Plymouth Barracuda 1969 Service Manual Download Page 1

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Summary of Contents for Barracuda 1969

Page 3: ...uis P Wyoming Export R Windsor ENGINE NUMBERS All engine serial numbers con tain fourteen characters and digits The first two des ignate power train the next three are the cubic inch displacement the...

Page 4: ...in which the car is operated and the type of service to which the car is Page SCHEDULE 5 6 SERVICES Normal Service 1 6 LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE Trailer Towing and Sever...

Page 5: ...heck lubricant level Brake Master Cylinder HTF Check fluid level Column Mounted Transmission Front Suspension Ball Joints MML Steering Linkage Ball Joints MML Inspect seals for leakage Relubricate Clu...

Page 6: ...cedure Floor Mounted Transmission Gearshift Controls EO Apply light engine oil to contact mechanism as required Engine Performance Evaluation Evaluate performance Automatic Transmission AA Check fluid...

Page 7: ...d 383 4 BBL Cu In Engines Barracuda only 225 Police or Taxi 21R Cii In Fnuinnwith 777 Transmission 426 Cu In Engir 383 4 BBL Cu 11 3834 BBL Cu Ir Transmission 3 Spl Model A 903 6 C Model A 745 8 C I V...

Page 8: ...SusDension Ball Joints Every 6 Months 22 X 8 X 7 X Rear Axle I 9 1 I X I I I Universal Joints Brake Master Cylinder Brake Hoses ___ ____ 21 X 10 X 1 1 X Headlight Aiming Hood Latch and Safety Catch Cr...

Page 9: ...OW 30 which indicates a multigrade o i l The API classification system defines oil perform ance in terms of engine usage Only engine oils desig nated For Service MS should be used These oils contain s...

Page 10: ...umpers are designed to accept a bumper jack in an emergency if it becomes necessary to change a tire on the road Notches are provided in the bumpers for the purpose of raising the vehicle with the bum...

Page 11: ...seal Stop when seal begins to balloon Removefittings and reinstall threaded plugs CAUTION If high pressure lubrication equipment is used stop filling when lubricant begins t o flow freely from bleed a...

Page 12: ...embly is a high quality product and regularly scheduled changes of the lubricant are not recom mended in vehicles where operation is classified as normal passenger car service lubricant has become con...

Page 13: ...hown below for the axles indicated Chrysler Hypoid Lubricant part number 2933565 for 7 1 4 and 8 3 4 inch Sure GripDifferentials number 2933565 are Oils Of this type and are carrier stating Use Limite...

Page 14: ...l replenish with Heavy Duty Hydraulic Brake Fluid conforming to SAE 70R3 for best brake performance and greater safety Such a fluid Hi Temp Brake Fluid is available under Part Number 2421352 Brake Hos...

Page 15: ...and refill as necessary Once a year preferably in the fall the cooling system should be drained and refilled This draining and refilling procedure however need not be performed until the fall followin...

Page 16: ...g it is recommended that the headlights be checked and if necessary re aimed properly every six months Changes in front and rear suspension such as front suspension height and or deflection of rear sp...

Page 17: ...ity oils are used In some instances such as infrequent operation or short trips only and during break in after a major overhaul addition of special materials containing NKV5 Fig 2I Shaded Area Covers...

Page 18: ...onths Under these conditions consult and follow the advice of any Chrysler Motors Corpora tion Authorized Dealer s Service Manager Taxi and Police Operation Severe service such as taxi and city police...

Page 19: ...e tested for AIR CLEANER HOSE proper operation and cleaned if necessary T h i s in cludes inspecting the operation of the valve checking the hoses and carburetor passages for deposits and cleaning the...

Page 20: ...ger is placed over valve inlet Fig 31 If vacuum is not felt at valve inlet remove valve hose at base of carburetor A distinct vacuum should be felt at end of fitting in carburetor Fig 32 If it is not...

Page 21: ...rburetor Remove and clean air filter Check operation of manifold heat control valve shaft choke Fig 33 Closed rype Oil Filler Cap valve shaft and choke diaphragm use solvents recommended Clean crankca...

Page 22: ...than one half its circum VALVE SHAFT NN301 Fig 36 Manifold Heat Control Valve 383 440 Cu In Engine THERMOSTAT NN963 Fig 37 Header Heat Control Valve 426 Hemi Engine NR88 Fig 38 Carburetor Air Cleaner...

Page 23: ...tor Air Cleuner Fresh Air System 1 Fig 42 Cleaning Filter Element To clean remove cover and filter element wash element thoroughly in kerosene and drain Element should be washed in an upright position...

Page 24: ...NIVERSAL JOINTS Under normal operating conditions relubrication of the propeller shaft universal joint is not recom mended Every six months however the front and rear joints Figs 48 and 49 should be i...

Page 25: ...ts use is recommended CAUTION When filling do not use a pressure gun as high pressure may damage the seals Power Steering Check fluid level in power steering reservoir every engine oil change On 1 06...

Page 26: ...se Gear Lubricant SAE 140 as defined by MIL L 2105B During cold weather if shift effort becomes ex tremely high transmission should be drained and re filled with Multi Purpose Gear Lubricant SAE 80 or...

Page 27: ...gauge indicates a normal warmed up condition and transmission fluid is heated to its normal operating temperature Check level with parking brake applied firmly and the engine idling CAUTION Before rem...

Page 28: ...ease NLGI grade 2 EP or Multi Mileage Lubricant Part Number 2525035 When re packing hubs Fig 57 make sure all surfaces of hub and outer grease cup interiors are covered with lubricant to minimize cond...

Page 29: ...ntil all frictional surfaces are covered Also apply a film of the same lubricant to pivot con tact areas of safety catch Barracuda Models Apply Multi Purpose Lubricant NLGI grade 2 EP or Multi Mileage...

Page 30: ...all and winter months to insure protection from water and ice Hood Hinges TorsionSpring Type Valiant and Barracuda Models of the hinge Fig 65 Apply engine oil to the two link pivots on each side Hood...

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Page 33: ...MileageLubriplate Part Number 2525035 Tail Gute Door Lubrication Fury Models NRl90 Fig 76 Tail Gate Door Lubrication Satellite Models pivot pins lower support pivot area check strap and link pivot bol...

Page 34: ...he same lubricant to the engine mounted bellcrank pin In the passenger compartment apply a thin film of the prescribed lubricant to the accelerator pedal pivot pin cable ball end and in the pocket in...

Page 35: ...in the accelerator shaft lever Fig 82 Be sure plug is in place Fury 8 Cyl Models Apply a thin film of the prescribed lubricant to ac celerator linkage bearing areas the accelerator pedal pivot pin cab...

Page 36: ...UBRICATION 0 33 Fig 80 Throttle Linkage Barracuda 383 Cu In Engine NR236A BELLCRANK PIN AUTOMATIC TRANSMISSION ONLY NP403A Fig 8 1 Throttle Linkage Lubrication Satellite273 3 18 Cu In Engines MyMopar...

Page 37: ...0 34 LUBRICATION A NU259 Fig 83 Throttle Linkage Lubrication Fury 8 Cylinder MyMopar com...

Page 38: ...ent failures In any event rubber bushings should not be lubricated not only because lubricants will cause rubber to fail but also will destroy their necessary friction characteristics The following pa...

Page 39: ...val 1 Remove instrument cluster See Group 8 2 Remove clock from cluster threescrews equipped 2 Remove clock reset knob 3 From under instrument panel disconnect elec 4 Carefully remove clock from under...

Page 40: ...ght outside thumbwheel controls balance between the left and right channel At mid rotation a detent i s provided as a reference point to obtain approximately equal output from each channel The four pr...

Page 41: ...cohol after depressing the tape player motor switch copper plate next to the capstan with a pencil Do not use carbon tetrachloride Dry parts with a clean rag Fader Control The speaker fader control lo...

Page 42: ...radio service RADIO NOISY pression system or voltage limiter wire place if necessary station for repair RADIO RECEPTION DISTORTED INTERMIlTENT RECEPTION SERVICE PROCEDURES ANTENNA TRIMMING point of an...

Page 43: ...curely mounted Faulty or deteriorated spark plug wires should be replaced ANTENNAS Removal All Models 1 Unplug antenna lead from radio receiver 2 Remove antenna by unscrewing from antenna 3 Remove cap...

Page 44: ...Connect battery ground cable and test operation of radio Removal Belvedere and Satellite Models 1 Disconnect battery ground cable 2 Remove radio trim panel 3 Remove radio finish plate 4 From under pan...

Page 45: ...ll Except Fury and V I P 2 Connect electrical leads and antenna lead to 3 Install center lower air conditioner duct so 4 Install radio mounting bolts 5 Install radio trim bezel See Group Electri 6 Ins...

Page 46: ...panel and 2 Connect wire leads at speaker 3 Install radio mounting bracket 4 Install air conditioner lower distribution center 5 Connect battery ground cable and test operation duct so equipped of rad...

Page 47: ...transmission driven servo gover nor assembly which controls the throttle linkage and a combination electrical vacuum brake switch which is used to deactivate the system when the brakes are applied The...

