tributor shaft 4 Slide cam and yoke on distributor shaft engage weight lugs with slots in the yoke In...

Page 187: ...se them to burn rapidly T h i s is easy to detect since the oil produces a smudgy line under the con tacts Clogged engine breather pipes permit crankcase pressure to force oil or vapors up into the distributor Over oiling of the distributor will also cause burning of the contacts If the contact opening is too small cam angle too large arcing will occur between the contacts result ing in low second...

Page 188: ... and secondary spring tabs on cam yoke tg increase or de crease spring tension The governor spring tabs can be reached through the access hole at breaker plate Rotate shaft until proper spring and tab line up with access holes Insert a screwdriver blade through ac cess hole and bend spring tab toward distributor cam to decrease spring tension and advance the spark or away from the distributor cam ...

Page 189: ...n the coil is cold the other after the coil has been warmed UP Test coil according to coil tester Manufacturer s in structions Test coil primary resistance Test ballast resistor resistance Test coil secondary resistance Re place any coil and ballast resistor that does not meet specifications Every time an ignition coil is replaced because of a burned tower carbon tracking or any evidence of arc in...

Page 190: ... Gap Bridging Fig 6 High Speed Glaring GapBridging Gap bridging Fig 5 is also relatively rare in auto motive engines It also may be traced to flying de posits in the combustion chamber In a few cases fluffy deposits may accumulate on the plugs during in town driving when the engine is suddenly put under high load this material can melt and bridge the gap High Speed Glazing High speed glazing may c...

Page 191: ...feeler gauge to check spark plug gap Reset gaps to 035 inch Before setting spark plug gap file center electrode flat make adjustment by bending ground side electrode never bend the center electrode When installing spark plugs tighten to 30 foot pounds Page Compensating the Aimers 49 General Information 48 Headlight Sealed Beam Replacement 51 Measuring Headlight Aim 50 Mounting and Adjusting the Ai...

Page 192: ... must be corrected before satisfactory adjustment can be made 4 Placevehicle on levelfloor 5 Adjust front suspensionheight as necessary 6 Inspecttire inflation 7 Rock vehicle sideways to allow vehicle to as sume its normal position 8 If gasoline tank is not full place a weight in trunk of vehicle to simulate weight of a full tank 6 1 4 pounds per gallon 9 There should be no other load in vehicle o...

Page 193: ...until target split image becomes aligned MOUNTING AND ADJUSTING THE AIMERS 1 While holding an aimer in alignment with lens of one outer headlight bring aimer up to and against headlight lens Make certain that headlight lens pads are making full contact with aimer mounting flange and that aimer target is facing inboard 2 Push release lever forward to expel air from suction cup and while holding aim...

Page 194: ... slide suction cup down ward and away from lens SEALED BEAM REPLACEMENT ALL MODELS The lens filament and reflector are sealed into one unit which can be removed as follows 1 Remove screws from headlight panel and re move panel 2 Remove screws from interior retaining ring and remove ring Do not disturb headlight aimer screws 3 Pull out sealed beam unit and unplug con nector pulling it straight off ...

Page 195: ...place bulb ter a Faulty flasher unit b Faulty external bulb c Faulty contact in switch a Replace flasher b Replace faulty bulb c Replace switch a Broken or loose cancellingfinger b Improperlyaligned cancellingfinger c Broken or faulty switch a Replace cancellingfinger b Align cancellingfinger properly c Replace switch a Open circuit in feed wire to switch b Faulty fuse c Faulty flasher unit a Loos...

Page 196: ...tion turn signal switch in steering column jacket tube and install attaching screws and connect all wire connections 2 Install turn signal operating lever Tighten to 30 inch pounds 3 Install steering wheel and steering wheel nut Tighten to 24 foot pounds Test operation of cancel When the flasher is operating application of the brake pedal will override the system and interrupt the flasher All ligh...

Page 197: ...l tone has a clear mellow sound Do not turn tone adjuster while horn is sounding Adjustment will only clear up sound and cannot change horn tone frequency 5 Connect a test ammeter between positive post of a 12volt battery and horn terminal post Connect a jumper lead from negative battery post to horn base Clean paint from horn bracket where connection is made Turn adjusting screw to obtain a readi...

Page 198: ...retaining screws 2 Connect the two switch wires to horn contact Insert locating pin of contact in hole in steering wheel hub and snap ears of contact over flange on steering wheel hub 3 Install hub lower cover and secure with the four screws Fig 2 4 Install steering wheel with scribed mark on hub aligned with mark on end of steering shaft Install and tighten retaining nut to 40 foot pounds 5 With ...

Page 199: ...LIMITER ON INSTRUMENT CLYSTER I I oLl pAl 5 VOLTS TO GAUGES F U E L TANK FUEL GAUGE FROM SENDING UNIT BULKHEAD CONNECTOR I ON DASH PANEL 64x418 Fig l Fuel Level Indicating System Page Printed Circuit Boards 60 Service Diagnosis 57 Specifications 68 Speedometer 60 Switch Replacement 61 Test in Vehicle 57 Tests out of Vehicle 61 Voltage Limiter 57 gauge metered to the capacity of the tank When the f...

Page 200: ...range between these positions a Faulty instrument panel temperature a Test wiring repair or replace as nec gauge wiring or faulty temperature essary Test gauge and sending unit sending unit in engine a Loose or dirty electrical connections a Clean and tighten all electrical con nections and test the gauge operation a Loose or dirty electrical connections a Test fuel tank sending unit and pro ceed ...

Page 201: ...es only when the park ing brake is applied with the ignition key turned ON The same light will also illuminate should one of the two service brake systems fail when the brake pedal is applied To test the system turn the ignition key ON and apply the parking brake If the light fails to light inspect for a burned out bulb discon nected socket a broken or disconnected wire at the switch To test the s...

Page 202: ...move four left bezel retaining screws two in lower face and two in underside of upper lip and remove bezel Fig 5 knob s and three center bezel retaining screws from underside of upper bezel l i p Remove two center bezel lower retaining screws from front face Fig 5 and pull bezel out far enough to disconnect auto pilot light if so equipped Remove bezel 6 Remove heater or air conditioning control 7 ...

Page 203: ... all instruments See Instrument Cluster Installa tion GEAR SELECTOR INDICATOR The gear selector pointer or the pointer shaft are serviced after removal of the instrument cluster See Instrument Cluster Removal With the cluster face down on a padded work bench remove the eight bezel to housing screws and separate the two Using a pair of needle nose pliers remove retainer clip from point er end of sh...

Page 204: ...unit does not perform to these specifications inspect stops or arm for possible distortion If stops or arm cannot be repaired or are not damaged the unit should be replaced It is importantthat the ohmmeter is accurate An accurate value cannot be obtained if the ohmmeter has an error of more than 1 ohm in 10 Test the ohmmeter with a known 10ohm resistor FUSE BLOCK The fuse block is located at the f...

Page 205: ... 4 Remove center bezel five retaining screws dis connect auto pilot light and remove bezel Fig 5 5 Reaching up through ash receiver opening re move heater or air conditioning control mounting nuts and movecontrol out of the way 6 Remove auto pilot switch screw from front of panel Fig 5 Reaching up through ash receiver open ing remove two retaining screws from control as sembly 7 Remove spring clip...

Page 206: ...Faultv motor a Relieve binding condition b Test Switch See Wiper Switch In c Repair as necessary d Test motor See Wiper Motor Bench e Test wiring for continuity Repair as switch strument Panel Mounted Testing necessary Open or groundedwiring Arm set at incorrect position Motor park switch timing incorrect 2speed only Improperly adjusted wiper arm Looseness of the motor crank or b Replace parts as ...

Page 207: ...shieldMoulding Right left 1 3 114 2 114 If the clearance is not in the specified range use Tool C 3982 and reposition the wiper arm and blade assembly Fig 1 CAUTION The use of a screwdriver or other prying tool to remove an arm may distort it in a manner that will allow it to come o f f the pivot shaft in the future regardless of how carefully it is reinstalled NEVER under any circumstances push o...

Page 208: ...all the three nuts that mount motor to dash panel and connect wiring to motor Make Sure ground strap is screwed to switch plate under one nut 3 Position drive crank on motor and install nut Tighten to 140 inch pounds Test operation of wiper motor 4 Install cowl grillepanel 5 Install windshield lower moulding 6 Using Tool G3982 install and adjust wiper arm and blade assemblies MOTOR BENCH TESTING T...

Page 209: ...emblies PIVOT REPLACEMENT To service either of the wiper pivots it is necessary to remove the wiper arm and blade assemblies the windshield lower moulding and the cowl grille panel The right pivot is serviced after disconnecting the connecting link at the pivot and removing the bolts that mount the pivot to the body Fig 4 The left pivot is serviced after disconnecting the connecting link at the ri...

Page 210: ...Remove three reservoir mounting screws re move reservoir and pump assembly Empty fluid from reservoir 3 Using a suitable extension and a 7 8 inch deep well socket through filler neck remove pump mount BOTTOM OF RESERVOI INTAKE SCREEN AND MOUNTING NUT ASSEMBLY FIBER C A C Y E T I 1 ing nut inside reservoir CAUTION It may be necessary in some older pumps to use a 15 16 in deepwell socket due to the ...

Page 211: ...Special Equipment Special Equipment Negative STARTING MOTOR SOLENOID SHIFT Reduction Gear Type Starting Motor Model Make Voltage No of Fields No of Poles Spring Tension Drive End Play Cranking Amperage Draw Free Running Test Voltage Amperage Draw Maximum Speed RPM Voltage Amperage Draw Pull In Coil Hold In Coil Lock Resistance Test Solenoid Switch Engineshould be at operatingtemperature 2095150 Ch...

Page 212: ... volts at the alternator If measured at the battery current output will be ap proximately5 amperes lower than above values Voltage is controlled by variable load carbon pile across the battery ALTERNATOR VOLTAGE REGULATOR Alternator Voltage Chrysler Built Regulator Identification Number 2098300 Volts 12 Ground Polarity Negative Point Gap 014 inch plus or minus 002inch Air Gap zyx 048to 0 52 inch n...

Page 213: ...5 L L L 0 zyxwv c I n si E cr A i V c 8 U W W 0 X al c 0 0 3 0 c v W V c al e B 3 L m W W V W m 2 MyMopar com ...

Page 214: ...b 2 zyxw 888 0 0 0 0 OOrnh L L Q W C K MM cc w w e C E a a S S S C Y n c 3 0 2 K MyMopar com ...

Page 215: ...2 5 L zyxwvuts o c i 0 C 8 U Q Q 0 X Q U 0 C E 3 0 r Q 0 c W 0 TI 2 L 5 Q 0 Q v c L e LL I I I a n p g r q Y E I I t MyMopar com ...

Page 216: ... d 3 5 L L zyxwvu o w 2 E a Q e 3 J i i t EiE E m E C E E C 4 a C c C Y MyMopar com ...

Page 217: ...0 0 O d O O d 4 8 d 5 K w L L MyMopar com ...

Page 218: ...ere Rating Rating 20 4 5 20 Tail Stop Dome 20 20 20 20 Heater or Air Conditioning Instruments Radio lnline fuse Emergency flasher and stoplight use same inline Dome light and front cigar lighter on same fuse fuse CIRCUIT BREAKERS Circuit Cigar Lighter Rear Convertible Top Door Locks HeadIights Power Seats Power Tailgate Power Windows Windshield Wiper Ampere Location Rating 15 Behind left front cow...

Page 219: ...I I 2 1 Y m zyxwvutsrqp 2 4 9 Y m 2 m 2 W MyMopar com ...

Page 220: ...MyMopar com ...

Page 221: ...HEATER BLOWER 8 78 ELECTRICAL WI RING DlAGRAMS E4 18 Y 4 L P Z I B K L3 16 R BATTERY l2 16 LGN 14 16 BK LOW Fig 4 Inrlrument Panel FOOT DIMMER SWITCH MyMopar com ...

Page 222: ...DIAGRAMS ELECTRICAL 8 79 RIGHT FRONT DOOR E2A 18 0 AUTOMATIC SWITCH RIGHT FRONT DOOR AUTOMATIC q F P LAMP 1 28 1BY 1 8 0 M2C 18 Y M2A 18 Y 1 M1 A1 15 P2 R2 L 1 D U I ACCESSORY CIRCUIT BREAKER 1 12 R MyMopar com ...

Page 223: ...T CONSOLE COURTESY LAMP GROUND AT TO CONSOLE LAMP FEE Ed Tm M1 16 P PANEL TO BODY WIRING TO LEFT FRONT 1 8 y DOOR SWITCH RIGHT CONSOLE M2 18 Y COURTESY LAMP TO CIGAR LIGHTER I I M1 18 P i GROUND M1 18 P LEFT CONSOLE COURTESY LAMP M2 18 Y TO CONSOLE LAMP FEEsTEd Tm M1 16 P 3 M1 16 P PANEL X2 16 BK M2 18 Y TO BODY WIRING TO LEFT FRONT 1 8 y X pM2 18 y DOOR SWITCH MI 18 P MANUAL TRANSMISSION TO BODY ...

Page 224: ...CH AUTOMATIC JRANSMISSION RIGHT CONSOLE COURTESY LAMP RIGHT DOOR COURTESY LAMP I TO CIGAR LIGHTEk GJ T12 18 V E2 18 0 X2 18 BK X2 16 BK Fk lT l cNJ MI 16 P X2 16 BK LEFT CONSOLE r l y MI 18 P mx3 MI l COURTESY LAMP L M2 18 Y A TO CONSOLE WIRING ON INSTRUMENT PANE1 TO BODY WIRING TO LEFT FRONT DOOR SWITCH I 1 M2 18 Y MI 16 P MI 16 P EZ 18 0 B1 18 v GROUND AT LEFT SIDE COWL M2 18 Y y l yIlz b MI 18 ...

Page 225: ...O LEFT COURTESY LAMP T O CONSOLE INSTRUMENT E2 184 PANEL B1 18V X2 16BK GROUND AT LEFT SIDE COWL TO BODY WIRING 2 1 1 ay TO LEFT FRONT DOOR SWITCH AUTOMATIC TRANSMISSION r 2 1 ay T O RIGHT COURTESY LAMP THRU BULKHEAD COIL T11 018 DGN TO BALLAST RESISTOR T O LEFT COURTESY LAMP TO CONSOLE 7 1 INSTRUMENT PANEL X2 16BK TO BODY W I R I N G M2 18Y GROUND AT 2 1 ay TO LEFT FRONT DOOR SWITCH MANUAL TRANSM...

Page 226: ... WIRING DIAGRAMS ELECTRICAL 8 83 TO CONSOLE LAMP FEEDCABLE O N MANUAL TRANSMISSION I AUTOMATIC TRANSMISSION NP432 Fig 8 Consok without Tachometer Pofrra MyMopar com ...

Page 227: ...engine has a 9 2to 1compres sion ratio hydraulic tappets two bore carburetor usesregularfuel All other engines with a 10 0 to 1 compression ratio 4 bore carburetor use premiumfuel The engine oiling system consists of a rotor type oil pump and a full flow oil filter The 318 cubic inch engine oil pump is mounted internally The 383 and 440 cubic inch engine oil pump is mounted externally Oil isforced...

Page 228: ...ltyfuel pump i Install new pump j Incorrect valve timing j Refer to Checking Valve Timing k Blown cylinder head gasket k Install new head gasket 1 Low compression 1 Test compression of each cylinder m Burned warped pitted valves m Install new valves n Plugged or restricted exhaust system n Install new parts as necessary 0 Faulty ignition cables 01 Replace any cracked or shorted p Faulty coil or co...

Page 229: ...n bearing for wear on f Crankshaft journals out of round or f Remove crankshaft and regrind jour g Looseflywheel or torque converter g Tighten to correct torque a Worn scuffed or broken rings a Hone cylinder bores and install new rings b Carbon in oil ringslots b Install new rings c Rings c Remove rings Clean grooves Check groove width d Rings fitted too tight ingrooves d Remove rings Check groove...

Page 230: ...nser 8 Reset ignition timing with vacuum advance line disconnected Ignition timing should be set to com pensate for altitudes and or gasoline grades 9 Set carburetor idle mixture adjustment Adjust throttle stop screw to specifications Perform a com bustion analysis 10 Test fuel pump for pressure and vacuum Re fer to Fuel System Group 1 4 Specifications 11 Inspect manifold heat control valve in the...

Page 231: ...el ler shaft wires linkage speedometer cable and oil cooler lines at transmission 9 Remove engine rear support crossmember and remove transmission from vehicle 10 Lower vehicle and attach a crane or other suitable lifting tool to fixture eyebolt 11 Remove engine front mounts Raise engine with lifting tool and work engine out of chassis 12 Place engine in repair stand 2 3167 and adapter C 3662 for ...

Page 232: ... to install the long stamped steel retainers in the number two and four positions tighten to 15foot pounds 2 Install cylinder head cover and tighten to 40 inch pounds 3 Install closed crankcase ventilation system Installation 3I 8 CubicInch Engine Canadian Built Slide rocker shaft into bore of strut and at the same time engage intake rocker arm Install spring and en gage exhaust rocker arm Install...

Page 233: ...eals after installation 10 a On U S Built position intake manifold on engine and install the twelve attaching cap screws Finger Tight in the tightening sequence shown in Figure 6 Tighten cap screws one through four to 25 foot pounds and tighten remaining cap screws to 25 foot pounds then retighten cap screws one through four to 35 foot pounds and follow by retightening the remaining cap screws to ...

Page 234: ...ze stems if dial indicator reading is excessive or if the stems are scuffed or scored d Service valve with oversize stems are available in 005 015 and 030 inch oversize Reamers to ac commodate the oversize valve stem are as follows Reamer Tool C 3433 379 to 380 inch Reamer Tool C 3430 389 to 390 inch Reamer Tool C 3427 404 to 405 inch CYLINDER HEAD ASSEMBLY I CYLlN AS Fig I Compmssing Valve Spring...

Page 235: ...ing or replacement valve springs should be tested zyxwvuts As an example the compression length of the spring to be tested is 1 5 16 inches Turn table of Tool C 647 until surface is in line with the BZI INTAKE VALVE VALVE SPRING RETAINER LOCK GROOVES 7 EXHAUST VALVE KH333 Fig It Teding Valve Springs 1 5 16 inch mark on the threaded stud and the zero mark to the front Place spring over stud on the ...

Page 236: ...KE VALVE Fig 15 lnstalling Valves CupSeals SpdIWs and Retainers Oil Level TooLow Low oil level may allow oil pump to take in zy air which when fed to tappets causes them to lose length and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same tappet action When tappet noise is due to aeration it may be intermittent or constant and usuall...

Page 237: ...their respective place in tappet holder Tool C 3068 Cleaning and Assembly 1 Clean all tappet parts in a solvent that will re move all varnish and carbon 2 Replace tappets that are unfit for further serv ice with new assemblies 3 If plunger shows signs of scoring or wear and valve is pitted or if valve seat on end of plunger indicates any condition that would prevent valve from seating install a ne...

Page 238: ...on damper 4 Removefuel lines and fuel pump Fig 18 Removing Damper Assembly 5 Loosen oil pan bolts and remove the front bolt at each side 6 Remove chain case cover and gasket using ex treme caution to avoid damaging oil pan gasket It is normal to find particles of neoprene collect between the crankshaft seal retainer and crankshaft oil slinger 7 Slide crankshaft oil slinger from end of crank shaft ...

Page 239: ...thrust plate If not within these limits install a new thrust plate n I f within limits slide the crankshaft oil slinger over shaft and up against sprocket flange away from sprocket Oil Seal Replacement Cover Removed Removal 1 Position remover screw of Tool 2 3506 through case cover with inside of case cover up Position puller blocks directly opposite each other and force the angular lip between th...

Page 240: ...e hub on crankshaft 4 Place installing tool part of Puller set Tool C 3688 in position and press damper hub on crank shaft Fig 27 13 Slide pulley over the shaft and attach with bolts and lockwashers Tighten the bolts to 15 foot pounds 14 Install damper hub retainer washer and bolt 15 Install fuel pump and fuel lines 16 Install water pump and housing assembly us 17 Install radiator fan and belt hos...

