Plymouth Barracuda 1965 Service – Technical Manual Download Page 317

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Summary of Contents for Barracuda 1965

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Page 3: ...INTRODUCTION AND GENERAL SPECIFICATIONS r Z l 1 SPORT FURY CONVERTIBLE 4 k 1 FURY II STATION WAGON SATELLITE TWO DOOR HARDTOP BELVEDERE II FOUR DO PLYMOUTH BARRACUDA NK1170 Fig 1 1965 Plymouth Models...

Page 4: ...cription of difficulty corrective action taken your recommendations as to what should be done and the reason for so doing Include Paint and Trim Code Numbers where finish upholstery body or sheet meta...

Page 5: ...rature Request for Parts Division literature such as Parts Books Parts Price Lists Parts Bulletins etc should be forwarded direct to Chrysler Motors Corporation P O Box 1718 Detroit 31 Michigan At ten...

Page 6: ...r shield near the battery The plate shows the body type schedule date trim code and the paint code Fig 6 1ST LETTER 2ND DIGIT 3RD DIGIT 4TH DIGIT CAR LINE MODEL OF VEHICLE YEAR BUILT ASSEMBLY PLANT Va...

Page 7: ...59 5 62 0 Tread Rear 55 6 58 5 60 7 Length with Bumper Except Station Wogan 188 2 StationWagon 188 8 203 4 208 5 209 4 216 1I Width with Bumper Except Station Wagon 70 1 Station Wagon 75 6 75 1 I 78...

Page 8: ...MML Steering Linkage Ball Joints Inspect seals for Universal Joints Inspect seals for leakage damage replace if damaged or worn Inspect joints parh for wear MML Roar Axle and Sure Grip Check level Mai...

Page 9: ...haft AMO MML Clutch Drive Lugs Release Bearing Sleeve or Fork Fingers and Pivot AMG EO Floor Mounted Manual Transmission Gear shMt Mechanism Lubricate mechanism from under car with light with SAE 30 F...

Page 10: ...RETOR AIR CLEANER 16 CARBURETOR CHOKE SHAFT AND LINKAGE 17 FUELFILTER 18 MANIFOLD HEAT CONTROL VALVE 18 DISTRIBUTORS 19 ALTERNATOR 19 BATTERY 19 STEERING GEAR 20 BRAKES 20 HEADLAMPS 21 WINDSHIELD WIPE...

Page 11: ...WHEELS Fig L S u p p o r t location for Frame Contact Hoisting AR 1 AR 2 Models 64x178 OF GRAVITY 53 58 _ I Llj I i r t 20 SQ MINIMUMA I FOUR PADS I 17 0 I k w 116 117 I tFRONT WHEELS tREA1 I Fig L S...

Page 12: ...LUBRICATION LUBRICATION AND MAINTENANCE SERVICES 0 5 6 Month Service When Necessary SERVICE INTERNAL 20 000 Miles 32 000 Miles...

Page 13: ...een a front and rear wheels This practice may result in permanent damage to the body The bumpers are designed to accept a bumper jack in an emergency if it becomes necessary to change a tire on the ro...

Page 14: ...o prevent contami nation of the lubricant or failure of the part NK665 Fig 9 Steering Linkage Lubrication Points AR I AR 2 AP I AP 2 Models When lubrication i s required use Multi Mileage Lubricant Pa...

Page 15: ...compartment It is sealed inside a rubber boot which should be in NK560 spected for condition and position If the boot is damaged it should be replaced and the mechanism lubricated by applying a film...

Page 16: ...be replaced with Multi Purpose Gear Lubricant SAE 140 in warm weather It is not necessary to change the lubricant when the car is used in normal service Where the car is used for other than normal pa...

Page 17: ...ment and its use is recommended Periodic changing of rear axle lubricant is not nec essary for vehicles used in normal service except when the axle lubricant has been contaminated with water or to pro...

Page 18: ...ck to the next slot and install the cotter pin 4 Install wheels tighten wheel nuts to 55 foot pounds on AV 1 AV 2 models and 65 foot pounds on AR 1 AR 2 AP 1 AP 2 models Install the wheel cov ers TIRE...

Page 19: ...t in carburetor cleaner followed by dry ing with compressed air During Break in Cars should be driven moderately during the first 300 miles After the initial 50 miles speeds up to 50 to 60 mph are des...

Page 20: ...ded that Engine Oil Filter Part Number 1851658 be installed to assure most efficient service CRANKCASE VENTILATION SYSTEM Periodic service of the positive crankcase ventila tion system Fig 27 is requi...

Page 21: ...noise should be heard if the valve shuttle is free If the noise is heard the valve is satisfactory and no further service is necessary If the valve does not click when shaken or the pa per is not dra...

Page 22: ...er tain the valve shuttle is free Shut off the engine re move the valve and shake it vigorously A clicking noise should be heard if the valve is satisfactory and no further service is necessary If the...

Page 23: ...d extensively for short trips with frequent idling Carburetor Remove the carburetor Hand turn a y4 inch drill through the passages to dislodge solid particles Under no circumstances should metal be re...

Page 24: ...with SAE 1OW 30 en gine oil This grade of oil is suitable for all tempera tures Reassemble the cleaner and install on carburetor CABURETOR CHOKE SHAFT RND LINKAGE Gum deposits on the choke shaft beari...

Page 25: ...LVE Freedom of movement of the heat control valve by removing lead deposits from the valve shaft bearings is assured by application of Manifold Heat Control Valve Solvent Part Number 1879318 Apply the...

Page 26: ...checked when the engine temperature gauge indicates a normal warmed up con dition and the transmission fluid is heated to its nor mal operating temperature While the level may be determined when the...

Page 27: ...o not use a pressure gun as high pressure may damage the seals Power Steering Fluid level in the power steering pump reservoir should be to the bottom of the filler neck Fig 49 when the engine is cold...

Page 28: ...alesman s products the headlamp aiming should be checked and adjusted to serve the new conditions Refer to Lighting System Group 8 for servicingprocedures WINDSHIELD WIPER BLADES Long exposure to heat...

Page 29: ...NCHC PIVOT POINTS NK661 Fig Sb Hood Hinge lubrication Points AR I AR 2 Models CAUTION Excessive lubricant may cause malfunc tion of the speedometer HOOD LOCK Lubrication of the hood lock mechanism and...

Page 30: ...torsion bar contacts Fig 57 Door Hinges AV 7 AV 2 Models On all hinges apply light engine oil sparingly to hinge pins and contact surfaces of the hinge halves Fig 58 Avoid lubricant on roller surface...

Page 31: ...rication AR 7 AR 2 AP 7 AP 2 Models Apply Lubriplate Part Number 1064768 sparingly to pivot contact areas including torsion bar contacts Figs 64 65 and 66 TORSION BAR HINGE SUPPORT ALL MODELS EXCEPT S...

Page 32: ...Torsion Bar and Check Arm Guide Plate Lubrication Points AV 1 AV 2 Models ION BAR GUIDE Fig 68 Tail Gate Torsion Bar and Check Arm Guide Plate Lubrication Points AR 1 AR 2 Models Tail Gate Torsion Bar...

Page 33: ...0 26 LUBRICATION NK398 Fig 70 Throttle Linkage Lubrication Points fModels AV 11 NK397 Fig 71 Throttle Linkage Lubrication Points ModelsAV 2...

Page 34: ...paringly to inner surfaces of lock through access hole Apply Lubriplate sparingly to all pivot and sliding contact surfaces of inside control handle linkage Also apply Lubriplate sparingly to sector g...

Page 35: ...Automotive Multi Purpose Grease NLGI grade 2 to both ends of the accelerator shaft at the mount ing bracket Fig 71 and on underside of the acceler ator pedal where it contacts accelerator shaft lever...

Page 36: ...of the accelerator shaft where it turns in the bracket and where the nylon roller rolls on it Fig 75 Also apply a thin film of the same lubricant to the engine mounted bellcrank pin Throttle Linkage...

Page 37: ...er solution Check breaker contacts for abnormal pitting bluing or misalignment and adjust Lubricate cam and wick see page 16 Be sure that all distributor secondary wires and tower caps are clean and c...

Page 38: ...WARNING PEDAL PRESSURE AT ALL SPEEDS including below 22 miles per hour a Faulty electrical circuit a See Electrical Tests Red Wire AUTOMATIC LATCHING a Insufficient brake switch clearance DOES NOT EN...

Page 39: ...erature control valve stuck in the open b Disconnected or broken control cable wire c Engine thermostat controlling at too high a d Thermostat stuck in closed position e Temperature control valve not...

Page 40: ...antenna and replace c Test the voltage at the fuse and tighten all d Send radio to authorized radio service station e Replace the speaker f Test the antenna and repair a Adjust the antenna trimmer b T...

Page 41: ...e pedal movement and the accelerator will revert to manual control Disen gagement of the automatic control may also be ac complished by pushing IN the button in the center of the instrument panel cont...

Page 42: ...on ELECTRICAL TESTS Fig 31 1 Turn the ignition switch to the ON or Acces sory position DO NOT START ENGINE 2 Pull out the auto pilot control button in the center of the instrument panel control Leave...

Page 43: ...void downward overshooting of the de sired mark on the dial 6 Examine the recorded speedometer readings at each dial setting for both upward and downward indications and adjust the dial for the best o...

Page 44: ...or de fogging Heat Button causes major portion of air to be di rected toward the floor of the vehicle HEATING THE VEHICLE Until the engine warms up make sure the OFF button is pushed in and the temper...

Page 45: ...o the housing and the one clip attachingthe vacuum unit rod to the actuated unit HEATER CORE Removal figs 2 3 and 41 1 Disconnect the battery ground cable 2 Drain the cooling system 3 Disconnect the h...

Page 46: ...temperature control lever in the ex treme down position Make sure the lever stays in this position through the remainder of the adjustment pro cedure 6 Place the water valve lever arm in the extreme...

Page 47: ...3 From in the engine compartment install the three heater assembly mounting nuts 4 From under the instrument panel install the flexible connector at the right end of the heater 5 Connect and adjust t...

Page 48: ...instrument panel connect the wiring to the blower switch and connect and adjust the three control cables 2 Position the control assembly in the instrument panel and install the four mounting screws 3...

Page 49: ...are provided SERVICE PROCEDURES HEATER ASSEMBLY Removal 1 Disconnect the battery ground cable 2 Disconnect the heater hoses from the heater and remove the heater hoses to dash panel seal and retainer...

Page 50: ...d the heater housing mounting studs 13 Connect and adjust the heater defroster cable and the temperature control cable to their respective control arms 14 Position the heater assembly on the dash pane...

Page 51: ...ground cable RADIO AND ANTENNA Description Available as optional equipment on Models AR 1 and AR 2 are AM radio Model 225 and AM FM radio Model 361 Available on Models AP 1 and AP 2 are AM radio Model...

Page 52: ...he instrument panel 1 From under the instrument panel position the radio into the instrument panel opening 2 From the front of the radio install the two nuts that attach the radio to the instrument pa...

Page 53: ...e two mounting nuts 2 Connect the speaker leads 3 Position the heater controls in the instrument 4 Install the heater control bezel 5 Install the heater control knobs 6 Connect the battery ground cabl...

Page 54: ...ed as follows Install the ignition coil capacitor as shown in Fig ure 4 NOTE The alternator is equipped with an internal capacitor which is integral with the output stud Install the thermal gauge supp...

Page 55: ...receptacle 5 Test the radio for proper operation AM FM RADIO The AM FM radio allows reception of both AM FM broadcast frequencies To select AM or FM re ception rotate the selector control located beh...

Page 56: ...RADIO AND ANTENNA N c II 1 19 I I I...

Page 57: ...circuit breaker is a serviceable item The pump and motor are serviced as an assembly only RADIO SPEAKER REVERBERATOR The radio speaker reverberator is used to produce a time delay of 025 to 030 secon...

Page 58: ...HES CENTER OF WINDSHIELD I SPRAY NOZZLES MEASURE DOWN FROM BOTTOM OF WINDSHIELD MOULDING 64x 149A Fig 3 Washer Aiming Requirements AR 1 AR 2 Models move the cover tor terminal the pump and motor brack...

Page 59: ...rication fitting over which the lubrication gun was installed A spe cial ball check is installed in the remaining portion of the fitting to prevent foreign materials from passing through the fitting T...

Page 60: ...t or brake fluid leaking onto d Loose strut bushings e Power steeringcontrol valve out of adjustment f Incorrectfront wheel alignment particularly 9 Broken or sagging front or rear spring h Excessivel...

Page 61: ...ended pressure All tires should be the same size in good condition and have equal wear Note the type of wear to aid in diagnosing Group 22 2 Inspect the suspension and steering linkage pivot points fo...

Page 62: ...art Camber and Caster Access holes to loosen the upper control arm cam bolt nuts have been provided for in the fender side shields Fig 3 of the Belvedere Satellite vehicles The front access hole is ma...

Page 63: ...r with 4 Slide the torsion bar into the hex opening of 5 Install the plug and lock ring in the rear anchor cupped end toward rear of bar Multi Mileage Lubricant No 2298947 the lower control arm 6 Pack...

Page 64: ...le and tighten the ball joint stud nut 55 foot pounds Valiant and 100 foot pounds all other mod els Install the cotter pin 4 Tighten the steering knuckle upper bolt nuts 55 foot pounds Tighten the low...

Page 65: ...m the steering knuckle arms Fig 9 Use care not to damage the seals 2 Remove the inner tie rod ends from the center link NK387 Fig 9 Removing Tie Rod End Stud 16elvedere satellif el 3 Remove idler arm...

Page 66: ...Tool C 3894 Fig 9 Fury Models use Tool C 3742 Use care not to damage 3 Remove the sway bar to strut strap 4 Remove the steering knuckle to brake support bolts and remove the steering knuckle arm Move...

Page 67: ...ake support on the steering knuckle and install the two upper bolts and nuts fin ger tight only 7 Position the steering knuckle arm on the steer ing knuckle and install the two lower bolts and nuts 8...

Page 68: ...val and Disassembly 1 Place a jack under the lower control arm as close to the wheel as possible and raise the vehicle until the wheel clears the floor 2 Remove the wheel and tire as an assembly 3 On...

Page 69: ...atellite police and taxi appli cation using the bushing support sleeve remove Tool C 3710after the bushing has been installed and 0 BALL JOINT 62x54C Fig 77 Upper Control Arm Assembly IAV 7 AV 21 Fig...

Page 70: ...out of the steering knuckle with tool alone 5 On Fury Models remove the upper ball joint stud nut and remove the stud from the control arm using Tool C 3964 6 Remove the tool then remove the ball joi...

Page 71: ...1 AV 2 Model 7 25 Ring Gear Diameter rear axle has a housing of one piece design Due to the integral type design the drive pinion and the differential case with drive gear are mounted directly to the...

Page 72: ...d 9 Damaged gears pinion OVER HEATING OF THE AXLE UNIT a Lubricant level too low b Bearing adjusted too tightly c Excessive wear in gears LOSS OF LUBRICANT a Lubricant level too high b Improper type l...

Page 73: ...ft IDitarrembledl BLOCKS BEARING ADAPTER SLEEVE SP 5041 RING BLOCK HOLDING SP 5017 NK360 Fig 5 1001 Set C 3971 The right hand shaft with the adjuster in the retainer plate will also have a lock on one...

Page 74: ...ull the roller retainer down as far as possible and cut it with a pair of side cutters and remove from the assembly Fig 12 6 Remove roller bearing cup from axle shaft 7 Using Tool C 3971 remove the be...

Page 75: ...ue end play reading is indicated 7 Remove one retainer plate nut Install the ad juster lock If the tab on the lock does not mate with a notch on the adjuster turn adjuster until it does Install the nu...

Page 76: ...screwing it securely into the pinion oil seal Tighten the puller screw to remove the seal 10 While holding one hand over the companion flange end of the carrier invert the carrier in the Fig 78 Markin...

Page 77: ...st not exceed 003 inch runout If the run out is in excess of 003 inch the differential case must be replaced 8 Measure the side gear clearances between the gear and the case Fig 21 Clearances should b...

Page 78: ...mage which might render it unfit for further service 4 Inspect the differential pinion shaft for exces sive wear Replace as necessary 5 Inspect the differential pinion gears for exces sive wear cracks...

Page 79: ...the thrust block through the hub so that the slot is centered between the side gears 6 While keeping all of these parts in proper align ment push the pinion shaft into the case until the locking pin...

Page 80: ...tions to make a complete revolution while tightening Remove the holding tool and rotate the assembly several turns in both directions to align the bearing rollers Retest torque to 240 foot pounds torq...

Page 81: ...ion marked 2 install a washer 084 inch thick 086 002 084 inch or when a washer 086 inch thick is too loose and 088 inch too tight use 086 inch Fig 29 lnrta hg Arbor in Carrier Fig 30 Determining Space...

Page 82: ...t a gauge washer that will just pass between the gauge block end of the tool and the machined surface of the bearing arbor As an example if a 090 inch spacer can be inserted but a 092 inch spacer cann...

Page 83: ...nut Tight en the flange nut to 240 foot pounds torque and re move the flange holding tool Differential Bearing Preload Without Using Depth of Mesh Tool C 758 If the differential assembly was satisfact...

Page 84: ...e until all adjust ments have been completed Fig 34 Measuring Backlash Between Drive Gear and Pinion DRIVE COAST CORRECT ADJUSTMENT Canter Cantar 1 PINION SPACER TOO THICK lor Lor Hael Lon PINION SPAC...

Page 85: ...elding Rear Axle Housing The axle housing should be completely disassem bled if it is to be welded with arc welding equipment It is also possible to weld the assembled housing with gas welding equipme...

Page 86: ...shaft housing using Tool 2 3724 Fig 41 4 Apply Automotive Multipurpose Lubricant Grade NLGI No 2 on the bearing outside diameter for prevention of rust 5 Install a foam gasket on the axle housing stud...

Page 87: ...mount a dial indicator Tool C 3339on pilot stud Tool C 3288 and load the indicator slightly when the plunger is at right angles to the back face of the drive gear Fig 42 5 Measure the drive gear runou...

Page 88: ...aws Fig 48 Removing Differential Carrier Bearing 16 Remove the drive gear bolts BOLTS ARE LEFT HAND THREAD Remove the drive gear 17 If the drive gear runout exceeded 005 inch in step 4 the differentia...

Page 89: ...Bearing cups should have a smooth unbroken surface 7 Differential pinion gears and side gears should have smooth teeth with a uniform contact pattern without excessive wear or broken surfaces The hub...

Page 90: ...ng with Tool 2 3281 Permit the tool to turn to several rotations during the tight ening operation Leave the tool in the carrier for de termining depth of mesh Drive Pinion Depth of Mesh Using Tool c 3...

Page 91: ...ch is moving through several full turns Correct preload is 15 to 25 inch pounds A reading which var TOOL 4 NY1024 Fig 57 Installing Pinion Yoke ies during rotation indicates a binding condition which...

Page 92: ...e tightening the spreader tool Spread the housing 010 to 015 inch CAUTION Never spread the housing more than 020 inch as the case may take a permanent set 11 Remove the dial indicator Fig 59 Feeler Ga...

Page 93: ...4 to a thickness great enough to reduce the zero end play backlash within the chart limits then follow the rec ommendedprocedure 3 Connect the hand brake cable support at the 4 Connect the propeller s...

Page 94: ...rning them If they both turn in the same direction the vehicle is equipped with a Sure Grip Differential or the letter S stamped on the identification pad o n the right side of carrier hous ing or by...

Page 95: ...to reinstall them Lubrication Multi purpose gear lubricant as defined by MILL 2105B is used in all rear axles Chrysler Hypoid lubri cant Part No 1879414is also recommended AnticipatedTemperature Visco...

Page 96: ...attaching bolts and re move the case cap Fig 66 and clutch plates Fig 67 3 Remove the side gear retainer Fig 68 and the side gear Fig 69 4 Remove the pinion shafts with pinion gears Fig 70 5 Remove th...

Page 97: ...lace the pinion gears on the shafts and install the assembly on the drive gear half of case Insert the thrust spacer in the pinion shaft Fig 75 5 Slide the cap half of the case over the edge of the be...

Page 98: ...as outlined for the conventional axle Installation outer oil seal and Seal Protector Tool C 745 when installing the brake support over the rear axle shaft Before lowering the rear wheels of the vehicl...

Page 99: ...ter cylinder and bleed the hydraulic system SPONGYBRAKE PEDAL a Air in hydraulic system b Improper brake fluid low boiling point c Excessivelyworn or cracked brake drums d Broken pedal pivot bushing a...