Page 48: ...ee Tests and Closed off brake switch vacuum line b Repair or replace vacuum line FauIty electricaI circuit c See Electrical Tests Faulty electrical circuit a See Electrical Tests Adjustments Speed con...

Page 49: ...e set screws have been factory set and under normal accuracy of the speed control unit When the direc conditions there should be no need for altering the tion signal lever push button is depressed at...

Page 50: ...Adjustment Fig 5 affects the road speed at which the system is deactivated during deceleration Turning the screw clockwise increases Fig 4 Cut in Screw Adjustment Fig 5 Cut out Screw Adjustment road s...

Page 51: ...th ignition switch On brake switch should energize and latch on when turn signal Speed Set button or Resume Speed switch is actuated When brake switch actu ator arm is depressed to open position the b...

Page 52: ...nks or routing interferences 3 Connect speedometer and transmission drive cables at servo 4 Align servo cable to servo pin and install re taining clip 5 Install cable cover on servo studs and install...

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Page 54: ...l the three wires have been threaded through the opening Make guide wire long enough so that it can be reached at bottom of column before wire is attached to the upper hook When all wires have been pu...

Page 55: ...gate The tail gate glass may be cleaned by 1 i the glass by activating the tail gate 2 Activate the tail gate washer switch 3 Raising the glass by activating the tail gate switch The wiped area is ac...

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Page 57: ...le feed hose and position yoke 8 Install wiper blade mounting arm and blades for off glass condition Do Not get lubricant on wiper blades Washer Reservoir and Motor Pump Assembly Fur y Removal open ta...

Page 58: ...1 1 20 TAIL GATE WIPER WASHER SYSTEM MyMopar com...

Page 59: ...loose a Clean nozzle jets b Replace hose c Replace motor and pump assembly a Clean ground wire terminal and tight en mounting screw b Tighten terminals c Repair or replace wires d Replace switch e Re...

Page 60: ...h outlets at wash er pump being careful not to break outlets identify hoses 5 Disconnect one wire to washer motor 6 Remove three mounting screws supporting res ervoir and remove rubber filler hose at...

Page 61: ...ication fitting After lubricating knock off that portion of the fitting over which the lubrication gun was installed A ball check is installed in the remaining portion of the fitting to prevent for ei...

Page 62: ...just steering gear c Loose steering gear to frame mount c Tighten steering gear to frame bolts d Worn tie rod ends d Replace tie rods as necessary e Worn steering gear parts e Replace worn steering ge...

Page 63: ...the number of degrees of forward or backward tilt of the spindle support arm at the top Forward tilt of the spindle support arm at the top is negative caster Backward tilt of the spindle support arm a...

Page 64: ...t to straighten any bent part Height Front suspension heights must be held to specifica tions for a satisfactory ride correct appearance prop er front wheel alignment and reduced tire wear The heights...

Page 65: ...rning anchor adjusting bolt Fig 5 counterclock wise 4 Remove lock ring from torsion bar rear anchor Fig 4 5 Using Tool 2 3728 remove torsion bar Fig 5 from its anchors It is advisable to place Tool C...

Page 66: ...enough to place upper stud under a load then strike steering knuckle sharply with a hammer to loosen stud Do not attempt to force stud out of steering knuckle with tool alone 7 Remove two upper bolts...

Page 67: ...ROD ASSEMBLY CENTER LINK KNUCKLE ARM NK379C Fig 8 Steering Linkage Fury opening If the parts have not lost all the lubricant or are not contaminated worn or rusted use new seals and reinstall otherwis...

Page 68: ...ve nuts retainers and rubber insulators and remove links from lower control arm I NN43C INSULATOR RETAINER NUT __O Fig 10 Sway Bar Assembly Valiant Barracuda 6NUT NP341C Fig 1 1 Sway Bar Assembly Sate...

Page 69: ...tors Install nuts and tighten to 100 inch pounds LOWER CONTROL ARM AND SHAFT Figs 13 14 and 15 Removal ON MODELS EQUIPPED WITH DISC BRAKES RE FER TO GROUP 5 FOR BRAKE DISC REMOVAL AND INSTALLATION PRO...

Page 70: ...lation 1 On Valiant models install new strut bushing in crossmember with a twisting motion Water may be used as a lubricant to aid in installation 2 Place strut bushing inner retainer on strut and ins...

Page 71: ...e and install safety floor stands under both lower control arms as far outboard as possible The upper control arms must not contact the rubber rebound bumpers 2 With the weight of vehicle on the contr...

Page 72: ...wheel as possible and raise vehicle until wheel clears floor 2 Remove wheel and tire as an assembly 3 On Valiant and Satellite models remove upper and lower ball joint stud nuts using Tool C 3711 On V...

Page 73: ...hing support sleeve remove Tool C 371OA after bushing has been installed and install adaptor SP 3827 in place of SP 3233A cup on tool and install support sleeve on rear bushing only Fig 27 I A REMOVE...

Page 74: ...oint make certain the ball joint threads engage those of the control arm square ly if original arm is being used Balloon type seals should always be replaced once they have been re moved 1 Screw ball...

Page 75: ...Arm Nuts at Center Link at Mounting Bracket Shock Absorber Nuts Front Lower Upper Steering Gear Mounting Bolts Steering Knuckle Bolt Nuts Lower except Valiant 130 180 150 85 200 40 65 50 25 80 120 VAL...

Page 76: ...oper lubricant See Lubrication section c Excessive spinning of one wheel c Replace scored gears Inspect all gears pinion bores and shaft for scoring or bearings for possible dam age Service as necessa...

Page 77: ...n Depth of Mesh Differential Drive Gear and Pinion Backlash Pinion Bearing Cup Installation GENERAL INFORMATION Page 3 5 9 8 7 The 7 1 4Rear Axle Assembly shown in Fig l is a semi floating type which...

Page 78: ...aft flange remove retainer nuts 4 Attach axle shaft remover tool C 3725 to axle shaft flange and remove axle shaft Remove brake assembly Fig 2 5 Remove axleshaft oil seal from housing CAUTION Under no...

Page 79: ...light film of Multi purpose Lubricant NK365 Fig 5 Tool C 3725 Installed on Axle Shaft Fig 6 Indulling Rear A x k Shaft Bearring NLGI grade 2 EP on outside diameter of bearing to prevent rust and corro...

Page 80: ...gear several complete revolutions and reading dial indicator Mark drive gear and differential case at point of maximum runout The marking of differential case will be very useful later in checking di...

Page 81: ...dial indicator in contact with drive gear flange face to take runout readings as in steps 3 4 and 5 Total allowable run NY1034 Fig 12 Spreading Rear Axle Housing Fig 13 Loosening Differential Assembl...

Page 82: ...surface areas in side the differential case should be polished and with no surface inperfections The pinion shaft bore in differential case should be round and smooth The differential pinion shaft sh...

Page 83: ...pinion has a minus 2 select a shim that many thousandths thicker for installation Treat other pinion markings in a similar manner Spacers are available in one thousandths of an inch incre ments from 0...

Page 84: ...ing preload set install differential case and ring gear assembly and cups Insert a 254 inch preload adjusting spacer on ring gear side Fig 22 of axle housing Do not install bearing caps 2 Install a pr...

Page 85: ...d Install Differential Spacers an re check backlash to bring within proper specifications 17 Apply a thin film of red or white lead on both the drive and coast side of the drive gear teeth Ro tate dri...

Page 86: ...ard the toe 19 When correct tooth contact pattern is obtained and cover and gasket surface is thoroughly clean in stall cover with new gasket on housing and insert cover bolts and tighten to 20 foot p...

Page 87: ...hafts with relatec parts Fig 2 differentialwith drive gear drive pinion with carrier and the axle housing Servicing of the above mentioned subassemblies with exception of the axle housing may be perfo...

Page 88: ...ty of damaging axle shaft seal surface slide protective sleeve SP 5041 over the seal surface next to bearing collar CAUTION Under no circumstances should axle shaft SEAL BEARING NK59A collars or beari...

Page 89: ...with a pair of side cutters and remove Fig 10 5 Remove roller bearing cup and protective sleeve SP 5041from axle shaft Fig 6 Notching Bearing Retainer Collar 5 NK356 Fig 7 Removing Roller Retainer L...

Page 90: ...g 12 Removing Bearing Cone with Tool C 3971 gasket on axle housing studs followed by brake sup port plate assembly on left side of axle housing 2 Apply a thin coating of Multi Purpose Grease NLGI grad...

Page 91: ...sorber from spring plate studs and loosen rear spring U bolt nuts and remove U bolts 8 Remove the assembly from vehicle lnstallation 1 With body of vehicle supported at front of rear springs position...

Page 92: ...r 6 While holding one hand over nose end of car rier invert carrier in stand The front pinion bearing ccne shim pack and bearing spacer where used will drop from carrier TOOL FLANGE I KP5B Fig 16 Remo...

Page 93: ...s while noting total indicator reading This reading must not exceed 003inch runout If runout is in excess of 003 inch differential case must be re placed In a case where the runout does not exceed 003...