Page 241: ...eak in The oil mixture should be left in the engine for a minimum of 500 miles Drain the oil mixture at the next normal oil change Whenever the camshaft is replaced all of the t a p pet faces must be inspected for crown with a straight edge If any negative crown dish is observed tappet must be replaced CAMSHAFT BEARINGS Engine Removedfrom Vehicle Removal 1 With engine completely disassembled drive...

Page 242: ...nstallation of Distributor 1 Hold the distributor over the mounting pad on cylinder block with vacuum chamber pointing toward right of engine 2 Turn rotor until it points forward and to ap proximate location of N o 1 tower terminal in distrib utor cap 3 Place distributor gasketin position I Fig 32 Instulling Distributor Drive Shaft Bushing 4 Lower the distributor and engage the shaft in 5 Turn dis...

Page 243: ...t honing oil available from major oil distrib utors Do not use engine or transmission oil mineral spirits or kerosene 3 Honing should be done by moving the hone up and down fast enough to get a cross hatch pattern When hone marks intersect at 60 the cross hatch angle is most satisfactory for proper seating of rings Fig 34 4 After honing it is necessary that the block be cleaned again to remove all...

Page 244: ...e positioning rings squarely in the cyl inder wall before measuring 2 Insert feeler stock in the gap The ring gap should be between 010 to 020 inch for compression rings and 015 to 062 inch for oil ring steel rails in standard size bores for new service rings Maximum gap in 005 inch O S bores should be 060 inch for compression rings and 070 inch for oil ring steel rails 3 Measure side clearance be...

Page 245: ...ck Method 1 Place an oiled 001inch brass shim stock 1 2 inch wide and 3 4 inch long between bearing and connecting rod journal 2 Install bearing cap and tighten to 45 foot pounds 3 Turn connecting rod 1 4 turn in each direction A slight drag should be felt which indicates clearance is satisfactory Correct clearance is from 0005 to 0015 inch 4 Side play should be from 006 to 014 inch two rods INSTA...

Page 246: ...o insure correct assembly Upper and lower bearing halves are NOT interchangeable Lower main bearing halves of 1 2 and 4 are inter changeable Upper main bearing halves of 1 2 and 4 are interchangeable Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine Fig 41 Bearing shells are available in ...

Page 247: ... a new bearing half with a used bearinghalf REAR MAIN BEARING OIL SEAL Crankshaft Removed Upper Seal 1 Install a new rear bearing oil seal in the cylin der block so that both ends protrude 2 Using Tool C 3511tap seal down into position until tool is seated in bearing bore Fig 43 3 Hold tool in this position and cut off the portion of seal that extends above the block on both sides Fig 44 lower Sea...

Page 248: ...0 C 9 0 0 C 0 C YI I w P MyMopar com ...

Page 249: ...r carefully for damage or wear Fig 47 Inspection 1 The mating face of the oil pump cover should be smooth If cover is excessively scratched or grooved it should be replaced 2 Check for excessive cover to rotor wear by lay ing a straightedge across cover surface If a 0015 inch feeler gauge can be inserted between the cover and straightedge discard cover and install a new one 63x931A Fig 46 Relief V...

Page 250: ...rs 8 Check clearance between inner rotor and outer rotor Fig 5 3 If measurement is more than 008 inch installnew rotor and outer rotor Assembly new oil sealringbetween cover and body 1 When assembling o i l pump be sure to use a 2 Tighten cover bolts to 10foot pounds 3 Prime oilpump 4 Install oil pump and strainer to rear main bear ing cap Tighten bolts to 35foot pounds Servicingthe Oil Pressure R...

Page 251: ...al 3 Tighten the intake manifold bolts to 50 foot pounds 4 Perform cylinder compression test Compres sion should not vary more than 20 pounds for 383 cubic inch engines with 9 2to 1 compression ratio 25 pounds for 383 and 440 cubic inch engines with 10 to 1 and 10 1to 1 compression ratios 5 Clean or replace spark plugs as necessary and adjust gap to 035 inch Tighten to 30 foot pounds using new gas...

Page 252: ...orque bolts to specified torque 1 Install rear engine mount to crossmember and 2 Install rear crossmember to frame and tighten ENGINE ASSEMBLY Removal assure proper adjustment when installing 1 Scribe the outline zyx o f hinge brackets on hood to 2 Remove hood 3 Drain coolingsystem and remove battery 4 Remove all hoses fan shroud disconnect oil cooler lines and remove radiator 5 Disconnect fuel li...

Page 253: ... to aid break in Engine Oil Additive No 1879406 or equiv alent The oil mixture should be left in the engine for a minimum of 500 miles and drained at the next normal oil change 15 Start engine and run engine u n t i l normal operating temperature is reached 16 Inspect ignition timing and adjust carburetor as necessary 17 Adjust accelerator and transmission linkages Road test vehicle ROCKER ARMS AN...

Page 254: ...der head bolts Starting at top cen ter tighten all cylinder head bolts to 50 foot pounds in sequence Fig 6 Repeat the procedure tightening all head bolts to 70 foot pounds 5 Inspect push rods and replace any worn or bent rods 6 Install push rods with small ends in the tappets maintaining alignment using rod Figure 7 7 Install rocker arm and shaft assembly starting each push rod into its respective...

Page 255: ...ol C 3973 over valve stem Fig 9 and install valve 5 The special sleeve places the valve at the cor rect height for measuring with a dial indicator At tach dial indicator Tool 2 3339 to the cylinder head and set it at a right angle to the valve stem being measured Fig 10 6 Move valve to and from the indicator Total dial indicator reading should not exceed 017 inch If the dial indicator reading is e...

Page 256: ...ermal expansion of the valve mechanism during high speed driving 6 The design of the valve mechanism includes a safety factor to allow for a limited amount of wear and the refacing of the valves and seats 7 To insure that limits have not been exceeded the dimension from valve spring seat in the head to the valve tip should be measured with gauge Tool 2 3648 Fig 1 2 8 The end of the cylindrical gau...

Page 257: ...erbore to bring the spring height back to normal 1 53 64 to 1 57 64 inch If spacers are installed measure from the top of the spacer Fig 14 Inspecting Valve Spring Squareness At9 RETAINER I N T A K E VALVE KU 51 Fig 15 Vulve Assembly Disussembled View HYDRAULIC TAPPETS Preliminary to Checkingthe Hydraulic Tappets 1 Before disassembling any part of the engine to correct tappet noise read the oil pr...

Page 258: ...ick will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes In either case tappet assembly should be removed for inspection and cleaning Tappet Removal 1 The tappet can be removed without removing intake manifold or cylinder heads by following this recommended procedure Remove cylinder head covers 2 Remove rocker arms and shaft assembly 3 Remove push rods a...

Page 259: ...operating temperature CAUTION To prevent damage to valve mechanism engine must not be run above fast idle until all hy draulic tappets have filled with oil and have become quiet VALVE TIMING All Models 1 Turn crankshaft until NO 6 exhaust valve is closing and NO 6 intake valve is opening 2 Insert a 1 4 inch spacer between rocker arm pad and stem tip of NO 1 intake valve second valve on the left ba...

Page 260: ...ds 3 16 inch e If chain is satisfactory slide crankshaft oil slinger over shaft and up against sprocket flange away from sprocket f If chain is not satisfactory remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets When installing timing chain use Tool C 3509 to prevent camshaft from contacting the welch plug in the rear of engine block Remove distr...

Page 261: ...E W T REMOVING A INSTALLING P TOOL SLEEVE TOOL CHAIN CASE Fig 25 Removing Oil Seal seal opening inside of chain case cover facing up 7 Place seal in cover opening with neoprene down Place seal installing plate into the new seal with protective recess toward lip of seal retainer Fig 26 The lip of the neoprene seal must be toward source of oil 8 Install flat washer and nut on remover screw hold scre...

Page 262: ...rings with the cam lobes 3 Remove camshaft being careful not to damage Installation 1 Lubricate camshaft lobes and camshaft bearing journals and insert camshaft to within 2 inches of its final position in cylinder block 2 Modify Tool C 3509 by grinding off index lug holding the upper arm on the tool and rotate arm 180 degrees 3 Install Tool 2 3509 in place of distributor drive gear and shaft as sh...

Page 263: ...r oil holes in the camshaft bear ings should be visible by looking down on the left bank oil hole above and between NO 6 and NO 8 cylinders to NO 4 camshaft bearing and on the right bank above and between NO 5 and 7 cylinders to NO 4 camshaft bearings If camshaft bearing oil holes are not in exact register remove and reinstall them cor rectly Use Tool C 897 to install a new welch plug at rear of c...

Page 264: ...oved from the top of the cylinder block When removing piston and connecting rod assemblies from the en gine rotate the crankshaft so each connecting rod is centered in cylinder bore 2 Remove connecting rod cap 3 Install Tool 2 3221 on one connecting rod bolt and protector over the other bolt and push each pis ton and rod assembly out of cylinder bore 4 After removal install the corresponding bear ...

Page 265: ...ston to assume a more nearly round shape It is important that old or new pistons be meas ured for taper and elliptical shape before they are fitted into the cylinder bore SeeFig 37 Finished Pistons All pistons are machined to the same weight in grams regardless of oversize so piston balance can be maintained For cylinder bores which have been honed or rebored pistons are available in standard and ...

Page 266: ...nectingrod When pin falls free from connecting rod stop press 7 Remove tool from piston sembly on a press Fig 40 to prevent damage t o bottomof anvil Installation 1 Test piston pin fit in the piston It should be a PISTON RING FEELER GAGE RING GROOVE J65 A ANVIL TOOL SCREW TOOL ONNECTING ROD KR195B GUIDE LARGE TOOL Fig 39 Tool Arrangementfor RemovingPiston Pin sliding fit in the piston at 70 degree...

Page 267: ...CRANKSHAFT IDENTlFlCATlON IMPORTANT A Maltese Cross stamped on the engine numbering pad Fig 44 indicates that engine is C PRESS MAIN SCREW TOOL PISTON PIN PISTON JVlL fTOOL ORQUE WRENCH ANVIL TOOL MAIN SCREW Fig 43 Testing Fit of Piston Pin in ConnectingRod equipped with a crankshaft which has one or more connecting rods and or main bearing journal finished 001 inch undersize The position of the u...

Page 268: ...rail gaps 2 The oil ring expander ends should be positioned toward the outside of the V of the engine The oil ring rail gaps should be positioned opposite each other and abovethe piston pin holes 3 Immerse piston head and rings in clean engine oil slide ring compressor Tool C 385 over the piston and tighten with special wrench part of Tool C 385 4 Be sure the position of rings does not change duri...

Page 269: ...rom the plain side 1 Start bearing in place and insert Tool C 3059 into oil hole of crankshaft Fig 48 Fig 48 Removing or InstallingUpper Main Bearing 2 Slowly rotate crankshaft counter clockwise slid ing the bearing into position Remove Tool C 3059 Measuring Main Bearing Clearance 3 Smooth edges of a 1 2 x 3 4inch piece of brass shim stock 001inch thickness 4 Install bearing in center main bearing...

Page 270: ...oil the seals will result in an oil leak ENGINE OILING SYSTEM OIL PAN Removal 1 Disconnect battery cable 2 Raise vehicle on a hoist and disconnect steering 3 Disconnect exhaust pipe branches from right 4 Remove clamp attaching exhaust pipe to exten 5 Drain crankcase oil 6 Remove converter dust shield 7 Remove oil pan bolts Turn flywheel until counterweight and connecting rods at front end of crank...

Page 271: ...D WASHERS INNER ROTOR PLUNGER SEAL KR173 RIN Inspection and Assembly 1 Clean all parts thoroughly The mating face of filter base oilpump cover should be smooth Replace filter base if it is scratched or grooved 2 Lay a straightedge across oil pump filter base surface Fig 53 If a 0015 inch feeler gauge can be inserted between the base and straightedge filter base should be replaced COVER STRAIGHT ED...

Page 272: ...ure Relief Valve Inspect oil pump relief valve plunger for scoring and free operation in its bore Small scores may be removed with 400 grit wet or dry paper providing extreme care is used not to round off the sharp edge portion of the valve The relief valve spring has a free length of 2 9 32 to 2 19 64 inch and should test 14 85 to 15 85 lbs when compressed to 1 19 32 inch Discard spring that fail...

Page 273: ...he ventilation system should be in spected at least every six months and the valve re placed once a year preferable to coincide with the CONTROL VALVE u THIS WASHER ISCOLOR V 8 CODED TO IDENTIFY VENT VALVE ASSEMBLY NP126 Fig I Crankcase Ventilation System annual engine performance evaluation This service will be required more frequently if the vehicle is used extensively for short trips driving le...

Page 274: ...he valve replaced once a year preferable to coincide with the annual engine performance evaluation This service extensively for short trips driving less than 10 miles with frequent idling such as city traffic With the engine running at idle remove the venti lator valve and cap assembly from the rocker cover If valve is not plugged a hissing noise will usually be heard as air passes through the val...

Page 275: ...is ob served THE CRANKCASE ventilator valve and associ ated parts should be checked for excessive deposit STANDARD SCREW FITS IN P L Fig 3 Heli Coil Installation Clean the metal housing and reinstall element These services will be required more frequently if vehicle is used extensively for short trips with fre quent idling REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads can be repaired b...

Page 276: ...m to Shaft to Bushing Clearance PISTONS Type Material Clearance in Bore with 0015 x 1 2 feeler stock Land Clearance diametrical Clearance at Top of Skirt Weight Std through 040 oversize Piston Length overall RingGroove Depth No 1 No 2 No 3 Pistons for Service PISTON PINS Type Diameter Length Clearance in Piston Light Thumb Push 70 F End Play Clearance in Rod Pins for Service Number of Rings per Pi...

Page 277: ...rviceAvailable in Standard and the following undersizes MAIN BEARINGJOURNALS CONNECTINGRODJOURNALS Diameter Maximum Allowable Out of Round and or Taper CAMSHAFT Drive Bearings Number Diametral Clearance Maximum Allowable before Reconditioning Thrust Taken By End Play Maximum Allowable Diameter No 1 No 2 No 3 No 4 No 5 Diameter No 1 No 2 No 3 CAMSHAFTJOURNALS CAMSHAFTBEARINGS 010 02 Y 015 055 0015 ...

Page 278: ...VE TIMING TIMING CHAIN TAPPETS CYLINDER HEAD VALVE GUIDES VALVES INTAKE VALVES EXHAUST Lift Zero Lash Number Free Length Load when Compressed to valve closed VALVE SPRINGS Load when Compressed to valve closed Valve Springs I D Maximum Allowable Out of Plumb Valve Spring Installed Height spring seat to retainer Use 1 16 Spacer to ReduceSpring Heightwhen Over Specifications Pump Type ENGINE LUBRICAT...

Page 279: ...ngine serial number M 2 3etc Indicating Crankshaftcounterwight No 2 3 main bearing journal and or R 1 4 etc Indicating No 1 4 connecting rod Journal 010 U S Crankshaft MalteseCross and X M indicates 010 U S all main journals and or R indicating 010 U S all rod journals Following engine serial number Crankshaft counterweight 020 O S Cylinder A Followingengine serial number Bores ENGINE Type Number ...

Page 280: ...ximum allowable Reconditioning Working Limits for taper and out of round Distributor Lower Drive Shaft Bushing press fit in cylinder block CRANKSHAFT MAIN BEARINGS Service CONNECTINGRODSAND BEARINGS Piston Pin Bore Diameter CAMSHAFT Drive Bearings Number Thrust Taken By Clearance Desired Bearing Installed 1 D Minus Journal O D Maximum Allowable Diameter CAMSHAFT BEARING JOURNALS No 1 No 2 No 3 No ...

Page 281: ...S PISTON PINS Type Diameter Length Clearance in Piston lnterfernce in Rod Piston Pins for Service Direction Offset in Piston Number of Rings Per Piston Compression OiI Oil Ring Type PISTON RINGS RingWidth Compression Oil Steel Rails RingGap Compression Oil Steel Rails Ring SideClearance Compression Oil Steel Rails Service Rings RingGap Compression Oil Steel Rails 440 Cubic Inch Power Pack 19 69 77...

Page 282: ... 1 7 16 1 53 64 1 57 64 100 110Ibs 1 55 64 236256 Ibs 1 23 64 1 53 64 1 5764 Type Cast in Head Guide Bore Diameter 374 375 std Number Used 2 Combustion Chamber Wedge Type Valve Seat Runout maximum 002 Intake Valve Seat Angle 45 Intake Seat Width 060 to 085 Exhaust Valve Seat Angle 45 Exhaust Seat Width 040to 06 Y Cylinder Head Gasket Compressed thickness 022 Pump Type Rotor Full Pressure Capacity ...

Page 283: ... INCH ENGINES Torque Foot Pounds Thread Sizes Connecting Rod Nut Plain Cylinder Head Bolt Main Bearing Cap Camshaft Lockbolt Camshaft Thrust Plate Chain Case Cover Clutch Housing Bolt Clutch Housing Vent Hole Clutch Housing Pan Drain Plug Crankshaft Bolt Vibration Damper Cylinder Head Cover Engine Front Mounting To Engine Bosses To Frame To Frame Bracket Stud Engine Rear Mounting To Transmission T...

Page 284: ...Flywheel Housing to Cylinder Block Bolt Flywheel Cover Bolt Fuel Pump Attaching Bolt Alternator Mounting Nut Alternator Adjusting Strap Bolt Alternator Adjusting Strap Mounting Bolt Intake Manifold Bolt Manifold Heat Control Counterweight Bolt Oil Pan Drain Plug Oil Pan Bolt Oil Pump Cover Bolt Oil Pump Attaching Bolt Rocker Shaft Bracket Bolt Starter Mounting Bolt Vibration Damper Bolt Valve Tapp...

Page 285: ...rackets at the top of the tail pipe kick up by flexible double loop type supports A U bolt and saddle clamping arrangement secures the tail pipe to the muffler outlet extension Flexible L shaped supports are used to suspend the rear ends of the tail pipes SERVICE DIAGNOSIS Condition Possible Cause Correction EXCESSIVE EXHAUST NOISE LEAKING EXHAUST GASES ENGINE HARD TO WARM UP OR WILL NOT RETURN TO...

Page 286: ...dy weight from rear springs and remove tail pipe installation 1 Assemble exhaust pipe muffler and tail pipe loosely to permit proper alignment Figs 1 2 and 3 2 Assemble exhaust pipe to exhaust manifolds using new gaskets where necessary Tighten bolt nuts to 35 foot pounds On models with 318 cubic inch engine with ball joint connections at manifold as semble pipe to manifolds but do not tighten bal...

Page 287: ...nder heads der heads Cleaning and Inspection with compressed air 1 Clean exhaust manifolds in solvent Blow dry 2 Inspect manifolds for cracks and distortion 3 On right hand manifold test manifold heat con trol valve Fig 5 or 6 for free operation If necessary to free up apply a suitable manifold heat control valve solvent to both ends of valve shaft A suitable solvent is available under Part Number...

Page 288: ...ad No gaskets are required Tighten stud nuts to 30 foot pounds 2 Install exhaust pipe on exhaust manifolds Tighten nuts to 35 foot pounds 3 Install alternator on right hand cylinder head and adjust belt tension 4 Install spark plug cables on spark plugs MANIFOLD HEAT CONTROL VALVE 318 383 and 440 Cu In Engines Servicing Operation of the manifold heat control valve Figs 5 and 6 should be inspected ...

Page 289: ...In Engine end of shaft by loosening clamp bolt Fig 8 from valve shaft slot 1 Remove counterweight lock and bumper from 2 Unhook thermostat from stop pin and remove Fig 7 Installing xhaust Manifold 3I 8 Cu In Engine BUk ER THERMOSTAT NK121 A L U C K NUT Fig 8 Manifold Heat Control Valve Disasmmbld 1 318 Cu In Engine Cleaning and Inspection 3I 8 Cu In Engine Move valve shaft back and forth and test ...

Page 290: ...lve deposits as outlined on page 5 If fabric on bumper is worn install a new bumper Thermostat Installation 383 440Cu In Engines 1 Be sure shaft retainer is in place on inner end of valve shaft Then turn valve shaft in extreme clock wise position 2 Install a new thermostat in slot in inner end of shaft Fig 12 with outer end in upper left hand position as viewed from right hand side of engine Press...