Page 100: ...Sticking or frozen brake cable f Broken rear spring 9 Bent or rusted cable equalizer a Adjust the brakes and check the fluid b Releasethe parking brakes c Replace the brake shoe return spring d Free u...

Page 101: ...Sticking or unseated actuating valve assembly GRUNTING NOISE IN BOOSTER ON APPLICATION a Air in hydraulic system b Lack of valve plunger lubrication c Fluid low in master cylinder a Adjust brakes and...

Page 102: ...be rotated freely then back off the cable adjusting nut two full turns Testing Automutic Adjuster Operation Place the vehicle on a hoist with a helper in the driver s seat to apply the brakes Remove t...

Page 103: ...ustment by prying up with the adjustingtool 4 Remove the wheel cover grease cap cotter pin lock adjusting nut outer wheel bearing and remove the wheel and drum assembly from the spindle 5 Inspect the...

Page 104: ...ers Springs and Pins of the brake shoe to backing plate retainer spring and while holding the backing plate retainer clip press in and disconnect the spring Fig 6 RETAINER CLIP 2 Fig Removing or Insta...

Page 105: ...tripped threads Grinding Recommendations Brake Shoe Lining New lining should be meas ured and ground 060 to 080 maximum under the drum diameter Drum Refacing Measure the drum runout with an accurate g...

Page 106: ...f keeping the master cylinder full while pressurizing the hy draulic system for bleeding The brakes may also b bled manually by having an assistant slowly pump the brake pedal while the brakes are bei...

Page 107: ...linder bore is not increased more than 002 inch A master cylinder bore that does not clean up at 002 inch should be discarded and a new cylinder installed Black stains on the cylinder wall are caused...

Page 108: ...ion can usually be cleaned with crocus cloth using a circular motion However cylinders that PUSH ROD BOOT PISTON have deep scratches or scoring may be honed using Tool C 3080 providing the diameter of...

Page 109: ...the brake shoes installed on the support apply a small amount of a putty type sealing material around the back side of all holes and openings of the support to prevent any water or dirt from entering...

Page 110: ...aining clips Steel tubing is used to conduct hydraulic pressure to the front and rear brakes Flexible rubber hose is used at both front brakes and at a rear axle junction block Steel tubing is used fr...

Page 111: ...r extending to parking brake pedal or release handls Figs 15 16 17 and 1 8 Fig 15 Parking Brake Cable Routing AR I AR 2 AP I AP 2 Purking Brake Adjustment IMPORTANT The service brakes must b properly...

Page 112: ...12 Service Brakes Installing the Rear Parking Brake Cable bracket Figs 17 and is When installing a new brake cable lubricate the 6 Using a screw driver force the upper end Of the cablewith short fibr...

Page 113: ...end of the cable into the parking brake pedal clevis 4 Insert the cable through the body crossmember and firmly press into place the housing and attaching clip 5 Attach the front cable to the equalize...

Page 114: ...plate attaching screws 10 Relax the retaining pressure on the end plate and expose the vacuum piston 11 Scribe alignment mark on the face of the pis ton to coincide with the cover and cylinder scribe...

Page 115: ...spring and poppet return spring 12 Align the front and rear piston plates and in stall 6 attaching screws finger tight Progressively tighten every other screw lightly until all are tight ened to 55 in...

Page 116: ...en to 100 inch pounds 3 Connect the push rod to the brake pedal link age 4 Attach the brake line to the master cylinder 5 Attach the vacuum hose to the power brake 6 Remove retaining wire from port of...

Page 117: ...long tangs on the housing Do not bend the lock at re moval as it must be reinstalled at assembly 6 Remove the check valve from the cover by pry ing out of the rubber grommet 7 Place Tool C 3281 over...

Page 118: ...be used when han dling the power piston diaphragm and metal parts The diaphragm should be kept clean Grease o i l and foreign matter can cause a deterioration o f the diaphragm Protect the diaphragm...

Page 119: ...iston 6 Remove the 0 seal ring from the end of the control piston 7 Remove the filter elements and dust felt from the control piston rod Cleaning and Inspection Thoroughly wash all metal parts in a su...

Page 120: ...resulting chips 9 Install the diaphragm on the power piston make sure diaphragm is seated in the power piston POWER BRAKE COMPONENTS Assembly 1 In the housing blocked to prevent bending drive the bloc...

Page 121: ...ds Install the attaching nuts and washers Tighten to 200 inch pounds Installation 1 Reinstall the dash panel to power brake seal 2 Position the power brake unit on the dash pan el then install the att...

Page 122: ...ching bolt from the power brake push rod and brake pedal linkage 5 Remove the four power brake attaching nuts and washers 6 Remove the power brake and master cylinder from the vehicle and place on a s...

Page 123: ...lows to the dia phragm Fig 40 10 Pull the bellows out of the bellows retainer and remove the retaining ring from the bellows 11 Slide the master cylinder push rod assembly off of the plunger Fig 41 12...

Page 124: ...f I REAR COVE1 63x349 b Fig 45 Rear Seal Assembly 10 Install the load ring onto the plunger with the concave face out 11 Press downward on the valve body and insert the spring clip into the groove of...

Page 125: ...ed in the lower hole on the master cylinder mounting face Install the master cylinder on the power brake unit install the four nuts and BRAKES POWER MIDLAND ROSS 5 27 tighten to 100 inch pounds Instal...

Page 126: ...the clutch The rollers wedge themselves between the pressure plate and the clutch cover with a force which increases with engine speed The wedging action of the rollers applies additional force to the...

Page 127: ...etween the throwout bearing and the clutch fingers Lhkage ad justment is required to restore pedal free play when it has been reduced by normal wear of the clutch 1 Inspect the linkage Figs 2 3 or 4 f...

Page 128: ...emove the clutch housing pan 3 Disconnect the clutch linkage and return spring 4 Pull out the clutch release bearing and sleeve 5 Mark the clutch cover and flywheel to assure that the cover and flywhe...

Page 129: ...ASHER TORQUE SHAFT NK993 Fig r l u t c h Torque Shaft and Linkage IAV I AV 2 Models S C R E W BEARING TORQUE SHAFT I SNAP PEDAL ROD RING BRACKET W A S H E R NK994 Fig 6 Clutch Torque Shaft and Linkage...

Page 130: ...lutch fork proceed as follows 5 6 or 7 Should it become necessary to replace remove or 1 Disconnect the clutch fork return spring Figs 2 Disconnect clutch rod from clutch fork 3 Pry dust seal boot out...

Page 131: ...tain that all oil or grease has been re moved 3 Hold the clutch disc pressure plate and cover in mounting position with the springs on the disc damper facing away from the flywheel Do not touch disc f...

Page 132: ...face of the housing parallel with that of the block when assembling Bore Runout follows To correctly align the clutch housing proceed as 1 Mount Tool C 870 with C 435 Dial Indicator on TOOL 61x131 Fig...

Page 133: ...Tool C 771 If the total indicator reading is greater than 006 note the amount of the total in dicator reading and the location of the lowest indi cator reading Le the point where the indicator arm or...

Page 134: ...hibitor must be added to the water cool ant for normal corrosion protection Air conditioned vehicles require year round protection with perma nent type anti freeze with a minimum of 15 F protection fo...

Page 135: ...er passages 9 Flush the radiator thoroughly Restricted engine water jacket h Flush the engine cooling system thoroughly a Fill radiatorto correct level b Replacethe hose and spring Low coolant level B...

Page 136: ...ned pulleys e Non uniform groove or eccentric pulley a Adjust belt tension b Replace belt c Replace belt d Align accessories file brackets or use spacers as required e Replacepulley BELT ROLLED OVER I...

Page 137: ...equipped vehicles Loosen the fan drive belt by loosening the alternator mount ing bracket and swing the alternator in towards the water pump on vehicles equipped with air condition ing loosen the idl...

Page 138: ...ool C 3468 positioned against the outer bearing race only press the shaft and bearing into the pump body so the end of the bearing is flush with the body hub end 5 While supportingthe pump on the impe...

Page 139: ...int socket and support the pump body at the seal end and with Tool C 3468 positioned against the outer bearing race only press the shaft and bearing into the pump body so the end bearing is flush with...

Page 140: ...3 Remove upper and lower radiator hoses using pliers Tool C 3250 4 On vehicles with fan shroud remove lower half of fan shroud 5 Remove radiator attaching screws 6 The radiator can now be lifted free...

Page 141: ...rom the engine and attach them to the radiator Attach the flushing gun hose to the lower radiator tank and the drain hose to the top tank 11 Fill the radiator with water leave the water valve open and...

Page 142: ...uction at medium or high engine speeds If this spring is weak or broken it should be replaced RADIATOR PRESSURE CAP A 14 psi pressure vent type radiator cap Fig 11 is used as standard equipment 16 psi...

Page 143: ...nth service in spection 3 Measure all belts by the deflection method at servicing and retighten if needed 4 The new belt tension specifications should be used on all belt replacements and the above pr...

Page 144: ...COOLING SYSTEM 7 11 NK48 1 ROLLER ASSY SINGLE BELT n NK485 NK483 Fig 74 Pelt Deflection locations...

Page 145: ...terminals CELLSSHOW MORE THAN 25 POINTS 025 SpecificGravity overcharge VARIATION Natural or prematurefailure essary Short circuit in low cell Loss of electrolyte by leakage or excessive Try to recharg...

Page 146: ...ortion of the stem should be about two inches long Clearance between the float and glass barrel at the smallest diameter should be a minimum of Ys around all sides and the barrel must be clean NOTE Hy...

Page 147: ...which does not gas freely on charge Unless elec trolyte has been lost through spilling or leaking it should not be necessary to add acid to a battery dur ing its life Acid should never be added unles...

Page 148: ...osts while battery is being fast charged If the total voltage dur ing charge exceeds 15 5volts the battery is sulphated and should be cycled and slow charged until specific gravity reaches 1 260 See S...

Page 149: ...hould be replaced Safe slow charging rates are determined by allow ing one ampere per positive plate per cell The proper slow charging rate would be 4 amperes for a 48 am pere hour battery or 5 ampere...

Page 150: ...est specific gravity Recharge or replace the b Test and replace the switch if necessary c Clean terminals and clamps replace if nec essary Apply a light film of petrolatum to terminals after tightenin...

Page 151: ...STARTING MOTOR REDUCTION GEAR a 7...

Page 152: ...the battery specific gravity is below 1 220 recharge the battery to full charge before proceeding with the test 2 Disconnect the positive battery lead from the battery terminal post Connect an 0 to 30...

Page 153: ...starter against the follow ing specifications 3 With applied battery voltage adjusted to 4 volts the amperage draw should be as shown in speci fications SERVICING THE STARTING MOTOR Disussembly 1 Pla...

Page 154: ...move the brush holder plate with the brushes as an assembly 11 Remove the solenoid assembly from the gear housing well Fig 6 12 Remove the nut steel washer and the sealing washer from the starter batt...

Page 155: ...e diameter of the pinion shaft oth erwise the lock ring can be damaged 19 Push the pinion shaft towards the rear of the housing Fig 10 and remove the snap ring and thrust washers clutch and pinion ass...

Page 156: ...ture shaft and each of the com mutator riser bars with a pair of test lamp test prods If the lamp lights it indicates a grounded armature Replace a grounded armature Testing Commutator Runout Refacing...

Page 157: ...Removing and Installing the Pinion Housing Drive Shaft Bushing Rotate the pinion The pinion gear should rotate smoothly in one direction not necessarily easily but should not rotate in the opposite di...

Page 158: ...8 1 4 STARTING MOTOR REDUCTION GEAR L ai n n n c...

Page 159: ...ed 6 Install the driven gear snap ring Fig 8 7 Install the pinion shaft retaining ring Fig 9 8 Bend the four 4 Tangs of the coil retainer up to a measurement of 5 32 to 3 1e above the sur face of the...

Page 160: ...der securely with a high temperature resin core solder and resin flux 15 Carefully enter the solenoid coil and brush plate assembly into the bore of the gear housing and position the brush plate assem...

Page 161: ...me and gear housing mat INSTALLATION OF THE STARTING MOTOR 1 Before installing the starting motor make sure the starter and flywheel housing mounting surfaces are free of dirt and oil to insure a good...

Page 162: ...normal portion of the circuit is removed from the test A definite change in the voltmeter reading indicates that the last part eliminated in the test is at fault Maximum allowablevoltage loss is as f...

Page 163: ...erminal 3 Connect the voltmeter 15volt scale across the starter 4 Rotate the carbon pile to the full resistance po sition 5 Connect the battery cable from the battery neg ative post to the starter fra...

Page 164: ...ng the field frame and coil assembly and or armature will damage the insulation Wipe these parts with a cloth only 2 Do not immerse the drive unit in a cleaning solvent The drive clutch is pre lubrica...

Page 165: ...ort Circuit Place the armature in a growler Fig 8 and hold a thin steel blade parallel to the core and just above it while slowly rotating the armature in the growler A shorted armature will cause the...

Page 166: ...ge the armature core NOTE Scribe a mark on the pole shoe and field frame to ensure the pole shoes are assembled in their original position TEST PROBES SHUNT LEAD Fig 7 l Testing Shunt Coil for o Groun...

Page 167: ...all the through bolts and tighten to 40 to 50 inch pounds ADJUSTING STARTER DRIVE GEAR PINION CLEARANCE 1 Place the starter assembly in a vise equipped with soft jaws and tighten the vise sufficiently...

Page 168: ...ingto specifications c install new brushes and or slip rings d Clean the slip rings and brush holders Install new brushes e Test all the field circuit connections and cor rect as required f Inspect al...

Page 169: ...new bearing as required d Remove and disassemble the alternator Cor rect the interference as required e Remove and disassemble the alternator Install a new rotor f Remove and disassemble the alternato...

Page 170: ...hat the field circuit is com pleted only when the ignition switch is turned ON The voltage regulator Fig 4 has two sets of con tacts using a common single armature The upper and lower stationary conta...

Page 171: ...es the armature spring tension and opens the upper contacts The armature contacts at this time do not touch either the upper or lower stationary contacts Field current now flows through the regulator...

Page 172: ...e belt 3 Inspect the condition of wires and their connec tions Before performing the test on the system cor rect any problem with the wiring such as loose con 64 x 472 Fig 7 7ester lead Connections V...

Page 173: ...tch of the Battery Post Adapter 9 With the tester Field Control in the OPEN posi tion start the engine and adjust to 1250RPM 10 Open the BY PASS Switch of the Battery Post Adapter 11 Rotate the tester...

Page 174: ...WITCH VEHICLE VA REGULATOR 64x476A Fig 7 I G r o u n d Circuit Resistance Test position 5 With the engine operating at 1250 RPM rotate the tester Control Knob clockwise until the Ammeter reads exactly...

Page 175: ...spe cific gravity in the winter or 1 245 specific gravity in the summer with a minimum water requirement not more than an ounce of water per cell per one thousand miles Regulator Mechanical Adjustmen...

Page 176: ...hese parts Allow solder to cool sufficiently for fusewires to make a good solder joint 4 Pull the new fuse wire up enough to remove the slack and wrap it around the bracket Solder the coiled wire to t...

Page 177: ...ons the brush vertically against one of the slip rings 1 Remove the retaining screw lockwasher insu lated washer and field terminal and carefully lift the plastic holder containing the spring and brus...

Page 178: ...nd the reading at the shorted rectifier will be zero Disconnect the lead to the rectifier reading zero and retest The reading of the good rectifiers will now be within the satisfactory range TEST PROD...

Page 179: ...microfarad plus or minus 20 e Unsolder the rectifier leads from the stator leads f Test the stator for grounds using a 110 volt test lamp Fig 22 Use wood slats to insulate the stator from the rectifi...

Page 180: ...ver Fig 26 9 Support the end shield and tap the rotor shaft with a plastic hammer to separate the rotor from the end shield NOTE The new bearing is lubricated with a pro determined amount of special l...

Page 181: ...nk NOTE The new bearing is pre lubricated and no additional lubricant should be added as an exces C 3770 3x65 Fig 29 Removing the RectifierEnd ShieldBearing SOLDER WITH GROUND BRUSH RING ORE SOLDER LU...

Page 182: ...F 1 Q I Fig 33 Insfalling the Slip Ring ROTOR 63x43 Fig 34 Installing Bearing Grease Refainer CAUTION Be sure the solder bead does not pro trude beyond the surface of the plastic material Do not use a...

Page 183: ...62x114 A RECTIFIER LEAD Fig 36 Soldering Rectiffer and Stator Leads Fig 37 Installing the Rectiffer End Shield Bearings 63 x 728 connection touch a dampened cloth aga nst it Th is will aid in forming...

Page 184: ...sition and tighten the lock nut 14 Position the stator on the rectifier end shield 15 Position the rotor end shield assembly on the stator and rectifier end shield Align the through bolt holes in the...

Page 185: ...ng adjust as necessary Replace and adjust the distributor contacts c Align and adjust contacts d Test and replace coil if necessary Replace and adjust contacts e Inspect conditions and correctly conne...

Page 186: ...re is identified by the word Radio stamped on the insulating jacket No additional re sistors are necessary The rotor and distributor cap electrodes should be inspected for burning Replace the rotor if...

Page 187: ...the distributor shaft bushings or breaker plate is indicated Remove distributor for complete inspection and testing on a distributor test er Dwell variation at speed above 1500 rpm does not necessaril...

Page 188: ...uge The wire loop must be down on the distributor shaft to insure a straight pull also be sure that the wire loop does not interfere with the indicator or indicator holding bracket Apply a five pound...

Page 189: ...ove through the Fig 5 Removing Distributor Housing Upper Bushing TOOL AMP rwit NY698 Fig Removing Distributor Housing lower Bushing Typical top of distributor body Remove the upper thrust washer d Rem...

Page 190: ...governor weights 3 Inspect all bearing surfaces and pivot pins for roughness binding or excessive looseness 4 Install the cam spacer chamfered end down on distributor shaft 5 Slide the cam and yoke as...

Page 191: ...g that the centerline between two of the gear teeth is in line with the cen terline of the rotor electrode Fig 12 drill a 124 129 inch hole and install the roll pin CAUTION Support the hub of gear whe...

Page 192: ...arcing and burningof the contactswill result TESTING DISTRIBUTOR ADVANCE Centrifugal Advance Curve Carefully mount the distributor assembly less cap and rotor in a reliable stroboscope type distributo...

Page 193: ...ed 11 Rotate the distributor housing so that the tim ing mark on the crankshaft damper is aligned with the BTC mark on the chain case cover Refer to Specifications Moving the distributor housing count...

Page 194: ...n wet weather Thoroughly wash the cap in a weak solution of liquid soap or non flamable detergent in warm water Do not use a concentrated solution or soak the cap in the solution Scrub the inner surfa...

Page 195: ...b utor terminal of coil and black lead to a good ground 2 Turn the Selector Switch to the 8 LOBE posi 3 Start the engine and operate at idle speed 4 Observe the dwell meter reading If the dwell readin...

Page 196: ...ckwise advances the timing and counter clockwise retards the timing 6 Tighten the distributor hold down clamp screw after the timing has been set and recheck the timing adjustment with a Power Timing...

Page 197: ...IGNITION SYSTEM 8 53 VACUUM SPRING 4 W R O T O R SCREW CAM SPACER SPRING GOVERNOR WEIGHT 7 WASHER SPRING 1 BEARING IT SCREW BASE e 61x109 B COLLAR PIN Fig 2 Distributor Disassembled View...

Page 198: ...ITION SYSTEM SPRING 1 r CONTACT LEAD BREAKER PLATE WASHER Av SCREW 1 SHAFT HOUSING CLAMP WASHER SCREW OILER WASHER SCREW GASKET 2 PLUG1 BUSHING COLLAR 62 x 310 Fig 3 Distributor Disassembled View IPre...

Page 199: ...Push the grommet towards the inside of the distributor to remove Do not pull on the wire 5 Remove the two screws and lockwashers attach ing the contact plate to the housing and lift out the contact p...

Page 200: ...5 to 5000 inch ASSEMBLING THE DISTRIBUTOR 1 Test operation of centrifugal weight and inspect the weight springs for distortion Lubricate the gov ernor weights 2 Inspect all bearing surfaces and pivot...

Page 201: ...op of the distributor cam with 3 to 5 drops of SAE 1OW oil 3 Wipe all old grease from surface of the dis tributor cam Apply a light film of new distributor cam lubricant number 1473595 NOTE Do not ove...

Page 202: ...ry lead of a Power Timing Light to the NO 1spark plug using proper adapter Connect the red primary lead to the positive termi nal of the battery and the black primary lead to the negative battery term...