Page 94: ...f differential pinions Shaft should be smooth and round with no scoring or metal SH AFT pickup 5 Inspect differential side gears and pinions they should have smooth teeth with a uniform contact pat te...

Page 95: ...he side gears having pinions exactly 180degrees opposite each other 3 Rotate side gears 90 degrees to align pinions and thrust washers with differential pinion shaft holes in case 4 From pinion shaft...

Page 96: ...types of pinions The method of determining pinion depth of mesh and bearing preload are the same for the small and large stem step pinions however the sequence of making the two adjustments change Sma...

Page 97: ...Position arbor SP 561 partof Tool C 758 D4 in differential bearing pedestals of carrier Fig 29 Cen ter the arbor so that an approximate equal distance is maintained at both ends Position differential...

Page 98: ...into carrier and install front pinion bearing cone over tool shaft and in its proper position in bearing cup Install tool spacer tool thrust washer and tool nut on shaft 3 With nose of carrier up pla...

Page 99: ...ndths of an inch increments from 014 026 inch 20 Loosen and remove drive pinion nut washer and flange after proper bearing preload has been established 21 Apply a light coat of sealer in seal bore of...

Page 100: ...remove tool nut centering washer and compression sleeve Lower tool down and out of carrier PINION BEARING PRELOAD Large Stem PinionWith CollapsibleSpacer 1 Position rear pinion bearing cone on pinion...

Page 101: ...eload obtained remove the drive pinion flange Apply a light coat of sealer to drive pinion oil seal and carrier casting bore and install drive pinion oil seal with Tool C 3980 synthetic rubber seal or...

Page 102: ...der Light Load Fig 33 in a notch at a time notch referred to is the adjuster lock holes until backlash between drive gear and pinion is a minimum of 006 to 008 inch This will preload differential bear...

Page 103: ...con tact on drive side to raise and move toward the heel low heel contact on coast side will raise and move toward the toe DIFFERENTIAL AND CARRIER lnstullcrtion 1 Thoroughly clean the gasket surface...

Page 104: ...er up and pinion nut 14 Hold universal joint flange with holding Tool C 3281 and tighten pinion nut to 100 foot pounds Ro tate pinion several complete revolutions to assure that bearing rollers are pr...

Page 105: ...ear The rear axle housing is an iron casting with tubu lar legs pressed into and welded to the carrier to form a carrier and tube assembly A removable stamped steel cover is bolted to the rear of the...

Page 106: ...ng a suction gun remove as much of the old lubricant as possible 3 Fill to proper level with special Sure Grip Lubri cant Part Number 2585318 or equivalent Reinstall fill plug and tighten 4 Start engi...

Page 107: ...y rotating drive gear several complete revolutions and reading dial indicator Mark drive gear and differential case at point of maximum runout The marking of differ ential case will be very helpful la...

Page 108: ...grees from point of maximum runout when reas semblingring gear on differential case 14 Position carrier and tube assembly in vise with nose of carrier in the up position Remove drive Fig 6 Measuring D...

Page 109: ...on the plates and discs It has four pinion gears positioned in the case by two pinion shafts which are at right angles to each other and loose fitting at their inter section Both ends of each shaft ha...

Page 110: ...and differential bearing caps should be smooth and free of any raised edges Front and rear pinion bearing cup bore machine surfaces should be smooth Raised metal on shoulders of bores incurred in re...

Page 111: ...t be distorted or cracked When replacing bearings always replace the cup and SIDE t RETA Fig 18 Removing or Installing Side Gear Retainer cone in a bet only 7 Inspect drive gear and pinion for worn or...

Page 112: ...ile as needed 1 Position drive gear on differential case pilot aligning threaded holes of drive gear with those in differentialcase flange 2 Insert drive gear screws through case flange and into drive...

Page 113: ...aced between the rear cup and carrier can be determined from the shims removed and the etched marking on the pinion The or figure indicates the variation from the nominal distance between the front of...

Page 114: ...g For example if a pinion marked 2 is being installed in a 9 3 4 axle add the 2 to pinion setting dimen sions 3 125 which will be the corrected dimension of 3 127 The 9 1 41 axle 2 688 dimension will...

Page 115: ...d in step 9 When the marking is plus subtract that amount Treat other pinion markings in a simi NP414 lar manner Shims are available in 003 005 and 010 inch thickness 11 Remove the tool arbor and tool...

Page 116: ...oint against back face of ring gear Move the differ ential and ring gear assembly tight against the drive pinion set the dial indicator on 0 Move the differen tial and ring gear assembly in the opposi...

Page 117: ...HEELEND OAST SIDE CONCAVE NR198 Fia 3 2 D d r d rooth Contact Under Liaht Load THICKER SPACER NEEDED HEEL END DRIVE HEEL END COAST SIDE CONVEX SIDE CONCAVE NR PP Fig 33 Incorrect Tooth Contact Pattern...

Page 118: ...ifferentials use only the special multi purpose gear lubricant intended for use in axles equipped with plate clutch Sure Grip differentials Such a lubricant is available under Part Number 2585318 Spec...

Page 119: ...differential case The grooves assure maximum lubrication of the clutch surface during operation The cones and side gears are statically spring preloaded to provide an internal resistance to different...

Page 120: ...ubricant Part Number 2933565 or equivalent Reinstall fill plug and tighten 7 Lower vehicle on hoist and return to customer to drive and evaluate for approximately 100 miles to determine if lubricant c...

Page 121: ...followed so the ring gear seats on the differential case properly 3 Using an Arkansas stone relieve the sharp edge of the chamfer on the inside diameter of the ring gear Fig 24 in 8 3 4 Axle section o...

Page 122: ...GS RING GEAR AND PINION DIFFERENTIAL SIDE GEAR CLEARANCE With Gauge WHEEL BEARINGS Type Tapered Roller Adjustment Adjusting Nut End Play 008 018 Multi Purpose Lubrication Grease NLGl grade 2 E P Capac...

Page 123: ...ential Case Bolts Left Hand Thread Drive Pinion Flange Nut Small Stem or Large Stem Step Pinion Large Stem Tapered Pinion Carrier to Axle Housing Bolt Nuts Axle Shaft Retainer Nuts Propeller Shaft Bol...

Page 124: ...place brake line Leaking or worn master cylinder f Recondition or replace master cylin der and bleed hydraulic system Excessively worn brake lining g Reline and adjust brakes Air in hydraulic system a...

Page 125: ...or out of round brake drums b Grind or replace drums Overheated brake drums c Inspect for dragging brakes Incorrect brake fluid low boiling d Drain flush refill and bleed hydraulic temperature brake s...

Page 126: ...if the automatic adjuster is working properly If by the described procedure one or more automatic adjusters do not function prop erly the respective drum must be removed for ad juster servicing BLEED...

Page 127: ...w copper seal washers should be used and the tube nuts and connections should be properly made and tightened Double wall steel tubing should Fig 2 W h d Stud Nut lightening Sequence always be used to...

Page 128: ...sh adjusting lever away from star adjust ing wheel Care should be taken not to bend adjusting lever 3 Insert Tool C 3784 into brake adjusting hole and engage notches of brake adjusting star wheel Rele...

Page 129: ...gs and nails Using Tool 7 4070 Fig 7 6 Spread anchor ends of primary and secondary shoes and remove parking brake lever strut and anti rattle spring Fig 8 7 Disengage parking brake cable from parking...

Page 130: ...threads of the adjusting screws then inspect for pulled or stripped threads New brake shoe return springs and hold down springs should be installed where the old springs have been subjected to overhe...

Page 131: ...iameter BRAKE SHOE INSTALLATION INSTALLING SPECIAL TOOL REMOVING AND SECONDARY SHOE RETURN ANTI RATTLE 1 PRINC ADJUSTING LEVER NU243 AVJU31 CK SPRING Fig 6 Removing Shoe ReturnSprings Left Rear lnstal...

Page 132: ...on s u p PRIMARY AND LII IDARY SHOE ID LINING Fig 9 Installing Brake Shoes Left Front port plate with Chrysler support plate lubricant Part number 2932524or equivalent Fig 11 1 Install parking brake...

Page 133: ...er Cylinder 12 Installing Master Cylinder 12 13 GENERAL INFORMATION The tandem master cylinder Fig 1 is of the com pensating type with the reservoirs cast integrally The master cylinder consists of a...

Page 134: ...ean brake fluid and inspect for scoring or pitting Master cylinder bore walls that have light scratches or show signs of corrosion can usually be cleaned with crocus cloth However cyl inder bores that...

Page 135: ...reservoirs with approved brake fluid 3 Using a wooden stick or dowel power brake must be bled on the bench as follows bleeding tubes Tool C4029 Fig 7 RETAINING S C R E W PIST AND G A S K E T F R O N...

Page 136: ...The hydraulic system safety switch Figs 8 and 9 is used to warn the vehicle operator that one of the hydraulic systems has failed A failure in one part of the brake system does not result in failure...