Page 291: ...ne Exhaust Manifold to Pipe Ball Joint Bolts 318 Cu In Engine Exhaust Pipe Ball Joint Bolts Exhaust Pipe Flange Bolts Nuts Foot Inch Pounds 15 3 0 15 2 5 3 0 3 5 CLAMP BOLT NN209 Fig 14 Installing Counterweigh 383 440 Cu In Engines tioning of valve plate while it isbeing welded to shaft 5 Remove drift from valve plate and shaft 6 Install new thermostat anti rattle spring shaft retainers and counte...

Page 292: ...ose dirt but should not be connectedto the vacuum inlet fitting IMPORTANT If the commercial solvent or cleaner recommends the use of water as a rinse it should be HOT After rinsing all trace of water must be blown from the passages with air pressure It is further advisablet e rinse all parts in clean gasolineor kerosene to be certain no trace of moisture remains Never clean jets with a wire drill ...

Page 293: ... increase in richness lower reading This step is very important since meter reverses its readings and indicates a richer mixture as carburetor is leaned out if carburetor is set very lean c When it has been established that meter is in dicating a lower reading richer mixture when idle mixture screws are turned in richer direction proceed to adjust carburetor to give 14 2 air fuel ratio turn in par...

Page 294: ...ear is apparent replace throttle body assembly d Damagedor worn idle mixture needle d Replaceworn or damaged idle needle Adjust air mixture e Lowgrade fuel or incorrect float level e Test fuel level in carburetor Adjust as necessary to obtain correct float level f Loose main body to throttle body f Tighten main body to throttle body screws securely to prevent air leaks and cracked housings g Worn ...

Page 295: ...n air cleaner b Disassemble carburetor Replace leaking float Test float level and cor rect as necessary to proper level c Adjust float level as necessary to se cure proper level d Test fuel pump pressure Refer to specifications for recommended pres sure If pressure is in excess of rec ommended pressure replace fuel pump assembly e Disassemble carburetor Replace worn metering jet using a new jet of...

Page 296: ...torted rich by b Replace since this problem can be corrected by use of proper choke assembIy c Choke vacuum diaphragm inoperative c Correct or replace d Choke vacuum passage blocked or d Correct a Incorrect gasket or gasket installation a Replace or correct than specified overheating or misadjusted leaking between carburetor and intake mani fold CARBURETOR RICH EXCESSIVESTALLSAFTER COLD START CHOK...

Page 297: ...own draft type Each throat has its own throttle valve idle and main metering systems and are supplemented by the float accelerating and power systems On each BBD series carburetor the model number is stamped on metal tag attached to air horn Do not remove or destroy this tag as it is the only means provided for carburetor model identification Before attempting to repair or overhaul carburetor refe...

Page 298: ... up piston and retaining screw and slide step up piston and rods out of well Fig 2 Lift out step up piston spring Remove step up piston gasket from bottom of well 12 Remove main metering jets Fig 3 13 Remove venturi cluster screws then lift ven turi cluster and gaskets up and away from main body Fig 4 Discard gaskets Do not remove idle orifice tubes or main vent tubes from cluster They can be Fig ...

Page 299: ...n screws lightly Hold up to a strong light to check for a proper position in bore They may have to be rotated slightly as the valves are eliptical When properly positioned tighten screws securely and stake using pliers BODY VENT Fig 5 POrtS in Relation to Throttle Valves 7 Turn idle mixture adjusting screws lightly against their seats with fingers Back off one full turn for approximate adjustment ...

Page 300: ...loat lip toward or away from needle Recheck the 5 16 inch setting again and STEP UP RODS MUST MOVE FREELY NK617 GUIDE SIZE INTERMEDIATE POWER STAGED MIXTURE STEP Fig 7 Step up Rods Free Play FINGER PRESSING FLOAT GAUGE AGAINST FULCRUM PIN RETAINER Fig I Checking Float Setting repeat the lip bending operation as required CAUTION When bending the float lip do not allow the lip to push against the ne...

Page 301: ...B LEVER TANG until correct setting has been obtained Fast ldle Speed and Cam Position Adjustment The fast idle engine speed adjustment should be made on the vehicle as described in the Fast Idle Speed Adjustment On the Vehicle Paragraph How ever the Fast Idle Cam Position Adjustment can be made on the bench This adjustment is important to assure that the speeds of each step of the cam occur at the...

Page 302: ...ces caused by bending operation Repeat adjustment if necessary to provide proper link opera tion TEM ACTED Choke Unloader Wide Open Kick The choke unloader is a mechanical device to par tially open the choke valve at wide open throttle It is used to eliminate choke enrichment during crank ing of an engine Engines which have been flooded or stalled by excessive choke enrichment can be cleared by us...

Page 303: ...and 4 aboveif necessary Measuring Float Setting Onthe Vehicle To measure the float setting with the carburetor mounted on the engine proceed as follows 1 Remove hairpin clip and disengage accelerator pump rod from throttle lever ind pump rocker arm Disconnect automatic choke rod by unsnapping clip 2 Remove air horn attaching screws and lift air horn straight up and away from main body Remove gaske...

Page 304: ...ype 1 Carburetor Adjustments 18 Accelerator Pump and Bowl Vent 1 9 Choke Vacuum Kick 18 Fast Idle Cam Position 18 Fast Idle Speed On the Vehicle 20 Choke Unloader Wide Open Kick 19 GENERAL INFORMATION The WWC3 Series Stromberg carburetor is a dual throat downdraft type with each throat having its own idle system main metering system and throttle valve The idle and main metering systems are sup ple...

Page 305: ...rying out 2 Remove vacuum power piston from air horn using an open end wrench and wood block Fig 5 Exert sufficientpressure on end of wrench to force CHOKE NK419A Fig 3 Removing orInstalling Air Horn ACCELERATOR PUMP PLUNGER Fig 4 Remwing or lnstollhg Accdwator Pump Plunger piston out of its well in air horn This assembly i s staked in air horn and care should be used at removaL Discard air horn g...

Page 306: ...aning and inspection It is usually not advisable to remove the throttle shaft or valves unlesswear or damage necessitatesinstallation of new parts To install new valves or throttle shaft refer to Inspectionand Reassemblyparagraph DISCHARGE ORIFICE SCREWS SHORT Fig 6 Removing or Installing Venturi Cluster Fig 7 Removing or Installing Power BySass Jat INSPECTION AND ASSEMBLY Throttle Body 1 Check th...

Page 307: ...ghtly against their seats then back Main Body follows main body Install two short screws to secure en securely using Tool T 109 173 Fig 8 en securely using Tool 73598 Fig 7 inch in pump well Fig 12 1 8inch in discharge passage Fig 13 To assemble the main body Fig ll proceed as 1 Place a new gasket on throttle body then install 2 Install main metering jets in main body Tight 3 Install power bypass ...

Page 308: ...t weight of floats only i s forcing needle against seat Be sure hinge pin does not drop out of float hinge Hold down with fulcrum pin spring D CHARGE SAGE NK427 Fig 13 lnztalling Discharge Check Ball THE DISCHARGE CHECK BALL NK428 Fig 14 resting Aceelerator Pump Discharge and Inlet Check Balls 2 Using Tool 73725 or a T scale measure float level Fig 15 There should be 5 32 inch from sur face of fue...

Page 309: ...o seal the opening Release the stem If the stem moves more than 1 16 inch in 10 seconds the leakage is excessive and the assembly must be replaced Install the diaphragm assembly on the air horn as follows 1 Assemble to air horn and tighten attaching screws securely 2 Install choke operating link in position between diaphragm plunger stem and choke lever Install clip to secure Be sure link is on th...

Page 310: ...le linkage to its original condi tion if disturbed as suggested in Step No 1 6 Make following check With no vacuum applied to diaphragm the CHOKE VALVE SHOULD MOVE FREELY between open and closed positions If move ment is not free examine linkage for misalignment or interferences caused by bending meration Re WWCLFUEL SYSTEM 14 19 A Wide Open Kick peat adjustment if necessary to provide proper link...

Page 311: ...the ve hicle odometer indicates over 500 miles to insure a normal engine friction level Prepare engine by driv ing at least 5 miles Connect a tachometer and set the curb idle speed and mixture then proceed as follows 1 With engine o f f and transmission in PARK or NEUTRAL position open throttle slightly 2 Close choke valve about 20 degrees then allow throttle to close The fast idle speed screw sho...

Page 312: ...ions respectively Car buretor Models AFB4326S and AF B 4327S are used on the 440 cu in engine High Performance when the vehicles are equipped with the manual or auto matic transmissions respectively The Special CAP Cleaner Air Package Carter carbu retor model AFB4309S is used on the 383 cu inch engine when the vehicle is equipped with a manual transmission The carburetor is supplied with a dash po...

Page 313: ...e five conventional systems are two float systems two low speed systems primary side only two high speed systems one accelerator pump system and one automatic choke control system SERVICE PROCEDURES DISASSEMBLING THE CARBURETOR To disassemble the carburetor for cleaning or over haul Fig 1 proceed asfollows 1 Place carburetor assembly on repair stand Tool C 3400 or T 109 287s elevating legs These t...

Page 314: ...e link from arm and pump stem Slide ac celerator pump plunger and spring out of air horn Remove gasket 4 Place accelerator pump plunger in a jar of clean gasoline or kerosene to prevent leather from drying out 5 Remove fuel inlet fitting and filter screen from air horn 6 Test freeness of choke mechanism in air horn The choke shaft must float free to operate correctly If choke shaft sticks in beari...

Page 315: ...Venturi Cluster Fig 6 Removing or lnstullingSecondary Venturi Cluster The valves are milled to give proper port relation If new throttle shafts should be installed in an old worn body it would be very unlikely that the original relationship of these ports to the valves would be ob tained A very slight change in the port relationship to the valves would adversely affect normal carbu retor operation...

Page 316: ...small clean brass rod hold discharge check needle firmly on its seat Again raise plunger and press downward No fuel should be emitted from either the intake or discharge passage 3 If fuel does emit from intake passage remove intake check ball and reclean the passage Fuel leak age at discharge check needle indicates presence of dirt or a damaged check needle Clean again and then install a new check...

Page 317: ...edle seated slide float gauge refer to specifications for carburetor being worked on be tween top of the float at outer end and air horn gas ket Fig 10 Float should just touch gauge T 10 106 2 Check other float in same manner If an adjust ment is necessary bend float arm using T o o l T 109 22 u n t i l correct clearance has been obtained After bending arm recheck the float alignment FlowDrop Sett...

Page 318: ...g link in position between diaphragm plunger stem and choke lever Install the clip to secure 3 Inspect rubber hose for cracks before placing it on correct carburetor fitting Fig 1 Do not connect the vacuum hose to the diaphragm fitting until after the vacuum kick adjustment has been made See Carburetor Adjustments CARBURETOR ADJUSTMENTS The following adjustments should be made with the carburetor ...

Page 319: ... if disturbed as suggested in step no 1 6 Make following check With no vacuum applied to diaphragm CHOKE VALVE SHOULD MOVE FREELY between open and closed positions If move ment is not free examine linkage for misalignment DRILL OR GAUGE 7 CLOSING PRESSURE ON CHOKE SHAFT LEVER CHOKE LEVER SLOT I DIAPHRAGM STEM MINIMUM OF 10 INCHES OF VACUUM ON TUBE FITTING Fig 14 Checking Choke Vacuum Kick Setting ...

Page 320: ...king Secondary Throttle Adjustment If an adjustment is necessary bend the shoe on the secondary throttle lever using Tool T 10922 until correct clearance has been obtained Secondary Throttle Lock Out Adjustment Crack the throttle valves then manually open and close the choke valve The tang on the secondary throttle lever should freely engage in the notch of the lockout dog Fig 17 If an adjustment ...

Page 321: ...ise richer just enough to regain lost r p m The procedure will assure that the idle has been set to the leanest possible mixture for smooth idle This setting is very important Since the correct speed was originally set using the speed screw the speed obtained after finding the leanest smooth idle setting will probably be too fast 5 Readjust speed screw to obtain correct idle speed Repeat steps 2 a...

Page 322: ...wn on the pump rocker arm On the 383 and 440 cubic inch engine a push rod operates between the camshaft and the fuel pump rocker arm This Page Specifications 50 Testing Fuel Pump on car 32 action lifts the pull rod and diaphragm upwards against the fuel pump main spring thus creating a vacuum in the valve housing and opens the inlet valve and fuel is drawn into the valve housing chamber On the ret...

Page 323: ... start engine and run at 500 r p m The reading should be from 3 1 2 to 5 p s i or from 5 to 7 p s i depending on pump and remain constant or return to zero very very slowly when engine is stopped An instant drop to zero indicates a leaky outlet valve If pressure is too low a weak diaphragm main spring or improper as 64x415 Fig I Fuel PumpAssembly 1383and 440 Cu In Engine sembly of the diaphragm ma...

Page 324: ... The Special CAP CleanerAir Package Stromberg WW3 series carburetor models WW3 274 and WW3 275 are used on the 318 cu in engines when the vehicles are equipped with the manual or automatic transmissions respectively The CAP carburetors are identified by a dab of green paint on the airhorn under the identification number SERVICE PROCEDURES DlSASSEMBLING THE CARBURETOR C 3225 This Tool is used to pr...

Page 325: ...ing or InstallingIdle tubes STER PUMP SAGE Fig 4 Removing or hsfallingDischargeCluster HIGH SPEED BLEEDERS DO NOT REMOVE FROM Fig 5 High SpeedBleeders 10 Lift idle tubes out of main body Fig 3 Theidle tubes are interchangeable 11 Remove screw and gasket from accelerator pump discharge cluster then lift off cluster and gasket Fig 4 12 Invert carburetor main body and drop out ac celerator pump inlet...

Page 326: ... nal relationship of these ports to the valves would be obtained Changing the port relationship would ad versely affect normal car operation between the speeds of 15 and 30 miles per hour However if it has been determined that a new shaft is to be installed adhere closelyto the followinginstructions 2 Mark valves to be sure each is replaced in same bore from whence removed 3 Remove screws that hol...

Page 327: ...lished with a spring loaded two position power jet actuated by vacuum on the power jet piston The purpose of this two stage action is to secure best fuel economy in the lower road load speed range without sacrificing performance in the intermediate speed range During initial or part throttle operation the vacu um above the piston is sufficient to overcome the compression spring and hold the piston...

Page 328: ...r test pour the gasoline from the carburetor bowl and remove the accelerator pump plunger 6 Check float for leaks or damage If satisfactory for further service install in position in carburetor bowl 7 Assemble fuel inlet needle valve seat and gas ket then insert in position in main body Tighten securely If needle is ridged or badly worn install a new needle valve and seat assembly 8 Install float ...

Page 329: ...piston plunger to be sure no binding exists If piston sticks or binds enough to W Fig 15 Bending Float Lip 1 4 x 319 STAKE IN POSITION AFTER INSTALLING P L U N G E R AND SPRING Fig 16 Installing Vacuum PowerPiston hinder smooth operation install a new piston assem bly 5 Slide a new air horn gasket over accelerator pump plunger and down against air horn Now lower air horn straight down on main body...

Page 330: ...RE APPLIED ON CHOKE DRILL O R GAUGE APPLIED ON CHOKE TO VACUUM SO JCHO KE Fig 18 Checking Choke Vacuum Kick Setting 1 If adjustment is to be made with engine running disconnect fast idle linkage to allow choke to close to kick position with engine at curb idle If an auxiliary vacuum source is to be used open throttle valves engine not running and move choke to closed posi tion Release throttle fir...

Page 331: ... Normally the bowl vent clip on the pump stem will be at the middle notch and the pump rod in the medium stroke hole The proper procedure is to adjust the amount of bowl vent opening instead of measuring and setting the height of the pump plunger To check or set the adjustment proceed as follows 1 Back off idle speed adjusting screw Open OnLE IN Fig 20 Checking Bowl Vent Valve Opening choke valve ...

Page 332: ...eanest mixture possible for smooth idle This set ting is very important Since the correct speed was originally set using the speed screw the speed obtained after finding the leanest smooth idle setting will probably be too fast 5 Readjust speed screw to obtain correct idle speed Repeat steps 2 and 4 above if necessary After proper idle speed has been obtained refer to Fig 3 in Throttle Linkage Sec...

Page 333: ...er post and the fin The fuel tank is fitted with a gauge unit including the suction pipe Fig 3 The filter on the end of the suction pipe is replaceable unit and prevents the entry of water and dirt When installing a tank unit be sure the filter is pushed on the end of the tube until seated SERVICE PROCEDURES REMOVING THE FUEL TANK Except CAUTION Be sure the ignition switch is turned off before dis...

Page 334: ...straps in position feeding attaching studs through holes in end of straps Install nuts but do not tighten 5 Guide button head of studs into slots in frame and down into position Tighten hold down strap at taching nuts securely 60in lbs 6 Install filler tube mounting screw and tighten securely 7 Connect lead wire to tank gauge unit reconnect fuel line and ground strap 8 Refill tank and check for le...

Page 335: ...ighten fuel tank hold down strap bolt square 7 Connect fuel line ground strap and lead to gauge unit Install stone shield Reinstall button plugs Refill tank and check for leaks 8 Swing rear axle rearward and connect rear hangers on both springs 9 Connect left rear shock absorber For cleaning fuel gauge refer to the Electrical lY Group 8 Gauges THROTTLE LINKAGE ADJUSTMENT Automatic Transmission Fig...

Page 336: ...hrottle slightly to release fast idle cam then return carbu retor to curb idle 3 Loosen cable clamp nut 4 adjust position of cable housing ferrule 5 in the clamp so that all slack is removed from cable with carburetor at curb idle To remove slack from cable move ferrule 5 in the clamp in direction away from carburetor lever 4 Back off ferrule 5 1 4 This provides 1 4 cable slack at idle Tighten cab...

Page 337: ...s Rich After Approx 500 Miles If Necessary Coil Spring Coil Spring Coil Spring Coil Spring 2 Notches Rich 2 Notches Rich 2 Notches Rich STROMBERG WWC3 SERIES 1 2 INCH CARBURETOR Type Model Engine Displacement cu in Bore a Venturi Main Metering Jet Standard 389323 One Step Lean 389323 Two Steps Lean 389323 Power Jet ADJUSTMENTS Idle Mixture Both Screws Idle Speed rpm With Air Conditioning ON Fast I...

Page 338: ...g Setting 2 Notches Rich 2 Notches Rich After Approx 500 Miles If Necessary CARTER AFB CARBURETOR Standard Type Model Engine Displacement Cu In THROTTLE BORE Primary Secondary Primary Secondary Primary Secondary Primary Standard 1 Size Lean MAIN VENTURI MAIN JET LOW SPEED JET STEP UP ROD 2 Stage 2 Sizes Lean ADJUSTMENTS Accelerator Pump top of plunger to air horn Fast Idle Cam Position drill size ...

Page 339: ...ader 5116 5116 Vacuum Kick drill size 44 44 Bowl Vent Valve Setting 5 32 c 1 64 Fast Idle Speed r p m 1 1400 1400 Idle Speed r p m 650 600 With air conditioning ON 650 600 Float Setting 5116 5116 Float Drop 314 314 Idle Mixture both screws open 1 2 Turns 1 2 Turns Type Well Well ControI Coil Spring Coil Spring Setting On Index On Index STEP UP ROD 2 Stage ADJUSTMENTS 7 16 50 5 32 1 64If Secondary ...

Page 340: ...ll a1x 067 028 x 067 2 Notches Rich On Index 65 035 16 480 16 512 16 513 7116 50 318 118 5 32 1 64 1400 650 650 17164 020 5116 314 1 2 Turns Well Coil Spring On Index Stromberg WW3 Series Carburetor 1 1 4 Type Engine Displacement Cu In 318 318 Model Standard CAP Cleaner Air Package ManuaI Transmission WW3 272 Automatic Transmission WW3 273 WW3 275 Bore 1 7 16 Venturi 1 1 18 1 1 18 Main Metering Je...

Page 341: ...ut the universal joints are slightly larger and have an in creased capacity although the service procedure is the same except where noted Fig 4 SERVICE DIAGNOSIS Condition Possible Cause Correction PROPELLER SHAFT a Undercoating or other foreign matter a Clean exterior shaft and wash with VIBRATI0N on shaft solvent b Loose universal joint flange bolts b Tighten bolt nuts to specified torque c Loos...