Page 203: ...st resistor temperature rises increasing the resistance This reduces the current flow thereby pro longing ignition contact life At high speed operation when the primary current flow is low the ballast...

Page 204: ...ed with regular cleaning techniques The plugs can then be reinstalled with good results as the en gine has scavenged itself Core Bridging Core bridging Fig 5 will be encountered only rarely in automot...

Page 205: ...rheating Overheating Fig 9 is indicated by a white or light gray insulator which appears blistered Electrode gap wear rate will be considerable in excess of 001 lo00 miles This suggests that a cooler...

Page 206: ...caused by some foreign object in the combustion chamber Since small objects can travel from one cylinder to another always check the other cylinders to prevent reoccurrence of damage Inspect the dist...

Page 207: ...High resistance in headlamp circuit d Faulty sealed beam units nection Make necessary repairs HEADLAMPS DIM en gine running above idle a High resistance in headlamp circuit b Faulty sealed beam units...

Page 208: ...ion 2 Test the high beam indicator indicates the highbeam is in operation when lighted 3 Inspect for badly rusted or faulty headlamp as semblies These conditions must be corrected before a satisfactor...

Page 209: ...targets are not aligned in the viewing ports ro tate the mirror adjusting screw until the target split image becomes aligned MOUNTING AND ADJUSTING THE AIMERS 1 While holding an aimer in alignment wi...

Page 210: ...ve the aimers by releasing the spring lock at the rear bottom of the aimer and pushing the release lever forward Do not attempt to r e move the aimers by pulling them away from the headlamp Iens slide...

Page 211: ...PERATURE GAUGE OPERATION ERRATIC OPERATION O F FUEL GAUGE ACTUAL ENGINETEM EXTERNAL LAMPS OPERATE NORMALLY NO INDICATION ON INSTRUMENT CLUSTER SYSTEM DOES NOT FLASH a Faulty instrument panel temperatu...

Page 212: ...left of the steering column con tains the alternator ammeter gauge fuel and tem perature gauges and the oil pressure indicator lamp The clock if so equipped is located on the instru ment panel in line...

Page 213: ...or if the fuel tank is empty the resistance is increased which decreases the current flow and consequently positions the in strument panel gauge pointer to low or empty When the tank is full the floa...

Page 214: ...e should show E or minus 3 32 inch NOTE The minus tolerance provides a small fuel reserve when the gauge is on E position With the gauge tester on M the fuel gauge should slowly advance to the Y 2 pos...

Page 215: ...e exception that Tester C 3826 is connected to the temperature gauge S terminal With the gauge tester on L position the tem perature gauge should show C or cold With the gauge tester on M position the...

Page 216: ...ect the battery ground cable before servicing the cluster 1 Disconnect the speedometer cable from the Removal speedometer 2 Remove the four mounting screws from the steering column opening cover in th...

Page 217: ...If voltage is available substitute a good lamp or gauge in the inoperative circuit 3 Connect the plug connector to the printed cir cuit board and connect a test lamp prod to the input side of the lam...

Page 218: ...PARK AND TURN PANEL INDICATORS BULKHEAD CONNECTOR LEFT TURN AND STOP RIGHT TURN SIGNAL I SWITCH 1 SWITCH FUSE BLOCK AMMETER TAIL STOP DOME 2 0 AMP FUSE IGNITION SWITCH 64x420A Fig I Turn Signal Wirin...

Page 219: ...the switch from the steering column When the switch is removed leave the string or wire in the steering column jacket tube as an aid to replacement of the wiring 8 Remove the screws attaching the tur...

Page 220: ...on glass glass MOTOR WILL NOT STOP WHEN INSTRU position MENT PANEL SWITCH IS TURNED OFF a Motor park switch failure in the closed MOTOR STOPS IN ANY POSITIONWHEN INSTRU position MENT PANEL SWITCH IS T...

Page 221: ...parking cam rotates 180 degrees lengthening the drive link slightly to park the wiper blades in a depressed position The drive link shortens when the motor runs in the wipe direction Figs 1 2 and 3 S...

Page 222: ...d Moulding Right left AV 1 AV 2 1x 3 x 2 AR 1 AR 2 4 21 4 2 A 1 A 2 1 3 2 If the clearance is not in the specified range use a suitable tool and reposition the wiper arm and blade assembly Fig 4 Wiper...

Page 223: ...the wiper motor at the wiper motor 3 Connect the wiper link at the wiper motor and install the retaining clip For variable speed motors position the spring trip as outlined in the Wiper Link Assembly...

Page 224: ...o the housing at the output shaft while being careful not to damage the inside diameter of the housing Press in a new seal before reassembling the wiper motor 6 Replace the gasket under the park switc...

Page 225: ...Variable Speed Models AR 7 and AR 2 right hand link in the same manner after removing the crank arm to lever nut and the spacing washers between the link crank arm and lever Assembly Variable Speed Mo...

Page 226: ...and left pivot out through the cowl grille panel opening The connecting link can be serviced on the bench after the links are removed from the vehicle lnstallation Make certain the wiper system is in...

Page 227: ...nal or in the grounding of the steering column Adjusting termine which horn is not operating 1 Disconnect the connections at each horn to de 2 Remove the horn and bracket assembly 3 With a suitable to...

Page 228: ...ns and Solenoid unit Clicks SLAVE UNIT IN OPERATIVE Motor UnitO K Solenoids and Drive EXCESSIVE FREE PLAY INTHE UNIT Seat has a RockingMotion Excessive Movementbetweenthe Slide and the Baseof the Trac...

Page 229: ...rc weld 2 Tighten the rack attaching pins by arc welding b Test and replace slave unit if necessary a Test for electrical continuity between the cir cuit breaker and the control switch Repair or repla...

Page 230: ...ace coupling and test motor and gear box alignment f Repair or replace lift motor Test for sticking door switch as possible cause of motor failure 9 Inspectand test wiring See Wiring Diagrams a Faulty...

Page 231: ...he switch One used for power two for motor field current which also actuates the relay for motor armature current and three wires at tach to solenoids controlling the movement of the front riser rear...

Page 232: ...t on the left side tubes Make sure the flexible cables seat in the slot in the drive unit RIGHTSEAT TRACK ASSEMBLY CABLE MOUNTING BRACKET BRACKET MOUNTING SCREWS FLEXIBLE CABLES AND TUBES ASSEMBLY 63x...

Page 233: ...4 2 Remove the two screws holding the plate and solenoidsto the drive unit Fig 6 3 Remove the plate and solenoid assembly Be careful not to lose the three springs under the sole noid 4 To remove the s...

Page 234: ...T RACK CLEVIS PINT H Fig 7 Removing Left Slave Unif 7 Fasten the solenoids to the drive unit 8 Install the drive unit Refer to Installation of Flexible Cables steps 1 through 4 CLUTCH SOLENOIDS fig 8...

Page 235: ...SIX WAY POWER SEATS 8 91 Fig 1 Seat Track and Rails Assembly USE WITH SINGLE LEFT RIGHT FOUR WAY I F3A I I T LEGEND 1 Fig 2 Four Way Power Seat Wiring Models AP 1 and AP 2...

Page 236: ...ng the seat assem bly to the seat track at the rear of the seat track rails 2 Operate the seat to the extreme forward posi tion to allow access to the two Phillips head screws attaching the seat assem...

Page 237: ...the gear housing A coupling is used on both the horizontal and vertical drive mechanisms Removal of the motor allows the coupling to be serviced by pulling the coupling off the end of the drive shaft...

Page 238: ...glass in serting the control arms onto the glass channel Place a leather washer on each side of the channel and secure in place with a retaining clip 5 Connect the wires to the lift motor and con nect...

Page 239: ...the trim panel switch and garnish moulding Quarter Glass Regulator 1 2 Door Hardtopl Models AR 7 and AR 2 NOTE If the window regulator is jammed in either the extreme UP or DOWN position it is neces...

Page 240: ...SIDE TO R E A R WINDOW DEFOGGER SWITCH M2A TO RIGHT FRONT DOOR AUTOMATIC SWITCH I TO STOP TRACER YELLOW WITH t I BULKHEAD CONNECTO R COMPARTMENT WIRING TOENGINE I I l l HEATER BLOWER MOTOR RESISTOR S...

Page 241: ...AIR CONDITIONING FUEL GAUGE SENDING UNIT VARIABLE SPEED BACK UP LAMP SWITCH AUTOMATIC TRANSMISSION 4 4 1 4 7 1 AIL GATE WINDOW AND TOP LIFT SWITCH AMMETER I I ACCESSORY CIRCUIT BREAKER I I TO BODY SI...

Page 242: ...CH I BLOWER MOTOR RESISTOR BLOWER SWITCH CIA I 1 I I B I TO BULKHEAD rD2 DOME STOP AND TAIL DISCONNECT i C3B SWITCH IAIR CONDITIONING AND HEATER I I INDSHIEL ARMATURE FIELD 2 FIELD 1 I I I I I A1 15 B...

Page 243: ...SHER SWITCH IVARIBLE SPEED Q3 I R6 18 L6 L2 HEADLAMP El BACK UP LAMP 1 7 SWITCH IAUTOMAIIC I TRANSMISSION I n1 I INSTRUMENT LAMP OPEN DOOR r M 2 C A M Ai I IlSlNGLE SWITCH SPEED 1 BLACK WITH NK887 Fig...

Page 244: ...AL TRANSMISSION WITHOUT TACHOMETER I DEFOGGER SWITCH MlC TO REAR AIR CONDITIONER WIRING DASH LINE TO MOTOR TURN SIGNAL TO AIR CONDITIONER CLUTCH RESISTOR BYPASS SWITCH TO INSTRUMENT PANEL TURN SIGNAL...

Page 245: ...WIRING DIAGRAMS 8 101 BRAKE SWITCH CIRCUITS A1 I 12 I RED CIR 1 GA I COLO R I A W I N G CIRCLE INDICATES NK 866 Fig 3 lnrtrument Panel Wiring Models AP I and AP 2...

Page 246: ...8 102 WIRING DIAGRAMS...

Page 247: ...WIRING DIAGRAMS 8 103 p 4 LL 5 5 5 n...

Page 248: ...8 104 WIRING DIAGRAMS I 3 L 3 d 3 f C 0 0 E C 0 0 c G...

Page 249: ...WIRING DIAGRAMS 8 105 c c I I f l z 1 I C 0 U v c c Q X u c c 0 C L 55 x D 0 9 h ci ii...

Page 250: ...8 106 WIRING DIAGRAMS I P m 6 U I J z I g z a 3 g 2 3 Q 2...

Page 251: ...WIRING DIAGRAMS 8 1 07 0 t z B I 5 E z 3 s E 6 v a Y t z P U d a Y I P s U D c Y c n I I I B...

Page 252: ...8 108 WIRING DIAGRAMS Y U Y E U 3 5 m PI x l w 3 2 n m 0 4 Y Y...

Page 253: ...AMS 8 109 RIGHT RIGHT SIDE HEADLAMP TEMPERATURE GAUGE SPARK PLUGS SENDING UNIT I RIGHT BANK Fig I I Engine Compartment Wiring Models AV I and AV 2 NK750 NK748 Fig 12 Engine Compartment Wiring Models A...

Page 254: ...UNIT LEFT TAIL STOP TO RIGHT AND LEFT INSTRUMENT PANEL WIRING AUTOMATIC DOOR SWITCHES Fig 13 Body Wiring fStafion WagonLModels AV 1 and AV 2 REAR WINDOW C PILLAR TO REAR WINDOW DEFOGGER MOTOR DEFOGGER...

Page 255: ...FEED CIRCUIT SEE INSTRUMEN BREAKERj j W 2 A A 1 PANEL WIRING DIAGRAM 63x797 Fig 15 Power Window Wiring Models AR 1 and AR 2 BACK UP LAMP SWITCH B M 1C RIGHT COURTESY LAMP GEAR SHIFT SELECTOR LAMP LEF...

Page 256: ...EFT SIDE COWL 3 GROUND X2D TO CIGAR LGHTER FEED SPLICE Fig 17 Console Wiring Automatic Transmissionand Vacuum Gauge Models AP 1 and AP 2 MlC RIGHT COURTESY LAMP M 2 C t IGNITION COIL T1 LEFT COURTESY...

Page 257: ...CONSOLE LAMP TO CONSOLE LAMP FEED CABLE ON INSTRUMENT PANEL TO M 2 CIRCUIT IN DOME LAMP WIRING TO LEFT FRONT AUTOMATIC DOOR SWITCH GROUND AT LEFT SIDE COWL GROUND X2D TO CIGAR x3 EX3A LIGHTER FEED NK...

Page 258: ...t Commando 383 8 B 383 Cubic Inch 9 2 to 1 2 BBI Carb Commando 383H 8 B 383 Cubic Inch 10 0 to 1 4 BBI Carb Spec Cam Commando 426H 8 RB 426 Cubic Inch 10 3 to 1 4 BBI Carb Spec Cam SIX CYLINDER ENGINE...

Page 259: ...mmando 361 has hydraulic tappets two bore carburetor 9 0 to 1 compression ratio uses regular fuel The Commando 383 has hydraulic tappets two bore carburetor 9 2 to 1 compression ratio uses regular fue...

Page 260: ...ons c Faulty starting motor 4 d e Faulty ignition cables e f Faulty coil or condenser f d Moisture on ignition wire and distributor cap Test battery specific gravity and recharge or replace as necessa...

Page 261: ...l or condenser distributor ENGINEMISSES ON ACCELERATION contact points ENGINE MISSES AT HIGH SPEED points a Dirty or incorrectly gapped distributor contwt b Dirty or gap set too wide in spark plug c W...

Page 262: ...ing clearance 9 Oil pump relief valve stuck h Oil pump suction tube loose bent or cracked a Check for correct oil level b Change oil c Check engine oil level d Clean tappets Install new push rods Insp...

Page 263: ...ied C At high altitudes or when using higher quality gasoline for example premium where regular is specified or super premium where premium is spec ified there is less tendency for spark ping In such...

Page 264: ...Fig 5 Rear Engine Mount AP I Fig Front Engine Mount AV I 10 Remove the speedometer cable and the gear 11 Disconnect the propeller shaft and tie up out 12 Install the engine support fixture Tool 2 380...

Page 265: ...ods and rods tube foot pounds torque ing a new gasket wiring to the engine DOWEL HOLE COOLANT PASSAGES head cover retor air cleaner 18 Install the radiator hoses battery and carbu 19 Fill the cooling...

Page 266: ...on only Install the rocker shaft bolts long bolt at rear of engine and tighten to 25 foot pounds torque 6 Loosen the 3 bolts holding the intake manifold to the exhaust manifold T h i s is required to...

Page 267: ...n to 25 foot pounds torque 4 Adjust tappets Hot intake 010 inch exhaust 020inch VALVES AND VALVE SPRINGS Valves are arranged in line in the cylinder head and operate in guides that are integral with t...

Page 268: ...of the valve seat us ing dial indicator No 13725 The total runout should not exceed 002inch total indicator reading 5 Inspect the valve seat with Prussian blue to determine where the valve contacts th...

Page 269: ...measure from the top of spacer If the height is greater than lll l j inches install a Il6 inch spacer in the head counterbore to bring the spring height back to normal inches to 111 16 inches TESTING...

Page 270: ...the cam shaft sprocket lock bolt and apply torque in the di rection of the crankshaft rotation to take up the slack 30 foot pounds cylinder head installed or 15 foot pounds cylinder head removed With...

Page 271: ...LER SCREW A REMOVING AND INSTALLING PLATE CHAIN CASE COVER NY161 Fig 23 Removing OilSeal Uool C 35061 INSTALLING PLATE TOOL SEAL A ASSEMBLY CHAIN cov Fig 21F Positioning Installer Plate Tool C 35061 3...

Page 272: ...ig 274nstalling Damper Assembly f T d C 3732AJ NY158 _ GEAR INTEGRAL WITH CAMSHAFT INTEGRAL WITH CAMSHAFT OIL PUMP AND DISTRIBUTOR DRIVE Fig 28 Camshaft and Sprocket Assembly Figure 28 Rearward camsha...

Page 273: ...nstall the horseshoe lock and drive the bearing shell into place Fig 3 0 The camshaft bearing oil hole or holes must be in exact alignment with the drilled oil passage or passages from the main bearin...

Page 274: ...F THE PISTON SKIRT SHOULD B E 008 TO 010 IN LESS AT DIAMETER A THAN ACROSS ETER B MEASUREMENT IS MADE e IN BELOW LOWER RING GROOVE NY221B Fig 32 Piston Measurements DIAMETERS AT C AND D CAN B E EQUAL...

Page 275: ...ANVIL TOOL S C R E W TOOL ONNECTING ROD KRl95B GUIDE LARGE TOO Fig 3 6 T o O iArrangement for Removing Piston Pin Tool C 37241 MAIN SCREW ANVIL TOOL1 Fig 35 Removing PistonPin Tool C 3724 4 Install t...

Page 276: ...rly positioning the pin in the connecting rod 11 Remove the tool and arrange the tool parts and piston assembly in the same manner as shown in Figure 34 for measuring the pin fit 12 Place the assembly...

Page 277: ...ng rod is toward the right side of the en gine 5 Screw the connecting rod bolt protector part of Tool C 3221 on one rod bolt and insert the rod and piston into the cylinder bore Rotate the crank shaft...

Page 278: ...oft copper or brass shim stock 001inch thickness 3 Lubricate the main bearing journals and posi tion the shim stock across the center main journals 4 Install the bearing in the center main bearing cap...

Page 279: ...the tool is seated above the cap Fig 4 4 seal retainer to 30 foot pounds torque 1 Install a new seal in the seal retainer so that the 2 Install the bridge on the tool and tap the seal 3 Trim off the p...

Page 280: ...ten in the crankcase continue tighten ing until screen is positioned as shown in Figure 46 Hold a steel rule against the flat surface inside the case and measure from the edge of rule to the edge of t...

Page 281: ...right side of the engine as shown in Figure 48 9 This will cause the 2x4 block and the front of the engine to slide to the left approximately 1 Y 2 inches as shown in Figure 49 10 This movement will a...

Page 282: ...Lay a straightedge across the oil pump cover surface Fig 51 If a 0015 inch feeler gauge can be inserted between the cover and straightedge the cov er should be replaced 3 If the outer rotor length mea...

Page 283: ...W FITS I N Fig 57 ffeli Coil Installation has a free length of 2 82to 219 64 inch and i s red in color 12 If the oil pressure is low inspect for worn bearings or look for other causes of possible loss...

Page 284: ...e using new gaskets 6 Test the resistance of the spark plug cables and if the resistance is more than 30 000 ohms replace the cable 7 Remove the distributor Clean the cap and ro tor using a non flamma...

Page 285: ...test FRONT ENGINE MOUNTS Figs 59 and 601 Removul 1 Disconnect throttle linkage at transmission and 2 Raise hood and position fan to clear radiator 3 Remove torque nuts from insulator studs 4 Raise the...

Page 286: ...4 Install the engine support fixture Tool C 3487 on the chassis to support the rear of the engine Re move the crane 5 Raise the vehicle on a hoist install the trans mission engine rear support crossm...

Page 287: ...er arm shaft INTAKE ROCKER ARM EXHAUST ROCKERARM R O C K E R SHAFT L O C K PLUG J 0 ADJUSTING SCREW INTAKt PASSACjtS EXHAUST CROSSOVER PASSAGE 63x711 INTAKE P SSAGES Fig 64 Cylinder Head Assembly 1318...

Page 288: ...istributor vacuum line Fig 67 Cylinder Head Tightening Sequence 1273 8 3 I 8 Cubic Inch 2 Disconnect the throttle linkage coil wires heat indicator sending unit wire and heater hoses at the en gine 3...

Page 289: ...ion may result if tappets are forced down too rapidly a Install tappet chamber cover and tighten end bolts to 9 foot poundstorque b Install the valve covers with new gaskets and tighten to 40 inch pou...

Page 290: ...the valve retaining locks valve spring retainers valve stem cup seals and valve springs NOTE Remove any burrs from the valve stem lock grooves to prevent damage to the valve guides when the valves are...

Page 291: ...e to inch The width of the exhaust seats should be 3 ln4 to Il6 inch VALVE TOOL Fig 76 Measuring Valve Stem length ITypicalJ 5 When the valves and seats are reground the position of the valve in the c...

Page 292: ...18 Cubic Inch Engines or lS7 inches for 361 383 and 426 Cubic Inch En gines install a Ilo inch spacer in head counterbore to bring spring height back to normal HYDRAULIC TAPPETS 361 383 and 426 Cubic...

Page 293: ...r by foreign particles becoming wedged between the plunger and tappet body causing plunger to stick in the down position This heavy click will be accom panied by excessive clearance between the valve...