Page 137: ...SASSEMBLING WHEEL CYLINDERS Front or Rear Figs 1 or2 1 Using a suitable tool pry boots away from cylin ders and remove Remove push rods if so equipped 2 Press in on one piston and force out piston cup...

Page 138: ...in suspension or tire interfer ence INSTALLING WHEEL CYLINDERS Front or Rear 1 Slide wheel cylinder into position on support front or rear Install attaching bolts and tighten from 7 to 10 foot pounds...

Page 139: ...st brakes PARKING BRAKES INDEX Page Page Adusting Parking Brake 17 Removing Front Parking Brake Cable 18 General Information 16 Removing Rear Parking Brake Cable 17 Installing Front Parking Brake Cabl...

Page 140: ...come necessary to remove the parking brake cable rear for installation of a new cable see Fig 3 Service Brakes 1 With vehicle jacked up or on a suitable hoist INSTALLING REAR PARKING BRAKE CABLE remov...

Page 141: ...ing and attaching clip out of body crossmember 4 Fold back left front edge of floor mat and re move rubber cable cover from floorpan 5 Depress parking brake pedal and work brake cable up and out of br...

Page 142: ...ter cylinder to brake 2 Disconnect vacuum hose from power brake 3 Remove nut and bolt that attach power brake 4 Remove nuts and washers that attach power 5 Remove power brake from vehicle unit Remove...

Page 143: ...ster cylinder d Add brake fluid e Shoe hanging up on rough platform e Smooth and lubricate platforms a Faulty vacuum check valve a Replace check valve b Collapsed or leaking vacuum hose b Replace hose...

Page 144: ...BLY SCREW AND BUSHING NP280 Fig 1 Power Brake and Master Cylinder FILTER RETAINER 3 Connect vacuum hose 4 Using lubriplate coat the bearing surface of bolt that connects power brake pedal link with br...

Page 145: ...gral with the vacuum power diaphragms controls the de gree of power brake application or release in accord ance with the foot pressure applied to the valve operating rod through the brake pedal linkag...

Page 146: ...lower pivot bolt if so equipped 3 Attach vacuum hose to check valve 4 Install master cylinder on power brake Tighten mounting nuts to 100 inch pounds Be sure power brake output push rod is set to cor...

Page 147: ...he control valve is of a singe poppet type valve with the atmospheric port and a vacuum port The vacuum port seat is a part of the valve body attached to the diaphragm assembly The atmospheric port is...

Page 148: ...tation 3 Attach vacuum hose to check valve 4 Install master cylinder on power brake Tighten KELSEY HAYES DISC BRAKES I D E X Page Assembling Caliper 33 Assembling Master Cylinder 11 Bleeding Disc Brak...

Page 149: ...ts within the caliper Fig master cylinder to the system applies pressure to the 6 and are supported radially by ears on the outer co axially aligned caliper pistons forcing the linings ends of the sho...

Page 150: ...s under a wide range of braking conditions The valve regulates the hydraulic pressure applied to the rear wheel cylinders thus limiting rear braking action when high pressures NN425 are required at th...

Page 151: ...functioning of the disc brake system but continued use until lining is completely worn away will cause disc damage Running Clearance To check the shoe and lining assembly to the brak ing disc clearan...

Page 152: ...ing adjustment e Readjust wheel bearings to specified torque Improper brake fluid boil f Drain and install correct fluid Damaged caliper piston seal g Install new piston seal Excessive out of parallel...

Page 153: ...ssemble caliper and install new c Scores or corrosion on surface of pis c Disassemble caliper and hone cylin ton der bore If necessary install new brakes seal pistons a Causes listed under Pull a Corr...

Page 154: ...e 4 Place shoe retainer assemblies in position on caliper 5 Pump brake pedal several times until a f i r m pedal has been obtained and shoe and lining have been properly seated 6 Install wheel and tir...

Page 155: ...Separate assemblies 5 Peel dust boot out and away from caliper hous ing retainer and out of piston groove Fig 1 0 Re move remaining dust boots in same manner 6 Using Tool C 3999 remove each of piston...

Page 156: ...ls in clean brake fluid and install in caliper grooves The seal should be posi tioned at one area in groove and gently worked around cylinder bore with a finger until properly seated Never use an old...

Page 157: ...jackstands or lower hoist REMOVING BRAKING DISC AND HUB 1 Remove wheel cover and wheel and tire as sembly 2 Remove caliper assembly as described under Removing Caliper paragraph but do not discon nect...

Page 158: ...bleeding equipment is not used It will be necessary to remove the front wheel and tire assemblies in order to gain access to the bleeder screw located on the outboard caliper housing at the top Fig 1...

Page 159: ...aster Cylinder 10 Service Diagnosis 29 Specifications 64 Testing Proportioning Valve 44 GENERAL INFORMATION The front wheel disc brake Fig 1 consists of a fixed caliper inner and outer housing two fri...

Page 160: ...A BRAKES 5 37 NNW8 Fig 2 Disc Brake Assembly Sectional View MyMopar com...

Page 161: ...brakes are not applied because there is no residual pressure maintained in front brake system See Master Cylinder The proportioning valve Fig 19 provides balanced braking action between the front and...

Page 162: ...ection reveals the rubber piston seals are worn or damaged they should be replaced im mediately 3 During removal and installation of a wheel and tire assembly exercise care so as not to interfere with...

Page 163: ...ng bolts and tighten 75 105 foot pounds 4 Make sure disc rotates freely and with mini mum drag 5 Install wheel and tire assemblies and wheel covers 6 Remove jackstands or lower hoist CAUTION Road test...

Page 164: ...ings for scoring or pitting Bores that show light scratches or corrosion can usually be cleaned with crocus cloth However bores that have deep scratches or scoring may be honed using Tool C 3993 provi...

Page 165: ...press down on tool forc ing boot sealing lip into caliper groove Fig 15 Remove tool Install remaining pistons in same man ner Fig 1 6 7 Test pistons for smooth operation in their bores by depressing w...

Page 166: ...line with cotter pin hole 5 Back off adjusting nut and lock assembly one slot then install cotter pin The resulting adjustment should be zero no preload to 003 inch end play This is very important wh...

Page 167: ...ls DiscBrake Equipped Vehicles To balance front wheels on a disc brake equipped vehicle the normal procedure for static balancing as described under Wheel Balance in the Wheels Bearings and Tires Sect...

Page 168: ...ide pins thread ed into the adaptor Two of the bushings are inserted in the outboard portion of the caliper and two on the inboard side Fig 3 Four machined abutments on the adaptor position and align...

Page 169: ...5 46 BRAKES A 15 650 O R 15 550 WHEEL CALIPER BRAKIN v BOLT BRAKING DISC SPLASH SHIELD t J I Fig 4 Disc Brake Assembly Sectional MyMopar com...

Page 170: ...ounting CALIPER ON DUST BOOT NN427B Fig 6 Piston Seal Functionfor Automatic Adjustment METERING VALVE All Kelsey Hayes Floating Caliper disc brake equipped vehicles are equipped with a pressure meter...

Page 171: ...er assembly must be removed before removal of the hub and disc as sembly 9 As lining wears reservoir level will go down If fluid has been added between relines then reservoir overflow may occur when t...

Page 172: ...he system after shoe and lining removal and installation However if a firm pedal cannot be obtained bleed the brake system as described in Bleeding Brake System paragraph It may have been necessary to...

Page 173: ...oove in piston bore Fig 12 Discard old seal Do not use a screwdriver or other metal tool for this operation because of por sibility of scratching piston bore or burring edges of 5 Remove outer bushing...

Page 174: ...4 Use extreme care in cleaning the caliper after hon ing Remove all dirt and grit by flushing the caliper with brake fluid wipe dry with a clean lintless cloth and then clean a second time in the same...

Page 175: ...all assembled guide pins through bush ing caliper adaptor inboard and outboard shoes and into outer bushings in caliper 5 Press IN ON END GUIDE PINS AND THREAD PINS INTO ADAPTOR USING EXTREME CARE SO...

Page 176: ...le hose 3 Remove grease cap cotter pin nut lock nut thrust washer and outer wheel bearing 4 Pull disc and hub off wheel spindle INSTALLING BRAKING DISC AND HUB 1 Bide brake disc and hub assembly on sp...

Page 177: ...n can be used when the disc surface is rusty or has lining deposits A sanding disc attach ment will remove surface contamination without re moving much material It will generally follow varia tions in...

Page 178: ...nd the front brakes The master cylinder used on vehicles not equipped with power brake units is serviced in the same man ner as the master cylinder with power brakes with one exception the master cyli...

Page 179: ...FRONT BRAKE TUBE SEAT NP29 RESIDUAL PRESSURE VALVE AND SPRING REAR BRAKES ONLY Fig 3 Removing or InstallingResidualPressure Valve and Spring scoring or pitting Master cylinder bore walls that have lig...

Page 180: ...securely Fig 6 4 Install residual pressure valve and spring Fig 3 in front outlet then install tube seats firmly When the bleeding tubes are attached the tube seats will be positioned correctly BLEED...