Page 342: ...ge SP 5060 from flange adjacent to the vertical wall of oil pan and separate the gauge from engine adapter 5 With gauge SP 5060adjusted for the correct engine angle reference position gauge SP 5060 squarely and firmly along underside of the propeller shaft Fig 7 Make sure Veeway is in alignment and that both adapter pins are contacting propeller shaft Be sure arrow on gauge is pointing toward the ...

Page 343: ...hown in Chart Fig 12 3 Remove gauge SP 5060 from differential and carrier assembly and position it squarely and firmly along underside of propeller shaft Fig 10 Make sure Veeway is in alignment and that both adapter pins are contacting shaft Be sure arrow on gauge is pointing toward the front of car 4 Observe position of bubble in spirit level and compare the position with that shown on Chart Fig ...

Page 344: ...angle 6 To install shims loosen spring U bolt nuts and install shims between rear springs and axle hous ing spring pads 7 Tighten spring U bolt nuts to proper specifi ADAPTER ENGINE ADAPTER DIFFERENTIAL Fig 5 Propeller Shaft Angularity tool C 3976 cations 8 Recheck rear universal joint angle after instal lation of wedge type shim to make sure position of bubble in spirit level is within the accept...

Page 345: ...l joint cross if so equipped CAUTION Do not allow propeller shaft to drop or hang loose from either joint during removal Wire up or otherwise support the loose end of shaft to prevent damage to joint Front Joint All Models 1 Slide propeller shaft with the front yoke from the transmission output shaft Fig 2 Be careful not to damage splines on output shaft or yoke Examine sliding yoke seal for evide...

Page 346: ...versal joint mark yoke cross and bushings to facilitate reassembly if inspectiondiscloses partsare serviceable 2 Remove four bushing retainers from universal joint cross assembly Using a socket approximately the same diameter as bushing press one bushing and roller assembly out of yoke by pressing opposite bushing in 3 Press out remaining bushing and roller as sembly by pressing on end of cross 4 ...

Page 347: ... 3 25 1 318 Cu In Engine Except Station Wagon 3 00 1 3 00 I 3 00 1 383 Cu In Engine Except Station Wagon 3 0 0 1 3 00 I 3 00 1 440 Cu In Engine Except Station Wagon 3 25 1 3 25 1 3 25 1 Station Wagon 3 25 3 25 Manual Transmission 4 Speed Automatic Transmission 3 00 I stat ion Wagon 3 W1 Station Wagon 3 25 1 3 25 1 UNIVERSAL JOINTS Type Front Sliding Spline Cross and Roller Rear Cross and Roller Fr...

Page 348: ...ecessary to replace shock absorbers in pairs Their action does NOT change with use Replace a shock absorber only if it is broken or leaking badly not just damp or has lost resistance in one or both directions due to internal damage Resistance in the rebound direction is usually greater than in the jounce direction Be sure to use the same replace ment part as the original equipment SERVICE DIAGNOSI...

Page 349: ...ding shock absorber in its normal vertical position and alternately extending and com pressing unit There should be no lost motion in either direction 4 Should lost motion be evident hold shock ab Ti KP71 Fig 2 Removing or InstallingShock Absorber Bushing sorber in its normal vertical position and fully extend it 5 Invert unit and compress it Do not extend unit while inverted 6 Repeat steps 4 and ...

Page 350: ...uring rear spring heights vehicle should be placed on a level floor have correct front suspension height on both sides correct tire pres sures no passenger or luggage compartment load and a full tank of fuel 1 Jounce car several times front bumper first Release bumpers at same point in each cycle 2 Measure shortest distance from highest point on underside of rear axle bumper strap at rear of bumpe...

Page 351: ...ng 3 Disconnect rear shock absorber at spring plate lower mounting stud Lower axle assembly permit ting rear springsto hang free 4 To replace front pivot bushing remove rear spring front hanger from body bracket Remove pivot bolt and hanger from spring 5 Place new bushings on Tool C 3709 Fig 5 Arrange tool in spring eye then press out old bushing while pressing new bushing in one operation Using T...

Page 352: ... With spring leaves still separated insert new interliner with retaining buttons i n alignment with locating holes SPEClFlCATlONS REAR SPRINGS NUMBER OF LEAVES Type Standard 318 383 C I Engine Except Station Wagon Standard 440 C I Engine all models Heavy Duty Station Wagon all models Heavy Duty Police and Taxi WIDTH inches LENGTH inches MOUNTING Front Rear Zinc lnterleaf usedwith heavyduty Policea...

Page 353: ...x tends through the housingcover SERVICE DIAGNOSIS Condition Possible Cause Correction HARD STEERING a Low or uneventire pressure a Inflate tires to recommended pres sures b Insufficient lubricant in the steering b Lubricate as necessary gear housing or in steering linkage c Steering gear shaft adjusted too tight c Adjust according to instructions d Front wheels out of line d Align the wheels See ...

Page 354: ...ted The worm bearing pre load adjustment is controlled JSTEERING SHAFT DIE CAST ALUMINUM HOUSING LEIALL BEARINGS RECIRCULATING BALL NUT A F A C R O S S SHAFT Inflate tires to recommended pres sures Balance as necessary See Wheels and Tires Inspectand repair as necessary Replace shock absorbers as neces sary Replace worn parts and adjust ac cording to instructions Replace worn parts See Front Wheel...

Page 355: ...ut rack and sector gear mesh load Readjust cross shaft adjustment screw if necessary to obtain proper torque reading 4 After adjustments have been completed place front wheels in a straight ahead position and with steering gear and steering wheel centered install steering arm on cross shaft 5 Tighten steering arm retaining nut to 120 foot pounds Gear Removal The manual steering gear can be removed...

Page 356: ...aft assembly ina clean place 10 Remove cross shaft needle bearing by placing steering gear housing in an arbor press insert Tool C 3786 in lower end of housing Fig 7 and press both bearings through housing The cross shaft cover as sembly including a needle bearing or bushing is serviced as an assembly 1 1 Remove wormshaft oil seal from wormshaft bearing adjuster by inserting a blunt punch behind 8...

Page 357: ...nit is reconditioned 19 Install cross shaft outer needle bearing by placing bearing on end of Tool C 3333with adapter ring Press bearing into housing to 1 2 inch below end of bore to provide space for oil seal 20 Install inner needle bearing by placing bearing on Tool C 3333 Fig 9 Press bearing into inside end of housing bore flush with inside end of bore surface 21 Install wormshaft bearing cups ...

Page 358: ... Rotate wormshaft to centralize ball nut 38 Place new cover gasket on housing cover 39 Carefully install cross shaft and cover assem bly into steering gear housing Fig 4 The cross shaft and sector teeth should be coated with steering gear lubricant before installing cross shaft in housing 40 Make certain some lash exists between cross shaft sector teeth and ball nut rack Install and tighten cover ...

Page 359: ...g procedure either on the bench or without removing steering gear from vehicle CAUTION When replacing oil seal in vehicle clean the exposed portion of cross shaft to help prolong oil seal life 1 Remove steering gear arm retaining nut and lock washer Remove arm with Tool C 3646 Fig 3 Use Tool C 3880to service cross shaft seal The tool consists of adapter SP 3056 half rings SP 1932 and nut SP 3610 2...

Page 360: ...akage at the lower sector shaft oil seal the sector shaft cover 0 ring 4 Recondition steering gear sures aIly accompaniedby pump noise Pump 1 Gear shaft adjustment too tight 2 Faulty or damaged valve lever 3 External leakage 4 Excessive internal leakage POOR RECOVERY FROM TURNS a Tires not properly inflated b Steering linkage binding c Improper wheel alignment d Damaged steering tube bearing e Ste...

Page 361: ...e of the hoses with components attached to the fen der shield Air in system work steer ing wheel from right to left until the air is expelled b Correct as follows 1 See Gear Shaft Adjustment 2 Recondition steering gear when the steeringwheel is turned b Chucking noise Cause as follows 1 Improper gear shaft adjustment 2 Improperworm shaft thrust bearing 3 Coupling loose on the worm shaft 3 Inspect ...

Page 362: ...urn from this NY1248 P W E R PISTON W Fig 2 Steering Gear Housing RING position and tighten lock nut to 50 foot pounds to maintain this setting Valve Body Recondition 1 Disconnect high pressure and return hoses at the valve body and tie the ends above the reservoir fluid level 2 Remove two screws attaching valve body to main gear housing 3 Lift valve body upward to disengage from valve lever Fig 8...

Page 363: ...orrect When tapping valve down hit valve body on end plug When tapping valve up tap on head of the screw attaching valve 0RINGS PISTON FITTING GASP SCREW KR48A STEERING VALVE BODY body to main valve body Do not hit control valve body 19 Turn steering wheel from stop to stop several times to expel air from system Refill reservoir as required CAUTION Do not turn hard against ends of travel This will...

Page 364: ...t two inches 4 Raise floor carpet and remove three bolts in lower steering column support plate at floor pan 5 Tap coupling and column assembly upward and carefully lift off end of wormshaft 6 Disconnect pressure and return hoses at steer ing gear valve Fasten ends of hoses above fluid level in pump 7 Remove gear shaft nut and washer and remove steering arm from gear shaft with Tool C 3646 Fig 4 C...

Page 365: ...power train It is important that cylinder head center race and spacer assembly and housing head be maintained in close contact with each other This will eliminate the possibility of reaction rings becoming disengaged from their grooves in both cylinder head and housing head It will prohibit center spacer from becoming separated from center race and becoming cocked in housing which may make it impo...

Page 366: ...MyMopar com ...

Page 367: ...the housing head aswm bled in the steeringgear housing 12 Remove large 0 ring from groove in hous ing head 13 Remove reaction seal from groove in face of housing head with air pressure directed into ferrule Fig 16 Removing Reaction Sealfrom Cylinder Heard AIR NOZZLE HOUSINIGHEAD NY1245A chamber Fig 1 5 14 Inspect all grooves for burrs Make sure pas sage from ferrule chamber to upper reaction chamb...

Page 368: ...ing as follows a Slide a new piston ring in place in piston groove then place piston and ring assembly in Tool 2 3676 with lower part of piston and ring resting on land of tool Fig 19 b Press down on piston to seat ring in piston groove forcing open ends of ring out for ease of lock ing the ring 28 Place piston assembly in a vertical position wormshaft up in a vise equipped with soft jaws 29 Inspe...

Page 369: ...stment remains constant after nut is securely locked REAC ION RING KR45B Fig 22 rnstalling Readion Seal Ringin Worm Shaft Support 37 Position spacer assembly over center race en gaging dowel pin of spacer in slot of race and slot of spacer entered over cylinder head ferrule This will align the valve pivot lever hole in the center bearing race with the valve pivot lever hole in center bearing space...

Page 370: ... the valve lever hole in center race and spacer must be Fig 23 Aligning Center BearingSpacer with Steering Valve Fig 24 lndalling Valve Pivot Lever in the up position CAUTION Make sure the cylinder head is bottomed on the housingshoulder Figs 1 and 2 53 Align valve lever hole in center bearing race and spacer exactly with the valve lever hole in the gear housing Turn the housing head by tapping on...

Page 371: ...usting screw until backlash is evident Then retighten adjusting screw until backlash just disappears Continue to tighten for 3 8 to 1 2 turn from this position and tighten lock nut to 50 foot pounds to maintain this setting d Starting from a point at least one full turn of the wormshaft either side of center torque at the sector shaft required to turn the unit through center at 2 rpm in each direc...

Page 372: ...96 can be recognized by the plain end of the shaft visible from the pulley end The second pump is the 1 2 pump and can be identified by a hexagon shaped hole in the pulley end of the shaft Before servicing a power steering pump it is necessary to make the proper identification because some of the special tools and specificationsare different Both pumps are belt driven constant displacement type pu...

Page 373: ...t or grease on pulley and correct Pump hose interference with sheet a Reroute hoses metal or brake lines Belt loose b Adjust belt See Cooling System Pulley loose or out of round Crankshaft pulley loose or damaged Bracket pivot bolts loose Group 7 c Replace pulley d Replace crankshaft pulley e If unableto tighten replace bracket Cap or filler neck leaks a Repair as necessary b Reservoirsolder joint...

Page 374: ... one extreme position to the other Turn the Fig 3 Pressure Ted wheels all the way to one or the other stop momen tarily and note the maximum pressure A pressure of at least the minimum pressure shown for the particu lar pump in Specifications should be read 6 If pressure is under the specified rating the steering system is not functioning properly To deter mine which unit is faulty momentarily clo...

Page 375: ... only otherwise pump body and rotor will be damaged 8 Press pulley hub on shaft with a heavy duty arbor press until hub of pulley is flush with end of I F CONTR LEY 63x665 Fig 7 Pulley fnstallcrtion shaft Fig 7 ket Lubricate zyxw 0 ring before installation screwsto 16foot pounds Cooling Group 7 9 Install new pump 0 ring and reservoir gas 10 Install reservoir and pump brackets Tighten 11 Install pu...

Page 376: ... on plug install in bore with projection OUT 8 Install snap ring with sharp edge UP 9 Install pulley Fig 7 new 0 ring on pump 10 Install pump on engine body new reservoir gasket reservoir and brackets Pressure Relief Valve The pressure relief valve should be replaced as an assembly if pressure test indicates it is incorrectly set or leaking The valve screws out of pump body after brackets and rese...

Page 377: ...ghly with solvent Cleanliness is essential throughout pump assembly Reassemble with new slipper springs if possible 7 Using a piece of wire 25 inches long make three turns around center of rotor fastening ends Fig 13 Bend ends of wire towards pulley end of shaft Use caution in handling rotor to prevent damage to sharp corners which are necessary for good pump performance 8 Install springs by turni...

Page 378: ...per springs are in place by rotating shaft and looking through end of each slipper 15 Lubricate rotor assembly and rotate to make sure slippers do not bind 16 Replace shaft seal See Oil Seal Replace ment and zyxw 0 ring seal on front insert Lubricate and position insert in pump body so punch marks align with punch marks on pump flange Fig 1 0 17 Support pump housing in an arbor press Fig 19 and us...

Page 379: ...ar pins 4 A mounting bracket connecting steering column to the instrument panel which allows the column to slide forward but blocks its rearward movement to ward the driver The center section of the column jacket has dia mond shaped perforations and is formed with accor dion pleats These pleats allow it to compress like a bellows from impact forces The gearshift tube is made up of three short sec ...

Page 380: ...unfit for further use The Special Tools required and their usage are coverad in the following service pro cedures STEERING COLUMN Automatic Transmission Removal 1 Disconnect negative ground cable from bat tery 2 Disconnect shift linkage rod from lever at lower end of steering column 3 Remove steering shaft lower coupling to worm shaft roll pin 4 Disconnect wiring connectors at steering col umn jac...

Page 381: ...move 8 While pulling slightly on wire Fig 7 insert a s m a l l screwdriver with thin blade above and below terminal to release tangs then pull wire from con nector Remove all wires in samemanner 9 Loosen the two bearing housing retaining bolts five complete turns each Fig 8 Unsnap dial pointer from lug on gearshift housing ifzyxwvut so equipped Work bearing housing off end of jacket and carefully ...

Page 382: ...r it should be replaced Assembly Apply a thin coating of Multi Purpose grease to all friction surfaces 1 Coat spring washer with grease and install on lower hub of gearshift housing Support column jacket upright with lower end resting on a wood block and position gearshift housing on the jacket Install shift lever crossover spring and seat in gearshift housing 2 With turn signal wiring threaded th...

Page 383: ...install the anti rattle spring Fig 1 4 Compress spring and push lever inward to align pivot pin hole then install the roll pin 12 Place a new back up lamp switch operating lever Fig 3 in gearshift tube opening Gently tap center pin of lever with a hammer to expand the fingers which hold lever in place With gearshift lever in NEUTRAL position install and adjust switch so actuator arm is snug agains...

Page 384: ...If necessary loosen the bolt and readjust link to alignpointer correctly 8 Attach finish plate to bottom of instrument panel 9 Install turn signal lever 10 Place steering wheel on steering shaft with master splines aligned Install retaining nut and washer tighten nut to 24 foot pounds Do not drive wheel on shaft draw wheel down with retaining nut 11 Install horn switch parts previously removed fro...

Page 385: ... assembly out of column Do not bump or hammer on steering shaft to remove 6 While pulling slightly on wire Fig 4 insert a small screwdriver with thin blade above and below terminal to release tangs then pull wire from con nector Remove all wires in same manner 7 Remove three screws securing lower support in the column jacket Fig 5 slide support and bearing assembly out of jacket Remove low reverse...

Page 386: ...in steps to prevent un seating bolt heads from the slots 4 Install column holding fixture and clamp column in a vise with both ends of column accessible 5 Lubricate floor plate O ring with a soap solution S E L E C T O R SPRING SHIFT T U B E ANDzyxwvu 7 LEVER ASSEMBLY NYLONBUSHING f ND530B Fig RemovingShlft Tube Assembly NUT 2 SPRING WASHER GEARSHIFT HOUSING JACKET A S S E M B L Y Fig 7 Upper End ...

Page 387: ... front wheels in straight ahetd position and master splines on wormshaft and coupling aligned engage coupling with wormshaft and install the roll pin 3 Hold column assembly with bracket against the instrument panel support Install but do not tighten Fig I0 Spreading Tang on Wire Terminal the two uppermost bracket bolts 4 Center steering shaft coupling at midpoint of its travel This is accomplished...

Page 388: ...g Preload 8 to 1 1 in Ibs Pull through high spot POWER STEERING GEAR Type Constant Control Full Time Power Ratio 15 7 to 1 Wheel Turns Stop to Stop 3 1 2 Cross Shaft Bearings 2 Needle Bearings and I Direct Bearingon Gray Iron Cover Worm Shaft Thrust Bearing Pre Load 1624 Ozs Cross Shaft Adjustment Tighten Adjusting Screw 3 8 to 1 2 turn past Zero Back Lash Center of High Spot Fluid Capacity of Hyd...

Page 389: ...g Screw Lock Nut Steering Shaft Coupling Bolts Gear Shaft Cover Nut Valve Body Attaching Bolts Pump Inlet Fitting 30 Valve Body End Plug Steering Arm Nut 120 Steering Wheel Nut PUMPS Foot Pounds 30 Pump Inlet Fitting 30 1 2 Pump Pump to Bracket Bolts Pump Reservoir to Pump Body Bolts Foot Inch Pounds 12 200 200 25 24 Foot Pounds 35 1 15 MyMopar com ...

Page 390: ... in constant mesh and is supported by two rows of needle type bearings at each end The mainshaft front end i s piloted i n roller bear ings in the end of the main drive pinion and i s sup ported by a ball bearing in the rear of the case The rear end of the mainshaft is supported by the sliding yoke and bushing in the extension housing The speedometer drive gear is integralwith the mainshaft SERVIC...

Page 391: ...de tent balls must be engaged to make this adjustment correctly To check this start engine with clutch disengaged then release clutch slowly 2 Inspect fore and aft movement of shift levers in steering column If movement at outer end of levers exceeds 1 16 inch loosen the two upper bushings screws Fig 2 and rotate bushing downward until all free play of levers has been removed Retighten 1ST AND REV...

Page 392: ...interlock when properly adjusted should allow pedal to return to about one inch from the floor SPEEDOMETER PINION Removal zyxw and installation Rear axle gear ratio and tire size determines pinion gear size requirements Refer to Speedometer Pinion Chart for pinion usage 1 Remove bolt and retainer securing speedometer pinion adapter in extension housing Fig 5 2 With cable housing connected carefull...

Page 393: ...propeller shaft at rear universal joint Carefully pull shaft yoke out of transmission extension housing CAUTION Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installationof the shaft assembly 2 Remove extension housing yoke seal Fig 8 TOOL NN361 Fig 8 Removing Extension Housing Yoke Seal with To01C 3985 3 To install a new seal position seal in opening o...

Page 394: ...The measurement of float should be taken before any further disassembly of trans mission is attempted 3 The synchronizer float should be between 050 and 090 inch when measured between synchro nizer outer ring pin and the opposite synchronizer outer ring Fig 11 This measurement must be made on two pins 180 degrees apart with equal gap on both ends for float determination 4 There should be a snug fi...