Page 294: ...plunger Test the leakdown by compressing the pliers If plunger collapses almost instantly as pres sure is applied disassemble the tappet clean and test again 6 If the tappet still does not operate sat...

Page 295: ...in the rear of the engine block Remove the distributor and the oil pump distributor drive gear Locate tool against rear side of cam gear and attach the tool with distributor retainer plate bolt Fig 8...

Page 296: ...IN CASE COVER I KR152 Fig 89 Puller Blocks Expanded to Puller Position Using Tool C 3506 4 Install a new timing chain if its movement ex ceeds Il6 inch for the 273 and 318 cubic inch engines and 111a4...

Page 297: ...KR155A Fig 92 Installing New Seal Tool C 3506 Fig 93 Measuring Seal for Proper Seating NOTE Lip of the neoprene seal must be toward the source of oil 4 Install the flat washer and nut on puller screw...

Page 298: ...Paragraph Timing Chain and Sprock ets NOTE Whenever an engine has been rebuilt and a new camshaft and or new tappets have been in stalled one quart of factory recommended oil ad ditive should be adde...

Page 299: ...ng Using Tool C 3053 Fig 98 Burnishing Distributor Drive Shaft Bushing Using Tool C 3053 drive shaft time the engine as follows 1 Rotate the crankshaft until the NO 1cylinder is at top dead center on...

Page 300: ...be re moved from the top of the cylinder block When removing the piston and connecting rod assemblies from the engine rotate crankshaft so each connect ing rod is centered in the cylinder bore 5 Remo...

Page 301: ...assume a more nearly round shape It is important that pistons be checked for taper and elliptical shape before they are fitted into the cylinder bore See Figs 102 and 103 Finished Pistons All pistons...

Page 302: ...p in 005 inch O S bores should be 060 inch for compression rings and 070 inch for PISTONR I N G FEELER GAGE RING GROOVE oil ring steel rails 3 Measure the side clearance between piston ring and ring l...

Page 303: ...Arrange the tool parts for installation of the piston pin as shown in Figure 108 4 Install the spring inside the pilot and install the spring and pilot in the anvil Install the piston pin over the ma...

Page 304: ...d 426 cubic inch engines with a X fol lowing a maltese cross indicates that all main jour nals and or all rod journals are 010 inch undersize The position of the undersize journal or journals will be...

Page 305: ...ore NOTE Rotate the crankshaft so that the connecting rod journal i s on center of the cylinder bore 5 Attach the puller part of Tool C 3321 on the other bolt and guide the rod over the crankshaft jou...

Page 306: ...s to 85 foot pounds torque 4 If a slight drag is felt as the crankshaft is turned move no more than y4 turn in either direc tioh the clearance is 001 inch or less and is con sidered satisfactory If ho...

Page 307: ...ntil the tool is seated 3 Trim off the portion of the seal that protrudes from the cap Figure 118 Side Seals Seals are cut to proper length Under no circum stances should these seals be cut off Perfor...

Page 308: ...m 0 z a x w m z 2 E Y U P i 2 5 z s z x w m 5 U E z Q L v i ii...

Page 309: ...stick fill with the proper grade and quantity of motor oil connect battery ground OIL PUMP Figs 121 122 Removal On the 273 and 318 cubic inch engine remove the oil pump from the rear main bearing cap...

Page 310: ...5 or 942inch for 361 383 and 426 cubic inch en gines a new rotor should be installed K B 66A Fig 124 Measuring Outer Rotor Thickness 4 Place the outer rotor in pump body Press the rotor to one side wi...

Page 311: ...lter should be replaced every six months to coincide with an engine oil change 1 Using Tool C 3845 Fig 129 unscrew the filter from the base on the bottom side of the engine and OUTER ROTOR INNER ROTOR...

Page 312: ...e a year preferable to coincide with the annual engine performance evaluation This service will be re quired more frequently if the vehicle is used exten sively for short trips driving less than 10 mi...

Page 313: ...umulate in the valve hose and the carburetor parts therefore the ventilation system should be in spected crankcase oil changed and the valve replaced once a year preferable to coincide with the annual...

Page 314: ...y if the vehicle is used extensively for short trips with fre quent idling STANDARD SCREW FITS IN I uL Fig I32 Heli Coil Installation REPAIR OF DAMAGED O R WORN THREADS Damaged or worn threads can be...

Page 315: ...or tail pipe b Replace gaskets as necessary c Remove restriction if possible or replace as necessary a Heat control valve frozen in the open position a Free up manifold heat control valve using Sol ve...

Page 316: ...be replaced cut the extension pipe just forward of the muffler with a hack saw or cutter It is not necessary to remove the exhaust pipe The replacement muffler can be installed attaching it to the ex...

Page 317: ...EXHAUST SYSTEM 11 3 Fig d E x h a u s t System AR 2 Models...

Page 318: ...nd hanger attaching bolts and nuts to 95 inch pounds at same time maintaining proper clearance with adjacent parts 6 Tighten the ball joint connection bolt nuts to 35 foot pounds When tightening bolts...

Page 319: ...EXHAUST SYSTEM 11 5 Fig Exhaust System AP 2 Models NK948...

Page 320: ...sed breather cap hose to air cleaner inlet tube if used TRIANGULbR WASHERS NY8458 7 Fig 8 Manifold Assembly l6 CylinderJ INTAKE MANIFOLD 273 Cubic Inch Engine NOTE Remove the intake manifold as outlin...

Page 321: ...G UNIT OVER PASSAGE MOUNTING FLANGE Fig I I Intake Manifold 1318 Cu In Engine 5 7 CARBURETOR MOUNTING FLANGE 1 3 EXHAUST CROSSOVER PASSAGE NY843 Fig 12 Intake Manifold 1361 and 383 Cu In Engines 3 Ins...

Page 322: ...or broken Removal 1 Remove the counterweight and lock from the end of the shaft by loosening the clamp bolt Fig EXHAUSI MANIFOLD RETAINER LOCK BUSHING VALVE I COll SPRING SHAFT NY1040C COUNlfRWflGHl...

Page 323: ...t control valve Figs 17 18 and 20 should be inspected periodically With the engine idling accelerate momentarily to wide open throttle The counterweight should respond by moving counterclockwise appro...

Page 324: ...ockwise until the bumper passes the stop pin Fig 24 Fig 22 Removing Thermostat4318 Cu In Engine Fig 234nstalling Thermostat1273Cu In Enginej 6 Press the counterweight on the shaft until seated Tighten...

Page 325: ...ght side Wrap the outer end of the thermostat clockwise and engage under the stop pin Fig 20 3 Place the counterweight on the shaft with the shield in the upper position and insert the lock in the SHA...

Page 326: ...he counterweight on the shaft and turn the valve counterclockwise until the bumper passes the stop pin Fig 28 5 Press the counterweight on the shaft until it is seated Tighten the clamp bolt to 50 inc...

Page 327: ...urements should be taken when straightening the frame Measure the distance between the points connected by line A in Figure 3 this distance should agree within v4 inch with the distance between the po...

Page 328: ...e fender to body sill bolts and the Fig 4 Fender to Wheel House Mounting r Fig 5 Splash Shield to Body Frame Mounting fender to body post bolts metal to the stub frame yokes Fig 6 9 Remove the bolts a...

Page 329: ...olts and tighten to 75 foot pounds 3 Measure the body to stub frame alignment See Fig 7 Body to Frame Outrigger Mounting 1 I L Fig 8 Body to Frame Crossmember Mounting paragraph Body to Frame Alignmen...

Page 330: ...e stub frame has been re moved replaced repaired or the front end sheet metal cannot be properly aligned To measure the body to frame alignment using Tool C 3802 refer to the Gauge Adapter Chart to de...

Page 331: ...sleeve fits over the outboard hex of the bolt or nut as the case may 3 I Fig 1 L E x t r u d e d Bars in Position Approximately 20 inches each Side of No 2 Hanger Schematic be Fig 13 NOTE All of the...

Page 332: ...a good job 1 The carburetor must be completely disassem bled 2 All parts except the choke diaphragm assem bly should be cleaned in a suitable solvent then in spected for damage or wear 3 Use air pres...

Page 333: ...as completely burned exhaust prod ucts For servicing procedures of this valve refer to En gine Section of this Manual PART 1 SERVICE DIAGNOSIS Condition Possible Cause Correction POOR IDLING a Idle a...

Page 334: ...buretor Replace the de fective gaskets and t e s t for leakage Be sure the screws are tightened securely Test the fuel level in the carburetor Make the necessary adjustment to obtain correct float lev...

Page 335: ...the open to the closed posi tion d Choke valve improperly seated e Air cleaner interferes with choke shaft or f Air cleaner gasket interferes with choke valve linkage or linkage LOW ENGINE OUTPUT lO...

Page 336: ...new fuel pump i Install correct fuel pump i Install a new filter a Tighten the mounting bolts b Install a new fuel pump c Install a new spring PART 2 HOLLEY 1920 R SERIES CARBURETORS Description The...

Page 337: ...by an external vent valve located in the top of the bowl The vent valve is con nected by linkage to the throttle lever so that the valve is opened a prescribed distance when the vehi cle is at idle o...

Page 338: ...CARBURETOR HOLLEY 14 7 w t I U w 8 I v Y 4 m h Y 3 Z 3 5 Q...

Page 339: ...l baffle and gasket as shown in Fig 6 Slide baffle out of bowl Discard the gasket Remove the float bumper spring 8 Using a suitable tool remove the float retain ing clip then slide float off the fulcr...

Page 340: ...be used at removal so as not to break in the shaft 4 Slide the throttle shaft out of the throttle body 5 Install new throttle shaft and lever or new valve 6 Install NEW screws but do not tighten Hold...

Page 341: ...ting to insure that the passage is not plugged with foreign material Leak check the diaphragm to determine if it has in ternal leaks To do this first depress the diaphragm stem Then place a finger ove...

Page 342: ...from the dia phragm and connect the hose from the vacuum sup ply as shown in Fig 12 A minimum of 10 inches of mercury HG will be required 3 Insert a number 32 drill 170 cu in engine CLOSING PRESSURE...

Page 343: ...on the engine the headlights should be turned on This will assure setting the idle to compensate for the alternator load On cars equipped with automatic transmissions unsnap the ball joint connection...

Page 344: ...t should be possible to insert a 1 16 0625 drill between the bowl vent and the seat as shown in Fig 17 This measurement should never exceed 090 inch 3 32tt drill If an adjustment is necessary bend the...

Page 345: ...40s carburetors used when equipped with air conditioning are serviced the same as the previously mentioned BBS carburetors Since the service procedures are identical on all BBS carburetors the illustr...

Page 346: ...the clip from the choke operating link and disengage the link from the diaphragm plunger stem and the choke lever Refer to Fig 1 5 Remove the vacuum diaphragm and bracket as sembly and place to one si...

Page 347: ...l T109 43plug remover remove the accelerator pump jet plug Using Tool T109 59T re move the accelerator pump jet as shown in Fig 7 16 Unscrew and remove the idle mixture adjust Fig 5 Removing or Instal...

Page 348: ...d or ridged a new idle mixture screw should be installed to insure having correct idle mixture control Do not use a screwdriver Turn the screw lightly against its seat with the fingers Back off 1full...

Page 349: ...t in the body and tighten securely 3 Invert the main body so that the weight of the floats only is forcing the needle against the seat Hold finger against retainer to fully seat the fulcrum pin 4 Usin...

Page 350: ...and setting the height of the pump plunger To check or set the adjustment proceed as follows 1 Back off the idle speed adjusting screw Open the choke valve so that when the throttle valves are closed...

Page 351: ...the diaphragm will extend as an internal spring is compressed The spring must be fully compressed for proper measure ment of the kick adjustment 4 An adjustment will be necessary if a slight drag is n...

Page 352: ...the Choke Unlooder Setting wide open kick Idle Speed Adjustment Curb Idle To make the idle speed adjustment the engine must be thoroughly warmed up A much more reliable idle adjustment can usually be...

Page 353: ...the cam and throttle after every screw adjustment to apply normal throttle closing torque FAST IDLE SPEED ADJUSTING CHOKE VALVE WIDE OPEN SCREW ON THE SLOWEST SPEED STEP OF THE Fig 19 Fast Idle Speed...

Page 354: ...TUREADJUSTING SCREW 2 I X U L A T i L CHOKE VALVE ACCELERATOR PUMP ROCKER ARM ACCELERATOR PUMP PLUNGER STEM BOWL V FUEL INLET N E E D L E 1 2 VALVE AND SEAT IDLE MIXTURE ADJUSTING SCREW 2 CARBURET OR...

Page 355: ...od On the 273 cubic inch engine the accelerator pump rod is located in the outer hole of the accelerator pump rocker arm and in the inner hole of the rocker arm for the 318 cubic inch engine refer to...

Page 356: ...ion MAll Fig 5 Removing or Installing Venturi Cluster It is usually not advisable to remove the throttle shaft or valves from the throttle body unless wear or damage necessitates the installationof ne...

Page 357: ...tor pump system fuel inlet and discharge check balls proceed as follows 3 Pour clean gasoline into the carburetor bowl approximately Y 2 inch deep Remove the pump plung er from the jar of gasoline and...

Page 358: ...compressed sufficiently to cause a false setting which will affect correct level of fuel in the bowl Fig IO Measuring the Float Setting BOWL VENT VALVE PLUNGER SPRING SEAT CLIP PFSITIONS I BOWL VENT V...

Page 359: ...necessary bend the pump op erating rod using Tool T109 213 at the lower angle until the correct bowl vent opening has been obtained Fig 72 Measuring Bowl Vent Opening This is an important adjustment...

Page 360: ...l be necessary if a slight drag is not obtained as the drill or gauge is being removed The adjustment of this opening will require the removal of the choke operating link CAUTION Damage to the diaphra...

Page 361: ...ecautions Because the alternator can charge at idle speeds and impose a load on the engine the headlights should be turned on high beam This will assure setting the idle to compensate for the alternat...

Page 362: ...very screw adiustment to a p ply normal throttle closing torque BBD 1 2 INCH CARBURETORS stamped on metal tag attached to air horn Do not re move or destroy this tag as it is the only means pro vided...

Page 363: ...ld plunger can be used again or if a new plunger is to be installed place the plunger in a jar of clean gasoline or kerosene to prevent the leather from drying out 9 Remove the fuel inlet needle valve...

Page 364: ...E These screws are staked on the opposite side and care should be used at removal so as not to break off in the shaft SPARK ADVANCE PORT THROTTLE Fig 5 Ports in Relation to the Throttle Valves Remove...

Page 365: ...g The carburetors are equipped with a rubber tipped fuel inlet needle The rubber tip is flexible enough to make a good seal on the needle seat and to give in creased resistance to flooding FINGER PRES...

Page 366: ...Install the clip to secure 3 Inspect the rubber hose for cracks before plac ing it on the correct carburetor fitting Do not connect the vacuum hose to the diaphragm fitting until after the vacuum kick...

Page 367: ...g is compressed This spring must be fully compressed for proper measurement of the vacuum kick adjustment 4 An adjustment will be necessary if a slight drag is not obtained as the drill or gauge is be...

Page 368: ...t curb idle there should be Ils inch clearance between the bowl vent valve and the air horn when measured at the inner most or smallest dimension with a drill shank 2 If an adjustment is necessary ben...

Page 369: ...ds may be hot it is dangerous to spill fuel onto these surfaces Take the necessary precautions to avoid spillage 4 With only the pressure from the buoyant float holding the lip against the inlet needl...

Page 370: ...ke position A small opening should exist between the shaft and the hub levers as shown in Fig 17 2 Using a drill or gauge measure the opening The opening should be from 020to 030inches 3 If an adjustm...

Page 371: ...he accelerator pump plunger rod from the rocker arm by removing the clip and the bdwl vent valve Slide the plunger and rod out of the air horn Slide the compression springoff the rod NOTE Place the ac...

Page 372: ...ring removal will not damage the jet 21 Unscrew and remove the idle mixture adjust ing screws and springs from the throttle body The carburetor now has been disassembled into three units the air horn...

Page 373: ...g 9 Slide them into DIAGONAL CUT TOWARD OPPOSITE SIDE OF SMALL VENTURI l e Y KH437 Fig 94nstalling Main Discharge Jets for tubes position in the main body Be sure the opening in the end of tube diagon...

Page 374: ...slide it down into the pump cylinder Raise the plunger and press lightly on the plunger shaft to expel the air from the pump passage 2 Using a small clean brass rod hold the dis charge check ball fir...

Page 375: ...at the center If an adjustment is necessary hold the float on the bottom of the bowl then bend the float lip toward or away from the needle using Tool 73605 Recheck the i 32 inch setting again then r...

Page 376: ...rubber hose for cracks before plac ing it on the correct carburetor fitting Refer to Fig 1 Do not connect the vacuum hose to the diaphragm fitting until after the vacuum kick adjustment has been made...

Page 377: ...oper ating link from the choke lever then disengage the link from the diaphragm stem The best bending re sults will be obtained by using a vise and a pair of pliers 6 Bend the choke operating link at...

Page 378: ...hole The proper procedure is to adjust the amount of bowl vent opening instead of measuring and set ting the height of the pump plunger To check or set the adjustment proceed as follows 1 Back off idl...

Page 379: ...ockwise direction leaner until there is a slight drop in r p m Now turn each screw out counterclock wise richer just enough to regain the lost r p m This procedure will assure that the idle has been s...

Page 380: ...protect the throttle valves from dam age and to provide a suitable base for working 2 Remove the hairpin clip that holds the pump rod in the center of the pump arm Remove rod from slot and disengage f...

Page 381: ...r horn This assembly is staked in the air horn and care ACCELERATOR PUMP PLUNGER w NK421 CHOKE DIAPHRAGM ATTACHING SCREWS Fig 5 Removing the Vacuum Power Piston should be used at removal Discard air h...

Page 382: ...nd in spection It is usually not advisable to remove the throttle shaft or valves unless wear or damage necessitates in stallation of new parts To install new valves or throt POWER BY PASS JET GASKET...

Page 383: ...n the high side of valves 7 Tap the valve lightly with a screwdriver to seat in the throttle bores Holding the valves in this posi tion tighten the screws securely and stake by squeez ing with pliers...

Page 384: ...lide the venturi cluster down into position Install attach ing screws and tighten securely Refer to Fig 6 Again depress the accelerator plunger A clear straight stream should emit from each jet orific...

Page 385: ...ump plunger into its well Be sure the leather does not curl or fold back Install retaining screws and tighten securely Refer to Fig 2 The choke valve must be held partially closed while install ing th...

Page 386: ...o Trans between the Fig 1 Measuring the Vacuum Kick Setting Fig 19 Choke Operating Link Measurement choke valve and the wall of the air horn Refer to Fig 18 Apply sufficient closing pressure on the ch...

Page 387: ...and the wall of the air horn as shown 2 To adjust bend the tang on the throttle lever using Tool T109 214 until correct opening has been obtained 3 Hold the choke valve open and then open and close th...

Page 388: ...700 r p m Automatic Transmission or 700 r p m Manual Transmission Reposition the cam and throttle after every screw ad justment to apply normal throttle closing torque AfterApprox 500 Miles If Necess...

Page 389: ...sing torque when cranking the engine at temperatures below zero Thus the spring staging of the choke is a better match for the engine s starting mixture requirements at the low temperatures To test th...

Page 390: ...to open until both pri mary and secondary throttle valves reach the wide open position simultaneously As engine speed in creases the forces exerted by the velocity of intake air down through the ventu...

Page 391: ...arm pivot screw and lift off the pump arm at the same time disengage the link from the arm and the pump stem Slide the accelerator pump plunger and spring out of the air horn Remove gasket 4 Place the...

Page 392: ...r or damage necessitates the installation of new parts During the manufac ture of the carburetor the location of the idle trans fer ports and the idle discharge ports to the valve is carefully establi...

Page 393: ...passage Raise the pump plunger and press lightly on the plunger shaft to ex pel air from the pump passages Using a small clean brass rod hold the discharge check needle firmly on its seat Again raise...

Page 394: ...After aligning the floats remove as much clear ance as possible between the arms of the float lever and the lugs of the air horn To do this bend the float lever The arms of the float lever should be a...

Page 395: ...re with a ball peen hammer Check the fit of the choke valve in air horn The valve should be evenly spaced on all sides Loosen screws and repo sition if necessary 7 Engage the throttle connector rod wi...

Page 396: ...cuum Kick Setting CHOKE OPERATING LINK NK596 Fig 15 Choke Operating Link Measurement phragm and connect the hose from the vacuum sup ply as shown in Fig 14 A minimum of 10 inches of mercury HG will be...