Page 181: ...ome on in the instrument panel t MOUNTING YL BRACKET LI Fig 9 Hydraulic System Safety Switch Exploded View NP34 thus warning the operator of the vehicle that one of the systems has failed and should b...

Page 182: ...f this group SERVICE PROCEDURES MASTER CYLINDER REMOVAL 1 Disconnect front and rear brake tubes from master cylinder and install a plug in rear outlet The residual pressure valve in front outlet will...

Page 183: ...re tainer then slide assembly into bore of cylinder Fig 5 Be sure cups enter bore evenly in order not to damage sealing quality of cups Keep well lubricated with brake fluid Fig 4 Rear Piston 1 Carefu...

Page 184: ...squirting up in the 4 brakes at cylinders using reservoirs This may only occur in the front chamber and so to determine if the rear port is open it will be necessary to pump up the brakes 2 Over mount...

Page 185: ...nted on the frame in a vertical position with the brake tubes connected Fig 8 If a malfunction occurs within the switch discon nect tubes from body assembly and install a new assembly The component pa...

Page 186: ...E IAPHRAGM CLAMP VALVE SPRING RETAINER RING Fig 2 Metering Valve Sectional bleeding procedures should be done as follows 1 Gravity Blead T h i s method of bleeding is not effected by the metering valv...

Page 187: ...In case of a metering valve malfunction remove valve and install a new one SPECIFICATI0NS BRAKES SERVICE AND PARKING Type DRUM DIAMETER NUMBER OF BRAKE SHOES Front Rear BRAKE LINING Front Primary Fron...

Page 188: ...BENDIX DISC BRAKE DISC BRAKE Type Location Master Cylinder Reservoir Proportioning Valve Location Brake Adjustment Residual Valve Location CALIPER ASSEMBLY Shoe and Lining Removal Number of Pistons Fi...

Page 189: ...r 1 per piston Moulded R u b b e r 4 per Caliper Assy 1per piston On Inner Housing top Rubber 0 Ring 2 per caliper VentilatedPast Iron 11 19 6 876 005 OOlrf in 30 and no more than 3 reversals in 360 4...

Page 190: ...ss of 180 Inch 1 1 8 002 O S Rear Brakes Only Vented Stamped Steel 3 Bolts to Knuckle Drop Center 15 x 5 50 15 x 6 50 TIGHTENING REFERENCE Pedal Link to Pedal Bolt Master Cylinder Mounting Nuts Power...

Page 191: ...service The clutch sizes for the various car models are de scribed in specification charts at end of this section The Semi centrifugal type clutch Fig 2 combines the feature of low pedal effort with t...

Page 192: ...lubrica tion SERVICE DIAGNOSIS Condition Possible Cause Correction CLUTCH CHATTER a Worn or damaged disc assembly b Grease or oil on disc facings c Improperly adjusted cover assembly a Replace disc a...

Page 193: ...ricate or replace bushing cover SERVICE PROCEDURES CLUTCH PEDAL FREE PLAY swivelclamp screw Fig 7 3 Adjust fork rod by turning self locking ad justing nut Figs 8 9 10 11 to provide 5 32 inch free move...

Page 194: ...el in the pawl 5 Shift transmission in normal manner from neu tral to first and from neutral to reverse disengage clutch while shifting and engage clutch when in gear Clutch action should be normal 6...

Page 195: ...to avoid bending cover flange 9 Remove clutch assembly and disc from clutch housing CAUTION Handle clutch and disc carefully to avoid contaminatingthe friction surfaces Cleaning and Inspection 1 Use...

Page 196: ...u In and Burnishing Tool can be used to gauge size of bushing The tool should be a snug fitin bushing If necessary to replace bushing proceed as detailed under Crankshaft to Transmission Drive Pinion...

Page 197: ...surface of pressure plate with kerosene mineral spirits or other suitable solvent 8 Using a straight edge check pressure plate for flatness The pressure plate friction area should be flat within 005...

Page 198: ...housing as far forward as possible Fig 1 U l u t c h Disc Aligning Arbor FORK CONTACT SLEEVE CAVITY AREAS RETAINING SPRING x CONTACT AREA NR133 Fig 15 Clutch Lubrication Points 8 Lubricate fork finger...

Page 199: ...ngage groove of seal in clutch housing 5 On all models insert threaded end of fork rod assembly in hole of release fork Figs 8 9 10 11 Install eye end of fork rod on torque shaft lever pin and secure...

Page 200: ...er surfaces of bearings should also be smooth and free from surface scratches or embedded foreign material The wear pattern should be uniform over the entire surface 4 Replace worn or cracked rubber s...

Page 201: ...us 007 inch dowels which equals 003inch runout 7 The amount of eccentricity of the dowel will n DOWEL PINS REAR FACE OF ENGINE B L O C K NY 1601A Fig 18 Offset Dowel Diagram 6 Cyl 2 f O CLOC 9 3 K REA...

Page 202: ...occurs it will neces sitate replacement of disc assembly flywheel and or clutch assembly Immediately after cleaning opera tion start engine and slip clutch in order to dry off disc assembly pressure...

Page 203: ...7 2768162 Part Numbers subject to change during model year TIGHTENING POUNDS FOOT INCH 200 200 200 Clutch Cover to Flywheel Bolts 5116 Clutch Cover to Flywheel Bolts 3 8 30 Clutch Fork Pivot Bolts Cl...

Page 204: ...overheating for unusually severe operation re quirements The trailer towing package is a combination of the maximum cooling package and the high capacity fan as necessary to provide protection against...

Page 205: ...air or replace the oil cooler a Low coolant level a Fill radiator to correct level b Collapsed radiator hose A bottom b Replace the hose and spring hose with faulty spring may collapse only at medium...

Page 206: ...eplace pulley ley a Broken cord in belt b Belts not matched A C c Belt is not Chrysler approved part d Belt too loose e Severely misaligned pulleys a Replace belt b Install matched belts c Install Chr...

Page 207: ...h 2 93 I or Higher Axle Ratio versa See specificationsfor proper pump Removal 1 Drain the cooling system Remove upper half of fan shroud if so equipped or set one piece shroud back on engine 2 Loosen...

Page 208: ...ns on Cleaner label 3 After cleaning operation flush entire cooling system until water runs clean 4 If vehicle is operated in areas where protection from freezing is not required and vehicle is not eq...

Page 209: ...ure in a direction opposite to that of the normal flow of water Flushing Cylinder Block 1 Drain radiator and remove hoses at radiator 2 Remove thermostat and reinstall thermostat housing 3 Install Too...

Page 210: ...g a new gasket position thermostat so pellet end is toward engine and attach with bolts through thermostat housing 2 If removed reinstall or replace the upper hose 3 Fill cooling system to 1 1 4 inche...

Page 211: ...ied used belt tension at new vehicle preparation Any belt that has operated for a mini mum for a half hour is considered to be used The new belt tension specification apply for all new belt replacemen...

Page 212: ...ll spring scale can be used to establish the five pound load See Figure 9 for correct location at which to measure deflection This method should be used only when it is not possible to use the torque...

Page 213: ...aa G2t a m E Z E 2 m E N I c i b TO9 NNN bbb y s 5 3 A z 4 a 4 a cnl iz mm zz 7 7 I I I I I I I I C V N N N ddhh 2 2 2 2 I g a g a s c e a s g g 0 0 0 N Z N Z R b L Z Z Z Z Y X h 2 w a w e 7 Y I WW h...

Page 214: ...a rn d l l T T T 52522 W W W C C K 0 0 8 0 4 l l z z z Y Y 3 m m a a c c c o o o 4 z z z E M z r 0 2 6 w e 5 2 5 3 I a E O r r n O N C n h O O O I h g m m m e h z a u a a a 1 e 3 I m V I m a L P g L k...

Page 215: ...7 1 2 SPEC I FlCATlO NS A w m 5 N N N 03 CU C U C U f l z c m m m 9 2 9 N r c u r i e 4 Q z7 I2 d 0 B o Y E 2 V I W m 5 L a z B C m Y 2 MyMopar com...

Page 216: ...5 32 5 32 5 32 5 32 5 32 FAN BELT IDLER 3 32 A C IDLER Clutch to Idler 1 8 1 8 3116 3 16 ALTERNAT0R Without A C 9 32 9 32 3 16 3 16 3 16 With A C 9 32 3 16 3 16 9 32 New Belt 383 426 Hemi 318 170 225...

Page 217: ...Coat all connections with light min eral grease or petrolatum after tightening 12 If electrolyte level is low fill to recommended level with mineral free water SPECIFIC GRAVITY TEST indication of how...

Page 218: ...s 015 minus 005 Test Conclusions a Battery specfic gravity is less than 1 220 bat tery should be recharged Make a high rate discharge test for capacity If battery cells test O K recharge and adjust gr...

Page 219: ...VARY BY 5 OR ISIONS 0 A GREEN BAND 0 oo C balance of the readings are within the first four scale divisions the battery is too low to make an accurate condition test Recharge battery and retest CAUTI...