Page 395: ...ing then partially remove the mainshaft 2 Cock mainshaft then remove clutch sleeve outer synchronizer rings front inner ring and 2 3 shift fork Fig 14 3 Remove clutch gear retaining snap ring Fig 15 Slide clutch gear off end of mainshaft 4 Slide second speed gear stop ring and synchro BEARING 611 SLINGER DRIVE PINION KP172B Fig 134rive Pinion Assembly SLEEVE STOP INNER RING OUTER RING ASSY S NBl2O...

Page 396: ...ever shafts then withdraw levershaft from inside transmission The detent balls are spring loaded as shaft is being withdrawn ball will drop to bottom of the case 3 Remove interlock sleeve spring pin and both balls from the case Fig 19 Drive out remaining tapered pin then slide lever shaft out of transmission 4 Using a suitable drift drive out lever shaft oil seals CLEANING AND INSPECTION Clean tra...

Page 397: ...avy grease and install 22 rollers next to spacer in each end of gear in area around arbor Place a bearing spacer ring in each end of gear next to bearing rollers and install an other row of 22 rollers in each end Coat with heavy grease and install bearing spacer in each end of gear 3 If countershaft gear end play was found to ex ceed 028 inch during disassembly install new thrust washers Coat with...

Page 398: ...l the rf TOOL Fig 20 lnrtalling Dentent Balls way around in groove Fig 15 4 Install 2nd and direct fork in lever shaft Fig 19 Hold synchronizer clutch gear sleeve and two outer rings together with pins properly entered in holes in clutch gear sleeve Engage 2nd and direct fork with clutch gear sleeve 5 While holding synchronizer parts and fork in position slide mainshaft forward entering synchro ni...

Page 399: ...end of main drive pinion shaft pilot bushing in flywheel and on pinion bearing re tainer release bearing sleeve area Do not lubricate end of pinion shaft clutch disc splines or clutch re lease levers 1 Remove transmission from repair stand place it on a suitable jack and slide assembly under vehicle 2 Raise transmission until drive pinion shaft is centered in clutch housing bore 3 Roll transmissio...

Page 400: ...d intothe gear The gearshifting is manually operated through shift control rods to the transmission Any forward gear may be engaged while the vehicle is in motion through the use of synchronizing clutches The transmission may be used as an aid to deceler ation by downshifting in sequence without double clutching or gear clashing due to the fact that all forward speeds are synchronized The reverm s...

Page 401: ...dure Replace thrust washers Inspect mainshaft and synchronizer hub and replace parts as necessary Replace worn gears Replace worn bearing SERVICE IN VEHICLE FOUR SPEED GEARSHIFT Removal tery 1 Disconnect negative ground cable from bat 2 Unscrew gearshift lever knob 3 Raise console lid and remove two screws from rear end of finish plate Raise rear end of plate and work it rearward to disengage from...

Page 402: ...flange portion of lower boot Fig 2 I LEVER ALIGNMENT TOOL I down Ehrough floor opening Insert lever alignment tool through slots in levers making sure its through all levers and against back plate Thisholds the three levers in neutral position 3 With all transmission levers in neutral position adjust length of control rods so they enter trans mission levers freely without any rearward or for ward ...

Page 403: ... 4 Carefully guide front universal joint yoke into extension housing and on mainshaft splines Con nect propeller shaft to rear axle pinion shaftyoke A D A L LOT RING a SEAL I TOOL NP2 Fig blnstalling Speedometer Pinion Seal Fig 7 Removing Extension Housing Yoke Seal SERVICE OUT OF VEHICLE TRANSMISSION REMOVAL nents refer to FOUR SPEEDGEARSHIFT 1 Remove console and Pspeed gearshift compo 2 Drain fl...

Page 404: ...er Plug 9 Gear 2nd Speed 10 Stop Ring 1 1 Shift Plate Springs 12 Clutch Gear 13 Shift Plates 3 14 Shift Plate Spring 15 Snap Ring 16 1st and 2nd Clutch Sleeve 17 Stop Ring 18 1st Speed Gear 19 Bearing Retainer Ring 20 Rear Bearing 21 Snap Ring 24 Baffle 25 Gasket Case to Extension Housing Gear 26 Lockwasher 50 Bearing Spacer 73 Gearshift Control Housing 27 Bolt 51 Countershaft Gear Cluster 28 Exte...

Page 405: ...21 16 TRANSMISSIONA SPEED MANUAL 64X740C MyMopar com ...

Page 406: ...r clutch gear and sleeve slide 3rd and 4th synchronizer assembly off end of mainshaft 6 Slide3rd speed gear and stop ring off mainshaft o not separate 3rd and 4th speed synchronizer clutch gear sleeve shift plates or springs unless in rb GASKET EXTENSION HOUSING 64x741 J f Fig 12demwing or InstallingExtension Houdng Muinshuft Assembly EXTENSION 1ST AND 7ND CLUTCH SLEEVE GEAR 34 TEETH 35 TEETH HOUS...

Page 407: ...faces of the gears Inspect these surfaces for signs of wear scoring or any condition that would not allow shaft to be used at reassembly 12 Using a feeler gauge measure end play of countershaft gear by inserting gauge between thrust washer and gear Fig 20 This measurement should BEARING RETAINING RING 64x746 Fig 17 Removing or Installing Rear Bearing Snap Ring Rear 1ST SPEED G E A R 0 RETAINING RI...

Page 408: ...Pinion and Countershaft Gear 1 Using countershaft arbor C 3938 and a plastic Fig 22 Removing or Indolling Reverse Slider Gear NN45 Fig 23 Reverse Slider Gear Shaft Remover Tool hammer drive countershaft out of case allowing countershaft gear to be lowered to bottom of case Thiswill permit removal of main drive pinion 2 Remove drive pinion bearing retainer attaching bolts then slide retainer and ga...

Page 409: ... locking in gear install a new part Inspect shift forks for wear on the shanks and pads Synchronizer Stop Rings Inspect stop rings for cracks at corners of shift plate indexing slots If rings are cracked or show signs of extreme wear on threaded bore install new rings at reassembly If excessive gear clashing in 1st or 2nd was encountered rough up synchronizer cones on gears with 120 emory cloth an...

Page 410: ...earshaft in position in end of case and drive it in far enough to position reverse slider gear on protruding end of shaft with shift slot toward rear Fig 22 At same time engage slot with reverse shift fork 4 With reverse slider gear correctly positioned drive reverse gear shaft into case far enough to install woodruff key Drive in shaft flush with end of case Fig 22 5 Install back up light switch ...

Page 411: ...REVERSE LEVER REVERSE POSITION REVERSE DETENT RETAINER BALL SPRING I REVERSE I D L E R G E A R DETENT SPRING NNMO P L U G Fig 29 Ist 2nd and Reverse Shift Levers er and nut Tighten nut securely 2 Place a detent ball in the sleeve followed by spring and interlock pin Coat other lever shaft with Multi purpose grease and start shaft into housing Place remaining detent ball on the spring and com press...

Page 412: ...rshift lever and con sole refer to FOUR SPEEDGEARSHIFT 12 Road test vehicle to make sure transmission shifts smoothly and operates quietly 13 If shift linkage requires adjustment refer to page 13 TORQUEFLITE TRANSMISSION A 727 A and B INDEX Page Page General Information 23 70 Hydraulic Control System 25 53 Operating Instructions 34 Installation Transmission and Converter 73 Service Diagnosis 35 Re...

Page 413: ...t Y 4 c Z E LL w z rn 3 CIC c w c 4 a c3 w D C 0 C 0 Y Y E 2 e I al c Y 0 3 0 c m F I t 4 I z U v Y 2 w 5 z w MyMopar com ...

Page 414: ...rque converter assem bly is a sealed unit which cannot be disassembled The transmission fluid is filtered by an internal Dacron Type filter attached to the lower side of the valve body assembly Engine torque is transmitted to the torque con verter then through the input shaft to the multiple disc clutches in the transmission The power flow de pends on the application of the clutches and bands Refe...

Page 415: ...IIICATION 5 30 pd TO LUb 1 1 1 1 1 1 Park Hydraulic Circuits OIL PRESSURES LINE 55 Psi PUMP SUCTION CONVtITEI 30 55 psi LUBRICATION 5 30 psi PUMP CONTROL SYSTEM IN PARK ENGINE RUNNINO NN34A CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING NN35A Neufral Hydraulic Circuits MyMopar com ...

Page 416: ... Izyxwvutsrqp e COOLER TO LUB PUMP GOV VA K OIL PRESSURES LINE 15 prl PUMP SUCTION THROTTLE GOVERNOR 0 75 psi CONVtRTER 30 15 psi LUBRICATION 5 30 ps CONTROL SYSTEM IN DRIVE BREAKAWAY HALF THROTTLE NN36A I I 1 1 1 1 1 I I J Drive Breakaway Hydraulic Circuits MyMopar com ...

Page 417: ... L L U I L F I T O LUB PUMP 1 d z c OIL FILTER OIL PRESSURES LINE 15 pi UY SUClIOW I ittiom COVElWOI D p i I CIS pi e COWElltl 30 75 pi LUBRICAIIOW 1 30 pi CONTROL SYSTEM IN DRIVE SECOND HALF THROTTLE I I Drive Second Hydraulic Circuits NN37A MyMopar com ...

Page 418: ...21 29 FDnVT CLUTCH LUB TO LUB PUMP 1 L J 1 GOV VA OIL FILTER OIL PRESSURES LINE 55 90 psi PUMP SUCTION THROTTLE 0 90 psi GOVERNOR CONVERTER LUBRICAIION 690 psi 30 75 p i I 5 30 pi CONTROL SYSTEM IN DRIVE DIRECT NN38A MyMopar com ...

Page 419: ...N TORQUEFLITE TORQUE 1 CONVERTER n TO LUB PUMP 1 OIL FILTER I OIL PRESSURES LlNt nIri Y GOVflNOR 0 0 psi CONVElTtl WIS psi CONTROL SYSTEM IN DRIVE KICKDOWN AT SO M P H NN39A Drive Kickdown Hydraulic Circuits MyMopar com ...

Page 420: ...xwvutsrqponmlkj 2 KD nSERVO COOLER T O TH LUB OIL FILTER PUMP m OIL PRESSURES LINE 55 psi PUMP IUCIION GOVERNOR 6 51 psi 1 CONVERTER LUIRICATION I CONTROL SYSTEM IN MANUAL SECOND CLOSED THROTTLE NN40A Selector Lever Second Hydraulic Circuits MyMopar com ...

Page 421: ...LITE I TORQUE CONVERTER TO OIL PRESSURES Lllf pl m P ruw sumow M V f U O U 0 3opsi 1 O l f U T I U 7S pl 1 tunicmow zyx s a pl CONTROL SYSTEM IN MANUAL LOW CLOSED THROTTLE NN41A Selector Lever Low Hydraulic Circuits MyMopar com ...

Page 422: ...EFLITE TRANSMISSION 21 33 TORQUE CONVERTER 1 A PUMP OIL PRESSURES LlNf 230 260pi PUMP SUCTION I CONVtRTfR 30 15 psi I LUBRICATION 5 30 psi I CONTROL SYSTEM IN REVERSE NN42A Rwersa Hydmulfc Cfrcufts MyMopar com ...

Page 423: ... rect The second function of the shuttle valve is to regulate the application of the kickdown servo and band when making direct to second kickdowns Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are re leased by spring tension when hydraulic pressure is released On the 2 3u...

Page 424: ...t c d Valve body malfunction or leakage d e Accumulator sticking broken rings e f Low reverse servo band or linkage f g Worn or faulty front and or rear g DELAYED ENGAGEMENT a Low fluid level a1 b Incorrect gearshift control linkage b or spring malfunction clutch IN D 1 2 AND R adjustment Hydraulic pressurestoo high or low c Oil filter clogged C d Valve body malfunction or leakage e Accumulator st...

Page 425: ...Valve body malfunction or leakage Accumulator sticking broken rings or spring Clutches or servos sticking or not operating a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A b Adjust throttle linkage c Adjust kickdown band d Perform hydraulic pressure tests and adjust to specifications e Remove and clean governor Replace parts if necessary 0 Perform pressure tests to deter...

Page 426: ...nd replace seal rings as re quired also inspect respective bores for wear Replace parts as required a Low fluid level a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A b Aerated fluid b Inspect for air leakage into pump suc tion passages c Incorrectthrottle linkageadjustment c Adjust throttle linkage d Incorrect gearshift control linkage d Adjust control linkage e Hydraul...

Page 427: ...w fluid level a Refill to correct level with Automatic Transmission Fluid AQ ATF Suffix A b Hydraulic pressurestoo low b Perform hydraulic pressure tests and adjust to specifications c Oil filter clogged c Replace oil filter d Valve body malfunction or leakage d Perform pressure tests to determine cause and correct as required e Faulty oil pump e Perform hydraulic pressure tests ad just or repair ...

Page 428: ...t bearing and or bushing damaged Governor support binding or broken seal rings Oil pump scored or binding Front and or rear clutch faulty Planetary gear sets brokenor seized a Adjust kickdown band b Adjust low reverse band c Remove extension housing and re place bearingand or bushing d Inspect condition of governor support and repair as required e Inspect condition of pump and repair as required f...

Page 429: ...ed in the aluminum case and valve body and the necessary tools and inserts for the repair of damaged or worn threads Heli Coil tools and inserts are readily available from most automotive parts jobbers Some thread drag may occur in screwing a bolt into the installed Heli Coil insert Therefore a torque reading should be taken of the thread drag with an inch pound torque wrench and added to the spec...

Page 430: ...tic Transmission Fluid AQ ATFSuffix A into the transmission 8 Start engine and allow to idle for at least two minutes With parking brake on move selector lever momentarily to each position ending in the neutral position Fig 4 Gearshift Linkage 9 Add sufficient fluid to bring fluid level to the ADD ONE PINT mark 10 Recheck fluid level after transmission is at normal operating temperature The level ...

Page 431: ...taining screws raise console enough to disconnect dial lamp and other electrical connec tions then lift off console assembly 4 Disconnect back up lamp switch wires Fig 6 5 Disconnect upper rod from gearshift unit Fig 8 Remove four gearshift to floor bracket bolts and remove unit lnsfallation 1 Install gearshift unit in its bracket install and tighten four retaining bolts securely Fig 8 Attach uppe...

Page 432: ... page51 BAND ADJUSTMENTS Kickdown Band The kickdown band adjusting screw is located on left side of transmission case near the throttle lever SEAL ASSEMBLY SWlTCG Fig 9 Neutral Starting Switch 64x4 Fig IO Bottom View of Transmission Pan Removed shaft Fig 5 1 Loosen lock nut and back off approximately five turns Inspect adjusting screw for free turning in the transmission case 2 Using wrench Tool C...

Page 433: ... 12 by pushing rearward on rod with a slight effort and turning the threaded ad justment 1 The rear end of slot should contact car buretor lever pin without exerting any forward force on pin when slotted adjuster link 1 is in its normal operating position against lever pin nut 7 Assemble slotted adjustment 1 to carburetor lever pin and install washer and retainer pin zy As semble transmission link...

Page 434: ...linkage from transmission throttle lever and move throttle lever gradually to full throttle position Line pressure must rise to a maximum of 90 96 psi just before or at kickdown into low gear Front servo release pressure must fol low line pressure up to the kickdown point and should not be more than 3psi below line pressure If line pressure is not 54 60psi at 1 000rpm adjust pressure as outlined o...

Page 435: ...en the manual valve valve in 1 low position and line pressure adjusting screw Fig 14 This measurement must be 1 7 8 inches correct by looseningspring retainer screws and repositioningthe spring retainer The regulator valve may cock and hang up in its bore if spring retainer is out of posi tion I f line pressure is not correct it will be necessary to remove valve body assembly to perform the ad jus...

Page 436: ...cessive oilleaks Rear Clutch Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating zyxw Also check for excessive oil leaks If a dull thud cannot be heard in clutches place finger tips on clutch housing and again apply air pressure Movement of piston can be felt as clutch is applied Kickdown Servo Direct air pressure into front serv...

Page 437: ...inch pounds la SPEEDOMETER PINION CHART TORQUEFLITE A 727 A and B OUTPUT SHAFT DRIVE GEAR 13 TEETH tire Axle Ratios Number of Pinion Gear Teeth and Color Size 2 7 6 l 2 9 4 l 3 2 3 l 8 2514 27 White Black 32 Black 8 5514 26 Red 28 B Iue 31 Green 7 75 15 27 White Black 32 Black 8 1515 27 White 28 Blue 31 Green 8 4515 Red 28 8Iue 31 Green EXTENSION HOUSING YOKE SEAL Replacement 1 Disconnect propelle...

Page 438: ...nap ring and re move bearing from the shaft Fig 24 2 If removed install snap ring in front groove on output shaft Install a new bearing on shaft with outer race ring groove toward front Fig 24 then install rear snap ring NOTE To replace the extension housing bushing refer to Page 60 lnstallation 1 Place a new extension housing gasket on the transmission case Position output shaft bearing re tainin...

Page 439: ... with passage in the support 2 Position support and governor assembly on out put shaft Align assembly so governor valve shaft hole in governor body aligns with hole in the output shaft then slide assembly into place Install snap ring be hind governor body Fig 25 Tighten body to support SPRING RINGS s OUTER WEIGHT INNER WEIGHT CONTROL ROD NN78A Fig 27 Parking lock Components bolts to 100 inch pound...

Page 440: ...e with knob posi tioned against the reaction plug and sprag Move front end of rod toward center of transmission while exerting rearward pressure on the rod to force it past the sprag Rotate propeller shaft if necessary 2 Install accumulator piston in the transmission case 3 Position accumulator spring on the valve body 4 Place the valve body manual lever in LOW posi tion Lift valve body into its a...

Page 441: ...e of transmission bell housing 12 Disconnect oil cooler lines at transmission and remove oil filler tube Disconnect the speedometer cable 13 Disconnect propeller shaft at rear universal joint Carefully pull shaft assembly out of the exten sion housing 14 Remove rear mount to extension housing bolts 15 Install engine support fixture Tool C 3487and raise engine slightly 16 Remove crossmember attachi...

Page 442: ...rsection of gear and front cover from an angle of 45 degrees from rear face of the gear 4 Inspect gear teeth and remove all nicks where metal is raised weld metal splatter etc in order to ensure quiet starter operation TORQUE CONVERTER FLUSHING In the event that any part has failed in transmission the torque converter should be flushed to insure that fine metal particles are not later transferred ...

Page 443: ... when major parts are replaced 1 Attach a dial indicator to transmission bell housing with its plunger seated against end of input shaft Fig 3 4 Fig 33 InrtalNng Pump Oil Seal a r TRANSMISSION VENT SHIELD I Fig 34 Mearuring D r h Train End Play 2 Chuck input shaft in and out to obtain end play reading 3 Record the indicator reading for reference when reassembling the transmission The end play spec...

Page 444: ...on housing mounting pad Spread large snap ring from output shaft bearing with Tool C 3301A Fig 2 3 With snap ring spread as far as pos sible carefully tap extension housing off the output shaft and bearing 4 Using heavy duty snap ring pliers C 4020 re move output shaft bearing rear snap ring Remove bearing from shaft then remove front snap ring Governor and Support 1 Carefully pry snap ring from w...

Page 445: ...nsmission case Fig SP Compressing Kickdown Servo Spring low and Reverse Servo 1 Compress low and reverse servo piston spring by using engine valve spring compressor Tool C 3422 then remove snap ring 2 Remove spring retainer spring and servo pis ton and plug assembly from the case RECONDITION SUB ASSEMBLIES The following procedures cover disassembly in spection repair and assembly of each subassemb...

Page 446: ...as an interference thread and does not turn easi ly on the screw 4 Slide regulator valve out of valve body Slide torque converter control valve out of valve body 5 Remove 17 transfer plate retaining screws Carefully lift transfer plate and steel separator plate assembly off the valve body 6 Invert transfer plate assembly and remove the stiffener plate Remove remaining screws securing separator pla...

Page 447: ... for being bent worn or loose If a lever is loose on its shaft it may be silver soldered only or the lever and shaft assembly should be replaced CAUTION Do not attempt to straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with cro cus cloth using only a very light pressure Using straightedge Tool C 3335 inspect all mating surfaces for wa...