Page 397: ...f an adjustment is necessary bend the unloader lip on the throttle shaft lever using Tool T109 41 un til correct opening has been obtained Accelerator Pump Adjustment Move the choke valve to wide open...

Page 398: ...he free flow of fuel as the carburetor is primed Idle Speed Adjustment Kurb Idle To make the idle speed adjustment the engine must be thoroughly warmed up A much more reliable idle adjustment can usua...

Page 399: ...tion of this Group for the procedure on adjusting the transmission control rod Fast Idle Speed On the vehicle To set the fast idle speed on the car connect a ta chometer to the vehicle then set the cu...

Page 400: ...top 14 5 Assemble ball socket 7 to ball end and remove inch rod 12 from upper bellcrank and lever 6 Hold the carburetor rod 15 forward against the transmission stop 14 and adjust its length by means o...

Page 401: ...top and adjust the length of the transmission rod by means of the threaded ad justment 5 at the upper end The rear end of the slot should contact the carburetor lever pin without exerting any forward...

Page 402: ...t the stop and adjust the length of the transmission rod by means of the threaded ad justment 5 at the upper end The rear end of the slot should contact the carburetor lever pin without ex erting any...

Page 403: ...that it does not interfere with the transmission rod throughout its full travel 10 Connect choke rod 3 or remove blocking fix ture MANUAL TRANSMISSION Fig 4 Models AP I AR 2 with 225 Cu In Eng 1 1 Ap...

Page 404: ...FUEL SYSTEM THROTTLE LINKAGE 14 73 Fig 5 Throttle Linkage Adjustment M o d e l AV 2 with 273 Cu In Eng NK334 Fig 6 Throttle linkage Adjustment fModel A V I with 170 225 Cu In Eng l...

Page 405: ...smission intermediate rod ball socket 5 from the bellcrank ball end 3 Disconnect choke at carburetor 4 or block choke valve in full open position Open throttle slightly to release fast idle cam then r...

Page 406: ...61 383 426 cubic inch engine a push rod operates between the camshaft and the fuel pump rocker arm This action lifts the pull rod and diaphragm upwards against the fuel pump main spring thus creating...

Page 407: ...ith starting mo tor There should be a noticeable vacuum present not alternated by blowback 2 If blowback is present the inlet valve i s not seating properly and a new pump should be installed If the f...

Page 408: ...Y COMPLETE 6 VENT TUBE l WHEEL Fig I Fuel Tank Assembly Installed 1106 W B Model3 VENT TUBE ASSY HOSE STA WAGON HOSE SEDAN SCREW 5 FILLER TUBE ASSY SEDAN VENT TUBE ASSY QUARTER PANEL OUTER RUBBER GROM...

Page 409: ...TANK NLlT VIEW 6 QUARTER PANEL INNER VIEW A STRAP r T A N K I rINSULATC R CEMENT 4eq 63x369 Fig 3 Fuel Tank Assembly Ilnstallation Station Wagon I106 W B Models Fig 4 Fuel lank Assembly flnstallationl...

Page 410: ...then raise the retaining strap and thread onto the J bolt Install the attaching nut and tighten securely Not over 60 inch pounds torque 3 Lubricate the rubber grommet using a suitable rubber lubrican...

Page 411: ...6 Reinstall the trim plate in the quarter panel 7 Reinstall the rear floor pan filler and secure 8 Reinstall the spare tire cover and the floor mat C 3582 with screws FUEL TANK RemovaL lJ16 J 19 5 W B...

Page 412: ...ain the fuel tank using the siphon method then disconnect the fuel line and the lead wire to the gauge unit under the rear fender behind the wheel house 2 Disconnect the left rear shock absorber then...

Page 413: ...e rear of vehicle Be sure the embossed side of the tank engages with the embossed surface of the support Make sure the filler neck is aligned with the opening in the top of the quarter panel Hold in t...

Page 414: ...foreign matter on shaft c Loose universal joint flange bolts d Loose or bent universal joint flange e Improper drive line angularity f Rear spring center bolt not in seat 9 Worn trunnion pin h Trunni...

Page 415: ...NGE WASHER RETAINER WASHER RETAINER BUSHING e Fig 2 Cross and Roller Universal Joint Rear All Models 63x571A AND ROLLERS NKW5 AND ROLLERS RETAINER Fig 3 r r o s s and Roller Universal loint Front AR 2...

Page 416: ...n proper alignment Propeller shaft and rear axle housing angles on all Models may be meas ured using propeller shaft alignment gauge Tool 2 3976 When using this gauge on AV 1 AV 2 Models use propeller...

Page 417: ...ft from the vehicle 3 Models with Cross and Roller Type Front Uni versal Joint with Sliding Front Y o k b l i d e the pro peller shaft and front yoke from the transmission out put shaft Fig 4 Be caref...

Page 418: ...ydraulic press and the correct jig as specified above The pin is prop erly centered when the press ram contacts the spacer portion of the jig Fig 12 NKl Fig 12 Installing Trunnion Pin 3 Pack the balls...

Page 419: ...ave operated on a worn cross should be re placed Rollers should have a uniformly good appear ance and roll freely inside the bushings Assembly 1 Lubricate the roller and bushing assemblies with Univer...

Page 420: ...E THEM DENCE OF OIL MOISTURE IS NOT CAUSE TO RE SERVICE DIAGNOSIS Condition Possible Cause Correction SPRINGSAND SHOCK ABSORBERS SPRING SAGS O R a BOTTOMS b SPRING BREAKAGE a b SHOCK ABSORBER a NOISY...

Page 421: ...sleeve from the shock absorber NOTE New shock absorbers are furnished with the lower bushing installed however bushings are fur nished separately for service installation 6 Test the shock absorber In...

Page 422: ...on shock absorber mounting studs 6 Position the shock absorber on the mounting studs and install the remaining cupped washers and AV models 50 foot pounds and the lower stud nuts the wheels 5 Position...

Page 423: ...ushings Figs 8 9 and 10 may be replaced with the spring NK546 Fig IO Rear Spring Valiant still on the vehicle by the following method the rear wheels just touching the floor 1 Raise the vehicle so the...

Page 424: ...ion is evident wrap sandpaper around a flat file or putty knife and snal until area is smooth and clean c Fig 13 Positioning Spring Interliner Fig 1Llnstalling Interliner Button 5 With the spring leav...

Page 425: ...Tool C 3729 1 Attach the front hanger to the front end of spring and start the pivot bolt nut Do not tighten 2 Assemble the rear shackle and bushings Figs 8 9 or 10 in the spring rear eye and the rear...

Page 426: ...and rear wheels out of alignment Broken or sagging rear springs Bent suspension parts Incorrect tire pressure Improper balance of wheels tires and brake drums Loose tie rod ends or steering connectio...

Page 427: ...Disconnect the steering gear arm from the cross 2 Removethe horn button or horn ring 3 Loosen the cross shaft adjusting screw lock nut and back out the adjusting screw approximately two turns This wi...

Page 428: ...the proper torque read ing Gear Removal All Models Except AV2 Equipped with 273 Cu In V 8 Engine NOTE The manual steering gear can be removed without removing the steering column assembly 1 Remove the...

Page 429: ...AR2 and Tool C 3786 for AP1 and AP2 models into the housing Figs 5 and 6 NOTE The arbor tool is not necessary on AVl and AV2 models 5 Remove the lock nut from the cross shaft ad justing screw and remo...

Page 430: ...required CAUTION The adapter ring must be used with re mover and installer arbor Tool C 3875 otherwise the bearings will be crushed NOTE Housings equipped with cross shaft bushings are serviced in as...

Page 431: ...sure the wormshaft has not been bent or otherwise damaged 18 The cross shaft and wormshaft oil seals should be replaced when the unit is reconditioned 19 Install the cross shaft outer needle bearing...

Page 432: ...adjuster and the threads on the housing 28 Place a protective sleeve of plastic tape over the wormshaft splines so that the splines do not dam age the seal and slide the adjuster assembly over the sh...

Page 433: ...e wormshaft and install the coupling bolt washer and nut 6 Tighten the nut to 30 foot pounds 7 While the jacket clamp bolts are loose position the jacket assembly so the steering shaft coupling is cen...

Page 434: ...r arm lock washer and nut on the cross shaft and tighten the nut to 120 foot pounds 12 Install the starting motor 13 Connect the battery ground cable 14 After the steering gear has been completely ins...

Page 435: ...of fluid in the system SERVICE DIAGNOSIS POWER STEERING GEAR Condition Possible Cause Correction HARD STEERING a Tires not properly inflated b Low oil level in pump reservoir usually c Loose pump belt...

Page 436: ...spension Section Remove jacket tube and replace bearings See Gear lnstaIlation Adjust or repair as follows 1 See Gear Shaft Adjustment 2 Remove steering gear diassemble inspect and reassemble as outli...

Page 437: ...rrection e in Diagnosis under Hard Steering c See Gear Reconditioning d Replace the worm and piston assembly e Replace the steering gear valve body assem bly a See Fluid Level b See Group 7 Cooling c...

Page 438: ...olumn jacket clamp bolts at the in 4 Tap the coupling assembly upward and carefully NOTE Tie the column jacket tube to protect it against damage during the steeringgear removal 5 Disconnect the pressu...

Page 439: ...Remove the steering arm retaining nut and re move the steering arm from the cross shaft with puller Tool 2 3646 7 Remove the three gear housing mounting bolts and remove the gear from under the vehicl...

Page 440: ...piston teeth with a screw driver using the gear shaft as a fulcrum and remove the complete power train Fig 8 NOTE It is important that the cylinder head cen ter race and spacer assembly and the housi...

Page 441: ...19 16 STEERING Y t c 2...

Page 442: ...ce thin 19 Remove the center bearing race 20 Remove the lower thrust bearing and lower 21 Remove the lower reaction ring and reaction 22 Remove the cylinder head assembly 23 Remove the two 0 rings in...

Page 443: ...the reaction 0 ring in the cylinder head e Center bearing race f Upper thrust bearing g Upper thrust bearing race thin h Start the wormshaft thrust bearing adjusting nut do not tighten 34 Turn the wor...

Page 444: ...ew seal with Tool C 3650 Fig 9 With the lip of the seal toward the bearing drive in the seal until the tool bottoms on the support 43 Lubricate and install the reaction seal ring in the groove in the...

Page 445: ...nter race Install the valve pivot lever spring small end first NOTE Turn the worm until the piston bottoms in both directions and observe the action of the Ievor It must be in the center of the hole a...

Page 446: ...ngle of 180 90 either side of center shall be 6 10 inch pounds Disconnect the test equip ment and mounting fixture and install the unit in the vehicle GEAR INSTALLATION Six Cylinder Models 1 On vehicl...

Page 447: ...ECONDITIONING 1 Remove the two screws attaching the control valve body to the steering valve body and separate the two bodies Fig 21 2 Compress the control valve spring and remove the retainer pin spr...

Page 448: ...ring over both portions of the tool Fig 22 Turn the tool nut counterclockwise to withdraw the grease retainer from the housing 4 Remove the oil seal snap ring with pliers Tool C 3229 and remove the se...

Page 449: ...hicle Refer to Gear Removal 1 Remove the oil seal with Tool C 3638 Fig 25 2 Drive the new oil seal in place lip of seal to ward housing head with Tool C 3650 Fig 26 POWER STEERING PUMP Description The...

Page 450: ...ving a false in dication of fluid leakage Pressure and return hose connectionsand fittings b Tighten all fittings check hose for deterioration a See Fluid Level Reservoir to pump body screws d Pump sh...

Page 451: ...t pump has a milled slot for machined hex in the end of the pulley shaft The 96 displacement pump does not have the milled slot CAUTION Do not close the valve for more than a few seconds as this would...

Page 452: ...stuck in the closed position 9 Decrease the engine speed to 500 rpm then slowly turn the pressure gauge shut off valve towards the closed position to obtain the following pressure readings on pressur...

Page 453: ...e examined for sharp burrs or corners and smoothed with a stone or fine emery cloth This will prevent Fig 74nstalling the PumpShaft Oil Seal seal damage when the new seal is installed Do not stone or...

Page 454: ...nd scratches The hose tubing flare should make an indentation in the ferrule which is concentric with the center hole and of approximate uniform depth all the way around If the ferrule is damaged or n...

Page 455: ...ored replace the pump assembly less pul ley and reservoir 3 Install the control valve spring seating the spring in the spring socket 4 Remove any burrs with a fine hone or crocus cloth but Do Not roun...

Page 456: ...one NOTE The cam insert has two machined notches one large and one small on the inside surface these are not to be interpreted as deep scoring 8 Smooth off burrs or corners on the pulley end of the pu...

Page 457: ...cket NOTE Make sure the proper springs are installed The springs for the 96 small pump are different than the springs for the 1 2 large pump 13 Install each slipper by sliding the slipper be tween the...

Page 458: ...ng fluid 21 After making sure the inner face on the front insert is smooth and free of burrs place the insert assembly on the shaft with care so that the shaft seal is not damaged by the end of the sh...

Page 459: ...icles is referred to as Model A 903 Fig l and the three speed Heavy Duty Manual Trans mission used on 8 cylinder vehicles is referred to as Model A 745 Fig 2 The Model A 745 with modifica tions is als...

Page 460: ...the needle type roller bearing within the gear are maintained by 4 thrust washers one being used between the rows of roller bearings and one at each end The reverse idler gear is supported on a bronz...

Page 461: ...izer hub c Inspect the low speed sliding gear and main d Inspect the mainshaft and flange splines Re e Replacethe worn gears and replace parts as necessary shaft Replace parts as necessary place parts...

Page 462: ...haft coupling to worm shaft clamp bolt 4 Disconnect the turn signal and horn wires 5 AVl AV2 Models Remove horn button by in serting a small screw driver into steering wheel slot at edge of the horn b...

Page 463: ...imited space between the joint and jacket tube on vehicles equipped with power Fig 8 Removing Steering Shaft Bearing HOUSING SUPPORTED 62x453 Fig 9 Removing Shift Lever Pivot Pin steering and manual t...

Page 464: ...ECTOR SPRING COLUMN JACKET NYLONBUSHING 8 62x530A Fig I I Removing Shift Tube Assembly Fig 124ackef Tube IDisarrembIed signs of roughness or wear it should be replaced Re placement bearings are pre lu...

Page 465: ...CTOR LEVER 7 rr s 62w Fig 13 lold ng Selector Lever in Neutral Position INSTALLING SLEEVE C 3879 62x524 Fig 14 lnsfalling Steering Column Upper Bearing 17 Slide the steering shaft into the column as s...

Page 466: ...teering Move the column assembly up or down in the instrument panel bracket so the dimen sion between the top of the coupling and the center of the gauge hole Fig 16 is 13 18 inch Tighten the steering...

Page 467: ...he pawl lever forward to bottom the pawl in the transmission low reverse lever pawl slot Then tighten the sliding clamp bolt to 100 inch pounds CAUTION Do not pull the interlock rod back wards against...

Page 468: ...21 1 0 TRANSMlSSlON 4 SPEED M A N U A L c 3 z 5 z E 0 n n 0 n 9 C 0 n n E e n C I 3 0 q I 2...

Page 469: ...TRANSMlSSlON4 SPEED MANUAL oc Lu I I n 4 3 n Z 4 3 Z I 1 OL Lu Lu 2 h 0 cy Y Z...

Page 470: ...EMBLY To disassemble the transmission for cleaning and overhaul refer to Fig 19 or 20 then proceed as follows 1 Using Tool C 3281 flange holding tool remove the flange retaining nut and washer 2 If ne...

Page 471: ...he clutch sleeve the outer synchronizer rings the front inner ring and the 2 3 shift fork Fig 24 or 25 SECOND SPEED GEAR SPREADER SPRING INNER STOP RING BRONZE CLUTCH GEAR S L E E V E I SECONDSPEED GE...

Page 472: ...Drive the countershaft the remaining way out of the case keeping the arbor tight against the end of the countershaft to prevent loss of the bearing rollers Low AND REVERSE LOW AND REVERSE SLIDING GEA...

Page 473: ...rs are present dress them off with a fine mill file If threads are stripped install Helicoil inserts Ball Beurings blow dry with compressed air Wash the ball bearings using a clean solvent and CAUTION...

Page 474: ...xt to the bearing rollers and install another row of 22 roll ers in each end Coat with heavy grease and install the bearing spacer in each end of the gear 4 If countershaft gear end play was found to...

Page 475: ...aft with the remaining tapered pin 6 Install the operating levers install and tighten the retaining nuts securely 7 Place the low and reverse fork in the lever shaft with the offset toward rear of tra...

Page 476: ...the cavity of the shaft 14rollers for the A 903transmission and 15rollers for the A 745 transmission Coat the bearing rollers with heavy grease then install the bearing retaining ring in its groove 5...

Page 477: ...ds 6 Remove the engine support fixture and disen gage the hooks from the holes in the frame side rails 7 Install the speedometer drive pinion and cable assembly 8 Reconnect the gearshift rods propelle...

Page 478: ...To remove the transmission on the 121Y2 inch wheelbase Plymouth Station Wagons it will be neces sary to first remove the torsion bar rear anchor cross 8 Slide the boot down the shift lever shaft to th...

Page 479: ...TRANSMlSSlON4 SPEED MANUAL 21 21 64 x 740A Fig 4O Transmission Assembly IDisassembledl...

Page 480: ...ricate lever opening in lower boot and push boot down over bolt heads unscrew the two bolts and remove shift le ver Non Console type floor shifts disconnect the transmission shift rods 2 Drain the lub...

Page 481: ...h the extension hous ing to the transmission case 2 Slide the third and fourth synchronizer sleeve slightly forward then using a soft hammer tap on the extension housing in a rearward direction Slide...

Page 482: ...and first speed stop ring 10 Again using snap ring pliers remove the snap ring that retains the 1st and 2nd clutch sleeve gear and clutch to the mainshaft Fig 48 Slide the 1st and 2nd clutch sleeve ge...

Page 483: ...FT I REVERSE LEVER DETENT SPRING RETAINER REVERSE SPEED GEARSHIFT FORK REVERSE GEAR SHIFTER SHAFT 64 x 749A Fig 51 Gear Shaft and Lever Identification i 64 x Fig 52 Removing or Installing Reverse Slid...

Page 484: ...signs of wear or galling Install new parts as required Gears Inspect the gear teeth on the synchronizer clutch gears and stop rings If there is evidence of chipping or excessively worn teeth install n...

Page 485: ...t this time as addi tional clearance is required to install the mainshaft assembly 11 Align the countershaft arbor with the bores in the case then drive or press the countershaft into the gear Install...

Page 486: ...the open ing for the countershaft Raise the countershaft gear into position then drive or press the countershaft into the gear install the woodruff key Continue to press the shaft into the case until...

Page 487: ...ts to 50 foot pounds torque 6 Remove the engine support fixture and disen gage the hooks from the holes in the frame side rails 7 Install the speedometer drive pinion and cable Connect the back up lig...

Page 488: ...clutch two servos and bands and two plane tary gear sets to provide three forward ratios and a reverse ratio The common sun gear of the planetary gear sets is connected to the front clutch by a drivin...

Page 489: ...lutch Repair or re place as required a Refill to correct level with Automatic Trans b Adjust the control cable c Replacethe oil filler d Perform the hydraulic pressure tests and adjust to specificatio...

Page 490: ...ct as required 9 Inspect accumulator for sticking broken rings or spring Repair as required h Remove the valve body assembly and perform the air pressure tests Repair as required i Perform the hydraul...

Page 491: ...ill to the correct level with Automatic Trans mission Fluid Type A Suffix A Inspect for air leakage into the front pump suction passages Adjust the throttle linkage Adjust the control cable Perform th...

Page 492: ...l to the correct level with Automatic Trans mission Fluid Type A Suffix A Perform the hydraulic pressure tests and adjust to specifications Replacethe oil filter Perform pressure tests to determine ca...

Page 493: ...ion of the planetary gear sets and replace as required f Inspect the condition of the overrunning clutch and replace parts as required a Adjust the kickdown band b Adjust the low reverse band c Remove...

Page 494: ...ed Adjust the control cable Test the operation of the switch with a test lamp Adjust or replace as required Inspect the lead and test with a test lamp Re pair the broken lead CLUTCH ENGAGEMENT AND BAN...

Page 495: ...MISSION TORQUEFLITE 21 37 KD nSERVO III I IIJ LINE I 5 pi PUMP SUCTION CONVERTER 30 75 psi LUBRICATION 5 30 pi TO LUB OIL FILTER Neutral Hydraulic Circuits CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING 62x...