Page 220: ...Discharge Test was under 9 5 volt the battery should be test charged to determine whether the battery can be satisfactorily charged Charging the Battery ThreeMinute Charge Test Fig 5 This test should...

Page 221: ...e ampere per positive plate per cell Proper slow charging rate would be 3 amperes for a 38 am pere hour battery 4 amperes for a 48 ampere hour Fig 6 Fast Charging the Battery battery 5 amperes for a 5...

Page 222: ...m of pet rolatum to terminals after tightening c Internal ground in windings d Grounded starter fields e Armature rubbing on pole shoes a Starter clutch slipping b Broken clutch housing c Pinion shaft...

Page 223: ...e between wind d Test and repair ing leads to solenoid terminal and main contactor in solenoid Faulty relay e Test and replace relay if necessary sary SERVICE PROCEDURES AMPERAGE DRAW TEST with Starte...

Page 224: ...part eliminated in test is at fault Maximum allowablevoltage loss is as follows Battery insulated cable 2volt Solenoid switch 1 volt Each connectioll o volt Replace faulty cables Clean and tighten al...

Page 225: ...set of brushes are connected to this terminal The other pair of brushes is attached to the series field coils by means of a terminal screw Carefully pull frame and field assembly up just enough to exp...

Page 226: ...ing at front of pinion shaft Fig 8 Do not spread retainer ring any greater than outside diameter of pinion shaft otherwise lock ring can be damaged 19 Push pinion shaft towards rear of housing Fig 9 a...

Page 227: ...aced 2 When resoldering the shunt field and solenoid lead make a strong low resistance connection using a high temperature solder and resin flux Do not use acid or acid core solder Do not break the sh...

Page 228: ...d Installing Pinion Housing Drive Shaft Bushing FIELD COILS REPLACEMENT A pole shoe impact screwdriver Tool C 3475 should be used to remove and install field coils to prevent damage to pole shoe screw...

Page 229: ...iped dry with a clean dry cloth Rotate the pinion Pinion gear should rotate smoothly in one direction not necessarily easily but should not rotate in opposite direction If starter clutch unit does not...

Page 230: ...allow for proper entry of terminal stud into brush holder with the double wires curved around the contactor CAUTION The contactor must not touch the double SHIFTING FORK Fig 18 Shifter Fork andClutch...

Page 231: ...n field frame to the exact position on 22 h IW523A Fig 22 Installing Solenoid and Brush Holder into Gear Housing Fig 23 Soldering Shunt Coil Lead Wire gear housing and enter armature into field frame...

Page 232: ...Starting Motor Bench Test 17 SERVICE PROCEDURES AMPERAGE DRAW TEST with Starter Tester Check battery electrolyte gravity with a reliable hydrometer Gravity should be not less than 1 220 temperature co...

Page 233: ...d in the test is at fault cific gravity should be 1 220 or above tion Maximum allowable voltage loss is as follows Battery insulated cable 2 volt Solenoid switch 1 volt Each connection ovolt Replace f...

Page 234: ...and remove brushes 4 Removebrush plate Fig 2 from brush holders 5 Disconnect field coil leads at solenoid connector Fig 3 6 Remove solenoid attaching screws and remove solenoid and boot assembly Fig 4...

Page 235: ...may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth BRUSHES AND SPRINGS REPLACEMENT 1 Brushes that are worn more than 1 2 the length of new brush or are oil soaked...

Page 236: ...g 9 If lamp lights it indicates a grounded armature Replace grounded armature Testing Commutator Runouf Refacing Place armature in a pair of V blocks and check runout with a dial indicator Check both...

Page 237: ...ll soaked in SAE 30 engine oil before it is installed New pre sized bushings should be pressed into the housing until bushing is flush with inner side of housing to provide proper clearance Use Tool C...

Page 238: ...r cage Fig 14 NOT THEFORK LEVER until plunger bottoms 3 Measure clearance between end of pinion and pin stop with plunger seated and pinion pushed toward the commutator end Clearance should be 1 8 inc...

Page 239: ...cessary e Open field circuit e Test all the field circuit connections and correct as required f Open charging circuit f Inspect all connections in charging circuit and correct as required g Open circu...

Page 240: ...Vehicle Field Circuit Resistance Test Fig 3 1 Disconnect the ignition wire at the coil side of the ballast resistor and connect the positive lead of a test D C voltmeter to the battery positive post a...

Page 241: ...erminals 6 Start and operate the engine at a speed to ob tain 10 amperes flowing in the circuit Observe the HEAT SINK GROUND BRUSH JTPI1 1 TERMINAL i BEARING r NDlOlA Fig 2 Alternator Assembly voltmet...

Page 242: ...ses in engine speed should not be large enough to allow voltage to go above 16 volts 11 Observe the reading on the test ammeter The current output should be within the limits shown in Specifications I...

Page 243: ...age test If upper contact voltage setting is not within specification remove regulator cover and adjust voltage setting as outlined in Regulator Adjustments step number 1 Lower Contact Test 1 Increase...

Page 244: ...tic force of the coil tends to attract the regu lator armature When battery line voltage is relatively Iow current flow through the voltage coil will be low The mag netic force or pull of the voltage...

Page 245: ...called for in the voltage regulator chart indicate a tolerance of one volt from the low setting to high setting at temperatures indicated for the upper contact setting To maintain battery in a full st...

Page 246: ...stationary contact bracket making sure con tacts are in alignment If lower contact gap is correct and voltage regulator setting is still outside the 2 to 7 volt increase adjust air gap as follows c z...

Page 247: ...lts 3 Again test by placing one of the test prods to a slip ring and remaining test prod to end shield If lamp lights rotor assembly is grounded and requires replacement If lamp does not light after r...

Page 248: ...e within satisfac tory range When one rectifier is open it will read approximate ly one ampere and two good rectifiers will read with in satisfactoryrange Negative Case Rectifier Fig 17 a Connect test...

Page 249: ...the three leads If lamp does not light stator winding is open Fig 21 TEST LAMP NOi67 BULB k k_y NK114 Fig 19 Testing Rectifiers with Test Lamp TO 110 VOLT POWER SOURCE w oD Fig 20 Testing Stator for...

Page 250: ...all bearing is an interference fit with the rotor shaft Remove bearing with Puller Tool C 4068 Fig 25 10 Remove output terminal nuts and washers and remove terminal screw and inside capacitor The heat...

Page 251: ...t through the copper of both slip rings at opposite points 180 apart Fig 29 d Break the plastic insulator and remove the old slip ring e Clean away dirt and particles of old slip ring from rotor f Scr...

Page 252: ...ng Field Coil Leads 1 L GREASE RETAINE 1 ASLIP RINGS Fig 33 Installing Grease Retainer when the inner bore of the installer tool bottoms on the rotor shaft ASSEMBLING THE ALTERNATOR 1 Check rectifier...

Page 253: ...by the soldering or pressing operations PRESS CAPACITOR STATOR Fig 36 Installing Rectifier End Shield Bearing BEARING AINER PRESSING TOOL SHIELD ROTOR ND116 Fig 37 Installing Drive End Shield Bearing...

Page 254: ...istributor Advance Testing 45 Distributor Contact Dwell 40 Distributor Contacts 44 Distributor Disassembly 42 Distributor Installation 45 Distributor Lubrication 45 Distributor Removal 41 Distributor...

Page 255: ...g connect one end of a test Fig I Installing Secondary Cable and Nipplesut Distributor Cap Towers Inspect conditions and correctly con nect the coil Test condenser and replace if neces sary Replace an...

Page 256: ...al of coil and connect to the followingpoints a Distributor primary terminal outside b Distributor primary terminal inside c Contact terminal bracket insulated bracket d Ground side of contacts e Dist...

Page 257: ...ousing in direction of rotor rotation If flash occurs when the vibration damper timing mark is located past the specified degree mark in the direction of engine rotation timing is retarded To adjust t...

Page 258: ...wire and grommet as an assembly Push grommet towards inside of distributor to remove Do not pull the wire 4 Remove two screws and lockwashers attaching contact plate to the housing and lift out contac...

Page 259: ...gear teeth is in line with centerline of rotor electrode Fig 6 drill a 124 129 inch hole and in CAUTION Support hub of gear when installing roll pin so that gear teeth will not be damaged 6 Install cm...

Page 260: ...y be replaced but the ignition system and engine must be checked to determine the cause of the trouble so it can be eliminated Unless the condition causing contact burning or excessive pitting is cor...

Page 261: ...grease will be thrown from the distributor cam when engine is running If this grease strikes the contacts arcing and burning of contacts will result DISTRIBUTOR ADVANCE TESTING Centrifugal Advance Cur...

Page 262: ...ibutor IGNITION COIL The ignitidn coil is designed to operate with an external ballast resistor When testing the coil for output include resistor in tests Inspect the coil for external leaks and arcin...

Page 263: ...tributor SERVICE PROCEDURES Secondary Circuit lnspection Check high tension cable connections for good con tact at the coil and distributor cap towers and at the spark plugs Terminals should be fully...

Page 264: ...p tower and check the cable resistance If resistance is more than 30 000 ohms replace cable assembly Test all spark plug cables in same manner To test coil to distributor cap high tension cable re mov...