Page 448: ...erefore a valve body that was functioning properly when vehicle was new will operate correctly if it is properly and thoroughly cleaned There is no need to replace the valve body unless it is damaged in handling Assembly 1 Place separator plate on the transfer plate Fig 42 Install stiffener plate and retaining screws Make sure all bolt holes are aligned then tighten stiffener plate screws to 28 in...

Page 449: ...king sure converter valve spring is engaged on the tang and position squarely in the retainer Tighten the three retaining screws to 28 inch pounds Measure and if necessary align spring retainer as described on Page 46 16 Install the oil filter and tighten the three r e taining screws to 28 inch pounds WASHERA N D S E TOOL After valve body has been serviced and complotoly assembled adjust the throt...

Page 450: ...ide governor weight remove inner weight and spring from the outer weight 3 If the lugs on parking gear are damaged re move the four bolts and separate support from the governor body Cleaning and lnspection Figure 26 shows a disassembled view of the gov ernor assembly Inspect all parts for burrs and wear Inspect inner weight for free movement in the outer weight and outer weight for freemovement in...

Page 451: ...cing Pump Bushing L d 1 Fig 51 Staking Pump Bushing with the rotor cavity down 2 Place removing head Tool SP 3550 in the bush ing and install handle Tool SP 3549 in the removing head Fig 50 3 Drive bushing straight down and out of the bore Be careful not to cock tool in the bore 4 Position a new bushing on the installing head 5 With pump housing on a smooth clean surface hub end down start bushing...

Page 452: ...e over the vent opening Install retaining bolts and tighten to 150inch pounds 3 Place a new oil seal in opening of pump housing lip of seal facing inward using Tool C 3860drive seal into housing until tool bottoms FRONT CLUTCH Disassembly Figure 53 shows a disassembled view of the front clutch assembly 1 Remove large selective snap ring that secures pressure plate in the clutch piston retainer Lif...

Page 453: ...tainer bore Be careful not to cock tool in the bore 3 Lay clutch retainer open end up on a clean smooth surface Slide a new bushing on installing head Tool SP 3628 and start them in clutch retainer TOOL HAN SP 3549 FRONT CLUTCH RETAINER REMOVER HEAD SP 3629 BUSHING INSTALLING HEAD SP 3628 NDSSO Fig 55 Repkacing Front Clutch Retainer 8ushing bore 4 Install handle Tool SP 3549in the installer Fig 55...

Page 454: ...CLUTCH Fig 58 Front Clutch Piston Return Spring Locution 8 Springs clutch assembly 1 Remove large selective snap ring that secures pressure plate in clutch retainer Lift pressure plate clutch plates and inner pressure plate out of the retainer 2 Carefully pry one end of wave spring out of its groove in clutch retainer then remove wave spring spacer ring and clutch piston spring 3 Invert clutch pis...

Page 455: ...ocks make sure they turn by hand Fig 61 4 Using a wrench screw remover into bushing 3 to 4 additional turns to firmly engage threads in the bushing 5 Turn hex nut down again cup to pull bushing from the input shaft 6 Thoroughly clean input shaft to remove chips made by removed threads Make certain small lubri cation hole next to ball in end of shaft is not plugged with chips Be sure no chips are l...

Page 456: ...e 6 Install inner pressure plate in clutch retainer with raised portion of plate resting on the spring 7 Lubricate all clutch plates install one lined plate followed by a steel plate until all plates are installed Install outer pressure plate and selective snap ring 8 Measure rear clutch plate clearance by having an assistant press downward firmly on the outer pressure plate then insert a feeler g...

Page 457: ... gear lnspection Inspect bearing surfaces on output shaft for nicks burrs scores or other damage Light scratches small nicks or burrs can be removed with crocus cloth or a fine stone Inspect speedometer drive gear for any nicks or burrs and remove with a sharp edge stone Make sure all oil passages in the shaft are open and clean Inspect bushings in sun gear for wear or scores replace sun gear asse...

Page 458: ...and drive cam from the case Fig 66 Alternate the punch from one bolt hole to another so cam will be driven evenly from the case IMPORTANT The output shaft support must be in the case to install the overrunningclutch cam If the support requires replacement drive it rear ward out of the case with a wood block and hammer SUPPORT i NN129 zyxwvut A OUTPUT NN13O Fig 67 Installing Output Shaft Support To...

Page 459: ...is ton Inspect piston bore in the case for scores or other damage and springs for distortion Inspect band lining for wear and bond of lining to the band If lining is worn so grooves are not visible at ends or any por SNAP RING NDlM Fig 70 Kickdown Servo tion of band replace the band Inspect band for dis tortion or cracked ends Assembly secure with snap ring 1 Install piston plug and spring in the ...

Page 460: ...ance for the low and reverse drum Install ADJUSTING S C R E W AND LOCKNUT LEVER SHORT zyxwvut 0 RING A ND21 LINK AND ANCHOR Fig 73 Low Reverse Bandand Linkage with transmission in an upright position If transmission repair stand DD 1014was not avail able to support transmission an alternate method is outlined in Steps 1and 2 1 Cut a 3 1 2 inch diameter hole in a bench in the end of a small oil dru...

Page 461: ...vernor valve on valve shaft insert the assembly into the body and through governor weights Install valve shaft retaining snap ring Output Shaft Bearing and Extension Housing 1 Install a snap ring in the innermost groove on the output shaft Install bearing on the shaft with its outer race ring groove toward the front Fig 24 Press or tap bearing tight against front snap ring then install rear snap r...

Page 462: ...haft and reaction shaft Make sure converter im peller shaft slots are also vertical and fully engage the pump inner rotor lugs Inspect for full engagement by placing a straight edge on face of the case Fig 77 The surface of converter front cover lug should be at least 1 2 inch to rear of straightedge when converter is pushed all way into the transmission 3 Attach a small C clamp to edge of convert...

Page 463: ...xtension housing and on the output shaft splines Then connect propeller shaft to the rear axle pinion shaft yoke 15 Connect oil cooler lines to the transmission Install the oil filler tube Connect the speedometer cable 16 Connect throttle rod to bellcrank at left side of transmission bell housing 17 Connect wire to the neutral starting switch 18 Install cover plate in front of the converter assemb...

Page 464: ...es Rear Snap Ring Selective SNAP RINGS Output Shaft Forward End TIGHTENING THRUST WASHERS Reaction Shaft Support to Front Clutch Retainer Selective Output Shaft to Input Shaft Plate Steel 1 Shell Gear Support Driving Shell Thrust Rear Planetary Gear to Driving Front Planetary Gear to Annulus Front Annulus Gear to Front Clutch to Rear Clutch Rear Planetary Gear to Driving Shell Annulus Gear REFEREN...

Page 465: ... Support Bolt Kickdown BandAdjusting Screw Lock Nut Kickdown Lever Shaft Plug Neutral Starter Switch FOOT 14 55 24 35 75 29 2530 INCH 75 270 100 150 Oil Filler Tube Bracket Bolt Oil Pan Bolt Oil Pump Housingto Transmis sion Case Bolt Output Shaft Support Bolt OverrunningClutch Cam Set Screw Pressure Test Take off Plug Reaction Shaft Support to Oil Pump Bolt Reverse Band Adjusting Screw Lock Nut Sp...

Page 466: ... will have longer life than tires used for high speed driving in hot climates with heavy loads Abrasive road surfaces will accelerate tire wear Driving habits have more effect on tire life than any other factor Careful drivers will obtain in most cases much greater mileage than severe or careless drivers Rapid acceleration and deceleration severe application of brakes high speed driving taking tur...

Page 467: ...also keep for eign material out of the valve L f l fROW RIQHT FRONT Tire Rotation Under normal operating conditions it is recom mended that tires be rotated at every second oil change This reduces the possibility of tire noise and equalizes tire wear Figure 1is the recommended se quence for the rotation of tires Under conditions of severe service trailer towing they should be rotated more frequent...

Page 468: ...types of abnormal tire wear with their causes and corrective action are shown in Fig CRACKED TREADS 3 CONDITION CAUSE CORRECTION WEAR ON ONE SIDE Underinflation For the maximum results in stability and handling ride quality and tire life tire inflation pressures should not be allowed to go below the recommended inflation pressures When a tire is underinflated this results in much faster wear of th...

Page 469: ... A wheel not in dynamic balance can produce wobble or shimmy Correction for static unbalance is made by first finding the location of the heavy spot then adding sufficient weight to counterbalance it follow the equipment manufacturers recommendations Half the balance weight should be added to the inside of the wheel and the other half to the out side Fig 4 Safety Type Rim TIRE AND WHEEL RUNOUT Whe...

Page 470: ...ly hang by brake hose as possible brake hose damage may result 6 Remove thrust washer and outer bearing cone 7 Slide wheel hub and drum assembly off the spindle 8 Drive out inner seal and remove bearing cone Cleaning and lnspection 1 Clean the hub and drum assembly and the bear ings in kerosene mineral spirits or other similar cleaning fluids Do not dry the bearings by air spin ning 2 Examine bear...

Page 471: ...ecifications 9 Install tire and wheel and tighten wheel nut Adjustment 1 Tighten wheel bearing adjusting nut to 90 inch poundswhile rotating wheel 2 Position nut lock Fig 7 on nut with one pair of slots in line with cotter pin hole 3 Back off adjusting nut lock assembly one slot and install cotter pin The resulting adjustment should be zero no preload to 003inch end play 4 Clean the grease cap coa...

Page 472: ...ot Inch Wheel Bearing Nut With Wheel Spinning Wheel Stud Nut 65 90 Vehicle Full Rated Load Lbr RecommendedFor 5 Pass or less The factory installed tires on your car are selected to provide adequate load carrying capacity for all vehicle loads up to the full rated capacity of your car as indicated in the table for the designated models Front Rear Front Rear DODGE Sedans Hard Top Convertible 28 28 2...

Page 473: ... front passenger compartment and is bolted to the Unibody MAINTENANCE AND CARE APPEARANCE DRAIN HOLES LUBRICATION INDEX Page Page APPEARANCE Headliners 3 ACRYLIC FINISHES 4 Kick Pad Panels 3 BRIGHT METALS 4 Luggage Compartment 3 CONVERT1BLE Package Shelfs Backlight 2 Sealers Leather and Vinyl 3 Boot 2 Seats 3 Top Spots and Stains 2 Well Test for Material Type 2 2 2 GLASS 4 POL1SHING INTERIOR TRIM ...

Page 474: ...iner etc remove as many spots as possible Use a putty knife to break up and remove en crusted foreign matter Vacuum thoroughly Apply the recommended spot removing agent with a clean cloth or sponge Work in a wide circle to prevent making a ring and work toward center Surface Spots Brush out with a small hand brush using care not to damage fabric when brushing Deep Penetrating Spots Apply the spot ...

Page 475: ...ned dirt by rubbing area briskly with a clean cotton towel or soft rag Make final strokes in one direction Nylon or Synthetic Fabrics For average conditions use methods and materials used in washing cloth up holstery When material is extremely dirty use multi purpose cleaner full strength and a stiff scrub brush Scrub thoroughly in all directions Wipe off dirt and excess cleaner with a clean cotto...

Page 476: ...are not to rub through the anodized coating Bumpers grilles exterior mouldings wheel covers mirrors etc should be thoroughly cleaned at least twice a year The product manufacturer recommendations should always be followed Clean metal thoroughly remov ing all traces of cleaner from corners etc After cleaning apply and rub out a coat of good body wax to the bright metal During winter months and in a...

Page 477: ... 28 28 28 28 28 28 30 30 30 30 22 22 24 24 25 24 25 25 14 26 26 27 14 19 14 17 17 18 19 16 14 14 14 15 15 19 Page Belt Outer 21 Roof Rail 21 Sedan Station Wagon 21 Hardtop Convert ible 21 Windcords 21 Alignment 10 Replacement 10 Wheelhouse 1 1 Fresh Air Inlet Vent 6 Rear Outlet System 7 Actuator 8 Drain Valves 8 Vent Doors 7 FRESH AIR VENT 6 GRILLE 12 HOOD Alignment 8 Hinge 10 Lock 9 Replacement 9...

Page 478: ...exhaust vent doors are installed in a plenum chamber at the rear of the shelf panel and are operated by a vacuum switch mounted in the in strument panel A vacuum actuator mounted in the plenum chamber controls door movement Drain valves connected to the plenum chamber outlets by flexible hoses are mounted to the floor pan in the luggage compartment FRESH AIR INLET VENT CONTROL CABLE Replacement Th...

Page 479: ...oved 2 Position seal in line with outer edge of housing flange Fig 3 3 Position fresh air door on cowl side panel and align attaching holes 4 Install attaching screws and tighten progres sively 5 Insert actuator cable assembly through hole in door frame flange and install coiled end of cable over pin on door 6 Position clip over cable and attach to door bracket 7 Adjust vent door cable housing 8 I...

Page 480: ...uator Drain Valves ward and inboard board flexible hoses secure with clamps valves securing with clamps panel on shelf panel 6 Install right valve on floor pan to point rear 7 Install left valve to point forward and out 8 Assemble clamps in 1st or 2nd convolutions of 9 Slide hoses on outlets of plenum chamber and 10 Use care not to twist hoses and install on drain 11 Test operation of vent system ...

Page 481: ...block gently apply pressure to hood 3 Repeat operation about every six inches un til contour of fender and hood conform evenly REPLACEMENT Removal 1 Place a protective covering over cowl and fender area 2 Mark outline of hinges on hood to aid in instal lation 3 Use extreme care not to permit hood to slide rearward and damage painted surfaces of the cowl and fender areas when removing hood bolts ln...

Page 482: ...sen fender to cowl attaching screws Protect fender edge with a cloth pad and position a floor jack under bottom rear edge of fender Raise jack until bottom edge of fender is in line with bottom edge of sill panel Tighten fender screws and remove jack Fender To Door Spacing If hood projects beyond front fender and fender to door spacing is too close the fender can be shifted slightly forward 1 Loos...

Page 483: ...move the bumper and fender The wheelhouse at the front end is attached between the frame and radiator yoke Figs 10 and 11 When installing wheelhouse make sure it is correctly aligned before tightening screws RADIATOR CORE SUPPORT FENDER FLANGE d lnstallation 1 Position core suppolt on frame and install frame to support screws finger tight to support screws finger tight only progressively with plas...

Page 484: ... avoid stressing or fracturing the die cast metal zyx v NP308 Fig 17 Orille Attaching Points DOORS Service procedures for internal door components do not include obvious operations such as removing door or quarter panel trim panels testing operation of windows or inspecting glass fit after adjustments or replacements have been performed ALIGNMENT Front Door Up and Down Up or down adjustment of the...

Page 485: ...ing In and Out Raising outer end of door will move upper part of door into door opening 1 With door in full open position place a wooden block on lifting plate of a floor jack and position it under outer edge of door 2 Loosen upper hinge to pillar bolts 3 Raise or lower jack until upper part of door 4 Tighten upper hinge to pillar bolts 5 Loosen lower hinge to pillar bolts 6 Raise or lower jack un...

Page 486: ...or open ing 2 Position hinge plates on door panel and install screws finger tight only 3 Adjust jack to align hinge plate scribe marks and tighten screws Prior to this installation on electric window lifts install wiring in doorsand attach to motor and control switch 4 Complete door aligning procedure and install interior trim and hardware REAR DOOR All Models Removal near the hinges 1 Open door a...

Page 487: ... BODY NP307 Fig 23 Arm Rest Applications INNER PANEL MONACO 2 DOOR HT VIEW CIRCLE A NN621 Fig 24 Front Door Trim Panel retaining clips between trim panel and door frame Snap retaining clips out of door panel and remove panel 4 Before installing trim panel inspect condition of watershield Fig 2 6 5 Align trim panel retaining clips with holes of door frame and bump into place with heel of hand 6 Ins...

Page 488: ...mote control screws Figs 27 and 28 rod front door only to lock assembly link to lock lnstallation nect link to control lever control LOCK REPLACEMENT Removal from lock by pulling link outward at lock from lock 1 Disconnect handle to lock link Figs 27 and 28 2 Disconnect locking lever rod front door only 3 Disconnect lock control rod from lock 4 Remove lock to door screws 5 Rotate lock and disconne...

Page 489: ...Y OPERATED I I RY Fig 30 Electric Door Lock System 3 On 2 door models Fig 29 connect cylinder link to cylinder position link bracket on door face and install screws Connect lock link to lock ELECTRIC DOOR LOCKS Fig 30 All doors may be locked or unlocked either me chanically or electrically To lock mechanically push the front door handle to the forward position and depress the rear door locking but...

Page 490: ...o load or 11 4 when locks are activated indicates a shorted solenoid A higher voltage reading indicates an open circuit To determine which solenoid is faulty disconnect the solenoid connectors one at a time while operat ing the door lock switch When faulty solenoid is disconnected the remaining door lock will operate SOLENOID REPLACEMENT Removal 1 Disconect link at solenoid Figs 33 and 34 2 Remove...

Page 491: ...osition re move retainer from link at handle connector Fig 37 2 Depress outside handle release button and re move link from handle connector 3 Remove handle to door nuts 1 Position handle in door and install mounting 2 Depress handle button and position link over 3 Install retainer over link and connector Installation nuts connector on handle WEATHERSTRIPS AND WINDCORDS Door Weatherstrips Make sur...

Page 492: ...MyMopar com ...

Page 493: ... inner lip When the up stop roof rail weatherstrip and glass are properly adjusted the outer lip of weatherstrip will seal along the top edge of the glass and the in ner lip of weatherstrip will seal along the upper inside edge of glass Outer Belt Weatherstrip INDEX Fig 39 Door Weatherstrips Sedan Station Wagon strip with fasteners 3 Index and install weatherstrip on door using fasteners as a loca...

Page 494: ...oves in run freely 3 Run window down until top of glass is even or Front Door Glassand Vent Wing Adjustments justment points halfway stop against bumper slightly below belt line of door outer panel 4 On manually operated windows position stop on regulator plate against stop on regulator sector 5 On electrically operated windows position down Refer to Fig 45 for door glass and vent wing ad 1 Open d...

Page 495: ...rss Adjustments Sedan Removal 1 Lower door glass fully and remove approxi mately four 4 inches of glass run at forward end 2 Remove screws attaching vent wing to facing of door and to belt line 3 Move glass forward and disengage regulator arm from lift bracket and guide assembly 4 Remove vent wing swivel to regulator screw 5 Remove glass and vent wing from door 6 Separate door glass and vent wing ...

Page 496: ...ry should be fully charged and the ter minal clean and tight before any tests are performed Wire connections at the ammeter and accessory circuit breaker mounted on the left cowl panel should be tight Vent wing motors have two separate field windings known as split series Direction of rotation is con trolled by energizing either field with the switch The fields are grounded to body through the mot...

Page 497: ...uld run To reverse direction of motor rotation switch leads of jumper wires at test battery terminals Vent Wing Motor Connect a jumper wire from positive post of a test battery to white wire terminal of motor and connect a second jumper from battery negative post to motor housing The motor should run in one direction un less it is against regulator stop In that event remove positive jumper wire fr...

Page 498: ...s of frame and inspect rollers LOWER FRAME SPRING NUT VIEW A Fig 53 Rear Door Glass Replacement Glass Lower Frame The glass lower frame Fig 54 is attached to the glass with plastic rivets Gaskets are used between the frame and glass Lubricate roller areas of the frame before installing Regulator Replacement Manual and Electric The regulator Fig 55 is attached to the door inner panel by screw and w...

Page 499: ...of rail weatherstrip 5 Position up stop down against regulator arm 6 Adjust vent wing division bar attachment at 7 With door open run glass half way down 8 Adjust rear lower track attachment to allow 9 Lower glass so top is even or slightly below 10 On manually operated windows position stop 1 1 On electrically operated windows position bottom to allow alignment with glass alignment with glass bel...

Page 500: ...r Models Removal 1 Loosen vent attaching screws adjusting stud nut and move glass out of run channel 2 Remove run channel reinforcement plate and screw from upper end of channel door face Fig 60 3 Disengage support on bottom of channel from door panel and remove channel WEATHERSTRIP NN777 ai uD ING LIFT BRACKET e GUlDE NK898A 5KET Fig 5943larr Lift Bracket fnstallation and install screw at door fa...