Page 496: ...CH CONTROL VA k I I TO LUB FRONT R E A R PUMP PUMP OIL FILTER OIL PRESSURES LlWt IS psi PUMP SUCTION THROTTU 40 pi GOVtMOR OJS pd C O N V E M B IO75pd LUMKATIOW I40pd Y CONTROL SYSTEM IN BREAKAWAY HAL...

Page 497: ...39 TORQUE CONVERTER OIL PRESSURES LINE 75 psi PUMP SUCTION THROWLt 40 I I GOVfRNOR bJ5 psi CONVtkTER 30 75 pi LUBRICAIION 5 30 p i CONTROL SYSTEM IN DRIVE SECOND HALF THROTTLE 62x232C OIL FILTER Driv...

Page 498: ...NT CLUTCH TORQUE CONVERTER OIL PRESSURES LiN I590pi PUMP SUCTION THROTTU 0 90 pu GOVtRNOR PO pti CONVERIER 30 75 psi LUBRICATION 5 30 psi TO LUB FRONT REAR PUMP PUMP OIL FILTER CONTROL SYSTEM IN DRIVE...

Page 499: ...N T C L U T C H OIL PRESSURES LINE 90 prl I Iwr SUCTI II THROTTLE 90 pi 6ovflllot Lo45 I CONVtRTEt 30 75 pi LUlUulHIII I40 psi CONTROL SYSTEM I N TO LUB REAR DRIVE KICKDOWN AT 50 M P H r FRONT PUMP 6...

Page 500: ...EFLITE TO LUB FRONT PUMP REAR PUMP OIL FILTER OIL PRESSURES LINE IS ps PUMP SUnlOW WVERNOI IS pi COWVERlER 1075pi LU IUTIOW lopsi CONROL S W R M I N MANUAL SECOND aosm THKITRE 62r235C Selector lever S...

Page 501: ...OIL PRESSURES TO LUB 2143 LlNt ISpsi PUMP SUCTION GOVERNOR 0 30 psi CONVfRTER 30 1S psi i LUBRICATION 130 psi u FRONT REAR PUMP PUMP CONTROL SYSTEM IN MANUAL LOW CLOSED THROTTLE 62a236C OIL FILTER Sel...

Page 502: ...21 44 TRANSMISSION TORQUEFLITE I OIL PRESSURES LINE 230 260pi1 wMr SUCTION I n CONVfMU LUBUCATION M O pi CONTROL SYSTEM IN REVERSE 62x237C OIL FILTER Reverse Hydraulic Circuits...

Page 503: ...QUEFLITE 21 45 I 0 I 2 1 0 a W a a W I 5 a w L n 0 W J m X W J a W W t a W z J a a 2 a I z 0 a LL W z a 2 m I W cn I 0 a a I 2 CL 2 0 a a W a I 0 I 2 J 0 1 1 W I cn Z 3 cn I LL I cn a k LL I cn Y z a...

Page 504: ...21 46 TRANSMISSION TORQUEFLITE i cy Y Z 0 P 0 c a c f B Y I Y n Z 2 I Y 3 V 6 Y W 5 t...

Page 505: ...d rear clutch pistons and both servo pistons are moved hydraulically to engage the clutches and apply the bands The pistons are released by spring tension when hydraulic pressure is released On the 2...

Page 506: ...4 11 Summary Chart may vary somewhat due to pro duction tolerances and rear axle ratios This is not too important however the quality of the shifts is very important All shifts should be smooth re spo...

Page 507: ...ened to the same torque SERVICE PROCEDURES TORQUEFLITE A 904 G A 904 LA A 727 A AND B Various transmission components can be removed for repairs without removing the transmission from the vehicle The...

Page 508: ...justments The following adjustments should be performed at 32 000 mile intervals or more frequent under abnor mal operating conditions 1 Adjust the kickdown band Refer to Page 59 2 Adjust the gearshif...

Page 509: ...nt panel retaining clamp and screws 10 On some models disconnect the brake pedal from the master cylinder so the pedal can be raised to provide steering column removal clearance Lift the steering colu...

Page 510: ...the operating le ver then slide the lever out of the groove on the gear DETENT PAWL CABLE BRACKET S P R F LEVER NK307 Fig 12 Removing or Installing Tapered lock Bolt shift tube 4 Remove plate and sea...

Page 511: ...ve Multi Purpose Grease Grade 2 to all parts in the column where friction occurs or where lubrication would be required 1 If removed install the insulator sleeve column support plate and lower lever s...

Page 512: ...he hair pin lock Align the seal boot and cable lock plates then install the rubber washer metal washer and nut Tighten the nut securely I DETENT PLATE SLOT IN SPRAG LEVER TIGHT AGAINST PIN PI OT Fig 1...

Page 513: ...inch Tighten the steering column bracket clamp screws securely AP 1 and AP 2 Models Move the column assembly up or down in the instrument panel bracket so the 1 GAUGE HOLE u COUPLING 62x457A Fig 20 Po...

Page 514: ...onsole Lift the plate upward far enough to remove the dial lamp and socket then lift off the plate Re move the four gearshift unit to console retaining bolts Raise the console lid remove two screws fr...

Page 515: ...e rear of the finish plate into position and install the retaining screws 3 AV 1 AV 2 Models Align the gearshift control unit in the mounting brackets install and tighten the four retaining bolts Fig...

Page 516: ...moving Parking Lock Cable OVER N Y2298 62x90A Fig 28 lnrtalling Parking Lock Cable CAUTION Do not use pliers or similar tool to with draw the cable from the adapter cover as the ca ble cover might bed...

Page 517: ...engine Hold the adjusting screw in this position and tighten the lock nut to 25 foot pounds torque A 727 A and 6 Back off the adjusting screw 2 turns Hold the adjusting screw in this position and tigh...

Page 518: ...n the adjusting link 6 just contacts the carbu retor lever pin 7 Lengthen the carburetor rod 15 two full turns by turning the slotted link 6 8 Assemble slotted link 6 to the carburetor 9 Loosen the ca...

Page 519: ...making sure it re turns to the full forward position 7 Loosen the cable clamp nut 4 then adjust the position of the cable housing ferrule 3 in the clamp so that all slack is removed from the cable wit...

Page 520: ...ing in place To check transmission linkage freedom of operation move slotted adjuster link 5 to the full rearward po sition then allow it to return slowly making sure it returns to the full forward po...

Page 521: ...the cable housing ferrule 4 in the clamp so that all slack is removed from the cable with the carburetor at curb idle To remove slack from the ca ble move the ferrule 4 in the clamp in the direction...

Page 522: ...stop lo and adjust its length by means of the threaded adjustment ll so that the ball socket l lines up with the ball end of the carburetor lever 7 Lengthen carburetor rod four turns by turning 4 Ins...

Page 523: ...tely 4 inches long in the holes provided in the transmission rod bellcrank bracket and lever assembly 5 Move the transmission lever 9 forward against the stop and tighten the transmission rod lock nut...

Page 524: ...of 90 96psi just before or at kickdown into low gear Front servo release pressure must follow the line pressure up to the kickdown point and should not be more than 3 psi below the line pressure If th...

Page 525: ...prevent the transmission from downshifting Throttle Pressure No provisions are made to test the throttle pres sure Incorrect throttle pressure should only be sus pected if the part throttle shift spee...

Page 526: ...ure the adjustment is made with the spring fully compressed and the valve bottomed in the valve body 6 Remove the tool and tighten the stop screw lock nut securely OlTLE LEVER NK 155 Fig 41 Throttle P...

Page 527: ...f the pinion and slide the pinion assembly off the cable Install a new seal on the cable housing If the clutches and servos operate properly no un shift or erratic shift conditions indicate that the m...

Page 528: ...bly 2 Cut the boot end off the seal then screw the taper threaded end of Tool C 748 into the seal Fig 48 Tighten the screw of the tool to remove the seal 3 To install a new seal position seal in the o...

Page 529: ...unds torque 3 Install and adjust the parking lock cable Refer to Page 4 Install the transmission flange and connect the propeller shaft 5 Install the speedometer drive pinion and sleeve 6 Add fluid to...

Page 530: ...tic or rawhide mallet remove the extension housing and bearing assembly by striking the square boss rearward on the bottom rear end of the extension housing Spread the large snap ring and remove the b...

Page 531: ...2 SNAP SNAP RII GOVERNOR BODY GOVERNOR SIJPPORT AND PARKING GEAR NY180C SPRING O U T E R WEIGHT RINGS INNER WEIGHT 61x358 VALVE SHAFT VALVE fig 55 Governor Assembly IDisassembled hole in the output s...

Page 532: ...lide the aligning fix ture Tool C 3864 A 727 A and B or Tool C 3762 A 904 G and A 904 LA all the way in until it bottoms against the rotors Fig 57 then retighten the cover Fig 58 Removing or Installin...

Page 533: ...he piston for scoring and the rings for wear or breakage Replace as required NOTE Servicing the valve body assembly is out lined on Page 81 lnstullution 1 Clean the mating surfaces and inspect for bur...

Page 534: ...ble Fig 26 Disengage the cable adapter lock spring by pushing the screw driver handle to the right while pulling outward on the cable 12 Disconnect the throttle rod from the throttle lever on the tran...

Page 535: ...ter on the face of gear at intervals during the heating process When the gear is hot enough to just boil the water installation of the gear on the torque converter can be made 1 After the ring gear i...

Page 536: ...nsmission case NOTE The vent shield is not used or required on the A 904 G and A 904 LA front pumps See Fig ures 63 and 64 1 A 904 G and A 904 LA Screw seal remover Tool C 3758into the seal Fig 63 the...

Page 537: ...or the A 727 A and B transmissions 2 Record the indicator reading for reference when reassembling the transmission Refer to Page 104 Oil Pan 1 A 904 G Place the transmission assembly in re pair stand...

Page 538: ...ring Make sure the snap ring is fully seated in the outer race ring groove of the bearing 6 Using a plastic or rawhide mallet remove the extension housing and bearing assembly by striking the square b...

Page 539: ...SEMBLIES The following procedures cover the disassembly inspection repair and assembly of each sub assem bly as removed from the transmission Heli Coil inserts are recommended for repairing damaged st...

Page 540: ...ntrol valve out of the valve body ONE LARGE STEEL BALL v 1 CHECK VALVE FIVE SMALL STEEL BALLS Fig 73 Front Pump Check Valve and SteelBall Locations 5 Remove the 14 transfer plate retaining screws Care...

Page 541: ...top screw assem bly Fig 75 be careful not to disturb the setting any more than is necessary 14 Remove the kickdown detent kickdown valve throttle valve spring and the throttle valve Fig 75 15 Remove t...

Page 542: ...ear pump check valve and spring in the transfer plate Fig 72 Position the steel plate on the transfer plate and install four steel plate to trans fer plate retaining screws Make sure the bolt holes in...

Page 543: ...if pressures were satis factory prior to disassembly use the original settings ACCUMULATOR PISTON AND SPRING Inspection Inspect the two seal rings for wear and make sure they turn freely in the piston...

Page 544: ...lve should fall freely in the bores when clean and dry Rough surfaces may be removed with crocus cloth Inspect the governor weight spring for distortion Inspect the lugs on the support gear for broken...

Page 545: ...ng a narrow bladed knife or similar tool re move the high points or burrs around the staked area Fig 81 Do not use a file or similar tool that will re move more metal than is necessary Reaction Shaft...

Page 546: ...h surface and install the handle Tool SP 3549 in the installing head Drive the bushing into the shaft until the tool bottoms 8 Thoroughly clean the reaction shaft support as sembly before installation...

Page 547: ...ody and reaction shaft support bushings for wear or scores Inspect the oil pump rotors for scor ing or pitting With the rotors cleaned and installed in the pump body place a straight edge across the f...

Page 548: ...location will suffice 8 Using a narrow bladed knife or similar tool re move the high points or burrs around the staked area Fig 86 Do not use a file or similar tool that will re move more metal than...

Page 549: ...h retainer assembly and bump it on a wood block to remove the piston Remove the seal rings from the piston and clutch retainer hub Inspection Inspect the facing material on all the driving discs Repla...

Page 550: ...5 Fig 89 and seat the snap ring in the hub groove Remove the com pressor tool 4 Lubricate all the clutch plates install one steel plate followed by a lined plate until all the plates are installed Ins...

Page 551: ...ng surface on the clutch retainer for scores Note the ball check in the clutch retainer make sure the ball moves free Fig 93 Removing or Installing Front Clutch Spring Retainer Snap Ring TOOL HAN SP 3...

Page 552: ...xactly as shown in Figure 95 Position the spring retainer and snap ring on the springs Compress the springs with TOO1 C 3863 Fig 931 and seat the snap ring in the hub groove Remove the compressor tool...

Page 553: ...clutch re tainer for smooth surfaces plates must travel freely in the grooves Note the ball check in the clutch re tainer make sure the ball moves freely Inspect the seal ring surfaces in the clutch...

Page 554: ...n retainer assembly and bump it on a wood block to remove the piston Re move the seals from the piston 4 If necessary remove the snap ring and press the input shaft from the clutch piston retainer Ins...

Page 555: ...and outer seal rings on the clutch piston Make sure the lip of the seals face toward the head of the clutch retainer and are properly seated in the piston grooves 3 Place the piston assembly in the re...

Page 556: ...rt from the annulus gear 4 Slide the sun gear driving shell and rear plan etary assembly off the output shaft 5 Lift the sun gear and driving shell off the rear planetary assembly Remove the snap ring...

Page 557: ...steel washer and snap ring 5 Carefully slide the driving shell and sun gear assembly on the output shaft engaging the sun gear teeth with the rear planetary pinion teeth 6 Place the front annulus gear...

Page 558: ...re 104 for parts reference 1 Position the rear planetary gear assembly in the rear annulus gear Place the thrust washer on the front side of the planetary gear assembly 2 Insert the output shaft in th...

Page 559: ...g bolts down evenly then tighten to 100 inch pounds torque 7 To install the rear oil pump body refer to Page 86 Overrunning Clutch Cam Replacement A 727 A and B If the overrunning clutch cam and or th...

Page 560: ...and spring Fig 111 Inspection Inspect the seal for deterioration wear and hard ness Inspect the piston and piston plug for nicks burrs scores and wear piston plug must operate free ly in the piston I...

Page 561: ...e output shaft through the rear pump housing Carefully work the assembly rearward engaging the L E V E R 1 LEVER SHORT LINK AND ANCHOR Fig 1 13 low Reverse Band and linkage rear planetary carrier lugs...

Page 562: ...Front Bund down band assembly Figure 114 shows a disassembled view of the kick 1 Slide the band over the front clutch assembly 2 Install the band strut screw in the adjuster just LEVER SHAFT BAND w 62...

Page 563: ...ing tight against the front snap ring then install the rear snap ring 2 Unwind and slide the yoke seal stop ring into place on the shaft Install the seal with lips of seal to ward the rear 3 Place a n...

Page 564: ...offset holes in the plate are located next to the 9 inch hole in the inner circle of the plate A stamped V mark identifies the offset hole in the converter front cover Fig 118 Carefully work the trans...

Page 565: ...er in the PARK position In sert the control cable in the transmission case push inward on the cable making sure the lock spring en gages the cable Install the control cable adjusting wheel lock screw...

Page 566: ...EARI NG S TIRES SIDE WEAR a Outside all wheels excessive cornering speed b Outside front excessive positive camber c Inside front excessive negative camber d Outside and inside under inflation or vehi...

Page 567: ...runout wobble B should not exceed 050inch NOTE Under no circumstances should point indi cated by C be used for measuring runout as this metal has been sheared in the manufacturing proc ess and i s no...

Page 568: ...Force lubricant between bearing cone rollers or repack with a suitable Bearing Packer 4 Install the inner cone and a new seal with lip of seal facing inward Using Tool 2 3893 drive the seal flush with...

Page 569: ...ended sequence Fig 6 LEFT FRONT nicw FRONT Fig Tire Rotation Repairing Leaks Leaks between the tire and wheel require the re moval of the tire Leaks in the tire can often be re paired without removing...

Page 570: ...WHEELS BEARINGS AND TIRES 22 5 Fig 9 Camber Wear Fig IO Toe Wear Fig I I Spotty Wear...

Page 571: ...SERVICE DIAGNOSIS MANUAL DOOR LOCK AND LINKAGE Condition Possible Cause Correction DOOR HARD TO OPEN a Striker rubbing on door face or on back rotor STICKS housing move interference b Lock striker not...

Page 572: ...ent of folding top header TOP FABRIC TOO LOOSE OR TOO TIGHT a Improper adjustment of number I roof bow AIR OR WATER LEAKS AT WINDSHIELD HEADER adjusted a Folding top header torsion bar not properly a...

Page 573: ...r so that the proper solvent may be used Most common stains can be removed either with a dry cleaning sol vent fabric cleaner or with a water solution contain ing one half of 1 of a laundry type deter...

Page 574: ...east two times a year to keep it in new condition The recommendations of the cleaner product man ufacturer should always be followed to gain the best results After the bright metal has been thoroughly...

Page 575: ...during jacking operations Rear Bumpers Refer to Figures 4 5 and 6 for the rear bumper attaching points The bumper on AR station wagon models must be held in the extreme up position while the support...

Page 576: ...in the open ing RADIATOR STONE DEFLECTOR To remove the radiator stone deflector Fig 11 on AP Models it is first necessary to remove the bump er and grille assembly The stone deflector is attached to...

Page 577: ...3 Install the air shield to support screws finger tight 4 After all the attaching screws have been in stalled align the support and tighten all screws se curely 5 Install the radiator connect the rad...

Page 578: ...LDINGS the retainer The moulding is then snapped over the retainer Refer to Figures 14 15 and 16 for the various type retainers and methods of attachment Exterior mouldings are held in place by numero...

Page 579: ...BUMPERS GRILLES FENDERS 23 9 NK1116 J K I DECK LID QUARTER PANEL TAIL GATE REFERENCE H J K REFERENCE M REFERENCE L SILL REFERENCE REFERENCE F G Fig IS Exterior Mouldings IAR Models A NKlll9 NK1120 B...

Page 580: ...23 10 BUMPERCRILLES FENDERS N K l l 2 2 _ _ L _ _ _ _ BELVEDERE II 2 DOOR D 4DOOR E BELVEDERE I NK117 4 BELVEDERE II NK1125 BELVEDERE I NK1126 H H N K l l 2 7...

Page 581: ...BUMPERS GRILLES FENDERS 23 11 K NK1128 b N K l l 2 9 CE A REFER SILL REFERENCE REFERENCE D NK1131 Fig 16 Exterior Mouldings IAV Modelsl NK1133 B...

Page 582: ...23 12 B U M P E R M R I L L E W E N D E R S NK1134 G NK1135 NKl139 H NK1136 N Kll37 J...

Page 583: ...BUMPERS GRILLES FENDERS 23 13 NKll41 I PUTTY KNIFE Fig 17 Removing Headlining of Roof Bows Fig 18 Headlining Roof Rail Bows...

Page 584: ...oors and quarter panels These waterproof water shields are on internal seal against water leaks The lower edge of the shield must be inserted into the slots provided for in the bottom of the inner pan...

Page 585: ...p the bow and ruining the fit of the headlining 12 After the listings are cut start at the front and trim the headlinings so that only Y 2 to 1 inch of the material hangs down below the rear window op...

Page 586: ...etainers and install the garnish mouldings Poly Foam Headlining The removal and installation procedures for poly foam headlining are the same as those for the hard board headlining When installing the...

Page 587: ...nsole by trim fasteners and cement Fig 27 The carpet CEMENT I I d NK850 Fig 28 Console Side Trim Carpet Fig 29 Six Way Seat Adjustment on the console side cover Fig 28 is pre formed Ap ply cement to b...

Page 588: ...bent over the lower edge of the seat back frame Station Wagon Rear Seats Removal Second Seat Backl 1 Remove the screws attaching the second seat back to the hinge assemblies Fig 30 2 Release the sprin...

Page 589: ...port panel as 3 Install the retainers on the stud sembly on the studs Removal Third Seat Cushion 1 The third seat cushion is attached to hinges which in turn are attached to the quarter inner pan els...

Page 590: ...the hold down straps in keeping the back panel locked in a down position FOLDED BOX Fig 37 Assembling Glove Box IAR Models I 4 MOLDED B O X 1 3 NK815 Fig 38 Glove Box Assembly IAV Models REAR COMPART...

Page 591: ...sired position Hood to Grille The height of the hood to grille clearance may be Fig 4 L H o o d Attachment IAP Models NK856 adjusted by lengthening or shortening the hood sup port studs The mounting o...

Page 592: ...ing screws prop the hood into the wide open position The prop should be positioned so the hood cannot move rear ward AV and AP Models remove the torsion bars from the hinges To remove the hood hinge i...