Page 265: ...t Tach Dwell red lead to distributor terminal of coil and black lead to a good ground 3 Turn SelectorSwitch to 8 LOBE position 4 Start engine and operate engine at idle speed 5 Observe dwell meter rea...

Page 266: ...rotated with a slight drag then turn distributor in the normal rotation until test lamp lights 4 Turn distributor against normal distributor ro tation until test lamp goes out If test lamp lights imm...

Page 267: ...rom bottom of housing using Driver Tool C 3041 Fig 7 f Soak new bushings in light engine oil for ap proximately 15minutes g Position new upper bushing with hole in bush ing up and in line with oil hol...

Page 268: ...g S N A P RING SHAFT ASSEMBLY SPRING BREAKER PLATE 2 WASHER SCREW j SHAFT WASHER T I CLAMP r T BEARING HOUSING CLAMP WASHER SCREW OILER LOCKRING WASHER SCREW PIN GASKET ND310A COLLAR PIN NU476 Fig 5...

Page 269: ...shing 11 Lubricate felt pad in the top of distributor cam with 1drop of light engine oil and install rotor CONTACT ARM SPRING TENSION 1 Hook a spring scale Tool MTU 36 on the breaker arm and pull in a...

Page 270: ...vapors up into the distributor Over oiling of the distributor will also cause burning of the contacts If the contact opening is too small cam angle too large arcing will occur between the contacts re...

Page 271: ...ons re place with a new distributor shaft with correct cali bration shaft cam yoke governor weights and springs as an assembly or with a new distributor as sembly less cap and rotor For Prestolite dis...

Page 272: ...low speed opera tion when the primary circuit current flow is high ballast resistor temperature rises increasing resist ance This reduces current flow thereby prolonging ignition contact life At high...

Page 273: ...have only one filament and are marked by a numeral 1 molded in the glass The bulbs cannot be installed wrong as the mount ing lugs for the number one 1 and number two 2 bulbs are offset at different...

Page 274: ...Place split image target in like position at right rear wheel 2 Adjust range screw on transit until target split image coincides or merges into one unbroken line Make sure that the line of sight is p...

Page 275: ...EADLIGHT AIM Horizontal Test Turn the RIGHT LEFT scale knob until the split image is in alignment If the RIGHT or LEFT POR TION of scale exceeds the following values the lights should be aimed Values...

Page 276: ...creen or wall Fig 6 a A horizontal line at the level of centers of head b A center vertical line which must be lined up c A vertical line on left of screen or wall in line lights line number 3 with ce...

Page 277: ...ct lamp socket connector at harness Belvedere Satellite Fury and VIP4Fig 10 FRONT PARK AND TURN SIGNAL LAMP Removal 1 Remove two screws attaching lamp to front bumper 2 Disconnect socket connector fro...

Page 278: ...ng nuts 1 From inside of trunk remove four caplugs and NUT ASSEMBLY 4 CAPLUG BULB NUMBER 1157 Fig 12 Tail Stop Turn Signal and Back up Lamp Valiant 2 Snap out lamp sockets from lamp housing and remove...

Page 279: ...move bezel from quarter panel lens from bezel studs SCR 4 BULB N U B E R 1157 NU617 Fig 15 Tai1 Stop and Turn Signal Lamp Station Wagons Belvedere and Satellite ASSEMBLY NU618 Fig 16 Tai1 Stop and Tur...

Page 280: ...d install the four attaching screws TAIL GATE TAIL STOP AND TURN SIGNAL LAMP Station Wagons Fury Models Fig 18 Removal 1 Remove four screws attaching lamp lens to tail gate and remove lens 2 Remove fo...

Page 281: ...change direction of travel moving the lever up causes the right turn signals to flash Moving the lever down causes the left turn signals to flash After completion of a turn the system is deacti vated...

Page 282: ...connection SERVICE PROCEDURES TURN SIGNAL SWITCH Removal h g counterclockwise 1 Disconnect the battery ground cable 2 Remove horn ring ornament assembly by turn 3 Disconnect horn wire at horn switch...

Page 283: ...wheel hub and a horn relay mounted in the engine compartment for Belvedere and Satellite models On Valiant and Barracuda models the relay is mounted in the passenger compartment under the instrument p...

Page 284: ...wire connector green wire and the other lead to a good body ground If test light illum inates there is a short in the horn wiring Repair or replace wire If the test light does not illuminate con nect...

Page 285: ...ove hub lower move switch Installation 1 Locate horn switch on bottom of horn ring and install three retaining screws 2 Position horn ring and switch assembly on steering wheel hub with horn wire rout...

Page 286: ...ture will be indicated on the gauge Fuel Level indicating System A hinged float arm in the fuel tank raises or lowers dependent on the fuel level The float arm contacts a variable resistor in the gaug...

Page 287: ...rminal at fuel tank sending unit Connect one lead of Tester C 3826 to disconnected wire and the other to a good ground Turn ignition key on 2 Turn knob on dial of tester to H and observe gauge on pane...

Page 288: ...is proven replace the brake warning switch in the brake line Tee fitting mounted on the frame rail in the engine compartment below the master cylinder BRAKE SYSTEM WARNING LIGHT ALTERNATOR INDICATOR T...

Page 289: ...bolts Install column cover ROADS1 D E WARNING SYSTEM SWITCH 4 Remove tape from top of steering column con nect battery ground cable and test operation of all gauges INSTRUMENT CLUSTER Barracuda Fig 2...

Page 290: ...l four screws in under side of crash pad and three screwsin front lower face of cluster 6 Reaching up under panel connect left printed circuit board multiple connector and speedometer cable 7 Connects...

Page 291: ...ery ground cable and test opera ing cover nuts finger tight Tighten bolts securely install column trim cover tion of all lights and gauges CLOCK OR TURN SIGNAL TEMPERATURE CONDITIONING OUTLETS COURTES...

Page 292: ...b to bezel so 4 Install trim bezel mounting screws 5 Install steering column cover 6 Install lamp panel 7 Connect battery ground cable equipped LEFT TRIM PANEL Air Conditioner Spot Cooler Removal 1 Re...

Page 293: ...own on padded bench remove housing to bezel screws and carefully separate the two 2 Remove terminal nuts of gauge to be serviced 3 Position new gauge in housing and install 4 Carefully position bezel...

Page 294: ...ument cluster base ground When the gauge tester is in L position the gauge being tested should read on the low side of dial With gauge tester on M the gauge should read in the center of the dial scale...

Page 295: ...zel nut and tighten with Tool C 3824 6 Insert switch knob into switch till a distinct 7 Position fuse block under panel and secure with click is heard screw Headlight Switch Belvedere and Satellite Mo...

Page 296: ...ant and Barracuda bracket 1 Remove emergency flasher from mounting 2 Remove switch spanner nut with Tool C 3824 3 Disconnect wire connector and pull switch out from under panel 4 Connect multiple conn...

Page 297: ...l mounting screws 3 Remove center outlet from panel lnstallation 1 Position center outlet and install bezel mount ing screws 2 Install center distribution duct Reach up under instrument panel and inst...

Page 298: ...CATOR LIGHT glove box opening Removal taching lamp to instrument lower panel lamp lnstallation 4 Install glove box door check arm mounting lnstallation and unfold into position From under instrument r...

Page 299: ...LL NOT MENT PANEL SWITCH I S TURNED OFF MOTOR STOPS IN ANY STRUMENT PANEL SWITCH I S TURNED 0FF NOSPEEDCONTROL STOP WHEN INSTRU POSITION WHEN IN a Binding Linkage a Relieve binding condition b Faulty...

Page 300: ...m affecting downward movement of the wiper arm and blade With this force applied the clearance between the tip of the wiper blade and the windshield moulding should be as follows Clearance in InchesBe...

Page 301: ...ch protects the cir cuitry To test the switch disconnect the wiring to the switch and remove the switch from the instrument panel For removal and installation of the wiper switch see Instrumentsand In...

Page 302: ...red lead to ground Connect third jumper wire from battery positive terminal to blue lead The wiper should run to the park position CAUTION Motor can be damaged if not wired cor rectly MOTOR REMOVAL V...

Page 303: ...l Remove motor drive crank arm from drive link after removal of assembly from vehicle Fig 7 WIPER ARM 4 COWL 1 SEALING WMancrc LEFT PIVOT CRANK ARM DRIVE I I IY E I LINK BUSHING u K RETAINER f a NP74A...

Page 304: ...s the parking spring in the two speed parking mechanism should be lubricated with Mopar Lubricant provided with service package Apply the lubricant to inside coils of spring first and to the out side...

Page 305: ...A WI N DSH I E LD WI PERS ELECTRICAL 8 89 1 Z MyMopar com...

Page 306: ...een The right pivot is serviced after disconnecting the connecting link at the pivot and removing the bolts that mount the pivot to the body Fig 9 The left pivot is serviced after disconnecting the co...

Page 307: ...ive connect a jumper wire from the blade ter minal of the pump Fig 4 to the positive terminal of the battery If pump operates check wiring and switch If pump does not operate it may be defective or fr...