Page 501: ...e position stop on regulator plate against stop on regulator sector and tighten nut 8 Move down stop on lower frame against bumper and tighten screws 9 Run window to fully up position 10 Loosen center support front track screw move support inboard against inside panel and tighten SCREWzyxwvuts 1 sckEw NK917 WASHER AND WASHER Fig 61 Glass Run Channel 4 Door UP STOP CENTER SUPPORT I Fig 62 Rear Door...

Page 502: ...ont doors Procedures for removing the regulator motor are FRONT TRACK ASSEMBLY Removal 1 Remove door glass assembly 2 Remove nut and washers attaching track as sembly to lower part of door inside panel Fig 65 3 Remove screw and washer assembly attaching track at belt line 4 Remove track assembly through large opening in door inner panel 5 Remove center support assembly from track Insftollation 1 I...

Page 503: ...RTER PANELS GARNISH MOULDING The garnish mouldings Fig 67 should be aligned and held in position to assure satisfactory alignment Do not over tighten screws or moulding will become damaged at screw hole area TRIM PANELS To remove quarter window trim panel Figs 68 69 and 70 it is first necessary to remove the rear seat cushion and back Quarter window trim panels are retained with screws and clips W...

Page 504: ...st upper front track attachment so front of window is aligned with rear of front door window at belt line Turn sleeve nut clockwise to move window in and counterclockwise to move window out 4 Adjust lower front track attachment so front of window is aligned with rear of front door window at roof rail Turn sleeve nut counterclockwise to move window in and clockwise to move window out 5 Adjust pivot...

Page 505: ...rm studs into rollers securing in place with spring nuts Fig 74 4 Install down stop on glass lower frame and adjust glass Regulator Replacement Manual and Electric The regulator assembly Fig 75 is attached to the door inner panel with screw and washer assemblies DOWN zyxwvutsrqp 4 VIEW A STOP BRACKET NP108 Fig 74 Quarter Glass Replacement NK935 Fig 75 Quarter Window Regulators The regulator arm st...

Page 506: ...top end into upper slide 3 Insert upper and lower track studs into holes in panel install nuts and washers and adjust glass CONVERTIBLE MODELS Adjustments Refer to Figure 79 for the adjusting points SLIDE NP107 Fig 78 Quarter Window Rear Track 1 With door closed and window approximately three quarters way up adjust upper stabilizer so rear of window touches lightly on belt line weather strip 2 Rai...

Page 507: ...ment Manual and Electric The regulators Fig 81 are attached to the quarter inside panel with screw and washer assemblies Lu Removal 1 Remove spring nuts from regulator arm studs Fig 80 studs from rollers and rollers from glass lower frame Inspect rollers 2 Remove glass and lower frame assembly bricate regulator tooth contact area approximately 1 2 inch wide along entire length of arc on outboard s...

Page 508: ...OPEN POSITION NER WHEEL HOUSE QUARTER PANEL Removal 1 Remove spare tire cover assembly Fig 84 2 Remove quarter window garnish mouldings 3 Remove front and rear upper pillar glass and 4 Remove glass and weatherstrip belt bar re 5 Remove roof side rail support retainer from Fig 85 weatherstrip lock retainer screws and retainer tainer screw and retainer G Fig 83 Quarter Window Stabilizer Fig 85 Quart...

Page 509: ...from 3 Support tail gate on jacks or stands 4 Loosen hinge pivot pin locking screws Fig 5 Outline hinge plate position on pillar post for 6 Remove hinge plate attaching bolts from pillar 7 Slide hinge plate and torsion bar in through 8 Lower tail gate out of body opening pillar guide plates 88 future assembly post Fig 88 guide toward center of tail gate lnstallation 1 With torsion bar and hinge pl...

Page 510: ...the three nuts attaching handle to the door Fig 90 To remove an inoperative handle when vehicle MANUAL N P l l O Fig 90 Tail Gate Lock Cylinders NN345 VIEW IN CIRCLE A Fig 9I Tail Gate Remote Control Handle is fully loaded prohibiting access to the tail gate inner panel remove the mounting studs from handle by drilling through handle Refer to Fig 92 for the location of the drilling points GLASS Ad...

Page 511: ... frame assembly into tail gate retainers REGULATOR REPLACEMENT The regulator assembly Fig 95 controls parallel adjustment of the glass and is attached to brackets on the tail gate inner panel by screw and washer assemblies TESTS REGU LATOR MOTOR A tail gate glass may not move due to a binding condition between the glass and run channels CONTROL SWITCH Disconnect black wire at control switch Fig 96...

Page 512: ... 98 3 Remove channel assembly lnstallation 1 Insert lower run channel into tail gate and position lower bracket over stud on hinge reinforce ment Install washer and nut finger tight only 2 Install upper bracket retaining screw and washer lower end washer and nut finger tight only 4 Install and adjust tail gate glass TORSION BAR Removal protect paint surface and remove trim panel 1 Remove tail gate...

Page 513: ...00 and 101 make certain seating area is free of all weatherstrip cement sealer and other foreign material Fig 100 Tall Gate Weatherstrip Apply an even continuous coat of cement starting at belt line down one side across bottom and up opposite side of lower opening Install weatherstrip and seal area at belt line UPPER RUN RETAINER AND SEAL Removal 1 Remove glass run retainer to roof rear header EAD...

Page 514: ... and Pillar Runs UPPER RUN AND PILLAR RUN Removal into retainer Fig 103 lower opening weatherstrip screw and remove run and retainer 1 Remove upper run from retainer a press fit 2 Remove pillar run to upper end of tail gate 3 Remove pillar run and retainer to pillar screws nstallatton 1 Position pillar glass run and retainer on pillar insert upper end into end of roof header glass run retainer and...

Page 515: ...el housing a push button control switch in the glove box and a vacuum actuated diaphragm as sembly connected to the lock Fig 106 Vacuum is supplied to system from intake manifold Rubber hoses are used to connect component units If failure of the system is accompanied with a rough engine idle remove hose from manifold fitting tube and plug end of the tube If engine idle improves noticeably inspect ...

Page 516: ...ly an even continuous coat of cement to entire weatherstrip contact surface of deck lid opening Fig 107 Install weatherstrip make sure weather strip molded corners are correctly positioned INTERIOR TRIM AND SEATS INDEX Page Page INTERIOR TRIM Hardtop 2 Door 58 Floor Covers 45 Monaco 500 57 Scuff Plates 45 Station Wagon 2nd and 3rd 59 Garnish Mouldings 44 4 Door Models 58 Glove Box 49 Cushion Front...

Page 517: ...ed under the rubber flap on the cowl trim panel With air conditioning the carpet front edge must be posi tioned on front of the air conditioning housing flange and secured with the floor air outlet retainer bracket HEADLlNlNG Removal Fabric Type 1 Remove rear seat cushion dome light bezel and lens sun visors rear view mirror and coat hooks 2 Remove headlining from cemented areas at windshield head...

Page 518: ...a dull putty knife secure liner on barbs nately from side to side install headlining on side rail at header area do not install material at top of wind retainers shield posts making sure there are no wrinkles and 14 Apply cement to rear window opening and to fabric seam is straight quarter panel area after cement becomes tacky 9 Locate sun visor mounting bracket screw holes install headlining star...

Page 519: ...Fig 4 Floor Covering REAR RETAINER S E C I N AA HEADLINING v NINDCORD Fig 5 Headlining Retainers MyMopar com ...

Page 520: ...LINING EXTENT OF CEMENT VIEW IN DIRECTION OF ARROW X WINDOW FRAME VIEW IN DIRECTION OF ARROW Y IN DIRECTION OF ARROW VIEW IN DRECTION OF ARROW U NP173 STATION WAGON i d c c RETAINER NNl48A Fig 7 Hurdbourd Heudlining MyMopar com ...

Page 521: ...n side re 3 Align edges of section with moulding retainer 4 Install mouldings and caps over ends 5 Install any garnish mouldings removed GLOVE BOX Refer to Figure 8 for the glove box attaching points GLOVE BOX The glove box light is installed in the top panel of the assembly SHELF TRIM PANEL Removal 1 Remove rear seat cushion and back assembly 2 Remove rear window defogger outlet 3 Loosen cemented...

Page 522: ...ion Fig 10 and insert fasteners in seat back support 3 Install shroud screws at outer edges 4 Position shroud side extension fillers to quarter 5 Install screws finger tight only obtain align 6 Install seat back and cushion panel and wheelhouse panel brackets ment and tighten screws SEATS ADJUSTMENT To raise or lower the front seat Fig ll loosen the adjuster mounting bolt nuts under floor pan and ...

Page 523: ...at HEATER CORE NN846 Fig 13 Rear Seat Heater Air Ducts adjuster mounting bolts under floor pan and re move seat Rear Seat Cushion The rear seat cushion Fig 12 is held in place by inserting the rear edge of seat cushion under lower edge of seat back The front lower frame of seat engages a slotted bracket welded to the floor pan On cars equipped with a rear seat heater extreme care must be used to m...

Page 524: ...e links 1 With seat back in the UP position Fig 18 re 2 Remove back and support panel assembly 3 The cushion is retained to the seat back panel Fig 18 with screws lnsfullution screws hinge links and install screws 1 Position cushion on back panel and install 2 Position back and support panel assembly on Cushion Removal 1 The third seat cushion Fig 18 is attached to hinges which in turn are attache...

Page 525: ...gs rear 6 Cover pad to the 8th bar of each center element with 31 hog rings rear 7 Cover to each slot in frame assembly with 121 hog rings front 61 hog rings right side 71 hog rings left side electric seat 8 Cover to each trim tab in frame assembly with 14 hog rings 7 each side manual seat 2 hog rings l each side electric seat 9 Cover listing to the 12th bar of each intermedi ate element with 1 1 ...

Page 526: ...to the 12th bar of each interme diate element with 1 1 1 hog rings rear 9 Cover listing to the 8th bar of each center ele ment with 3 hog rings rear 10 Cover to the 12th bar of each intermediate element with 1 1 1 hog rings rear 11 Cover to the 8th bar of each center element with 31 hog rings rear 12 Front seat back side facing to slots or trim tabs to cushion frame outer with 6 hog rings 3 each s...

Page 527: ...om rim with 4 hog rings 2 per rim bottom 6 Cover front to cover rear with 7 hog rings equally spaced bottom 7 Cover rear welt to cover front with 2 hog rings l each side 8 Side facing extension flap to cover front and cover rear wires with 2 hog rings l each side bottom Carpet end to lower side facing with l hog ring Two Door Polara Models Fig 23 1 Spring pad to listing and trim brace with 5 hog r...

Page 528: ...res 3 Pad support with 151 hog rings to trim wires Fig 24 Front Seat Back 4 Door All STYLED WRINKLES ACCEPTABLE I N p THE HORIZONTAL I PULL DOWN AREA Fig 25 Bucket Sed Back 4 Cover pad with 4 hog rings to spring re 5 Cover pad with 8 hog rings to trim wires 4 6 Cover pad with 8 hog rings to spring retainer 7 Cover listing with 8 hog rings to the vertical 8 Cover listing with 3 hog rings to the hor...

Page 529: ...ith 4 hog rings See circle A 1 Spring pad to the 6th bar of the lst 3rd and 5th intermediate element each side and to the 4th bar of the 2nd center element each side with 8 hog rings front 2 Spring pad to top rim with 6 hog rings 3 each side equally spaced 3 Spring pad to each slot in retainer with 13 hog rings omit 2 rear 4 Cover to trim brace with 121 hog rings front 5 Cover to retainer with l h...

Page 530: ...ed 3 Spring pad to each slot in rear retainer with 151 hog rings 4 Cover to each slot in bottom frame with 28 Fig 30 Rear Seat Back 2 Door Polara Monaco 5 Cover to each slot in rear retainer with 15 hog rings front and sides hog rings Back 2 Door Polara Monaco Fig 30 equally spaced top rings requires 3 each side equally spaced bottom spaced top 7 each side hog rings bottom 1 Spring pad to trim bra...

Page 531: ...ch slot in bottom frame with 8 hog rings 4 each side 6 Cover to bottom rim with 131 hog rings equally spaced bottom 7 Back of rear back panel and radio speaker cover to horizontal bottom brace with 8 hog rings 4 Door Models except Station Wagon equally spaced top Fig 33 1 Spring pad to trim brace with 121 hog rings 2 Burlap listing to each slot in J rim with 6 Fig 32 Rear Seat Back Convertible Fig...

Page 532: ...hog rings 3 each side equally spaced 3 Cover pad to the 9th loop of the lst 3rd and 5th element with 6 hog ringsrear 4 Cover to each slot in bottom retainer with 121 hog rings f ront 5 Cover to each slot in J rim with 121 hog rings 6 each side 6 Cover to 3rd loop of each element with 121 hog rings rear 7 Silencer to the 4th loop of every other element with 71 hog rings rear 8 Silencer to the 2nd b...

Page 533: ...de equally spaced 3 Cover to each slot in J rim with 141 hog rings top 121 hog rings 6 each side and 141 hog rings bottom POWER SEATS The power seat can be moved six ways forward back up down tilt forward and tilt rearward The horizontal travel is five inches and horizontal plane of seat track is inclined eleven degrees The vertical travel is 1 1 2 inches at front and rear The available tilt is 8 ...

Page 534: ...e move adjuster installation 1 Install adjuster and seat guide stud nuts 2 Connect seat adjuster red feed wire 3 Install front seat assembly 4 Connect control wires to switch and tighten 5 Connect battery ground cable To replace a broken cable it will be necessary to mounting screws securely Flexible Cables or Tubes remove the tube also The seat mounting nuts must be removed from under the vehicle...

Page 535: ...s the rear jack replacement except that the jack is not removed from the base See Rear Jack Removal and Installation The jacks must be synchronized Turn the cable to raiseor lower jack as necessary Rear Jack Switch Removal The seat track assembly must be removed from the vehicle separated and mounted in a vise Fasten a 10 inch C clamp from the base to the upper side just tight enough to keep it in...

Page 536: ...y Be careful SHOULDER BELT FR B CHRYSLER IMPERIAL POLARA MONACO Fig 43 Front Seat Shoulder Belts not to lose three springs under solenoid 4 Remove solenoid coils bend back on tabs of solenoid cover Unsolder coil ground wire at cover tab and remove coil cover from coil 5 Remove screws holding cover on drive unit 6 Remove cover and lift out clutch lever and shaft Assembly properly seated on collar 1...

Page 537: ...d remove from glass strip and glass GLASS REPLACEMENT Removal tective covering 1 Cover cowl hood and fender areas with a pro 2 Remove windshield wiper arms and blades 3 Remove windshield outer mouldings Fig 1 4 Remove cowl grille panel 5 Using a fibre wedge loosen weatherstrip from fence at top and sides on inside and outside areas 6 With an assistant supporting glass on the out side exert hand pr...

Page 538: ...ass groove in weatherstrip and position glass in weatherstrip 2 Insert twine starting at top center of weather strip into fence groove portion of weatherstrip across top and down both sides Fig 4 3 With an assistant position glass and weather strip on fence 4 With pressure applied against glass from out side enter car and starting at one of the lower corners alternately pull ends of twine half way...

Page 539: ... for damage 7 Remove weatherstrip from glass If removed weatherstrip or glass is to be reused remove all sealers and cements from weatherstrip groove and glass surfaces REAR WINDOW GLASS REPLACEMENT With Weatherstrip Removal 1 Place a protective covering over deck panel quarter panel and rear window areas 2 Remove outer mouldings Fig 5 using Tool C 4009 and inner garnish mouldings Fig 6 3 Using a ...

Page 540: ...f weather strip and fence at top corners 8 Remove all excess sealer and cement and water test window area 9 Install inner and outer mouldings and remove protective covering CEMENTED IN TYPE WINDOW Identification of a polysulfide adhesive sealed rear window can be made by noting if rubber weatherstrip is visable between outer mouldings and glass If not the following procedures should be performed a...

Page 541: ... mini mum should be equal across the top and sides Use waterproof shims under spacers to obtain required overlap 7 Apply a piece of masking tape over each side of glass and roof extensions Slit tape vertically at edge of glass so when glass is installed tape on glass can be aligned with tape on body 8 Remove glass from opening and place on a protected surface with inside surface up Fig 1 1 Spacer ...

Page 542: ...sm 71 Major 71 Raising or Lowering Top 70 Minor 71 Reservoir 71 Prop Link 72 Header 75 Roof Side Rail 72 Roof Side Rails 74 Stack Height 72 Well Liner 74 Power Link 73 Weatherstrips Shifting Top 72 Seals and Sealers 75 SERVICE DIAGNOSIS Condition Possible Cause Correction TOP AND WINDSHIELD HEADERS NOT MEETING front hinge AT CORRECT ANGLE IMPROPER MEET1NG fore and aft OF TOP AND WINDSHIELD HEADERS...

Page 543: ...ion They are also provided to assure correct align ment of the roof side rails with door and quarter glass to prevent leakage Adjustments are provided to eliminate wrinkles in the top material Major Adjustments Major Adjustments are at the prop controi link bracket and the power cylinder mounting brackets These adjustments are necessary to improve roof side rail alignment if minor hinge and header...

Page 544: ...s pos sible at the hinge and the set screw is also used as a means of eliminating noise at the front hinge by progressively tightening Front Hinge Adjustment To avoid stripping the set screw threads unfasten header latches to relieve tension on linkage before iER POWER CYLINDER ATTACHING PLATE VIEW IN DIRECTION OF ARROW 9 2 3 Fig 3 Power Cylinder adjusting set screws Leakage between the top and do...

Page 545: ... side rail indicate the amount of cam rotation when adjusting The marks are located at the full forward position of the high side 45 degrees up and 90 de N P 274 VIEW IN CIRCLE Fig 4 Cam Assembly grees up When adjusting the cam high side position can be determined by referring to the notch and the triangular marks Before adjusting place top in half raised position to remove all possible strain off...

Page 546: ...LAP I CEMENT NK919 I FOAM FILLh rAU Fig 7 Well Liner 5 Mark position of curtain and top cover screw holes on masking tape and remove screws 6 Remove well liner seals and sealers 7 Clean sealing and cementing areas thoroughly to assure good adhesion on new liner nstallation 1 Install a strip of sealer cement 120 inches long to top of quarter outside panels and deck opening upper panel at belt area ...

Page 547: ...nd stay pads for exces sive wear or moisture stains 1 Place protective covers over deck lid upper panel hood and cowl areas 2 Apply masking tape directly below quarter panels and rear window mouldings 3 Remove mouldings at quarter belt area and from bottom of rear window Fig 10 4 Mark location of moulding retainer screws on masking tape at quarter panel areas and first two screws at each side of r...

Page 548: ...s are removed the cord should be left in listing to aid in reinstalling cables 23 Remove cover from folding linkage installation Prior to installing cover inspect the bow felt pads for moisture or damage The pads are a press fit in the bows The cover stay pads should be inspected for damage and moisture The backlight zipper top half is attached to therear bow with staples 1 Insert cables in cover ...

Page 549: ... inspect fit of cover in relation to top of door glass and vent wings Should either vent wing or door glass contact beading on edge of cover on one side the cover may be loosened at the header and moved slightly toward the opposite side until clear ance is obtained Should contact at both doors be made it will be necessary to build up cover pads on both sides to eliminate interference 25 While keep...

Page 550: ...le These areas should be considered when test ing for leaks When sealing joints with balls of sealer press the sealer into the area firmly SERVICE PROCEDURES Water Method Normally a visual inspection of an area will in dicate the area for sealing When testing with water use a spray simulating rain or a garden hose without the nozzle and regulate the pressure to an approxi mate 3 inch stream All wa...

Page 551: ... BODY AND FRAME 23 79 ALL SCREWS SEAMS AND OPENINGS NN308 NN307 Fig 2 Floor Pan and Side Sill Area MyMopar com ...

Page 552: ...23 80 BODY AND FRAME SEALER VIEW B SEALER LOWER PILLAR AND PAN OUTER PANEL Fig 3 Wheelhouse and Tall Gate Opening NN309 MyMopar com ...