Page 593: ...tighten to 180 inch pounds after alignment has been accom plished 12 Engage the torsion bar roller with the hood hinge BELVEDERE SATELLITE VALIANT NK818 Fig 45 Hood LockAssembly IAR Modelsl A SPRING...

Page 594: ...djustment This is made through an access hole in the inner door panel Front Door Up and Down 1 Remove the trim panel and water shield 2 Scribe a line around upper and lower hinge straps 3 Place a wood...

Page 595: ...from dropping in the door opening 9 Adjust the door lock striker door opening In und Out hinge plate loor ti position a floor jack taching bolts n and raise or lower s1 5 Adjust the lower hinge Remov...

Page 596: ...panel and water shield 2 With the door glass in the up position through the inner door panel openings remove the attaching nut and washer and the attaching screw and washer from the door handle Figs 4...

Page 597: ...are Door Lock Cylinder Removul 1 Remove the inside handles trim panel and wa tershield 2 Using a screwdriver through the access hole of the door panel pry the U shaped retainer Fig 52 off of the back...

Page 598: ...ly over size allowing a partial deck lid adjustment Additional alignment is obtainable at the hinge to deck upper panel mounting Fig 54 Deck Lid Replacement The deck lid is attached to the hinges by t...

Page 599: ...d and Cylinder fAV Models1 149 Deck Lid Lock Adjustment Vertical adjustment of the deck lid lock is made at the lock attaching screws The side adjustment is made at the deck lid striker attaching bolt...

Page 600: ...assembly 5 Remove the hinge plate attaching bolts from the pillar post 6 Slide the hinge plate and torsion bar in through NK719 Fig 6 L T a i l Gate Handle Stud Locations IAP Models J I NK718 Fig 61...

Page 601: ...r horseshoetype Tail Gate Regulator Handle the inner tail gate panel and remove the three nuts at taching the handle to the outer panel To remove a handle which is inoperative and the vehicle is fully...

Page 602: ...w and inspect alignment and test for ease of operation IAR Models Refer to Figure 64 for the adjustment points and methods of adjustment for the door glass and vent wing assembly The adjustment proced...

Page 603: ...channel Raise and lower the glass to make sure that it operates freely In some cases you may have to readjust the lower end of the division channel in or out to get the best possible alignment of the...

Page 604: ...or glass assembly into the door and position the vent wing pivot swivel as sembly into the vent wing regulator 5 Position the regulator arm roller into the glass lift bracket and move the glass rearwa...

Page 605: ...the lower frame stud from the door bracket the window regulator arms from the window channel and slide the window out of the run channels 5 Disconnect the cat whisker for a short distance to provide c...

Page 606: ...ust make sure that the head of the plastic rivet is tight against the bracket and the expandable end of the rivet is all the way through the hole in the glass Drive the plug into the rivet to lock the...

Page 607: ...osition the glass into the door frame 4 Position the regulator arm roller into the lift 5 Position the glass into the glass run channels 6 Install the door interior trim and hardware bracket channel a...

Page 608: ...ment is also provided at the lower end of the rear run channel Quarter Window Glass Replacement Removal IAP Models 1 Remove the rear seat cushion and back 2 Remove the quarter window regulator handle...

Page 609: ...m rest Removal fAV Models 1 Remove the quarter trim panel and hardware 2 Lower the glass and reaching through the front access opening remove the clip from the regulator arm stud pin 3 Pull the regula...

Page 610: ...ot slide 1 Place the regulator up into position and install 2 Install the regulator attachingscrews 3 Insert the regulator arms into the lower frame 4 Test the operation of the regulator and adjust 5...

Page 611: ...ower the front of the glass raise the front of the pivot bracket 3 On manual operated regulators run the window down so the top of glass is even with or slightly be low the belt line 4 Position the st...

Page 612: ...it from the glass run channels 6 After the door glass is free of the glass run channels pull the glass up and out of the door open ing Installation 1 Slide the door glass down into the door rear port...

Page 613: ...er shield 7 Install the trim panel arm rest door handle for ease of glass movement and alignment regulator handle and the lock rod plastic knob Removal fAV Models water shield screw glass out of the c...

Page 614: ...djust the vent wing leg so the boss of the ad justing stud is against the support and the top of the vent wing and door glass are inboard against the roof rail weatherstrip 5 Position the up stop down...

Page 615: ...r the belt line permit shifting of the vent assembly fore or aft and up or down The two vent frame attaching screws at the front of the vent must be loosened to allow the frame to move The adjusting s...

Page 616: ...vent wing assem L V LIFT BRACKET NK8B5 Fig 101 Vent Wing and Door Glass Attachment Hard Top Convertible fAP Models DJUSTING STUD LIFT BRACKET GUIDE RIVET NK898 GASKET Fig 102 Glass Lift Bracket fAP Mo...

Page 617: ...n into the door 8 Install the division bar adjusting screw and the vent wing to door panel screws 9 Position the tilt adjustment screw in the door inner panel and install the lock nut 10 Install the t...

Page 618: ...ass with the division channel is also important Shift the rear of the regulator assembly up or down to level the glass and align it with the division channel Glass Run Channel fTwo Door Models Removal...

Page 619: ...indow Yz way down and tighten the lower rear roller track attaching screw UP STOP CENTER SUPPORT IN AND OUT IN AND OUT IN AND OUT LOCK WASHER NK916 Fig 107 Rear Door Glass Adjustment Hard Top 7 Run th...

Page 620: ...Remove the door glass assembly 2 Remove the nut and washers attaching the track assembly to the lower part of the door inside panel Fig 72 3 Remove the screw and washer assembly attach ing the track...

Page 621: ...the lower front track attachment so the front of the window is aligned with the rear of the front door window at the roof rail Turn the sleeve nut counterclockwise to move the window in and clockwise...

Page 622: ...the regulator plate 9 Operate the window and inspect alignment and ease of operation 10 Install the water shield trim panel and hard ware Adjustments AVP29 Models 1 With the hardware trim panel and wa...

Page 623: ...from the roller assemblies in the glass lower frame from the quarter panel Installation 1 Inspect the front and rear track roller assem blies for damage or excessive wear 2 Apply lubricant to the regu...

Page 624: ...screw washer grommet and spac er attaching the glass to the frame at the rear attach ment through the access opening at the top rear por tion of the inner panel 4 Remove the glass from the quarter pa...

Page 625: ...d 2 Remove the nut and washers attaching the track to the belt line Fig 119 3 Remove the nut and washers attaching the track brace to the stud on the track Fig 120 and the screw and washer assemblies...

Page 626: ...nut and washers attaching the track to the belt reinforcement 5 Test the window for alignment and ease of op eration 6 Install the water shield trim panel and regulator handle Quarter Glass Channel Re...

Page 627: ...with or slightly below the belt line of the quar ter outside panel 11 Adjust the lower stabilizer attachment in or out as necessary 12 On manually operated windows position the stop on the regulator...

Page 628: ...ndow and inspect alignment and operation 7 Install the water shield trim panel rear seat back cushion and quarter window regulator handle Regulutor Assembly The regulators Fig 127 are attached to the...

Page 629: ...r track brack 7 Remove the track upper sleeve nuts and remove ets and remove the lower track attaching screws the tracks from the quarter panel lnstallation 1 Position the tracks down in the quarter p...

Page 630: ...trip on the low er glass frame 2 Position the tail gate glass on the weatherstrip and lower frame and install the washers spacers and retaining screws 3 Apply lubricant to the regulator arm studs and...

Page 631: ...gate glass and open the tail gate 2 Remove the tail gate inside handle and trim 3 With an assistant raise the glass and support 4 Disconnect the regulator arms Fig 136 from 5 Remove the door glass 6 D...

Page 632: ...he seal up and across the roof header and down the opposite pillar 4 Position the roof rear header tailgate glass run retainer on the seal and install the retaining screws Upper Run und Pillar Run Rem...

Page 633: ...ight hand side by two inches maximum 6 If the overlap is greater than two inches trim off the excess at approximately a 30 degree angle Fig 141 7 Hand pressurize the seals to eliminate all wrinkles or...

Page 634: ...ld mould ing over the top of windshield CAUTION Make sure to exert sufficient pressure on the center of the moulding to force it all the way down on the clips 7 Align and install the lower center chro...

Page 635: ...ION BB SECTION CC NK950 Fig 143 Rear Window Mouldings tAP Models EA1 z f VIEW IN CIRCLE B u 750 MAXIMUM OVERLAP CLEFTHAND SIDE wx VIEW IN CIRCLE A OVERLAP RIGHT HAND SIDE VIEW I N CIRCLE B SEAL NK949...

Page 636: ...strip from the rear window using a fibre wedge 6 With an assistant supporting the glass on the outside remove the glass by pushing from the inside 7 Use of gloves will protect the hands against possib...

Page 637: ...e body flange groove of the weatherstrip 2 Carefully position the weatherstrip over the body flange making sure it fits smoothly and evenly over the entire flange especially at the corners 3 Coat the...

Page 638: ...allation 1 Install the weatherstrip on the quarter glass 2 Position the glass and weatherstrip assembly in the window opening from inside the vehicle Fig 151 3 Position the roof side rail retainer Fig...

Page 639: ...quarter window Installation 1 Remove all old sealer and cement from the quarter window fence and from the original weather strip if it is to be reinstalled 2 Apply sealer to the fence groove in the we...

Page 640: ...IN DIRECTION OF ARROW A NK827 erstrip will transfer to the A post when the door is closed if a good contact exists Fig 155 Door and Quarter Panel Belt Weatherstrip IAV Models and the inner lip of the...

Page 641: ...eel surfaces is desired It can be used for such purposes as the attachment of weatherstripping on doors and luggage compartment lid or for the at tachment of felt pads Windshield Rubber Sealer A heavy...

Page 642: ...method of applying sealers Cowl Panel OuterJ Inspect dash panel seams screws clip and punch holes Inspect the sealing of rubber grommets Make sure the heater drain hole tubes are properly installed a...

Page 643: ...djustments will correct leaks between the vent glass and the weatherstrip To in crease the pressure of the glass against the upper portion of the weatherstrip install shims made from the closed cell r...

Page 644: ...le type applicator sealer gun to force the sealer deeply around the en tire edge It is rarely necessary to reseal between the glass and the weatherstrip unless the glass has been replaced If faulty se...

Page 645: ...eel housing and quarter panel may originate at the corner of the rear quarter win dow IMPORTANT Do not confuse condensation on metal parts with water leaks When the actual source of the leaks has been...

Page 646: ...a 3h inch bead of sealer to the seam of the Fig 168 Tail Gate Seals and Weatherstrips IAP Models I FLOOR PAN RIGHT HAND SIDE NK927 PAN REAR PANEL Fig 169 lail Gate Sill and Floor Panel IAP Models whe...

Page 647: ...ME WITH OFFSET FOLDING LINK 1 AGE I Fig 777 Folding Top Structures Operate the engine in NEUTRAL at a speed above idle Turn the top control switch located on the in strument panel to the right and hol...

Page 648: ...e necessary to improve roof side rail alignment if minor hinge and header adjustment do not completely correct the condition DOOR AND GLASS ALIGNMENT Before making any top adjustments doors vent wings...

Page 649: ...ECTION OF ARROW 9 2 3 Fig 175 Power Cylinder Assembly AP Modelsl to fold into the well when not in use Hinges are pro vided between the front and center rails and the cen ter and rear rails The rails...

Page 650: ...ssembly has been re moved for servicing or replacement of linkage parts When this is done be sure both sides are adjusted to provide identical travel of the piston rods The power links are part of the...

Page 651: ...ew locations on the tape to aid in reassembly Remove the moulding screws moulding retainer screws and retainer Stretch the backlight and quar ter trim to remove the wrinkles Trim off excess back light...

Page 652: ...liner seals and sealers 7 Clean the sealing and cementing areas thor oughly to assure good adhesion on the new liner lnstallation 1 Install a strip of sealer cement 120 inches long to the top of the q...

Page 653: ...erstrip is not sealing properly the re tainer and weatherstrip can be adjusted to improve the seal The retainer has elongated attaching screw holes which permit the retainer and weatherstrip to be mov...

Page 654: ...uld ings at the rear quarter panels and rear window 3 Remove the mouldings at the quarter panel belt area and from the bottom of the rear window Fig 185 4 Mark the location of the moulding retainer sc...

Page 655: ...bly Fig 189 at the front roof rail and the number 3 roof bow If the original cover is to be reinstalled tie a cord to one end of the cables prior to removing When the cables are removed the cord shoul...

Page 656: ...ther the vent wing or door glass contact the beading on the edge of the cover on one side the top material may be loosened at the header and moved slightly toward the opposite side until clearance is...

Page 657: ...e quarter panels and rear window moulding retainers and install snap retainer and screw assemblies Do not overtighten 42 Test the operation of the top assembly and in spect the fit of the top at the w...

Page 658: ...o the vinyl cover half on the same side Fig 191 6 When the cement becomes tacky but not wet to the touch position the cover on the panel 7 Repeat steps 5 and 6 for the opposite side 8 Using a new pain...

Page 659: ...n trough 20 Apply a bead of sealer black or white de REAR RETAINER Fig 19Wnstalling Cover Side Retainers IAR AV Models1 Fig 195 Trimming Cover at Drain Trough pending on cover color over the trimmed e...

Page 660: ...r Mark the plumb bob contact point on the floor Repeat the process at points B C D E and F at both sides of the body Snap a chalk line between points as illustrated Compare the dimensions with the spe...

Page 661: ...BODY ALIGNMENT 23 91 d t Fig 198 Body Frame Dimensions IAR Models I I K MEMBER ATTACHING BOLT I I BOTTOM VIEW E SIDE VIEW NY1457A W 4 4 X Fig 199 Body Frame Dimensions IAV Models1...

Page 662: ...23 92 BODY ALIGNMENT t HEADER PANEL ROOF 7 I DECK LID HOOD FENPER RADIATOR YOKE ROOF RAIL COWL TOP PANEL LOWER PANEL NKll78 Fig 200 Sheet Metal Replacement Panels...

Page 663: ...etic Primer Surfacer DPS 30 Gray DuPont Hi Speed Primer Surf acer or R M Rinshed Mason APS 403 Primer Surfacer Sealer 3 Sand when dry and proceed with application of finish coats according to the pain...

Page 664: ...e surface with wax and grease re mover This ensures positive adhesion 15 Tack rag the entire surface to remove lint and dust polish 17 When the color has dried hard compound and 16 Apply acrylic color...

Page 665: ...X9 All Models AAYlBl All Models VAY2B6 AAY2B9 AAY2U6 AAYlQl AAY2Q6 VAY209 AAY2A4 TAY1R6 TAYlYl AAY2R7 VAYlWl AAYlTl VAY2T6 AAQ6S2 All Models All Models All Models All Models All Models All Models All...

Page 666: ...garnish mouldings roof rail rear window garnish mouldings center pillar station wagon seat and floor components COLOR NAME Black MediumTurquoise Poly Medium Blue Poly MediumTan Poly LightGold Poly Da...

Page 667: ...ks Fury and Sports Fury Modelsonly Bucket seat tracks only Fury and Sports Fury Modelsonly Rear shelf radio speaker grille B pillars Rear shelf radio speaker grille B pillars Rear shelf radio speaker...

Page 668: ...ly center floor pan rear cover panel filler quarter insiderear COLOR NAME CHRYSLER DITZLER CODE NUMBER CODE Black TAB1X9 Po00 MediumTurquoisePoly VAB206 12647 Medium Blue Poly VAB2B6 12656 MediumTan P...

Page 669: ...ue Poly AAB6B8 12925 Air IntakeGrille Only MediumTurquoisePoly AAB6Q4 12928 Medium Blue Poly AAB6B4 12933 Medium Tan Poly AAB6T6 22465 Rear Shelf FastenersOnly Rear Shelf FastenersOnly Rear Shelf Fast...

Page 670: ...ING a Low refrigerant moisture frozen stuck or faulty expansion valve stuck or faulty E P R valve a Add refrigerant test for leaks and repair re place strainer drier clean or replace expan sion valve...

Page 671: ...comfortable level in heat defrost and cool Rotary blower switch has four posi PUSH BUTTONS OFF to shut off system HEAT to be used when heating the car DEFROST to be used when defrosting the windshiel...

Page 672: ...IVATED 2 62x672 Fig Air Flow Off Position HEAT POSITION FRESH AIR THRU COWL VENT MAXIMUM COOL SWITCH NOT ACTIVATED BLACK HOSE ACTIVATED SPOT COOL DOOR CLOSED DEFROSTER DOOR CLOSED 2 BLOWER SWITCH IS I...

Page 673: ...VATED WHEN POSITION 3 OR 4 BLOWER SWITCH IS IN POSITIONS HEATER DOOR 62x674 Fig Air Flow Defrosting Position COOL FRESH POSlllON FRESH AIR THRU COWL VENT MAXIMUM COOL SWITCH NOT ACTIVATED BLACK HOSE A...

Page 674: ...OR 4 REAR VIEW OF SWITCH 62x676 HEATER DOOR Fig 8 Air Flow Recirculating Cool Position OFF POSITION MAXIMUM COOL SWITCH ACTIVATED BLACK HOSE ACTIVATED FRESH AIR THRU COWL VENT EVAPORATOR HEATER CORE C...

Page 675: ...2 4 6 AIR CONDITIONING I Q U I cy I JfZ 0 E Z 0 U OC 6...

Page 676: ...d circuit is shown in Figure 10 A 20 ampere fuse in the fuse block accessory terminal controls the blower speeds and the clutch feed The clutch circuit is energized hot only when the Cool push button...

Page 677: ...er operation of the MAXIMUM COOLING 62 x 671A Fig 73 Fast Cool Down ITypicalJ controls at the time of new vehicle delivery It should never be assumed that the new owner will study the Owner s Manual o...

Page 678: ...affect air conditioning performance Under severe heat conditions a bug screen may cause the engine to overheat Satisfactory performance of the combined air con ditioning and heating system is depende...

Page 679: ...e manifold Push each button to test the over all operation of the electrical and vacuum controls The Push Button Control Chart summarizes the actions that should take place when each button is pushed...

Page 680: ...gauge needle oscillations so that accurate read ings can be obtained The Compressor Inlet Gauge is mounted at the right side of the manifold This mounting is for con venience only There are no passag...

Page 681: ...e connected wrong the system must be purged the lines reversed and the system recharged Block the air flow across the condenser to raise the discharge pressure to 225 to 250 psi and check the sight gl...

Page 682: ...urn to let the sweep test charge escape slowly Allow the system to discharge until the discharge pressure gauge registers zero Open the left hand gauge valve to allow any refrigerant trapped in the su...

Page 683: ...re frigerant dispensing manifold 4 Close two of the dispensing manifold valves and open the remaining dispensing manifold valve Remove the protective cap from the opened valve 5 Screw a can of refrig...

Page 684: ...he temperature of the air delivered to the vehicle in terior Evaporator capacity used to reduce the amount of moisture out of the air entering the vehicle adds ma terially to the comfort of the passen...

Page 685: ...Test 3 The Expansion Valve Test 89 90 63 64 TEST 6 EVAPORATOR PRESSURE REGULATOR VALVE TEST AR 1 2 TEST 6 is divided into two parts to simplify the test procedures As both parts of the test must be ma...

Page 686: ...EPR valve test If the system failed to pass the Over All Perform ance Test but passed the EPR valve test proceed with the Compressor Capacity Test 7 PART 2 This part of the test will save time as the...

Page 687: ...lve is flooding the evaporator and the expansion valve should be replaced If the temperature is above the maximum either the compressor or the expansion valve is faulty in which case the system will h...

Page 688: ...e pressure gauge registers zero lease any vapor trapped at the suction side Test Preparation and Connections After the system is completely discharged isolate the compressor and connect the gauge set...

Page 689: ...Install a Vi connector and a Vi tee fitting at the left side of the gauge manifold Install the test cap SP 2922 on the tee fitting and connect the test hose to the lower end of the tee fitting 3 Conn...

Page 690: ...does not pass these tests it must be replaced For detailed instructions on expan sion valve replacement refer to Expansion Valve Replacement An expansion valve which passes the above tests has the pro...

Page 691: ...the refrigerant contain er with a blow torch or any other means that would raise temperature and pressure above this tempera ture Do not weld or steam clean on or near the sys tem components or refrig...

Page 692: ...ept tightly capped until it is ready for use and then tightly capped after use to prevent entrance of dirt and moisture Refrigerant oil will quickly absorb any moisture with which it comes in contact...

Page 693: ...sh Air Door Linkage The lack of clearance could break the switch lever also too much clearance would fail to close the fresh air door and open the recirculating door in the NO 3 and 4 positions With t...

Page 694: ...ach operation is inch If the vacuum drop is more than inch first re check the tester for reading exactly 8 inches If cor rect inspect the fit of the 7 hole connector plug on the control switch Fig 27...

Page 695: ...oses operate the fresh air door actuator Test whether the actuator or Fig 31 Temperature Selector Switch lesl hose is at fault use the test hose on the actuator in volved Fig 30 A leak in a hose may b...

Page 696: ...st the control cable 1 Remove the retainer clip and cable at the con trol lever end 2 Pull out on the control cable wire to move the thermostat valves to the full off or closed position 3 Hold the tem...

Page 697: ...tatic Valve Test hand valve The valve and its hoses are identified by green color coding green stripes on the hoses and two green paint dots on the valve itself To test this valve attach the test hose...

Page 698: ...d with the cable over the hose there s a good chance that the hose will be pinched affecting the temperature con trol system After the stats are installed remember to LEAD WIRE HUB AND SHOEASSEMBLY HU...

Page 699: ...assembly with the pulley side up on an arbor press and insert a new bearing into the bore Install the Tool 2 3807against the bearing and press into position Fig 39 2 Install the pulley assembly with p...

Page 700: ...g pressures and reduce the performance of the entire system Complete disassembly and assembly of the com pressor must be performed with the compressor re moved from the vehicle However on some models...

Page 701: ...ystem 4 Disconnect the magnetic clutch to control unit 5 Loosen and remove the compressor pulley belts 6 Remove the compressor to bracket attaching wire bolts and remove the compressor TOOL Fig 41 Rem...

Page 702: ...hten each bolt al ternately and evenly 23 to 27 foot pounds torque Piston and Connecting Rod Removal 1 Drain the oil from the compressor 2 Remove the sump attaching bolts 3 Separate the sump from the...

Page 703: ...hen the gas seal assemblyis replaced 4 Remove the gas seal from the crankshaft Installation The crankshaft gas seal replacement package con sists of the crankshaft gas seal assembly and the crankshaft...

Page 704: ...haft ball bearing is in good condition and clean protect it against entry of dirt and re use it If bearing is serviceable but dirty or there is evidence of dirt clean it carefully with mineral spirits...

Page 705: ...and recharged Heuter Core Evuporutor Assembly Removal from Vehicle The heater core and evaporator are compactly packaged forward of the instrument panel and must be removed as a single unit The system...

Page 706: ...ket 3 Install the mounting bolt and nuts to studs through the firewall 4 Install the electrical wires to the resistor block and relay 5 Install the temperature control cable thermo stat the vacuum hos...

Page 707: ...gauge valve a small amount This will allow the refrigerant vapor to discharge slowly CAUTION Do not allow the system to discharge rapidly since this would sweep some of the refrig erant oil out of th...

Page 708: ...sampling hose directly below the point being tested Be careful not to pinch the sampling tube since this will shut off the air supply to the flame and cause a color change 3 Watch for a change in the...

Page 709: ...M Whenever the system has been opened to atmos phere it is absolutely essential that the system be swept with refrigerant and evacuated or vacuumed to remove all the air and the moisture If any ap pre...

Page 710: ...e center hose from the gauge set man chargingthree full cans of refrigerant at one time ifold to the refrigerant dispensing manifold Turn the refrigerant manifold valves completely counterclock wise s...

Page 711: ...Diameter inches Std Suspension 6 cyl 8 cyl Heavy Duty Suspension Station Wagons 2 2 zk 6 9 6 3 1 inch to 5 3 1inch Preferred I 8inch 1 7 8 1 8 8 1 7 5 4 1 44 3 5 8 0 86 0 88 0 9 0 0 88 0 8 8 Tread in...

Page 712: ...as follows Anticipated Temperature Viscosity Grade Above 1OOF SAE 90 SAE 80 Below 3OOF SAE 75 Range As low as 3OoF AXLE RATIOS Ring AV 1 AV 1 AV 1 AV 1 Gear 170 Cu In 170Cu In 225 Cu In 225 Cu In Dia...

Page 713: ...e Temperature Range As low as 3OoF Above 1 O O F SAE 90 SAE 80 Below 3OOF SAE75 AXLE RATIOS Ring Plymouth AR 1 Plymouth AR 1 Plymouth AR 2 Plymouth AR 2 Gear 225 Cu In 225 Cu In 273 Cu In 318 Cu In Di...

Page 714: ...h AP 1 Plymouth AP 2 Gear 225 Cu In 273 Cu In 225 Cu In 318 Cu In Diameter Engine Engine Engine Engine TAXI ManuaITransmission 8 75 3 55 3 55 3 55 3 55 Optional 8 75 2 93 Automatic Transmission 8 75 2...

Page 715: ...e 0 C C C C 0 0 0 0 a a a e 0 U U 0 U C 0 m VI VI 2 5 4 9 a 0 a 3 8 x T m m s 0 3 0 3 c Q 2 5 03 1 n Y 7 7 I x e 0 x 0 a I...

Page 716: ...in Borg Beck AR 1and AP 1 Police 225 cu in CLUTCHDISC FacingType MoldedWoven Molded Woven Facing Material Asbestos Asbestos Outside Diameter 11 10 Thickness 135 125 135 Disc Springs 6 6 Spring Color...

Page 717: ...l Asbestos Asbestos Outside Diameter 10W 1o l Thickness 125 125 Spring Color 5 Green 5 Tan Disc Springs 10 10 5 Green 5 Tan CLUTCHCOVER Pressure Springs 9 12 Spring Color 3 White 6 No Color Spring Pre...

Page 718: ...i q c y a ncy U Y 0 0 z z Y O Z z x 51 u z o z Y Y 8 8 5 2 0 0 z z x 61 u z o z Y 0 0 z z L b 2 a v Q 1 I b 2 0 c y c y 2 b mcy 7 2 b zsr sr Lu Z X 9 2 o o z z z Y X P 2 z 2 Lu Z X 2 i n 2 9 P n L u E...

Page 719: ...LER 50 55 80 80 45 45 30 40 30 45 30 30 40 20 20 25 55 35 35 30 50 35 85 90 45 70 50 60 50 70 50 50 60 35 75 85 50 40 Any belt that has operated for a minimum of a half hour is considered to be used T...

Page 720: ...e 20 HB 38 48 12 9 Negative 24 MB 48 AV 1 With 225 Cu In Engine AP 1 AP 2 AR 1 AV 2 AR 2 With 225 Cu In 273 Cu In or 318 Cu In Engines StandardEquipment 48 12 9 Negative 24 MB 48 AR 2 AR 2 AP 2 AV 1 W...

Page 721: ...unt 4 4 32 to 36 Ounces Overrunning Clutch 010 045 11 90 1925to 2400 4 400 to 450 14 4 16 0 Amps 6 0 Volts 115 12 6 Amps 6 0 Volts Reduction Geur Type All Models Equipped With the 170 Cu In Engine Sta...

Page 722: ...ion Clockwiseat Drive End Voltage 12VoltSystem Current Output DesignControlled Voltage Output Limited by Voltage Regulator Brushes Field 2 Condenser Capacity SOMicrofarador minus20 FieldCurrent Draw C...

Page 723: ...r Arm Spring Tension Condensercapacity Shaft Side Play New or Rebuilt Shaft End Play After Assembly Rotation Timing Spark Plug Type Size Gap Coil Identification Number Primary Resistance 70 80 F Secon...

Page 724: ...15 0 4 4 to 7 1 3 to 5 10 5 5 25 to 7 5 13 017 to 023 40 to 45 17to 20 oz 25 to 285 mfd OW to 003 003 to 017 Clockwise 2Y2 BTC N14Y Championor P 6 6PMOPAR 14MM Reach 035 1 5 3 6 2 4 Chrysler Prestolit...

Page 725: ...5 to 0 6 ohms 3 0 Amperes Engine Idling 1 9 Amperes Service wear tolerance should not exceed 006 inch VEHICLE MODEL With Manual Transmission With Automatic Transmission APPLICATION and 2 Barrel Carbur...

Page 726: ...rcury PF 4217 Breaker Point Gap Dwell Angle Breaker Arm Spring Tension Shaft Side Play New or Rebuilt Shaft End Play After Assembly Rotation Counter Clockwise Timing 10 BTC Spark Plug Type 0 4 5 to 8...

Page 727: ...to 540 0 to 2 540 3 5 to 5 5 1050 7 to 9 2400 0 6 to 9 7 5 to 10 5 14 3 014 to 019 One Set Points27 to 31 Both Sets Points36 to 40 17to 21 5 oz 25 to 285 mfd OOO to 003 003 to 010 Counter Clockwise 10...

Page 728: ...Heater or Air Conditioning 20 AMP Accessories 20 AMP Cigar lighter 20 AMP Tail Stop Dome 20 AMP Instrument lamps AV 1 and AV 2 2 ampere AR 1 and AR 2 3 ampere AP 1 and AP 2 4 ampere Ampere Rating CIR...

Page 729: ...vailable in Standard and the following Undersizes Type Length Center to Center Weight Less Bearing Shells Bearings Diameter and Length Clearance Desired Maximum Allowable before Reconditioning Side Cl...

Page 730: ...on Offset in Piston PISTON PINS Length PISTON RINGS Number of Rings per Piston Compression Oil Width of Rings Compression Piston Ring Gaps Compression Service Rings Oil Control Oil RINGSIDE CLEARANCE...

Page 731: ...e standard VALVE SPRINGS CYLINDERHEAD CYLINDER BLOCK Cylinder Bore Out of Round Max allowable before reconditioning Cylinder Bore Taper Max allowable before reconditioning ReconditioningWorking Limits...

Page 732: ...nch or more 012 inch 010 inch or more OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS Engine Displacement Condition Identification location of Identification 170cu in 001 U S Crankshaft MalteseCross...

Page 733: ...C E E 0 U 8 z z Y 9 0 h W uid c y c j f c P c y 9 4 9 9 c P c y L Q O B E m u E a 0 c g 0 2 c c 2 u 9 0 u 9 0 u 9 0 u 0 9 3 h P C 0 s 8 2 9 2 9 9 9 9 9 9 9 b u I B g 8 8 8 a b L b 9 u o O P 0 9 9 8 9...

Page 734: ...SPECIFICATIONS b 9 m m cy o o h n 1 p L 5 J c a I f 1 P...

Page 735: ...SPECIFICATIONS 25 I u...

Page 736: ...V h c C I lJ E p ea xu h I V h c l J 2 E q ea V h c C I lJ2 s E q ea V h c I i h c c y n 3 5 3 8 7 S v 9 0 v Y 4 0 0 0 0 4 9 0 Y 0 0 0 0 0 0 c 3 a c y C y v Y v v Y e 4 h h c 0 0 0 3 Y m 2 E 7 0 m i 0...

Page 737: ...SPECIFICATIONS 27...

Page 738: ...28 a R h 0 L 3 n r E L L z n c E 5 s YI U z 0 k L e s g 2 o p I...

Page 739: ...or Crankshaftcounterweight R indicating 010 U S all rod journals 020 O S Cylinder A Followingengine serial number Bares 361 cu in 001 U S Crankshaft Maltese Cross Top pad Front of engine 383 cu in 426...

Page 740: ...30 SPECIFICATIONS 3 0 a Z S G I x U a 4 3 cy Z 0 F p E L t E T L 2 z i o g p 2 E o I U 2 c 0 c 0 0 f V e 0 e g g s gCJI_xs 3 c...

Page 741: ...SPECIFICATIONS 3 1 n C I e o L 2 ui C I 0 3 C F r n C I e o L 2 ui C c 0 3 C e r v cy a 2 cy cy n 5 e cy cy I 2 f s n n g a g 9 Q h B Z 0 F c...

Page 742: ...tment drill size Fast Idle Cam Position Adjustment drill size Bowl Vent Valve at curb idle Choke Unloader Idle Mixture Screws Turns Open OneStep lean ADJUSTMENTS Ball and Ball Dual Downdraft 273 Cu In...

Page 743: ...e Screws turns open Idle Speed curb idle Air Conditioning ON Fast Idle Speed Fast Idle Cam Position Bowl Vent closed throttle Vacuum Kick Float Setting Choke Unloader CHOKE Control Type Setting After...

Page 744: ...lerator Pump Travel throttle fully closed Bowl Vent Valve throttle at curb idle Vacuum Kick drill size Float Setting Unloader Adjustment wide open kick Manual Transmission DualThroat Downdraft WWC3 25...

Page 745: ...SPECIFICATIONS 35 C h 9 d c i k 9 d c u c 9 d w u 0 9 d w 0 0 u...

Page 746: ...ODEL APPLICATION AV 1 AV 2 AR 1 AR 2 AP 1 AP 2 PROPELLERSHAFT Type Angularity Length Inches Manual Transmission 3 Speed Station Wagon Manual Transmission 4 Speed Station Wagon Automatic Transmission 1...

Page 747: ...bber Bushing STEERING MANUAL POWER AND PUMPS 4 5 4 5 5 5 6 6 7 MODELAPPLICATION API AP2 ARI AR2 AV1 AV2 REAR SPRINGS NUMBER OF LEAVES Type Semi Elliptic Sedan Standard 5 5 5 Heavy Duty 6 5 5 383 426 E...

Page 748: ...hings 2 Caged Ball Bearings ooO 004 Inch 1 a to 4 in Ibs to Keep Wheel Moving 1 to 4 in Ibs to Keep Wheel Moving 8 to 11 in Ibs Pull through high spot 7 to 11 in Ibs Pullthrough high spot ConstantCont...

Page 749: ...Helical 004 to 014 0045 to 028 006 Max 008 Max 050 to 090 APl AR2 ARl AVI AV2 AP2 AP2 225 273 361 383 426 TRANS MODEL GEAR RATIO First 3 09 Second 1 92 Third 1 40 Fourth 1 oo Reverse 3 00 LUBRICANT C...

Page 750: ...361 383 426Cu In Eng GEAR RATIOS 1 Low 2 Second D Drive R Reverse N Neutral FRONT REAR PUMPS Type End Clearance 2 45 to 1 1 45 to 1 1to 1 2 20 to 1 Gear Rotary Front 001 to 0025 inch Rear 0015 to 003...

Page 751: ...to 125 inch 043 to 045 inch 043 to 045 inch SPEEDOMETER PINION CHARTS TORQUEFLITE TRANSMISSIONS A 727 A AND B OUTPUT SHAFT DRIVE GEAR 8 TEETH 061 to 063 inch Green 084 to 086 inch lo2 to lo4 inch yell...

Page 752: ...Color 2 93 l 3 23 l 3 31 l 3 55 l 3 91 l 6 50 13 17 Orange 19 Dk Blue 20 Green 21 Gray 6 70 1 3 16 Brown 17 Orange 19 Dk Blue 21 Gray 7 00 13 17 Orange 18 Dk Purple 20 Green 21 Gray 7 35 14 16 Brown...

Page 753: ...Red 18 Natural 3 31 l 3 551 3 91 l 20 Black 22 Yellow 22 Yellow 21 Lt Blue 20 Black 22 Yellow 20 Black 20 Black 22 Yellow 20 Black 21 Lt Blue 21 Lt Blue 20 Black 21 Lt Blue 21 Lt Blue 20 Black 22 Yel...

Page 754: ...22 26 22 Steel Disc Drop Center SafetyRim 14x 5K 14x 5HK 14x5K 14x5 K 14x5HK 14x6K 14x 6K 5 H 20 4 65 ft lb 90in lb 14x6HK Super Cushion Tubeless 7 35 14 2 7 75 14 2 8 25 14 2 8 55 14 2 7 75 14 2 8 25...

Page 755: ...ely 1250rpm at 25 mph Oil Capacity Refrigerant Oil 11 ounces Clutch Stationary Coil Mufflers InCompressor DischargeLine In Compressorand Suction Line CONDENSER location RECEIVER DRIER STRAINER Type Lo...

Page 756: ...3 REAR AXLLKontinued FOOT INCH POUNDS Rear Axle DrivePinion Companion Rear Spring U Bolt Nuts 50 Propeller Shaft Bolts Front 32 Rear 15 Wheel Stud Nuts 65 Flange Nut 240 Min AV 1 AV 2 MODELS Axle Sha...

Page 757: ...Mounting Bolt Intake to Exhaust Manifold Bolt Manifold Heat Control Counterweight Bolt Oil Pan Drain Plug Oil Pan Bolt Oil Pump Cover Bolt Oil Pump Attaching Bolt Oil Filter Attaching Stud Oil Pressur...

Page 758: ...rburetor to Manifold Nut Chain Case Cover Bolt Torque Converter Housing Bolt Clutch Housing Bolt Crankshaft Rear Bearing Seal Retainer Crankshaft Bolt Vibration Damper Cylinder Head Cover Stud and Nut...

Page 759: ...Ur 20 Water Pump to Housing Bolt 30 3 66 16 Water Pump Housing to Cylinder Block Bolt 30 36 16 A C Compressor to Engine Bolt 30 3 6 16 GROUP 11 EXHAUST SYSTEM 6 Cylinder 8 Cylinder Ft Lbr In Lbr Ft Lb...

Page 760: ...PUMP Pump Inlet Fitting Pump to Pump Bracket Bolts Reservoir to Pump Body Bolt 30 30 10 15 GROUP 21 TRANSMISSION MANUALA 903 A 745 Front Bearing Retainer Bolts Extension Housing Bolts Gearshift Operat...

Page 761: ...TAL Door Hinge Bolts Deck Lid Hinge Bolts Fender Attaching Bolts 65 55 150 40 10 150 75 150 140 28 100 150 90 70 180 180 60 GROUP 23 BODY AND SHEET METAL Continued FOOT INCH POUNDS Hood Hinge Bolts 18...

Page 762: ...ustment 4 Automatic Operation 4 Control Cable Adjustment 5 Description 4 Drive Mechanism 6 Electrical Tests 5 InstrumentPanel Control Dial Calibration 6 GROUP 1 ACCESSORIES Continued Page Lubrication...

Page 763: ...Power Brake Midland Ross 24 Service Procedures 24 Service Brakes 3 Bleeding the Brake System 8 Brake Drum Removal 5 GROUP 5 BRAKES Continued Page Brake Hose and Tubing 12 Brake Shoe Installation 7 Br...

Page 764: ...tor 26 BAllERY Adjustment of Battery Acid 3 Battery Visual Inspection 2 Charging the Battery 3 Fast Charging 4 Slow Charging 5 Three Minute Charge Test 3 Capacity 3 Service Diagnosis 1 Specific Gravit...

Page 765: ...mbling Starting Motor 19 InstallingStarting Motor 23 Removal of Starting Motor 19 GROUP 8 ELECTRICAL Continued Page Replacing the Field Coils 22 Servicing the Bushings 22 Servicing the Drive Unit 22 S...

Page 766: ...Pan 23 Console Wiring Models AR 1 and AR 2 107 ConsoleWiring Automatic Transmission and Tachometer Models AP 1 and ConsoleWiring Manual Transmission and Tachometer Models AP 1 and AP 2 111 AP 2 112 Co...

Page 767: ...2 Intakeand ExhaustManifold Assembly 6 Cyl Engines 4 Intake Manifold 273 Cu In Engine 6 IntakeManifold 318 361 383 426 Cu In Engines 7 Manifold HeatControl Valve 170 and 225 Cu In Engines 8 Manifold...

Page 768: ...nes 22 Gear Removal 13 PowerSteeringGear Gear Reconditioning 14 Gear Shaft Oil Seal Replacement 22 Steering Valve Reconditioning 22 Worm Shaft Oil Seal Replacement 24 Fluid Level 25 PowerSteeringPump...

Page 769: ...102 Low ReverseServo and Band 102 Overrunning Clutch 100 Parking Sprag and Lever 85 Planetary Gear Assemblies Sun Gear and Driving Shell A 904 G and A 904 LA 97 Planetary Gear Assemblies Sun Gear and...

Page 770: ...and Backlight 3 Cleaning Interior Trim 3 Cleaning the Vinyl Roof 3 Station Wagon AR AV Models 69 Rear Window Windshield Headlining Replacement 14 Drain Holes 4 Lubrication 4 Page Acrylic Finishes 93 P...

Page 771: ...ling Tubing and Fittings 22 Heater Thermostatic Valve Test 27 Inspection and Adjustments 19 Magnetic Clutch 29 Owners Operating Instructions 8 Push Button Control Chart 10 Operation 2 Radiator Pressur...

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Plymouth Barracuda 1965, Service – Technical Manual

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Summary of Contents for Barracuda 1965

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