Page 553: ... BODY AND FRAME 23 81 4 DOOR SEDAN AND HT 4 DOOR SEDAN STATION WAGON AND CONVERTIBLE Fig 4 Lock Pillars and Drain Trough S E L R CENTER P I L L A R NN318A MyMopar com ...

Page 554: ...23 82 BODY AND FRAME IEW IN CIRCLE SEALER 1 2 BALL INNER OUTER fig 54ucrrter OutsidePanel and Roof Extension Fig Wheelhouse and Spare tire Compartment MyMopar com ...

Page 555: ...FLOW O R SPRAY MIDDEN SURFACE MIDDEN SURFACE APPLICATION OF SEALING PUTTY MOLD G U N NOZZLE IN DIRECTION OF ARROW IN ORDER TO EFFECTIVELY OF ARROW SEALER APPLIED AS SHOWN SEAL METAL JOINTS IS INEFFECTIVE DO NOT MOLD GUN NOZZLE IN DIRECTION 114 2 zyxwvutsrqponmlk 3 v METAL THICKNESS NY1446 APPLICATION OF SEALER WHERE SEAL IS REQUIRED BETWEEN WELDED PANELS 3 METAL THICKNESS NN315 Fig 8 Methods of Ap...

Page 556: ... SEALER VIEW ARROW B VIEW CIRCLE A NN311 Fig 13 Tail light and Deck Drain trough Fig 14 Rear Floor Pan and lower Panel Fig I I Front Pillar Area MOULDING JOINT SEALER ARROW v I I W CIRCLE Y V Y E W ARROW B VIEW ARROW B NN314 NN587 Fig 12 Rear Roof Rail Areas Fig 15 Convertible Wheelhouse and Belt Bar MyMopar com ...

Page 557: ...ve roof side mouldings Remove all sealer from drain trough windshield and rear window reveals lnstullution 1 Mask body from edge of drain trough across upper A pillar across windshield and rear window reveal across top of deck upper and bottom of roof panel at the belt line 2 Locate and mark center line of roof panel and vinyl cover at front and rear ends 3 Apply a thin film of cement to the cente...

Page 558: ...ide corner of C pillar face and blend upper trimmed edge to join trimmed edge of cover at drain trough Fig 5 15 Locate and punch holes in cover material at belt moulding holes in roof extension on a line 3 16 inch below the holes 16 Grasp edge of cover and while pulling material outward and down use upper edge of drain trough flange as a breakover for draping material on to the WINDSHIELD 2Door RE...

Page 559: ... inserting a locating pin in index hole and align moulding 28 Using hole in moulding as a guide drill a 120 diameter hole in pillar and fasten in place with a screw original installation only 29 Install side drain trough windshield and rear window mouldings 30 Remove masking tape and paper and inspect cover for air bubbles AIR BUBBLE REMOVAL bubble 1 Place strips of masking tape over surface of 2 ...

Page 560: ...y mix two to three level teaspoons of mild powdered household detergent per gallon of clean warm 80 to 90 degree water in a non rusting type retainer APPLICATION OF OVERLAY Fig 1 It is mandatory to remove the paper backing from the overlay and not the overlay from the backing as possiblestretching or tearing may result Cut overlay 1 2 inch larger than area to be covered and lay on a clean flat sur...

Page 561: ...ION Upon completion of an area inspect for blisters due to trapped air or water All blisters should be worked out with the squeegee or punctured with a sharp needle or pin and then pressurized until the film adheres to the body surface All edges must be adhered to the body surface REFINISHING PROCEDURES INDEX Page Page 89 Refinishinn 91 AeryIic Finishes Definitions Technical Terms 89 Spot Repairs ...

Page 562: ...ed to reduce alkyd synthetic and orthodox materials to the proper consistency for application The function of a primer is to form a bond between SANDING BLOCK As a rule a sanding block is a flexible rubber block so arranged sandpaper may be fastened to it securely It affords a good grip for the operator Wherever possible sanding should be done with a block as it distributes the pressures and gives...

Page 563: ...t to be painted If a complete color change is being made mask off interior parts adjacent to door openings to prevent paint spray from soiling interior trim and upholstering 6 Reclean entire area to be painted with wax and grease remover eliminating workman s fingerprints 7 Chemically treat bare metal This conditions exposed metal to inhibit rust Use a good metal con ditioner Priming The Surface T...

Page 564: ...r Shimming of the stub frame outriggers to keep them in alignment with the balance of the frame is performed prior to the body being installed on the frame SERVICE PROCEDURES FRAME ALIGNMENT MEASUREMENT The various frame dimensions Fig 1 and 2 may be used as a guide in measuring the frame alignment Diagonal measurements should be taken when straightening the frame Measure the distance between the ...

Page 565: ...ements Fig 3 Fender to Cowl Mounting 14 Place a hydraulic jack under stub frame rear cross member to hold it in position when body to frame mounting bolts Figs 6 and 7 are removed Two bolts are located near the top of the curved por tion of the body to frame cross member 15 Remove frame to body bolts then lower front end assembly and at the same time move front end assembly out and away from body ...

Page 566: ...er plate and tighten screws securely 7 Install fender to cowl stud nuts and fender to rocker panel bolts Align fenders with doors and hood as described in Body Group of this manual 8 Carefully guide antenna cable through cowl and connect to radio 9 Reconnect windshield washer tube at cowl 10 Reconnect steering gear at flexible coupling 1 t zyxw A Fig 6 Body to Frame Outrigger Mounting Fig I Body t...

Page 567: ...chematic bracket to cowl and wheel house Fig 3 both sides Group of this manual and all connections between engine and dash panel 13 Check alignment of hood as described in Body 14 Reconnect electrical leads to junction block GAUGE ALIGNMENT CHART Wheelbase 122 122 122 All Except Spring Station Wagon 122 Station Wagon Spring Distance Below Body 0 Line 3 07 Letter D Hole Centerline of Lower Control ...

Page 568: ...ear frame gauge from centerline of frmt eye bolt of rear spring The attached rod eye and or adapter sleeve fits over outboard hex of bolt or nut as case may be Fig 12 All of the attaching rods must be placed outboard of their respective at taching positions so that by closing the self centering gauges and tightening the center wing screw the gauges will not fall off 4 Place long aluminum checking ...

Page 569: ... Code 8293 goo0 13074 71498 Single Tone AA 1 BB 1 etc 88 1 Ditzler Code 32398 9300 go00 13159 13043 13040 43547 43540 22659 22704 13195 13214 60492 71483 71552 50731 81539 22706 22701 8362 22700 22715 13336 Chrysler Code Number AAY2A4 TAY1x9 CAY2B7 BAY2B4 BAY2B9 CAY2F4 CAY2F9 CAY2K8 CAY2T8 CAY2Q4 CAY2Q8 BAY2K6 BAYlH6 CAY2R7 CAY2M4 CAY1Y1 CAY2K4 VAYlWl CAY1T1 CAY2T4 CAY2Y4 CAY2B6 STRIPING COLORS Ch...

Page 570: ...3230 13231 13235 22729 22731 22732 22733 22734 22735 71495 Used on StationWagon Air Conditioning Unit White VAB3W2 8355 Usedon A Pillar with Vinyl Roof Semi Gloss Black CAT3X8 9028 Suede Finish Colors Color Name Chrysler Code Number Ditzler Code Used on b f j Used on a b c d e f g h i j Used on a g i j Used on b d e h j Used on a g i j Used on b d e f h j Used on j Used on a Used on b e j Used on ...

Page 571: ...TIONER CONTROLS Two air conditioner options are available The first option Front Unit is a combination air conditioning and heating unit which is installed inside the pas senger compartment behind the instrument panel The controls and cooling air outlets are integral with the instrument panel This system functions on the reheat principle The second option Station Wagons Only includes the first opt...

Page 572: ...by the distance the knobs are pulled out Pushing the knobs all the way in closes off the air intake Be sure the air intake controls are pushed all the way in before operating the air conditioningsystem ELECTRICAL CONTROLS AND CIRCUITS There are three switches push button switch air conditioner and heater vacuum switch fan switch air conditioner and heater blower switch and the air conditioner and ...

Page 573: ... AIR CONDITIONING 24 3 FRESH AIR THRU COWL VENT n n n n n NK1424A Fig 2 Air Flow MaxZmum Cooling FRESH AIR THRU COWL VENT HEATE CORE btj NK1425A Fig Air Flow Fresh Air Cooling MyMopar com ...

Page 574: ...FRESH AIR THRU COWL VENT LnYYYv RECIRCULATING NK1426A Fig Air Flow Heating FRESH AIR THRU COWL EVAPORATOR HEATER CORE AIR INLET CLOSED HEATER DOOR POSITIONS 2 REAR VIEW OF SWITCH NK1427A Fig 5 Air Flow Defrosting MyMopar com ...

Page 575: ... AIR CONDITIONING 24 5 I l l C22A 1 T GROUND AT 0 LEFT ROOF RAIL C 2 i A 1 BULKHEAD DISCONNECT L c2tY FUSE BLOCK NP675 Fig 6 Electrical Control Circuits MyMopar com ...

Page 576: ...cause the air condi tioner compressor to pump oil to the compressor seal preventing the seal from drying out and causing loss of refrigerant Anti Freeze Required for Summer Operatlon Air conditioned cars must be protected with a per manent type antifreeze during summer to 15 F or lower to prevent the heater case from freezing However this protection does not provide sufficient corrosion inhibitors...

Page 577: ...d retest the adjust ment RADIATOR CAP The 1967air conditioned vehicles must be equipped with a radiator cap having a holding pressure of 15 to 16 psi Replace the radiator cap that does not test within these specification swith a cap that does CONDENSER Inspect the condensor for obstructions for foreign matter Clean if necessary Any obstructions to the free flow of kr across the condenser will decr...

Page 578: ...r Inlet Gauge is mounted at the right side of the manifold set This mounting is for conven ience only There are no passages between this gauge and the gauge manifold The compressor inlet gauge is calibrated to register 0 to 30 of vacuum and 0 to 150 psi This gauge and the evaporator suction gauge must be accurately calibrated so that the needles of both gauges are exactly at 0 before making tests ...

Page 579: ... clean on or near the sys tem components or refrigerant lines CAUTION Keep Refrigerant 12 containers upright when chargingthe system When metering Refrigerant 12 into the refrigera tion system keep the supply tank or cans in an up right position If the refrigerant container is on its side or upside down liquid refrigerant will enter the system and damage the compressor CAUTION Always work in a wel...

Page 580: ...181 0 31 29 3 56 53 2 81 85 7 106 128 5 131 183 5 32 30 1 57 54 3 82 87 2 107 130 4 132 185 9 33 30 9 58 55 4 83 88 7 108 132 4 133 188 5 34 31 7 59 56 6 84 90 2 109 134 4 134 191 0 If no pressure is indicated on the gauges it means that the system is empty due to a leak It will be necessary to evacuate charge with a sweep test charge locate and correct the leak purge the test charge replace the d...

Page 581: ...he burning of refrigerant gas Large concentrations of refrigerant in the presence of a live flame become dangerously toxic Observe the flame through the window of the burner shield not through the top of the shield If the flame remains bright yellow when the tester is removed from possible leak point insufficient air is being drawn in through the sampling tube or the reaction plate is dirty Remove...

Page 582: ...This will purge air from the charging hose Tighten connection as soon as air is purged 11 With vehicle windows open and hood up oper ate engine at 1300rpm 12 Push in A C button fan switch on high On dual installation both blowers must be on high speed during charging operation 13 If necessary block the condenser to maintain a discharge pressure of 225 to 250 psi The system must be charged through ...

Page 583: ...as been established One of the most important steps in making the over all performance test is that the en gine must be operated at 1300rpm for approximately five minutes to allow all the under hood components of the system to reach their operating temperature 8 Partially close the needle valve located below the discharge pressure gauge to minimize oscillation of the pointer Do not close the needl...

Page 584: ...auges and thermometers has been established One of the most important factors in making the over all performance test is that the engine must be operated at 1300 rpm for a sufficient time to build up to operating temperatures and allow all the under hood components of the sys tem to be subjected to the under hood operating pressure temperatures for a period of time 5 Partially close the needle val...

Page 585: ...rming Tests 1 through 5 conduct the Expansion Valve and EPR Evaporator Pressure Reg ulator Valve Test as follows a Close the windows and operate the engine at the rp m shown below Set air conditioning controls for Max A C high blower and temperature control lever to full reheat position Set R P M 3 at 800 b Operate the system for a few minutes to obtain partial stabilization and sufficient reheat ...

Page 586: ... of the front unit in a container of 32 F ice water The evaporator suction pressure should read 21 to 28 psi The compressor inlet pressure should be 22 psi or less If the compressor inlet pressure is higher than 22 psi the EPR valve should be replaced If the evap orator suction pressure is greater than 28 psi the EPR valve cannot be checked until after the expan sion valve passes the test Read Ste...

Page 587: ...allow trapped pressure to bleed off very slowly Use a suitable tube bender Tool C 3362 when bending the refrigerant lines to avoid kinking Never attempt to rebend formed lines to fit Use the correct line for the installation you are servic ing A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose Sharper bends will reduce the flow of re ...

Page 588: ...nsing manifold the gauge set manifold and test hoses should be kept clean and dry The special refrigeration oil supplied for the system is as clean and dry as it is possible to make it Only refrigeration oil should be used in the system or on the fittings and lines The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent entrance of dir...

Page 589: ...radiator pressure cap testing below these specifi cations will permit loss of coolant during a hard pull on a hot day or in slow moving traffic or when the engine is stopped on a hot day Test the radiator pressure cap using Tool C 3499 Fig 18 Before assembling adapter and radiator pressure cap to the pump dip radiator cap and both ends of adapter into clean water to assure a tight seal Hold the as...

Page 590: ...od is covered with a finger Disconnect engine vacuum source hose at engine intake manifold and insert vacuum tester hose prod into source hose leading to control switch Place vac uum gauge on the cowl so it can be observed from the driver s position as push buttons are operated Start the test by pushing the H or heat button Vacuum tester gauge needle will drop until the actu ator has operated and ...

Page 591: ... spot may be cut out Fig 24 Vacuum Actuator lest ASSEMBLY PULLEY ASSEMBLY N B32 Fig 25 Warner Clutch Plate lype and the hose spliced using 1 8 inch 00 copper tubing A vacuum drop in excess of 3 4 inch below the 8 inches needed in this test would not interfere with the engine operation other than perhaps to cause a rough idle It could however interfere with the prop er operation of the air conditio...

Page 592: ...rner Plate Type install drive hub puller Tool C 3787aligning the three pins of the Tool in the three holes in the hub and shoe assembly Tighten the hex head bolt down until the drive hub is removed from the bearing Fig 27 b On Pitts Electro Loc install a bolt 5 8 11 x 2 1 2inch into the rear of the hub and while holding the pulley in the hand use a soft hammer and drive hub from the pulley ELECTRO...

Page 593: ...e re moved for repair or replacement measure the re frigerant oil level in the compressor before the com pressor is removed from the vehicle so that the same oil level can be established when the new or repaired compressor is installed on the vehicle Too much refrigerant oil in the system can cause abnormal operating pressures and reduce the per formance of the entire system Complete disassembly a...

Page 594: ...OMPRESSOR Removal 1 Discharge the system Refer to Discharging the System 2 Measure and record the refrigerant oil level so that the oil level of a replacement or repaired com pressor can be adjusted to the exact level in the compressor removed from the vehicle See Oil Level 3 Disconnect suction line from suction muffler and the discharge line from the muffler fitting CAUTION Plug or cap a11 the li...

Page 595: ... level to the minimum shown in the table above Remove any oil in excessof eight ounces Dipstick Reading Inches Inches Engine 6 ounces 8 ounces Minimum Maximum 318 2 2 318 383 4 40 zyxwvuts 2 718 3 112 Vertically on Bench 2 2 3 I8 Compressor Set CYLINDER HEAD AND VALVE PLATE ASSEMBLY Removal 1 Remove the cylinder head bolts head and valve plate assembly If plate does not separate from head tap the ...

Page 596: ...t rod bearing for pits and for chipping Replace parts if damaged installation 1 Remove bearing cap and install piston in bore Use piston ring compressor to prevent ring damage 2 Install bearing caps and tighten screws 50 to 60 inch pounds Be sure each cap is installed in its original position 3 Install valve plates and cylinder heads 4 Turn compressor upside down Install pilot studs gasket oil pre...

Page 597: ...ish seal ing surface of the face plate Tap sleeve lightly until the seal seat is fully seated in the housing Cleanliness is important Wipe seat clean with a lint free cloth and re oil with refrigerantoil 6 Install the bearing housing oil seal using plenty of refrigerant oil Fig 37 Removing the Crankshaft BearingHousing CARBON SEAL COIL SPRING TAN WAVE SPRING CARTRIDGE TYPE UNITIZED TYPE NY89 I Fig...

Page 598: ...E Removal The system must be completely discharged before opening any of the refrigerant lines 1 Disconnect equalizer from suction line fitting Fig 40 2 Disconnect expansion valve from liquid line and evaporator Use two wrenches to loosen each of these connections 3 Carefully pull out capillary sensing tube from suction line well 4 Remove rubber seal from the capillary sensing tube Inspect conditi...

Page 599: ...m mounting bracket and remove the two support braces 9 Remove five retainer spring clips and ten screws attaching cover to the case 10 To remove the cover and heater core it will be necessary to pull lower edge rearward then lift as sembly 3 8 inch to unhook the cover lip from the case Carefully lower the assembly and out to the right side lnstaIlation Install the water by pass valve with linkage ...

Page 600: ...tall fresh air recirculating air inlet hose 9 Install the heater core inlet outlet tube assem AIR CONDITIONING Fig 47 By Pass Switch Adjustment bly a drop or two of clean water on the zy 0 rings will facilitate installation 10 Install temperature control valve capillary tube in heater core cover 11 With the air conditioning door open approxi mately one inch install the distribution housing 12 Inst...

Page 601: ...es 4 Remove distribution housing defroster hoses INSERT TUBE FROM EXPANSION VALVE UNTIL END and fresh air hose 5 Remove glove box 6 Disconnect actuator vacuum hose cluster at control switch and at Tee source connector 7 Disconnect electrical connections at resistor block bypass switch blower motor and blower motor ground wire 8 Remove right hand spot cooler duct and spot cooler held by two button ...

Page 602: ...ctuator and the fresh air recirculating actuator hose with red stripe to the rod side Connect floor air actuator rod to the linkage with the retainer clip CASE BY PASS Fig 50 Evaporator Removed from Case DRAIN7 TUBE zyxwvut 7 COLLAR INSULATOR NKlaOl Fig 51 Evaporator Drain Tube Collar and Insulator 13 Connect actuator vacuum hose cluster at con trol switch and vacuum source hose at Tee connec tion...

Page 603: ...n the gauge set manifold needle valve and close both of the gauge set manifold gauge valves 3 With the vehicle windows open and hood up operate the engine at 1300 rpm 4 Push in A C button fan switch on high On dual installation both blowers must be on high speed during the charging operation 5 Allow the system to operate at full capacity for at least 15 minutes at the rpm shown in step 3 T h i s w...

Page 604: ...right yellow when the tester is removed from a possible leak point insufficient air is being drawn in through the sampling tube or the reaction plate is dirty REMOVE SWEEP TEST CHARGE If the system is free of leaks or after correcting a leak if no air conditioning components have been re moved add the necessary refrigerant as described under Correcting the Low Refrigerant Level If any parts of the...

Page 605: ...of refrigerant at one time Keep the refrigerant manifold valves capped when not in use Keep a supply of extra refrigerant can to refrigerant manifold gaskets on hand SO that gaskets can be replaced periodically This will insure a good seal without excessive tightening of the can or the manifold nuts 1 Attach center hose from gauge set manifold to refrigerant dispensing manifold Turn refrigerant ma...

Page 606: ...ction side of the system by slowly opening the left hand gauge set manifold valve Adjust valve as necessary so charging pressure does not exceed 50 psi Maintain the tem perature of the water in the pan by adding warm water as necessary b When all three cans of refrigerant are com pletely empty close gauge set manifold valves and refrigerant manifold valves c If more than three cans of refrigerant ...

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Dodge Monaco 1967, Service Manual

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Summary of Contents for Monaco 1967

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