Page 308: ...from reservoir 3 Using a suitable extension and a 7 8 inch deep well socket through filler neck remove pump mount ing nut inside reservoir It may be necessary in some older pumps to use a 15 16 in dee...

Page 309: ...st be fully charged before testing Make certain solenoids are correctly adjusted before circuits are tested The circuit breaker is located be hind the left side cowl trim panel The relay is lo cated b...

Page 310: ...witch Should motor fail to run replace switch body Each switch is tested ih same manner The motor should run if not test continuity of wiring Should continuity be established and motor still does not...

Page 311: ...ion should start to rise If top operates during these tests but fails to operate when the control switch lever is moved to UP or DOWN position the switch is at fault and should be replaced If the top...

Page 312: ...od ground If test lamp lights feed in wiring is good 3 Remove test lamp and connect feed to circuit breaker 4 Disconnect wiring from other side of circuit breaker Connect test lamp C 744 in series bet...

Page 313: ...move seat assembly from vehicle following procedure outlined under Seat Assembly and Ad juster 2 Lay seat on its back on some clean object 3 Remove bolts attaching adjuster to seat as sembly Installat...

Page 314: ...key and the front 5 16 clevis pin 4 After clevis pin is removed slowly release the tension on the vertical spring 5 Remove cotter key and rear 3 8 clevis pin and upper channel assembly 6 Remove horizo...

Page 315: ...ours 70 70 Number of Plates Per Cell 13 13 Ground Terminal Negative Negative Cu In Engines Standard 440 Cu In Engines Equipment Special Equipment Voltage 12 12 Model Identification Number 27 MB 70 27...

Page 316: ...Inch Clutch and 225 Cu In Engine Starting Motor Model Make VoItage No of Fields No of Poles Brushes Spring Tension Drive End Play Cranking Amperage Draw Test Free Running Test Voltage Amperage Draw M...

Page 317: ...egulator 2 50 Microfarad plus or minus 20 2 38 to 2 75 Maximum amperes 26 plus or minus 3 amperes 34 5 plus or minus 3 amperes 41 plus or minus 3 amperes 51 plus or minus 3 amperes Plus or minus three...

Page 318: ...5 10 017 to 023 42 to 47 17to 20 oz 25 to 285 mfd OOo to 003 003 to 017 CIockwise Chrysler Prestolite or Chrysler Essex 1 65 to 1 70 Ohms 9400to 11700Ohms 2444242 2444241 2095501 0 5 to 0 6 Ohms 3 0a...

Page 319: ...In 2875790 Advance Centrifugal Distributor Degrees at Distributor RPM 2 to 8 5 550 RPM 11 5 to 13 5 900 RPM 14 to 16 1900 RPM 2 to 5 5 8 5 10 5 to 13 5 13 5 014 to 019 30 to 35 17to 20 oz 25 to 285 mf...

Page 320: ...0 to 35 both sets points 37 to 42 17 to 21 5 oz 17 to 20 02 25 to 285 mfd 25 to 285 mfd 000 to 003 OOO to 003 003 to 017 003 to 017 CIockwise CIockwise TDC 5 BTC N9Y Champion N9Y Champion 14MM 3 4 Rea...

Page 321: ...Spring Tension Condenser Capacity Shaft Side Play New or Rebuilt Shaft End Play After Assembly Rotation Timing Spark Plug Type Size Gap Firing Order Coil Identification Number Primary Resistance 7O0...

Page 322: ...2444241 Primary Resistance 7O0 8O F Secondary Resistance 70 80 F Resistance 70 800F in circuit Engine Stopped Service wear tolerance should not exceed 006 inch 1 65 to 1 79 Ohms 9400 to 11700 Ohms 1...

Page 323: ...tors Manual or Automatic Trans Engine Application Engine Displacement Distributor Part No Chrysler Built 426 Cu In 2875140 Prestolite Built lBS 4014A Advance Ce ntrifugaI Distributor Degrees at Distri...

Page 324: ...003 to 017 CountercIockwise 7 5 BTC J 13Y Champion or Mopar P 3 5P 14MM 3 8 Reach 035 1 8 4 3 6 57 2 Chrysler Prestolite or Chrysler Essex 1 65 to 1 79 Ohms 9400 to 11700 Ohms 2444242 2444241 1 41 to...

Page 325: ...ner Control and Auto Temp 1445 1445 1892 2 1893 FL Ash Receiver 1445 1445 1892 1445 Back up Lights 1156 2 1156 2 1156 2 1156 2 C Pillar Light 211 1 2 Clock 57 1893 FL Cornering Lights 1293 2 Courtesy...

Page 326: ...am Valiant 113 Body Wiring Diagram Station Wagon Fury 114 Console Wiring Fury and VIP 115 Electric Window Lift and Electric Door Locks Wiring Diagram Fury and VIP 116 Electric Window Lift Wiring Diagr...

Page 327: ...EIVER LAMP 16P CIGAR TIGHTER X 1 1 6 R Y b PART OF INSTRUMENT PANEL MAIN HARNESS i1 M3B E2B 18 0 I M I t 3P M2 SWITCH B I O J5 1 8Y I E2 18 0 J y M 2 A 1 8 Y a M2E 18Y M2F 18Y e M 2 F 1 8 Y TO RlGni A...

Page 328: ...SIGNAL L 7 1 B B K D x q LAMP r RIGHT BACK UP LAMP s a 8 1 A l E V B 2 A 1 8 V 7 1 8 B L 7 l 8 8 K g LICENSE LAMP F K UP LAMP B2 I8V B2 IBV LEFT TAIL STOP AND INSTRUMENT PANEL WIRING M2 18Y TO LEFT C...

Page 329: ...8BK DE 18DGN TO SWITCH WIRING ON INSTRUMENT PANEL D7 18BL SIGNAL LAMP TO LEFT FRONT DOOR JAMB SWITCH NU232 Fig 4 Body Wiring Diagram Except Station Wagon Fury and VIP TO REAR WINDOW DEFOGGER SWITCH WI...

Page 330: ...8 114 E L E C T R I C A L W I R I N G DIAGRAMS A MyMopar com...

Page 331: ...MALE FEMALE PINK NU107 TO LEFT FRONT AUTOMATIC DOOR SWITCH M2 18Y I TO COURTESY LAMP INSTRUMENT PANEL M1 18P WITH MANUAL TRANSMISSION M1 18P m FEED CABLE ON M2 18Y Fig 7 Console Wiring Fury and VIP TO...

Page 332: ...ELECTRICALWIRING DIAGRAMS A f 4 c r i MyMopar com...

Page 333: ...A WIRING DIAGRAMS ELECTRICAL 8 1 17 11 I n 6 A W VJ 7 2 n W Z I Y m co m 1 MyMopar com...

Page 334: ...8 1 18 ELECTRICAL WIRING DIAGRAMS A I Y t I t MyMopar com...

Page 335: ...A WIRING DIAGRAMS ELECTRICAL 8 1 19 MyMopar com...

Page 336: ...HEADLAMP GROUND K RIGHT PARK AND TURN SIGNAL LAMP IB R GROUND AND TURN SIGNAL LAMP L9 16BK I NRllPA A V A 3 RIGHT FRONT FENDER TURN INDICATOR LAMP Z S R J H A BULKHEAD DISCONNECT TO BULKHEAD DISCONNE...

Page 337: ...FRONT FENDER TURN INDICATOR LEFT CORNERING LAMP GROUND 8 121 NU200 Fig 15 Front End Lighting Fury and VIP RIGHT FRONT FENDER TURN INDICATOR BULKHEAD DISCONNECT B LAMP P D5A 18BK T L3 18R D6A 18BK LGN...

Page 338: ...8 122 ELECTRICAL W IRING DlAGRAMS A BULKHEAD DISCONNECT oii I P CENTER SPEAKER RIGHT SPEAKER X51 18V CONNECTOR SPEED CONTROL BRAKE SWITCH TO BODY WIRING M 2 A l 8 Y MyMopar com...

Page 339: ...SWITCH DEFOGGER E28 18 oa ASH RECEIVER LAMP E28 18 0 TO AIR CONDITIONER AND HEATER AIR CONDITIONER AND HEATER LAMP AND SOCKET E2A 18 0 L6 18BKa LAMP ON REMINDER BUZZER FEED MAIN ASSEMBLY I I I TOP LI...

Page 340: ...8 124 ELECTRICALWIRING DIAGRAMS A U MyMopar com...

Page 341: ...ED 18DBL ERVO 1 rX30 18DBL SPEED CONTROL BRAKE SWITCH CONTROL COIL BULKHEAD LINE TOACCESSORYTERMINAL ON FUSE BLOCK 1 Fig 18A Speed Control Wiring Diagram COLOR CODE FROM TERMINAL SIDE MALE FEMALE NR22...

Page 342: ...TOR SWITCH rL44a 1 14BK y 16BR COLUMN SUPPORT BRACKET HS 18BK P HEATER BLOWER MOTOR RESISTOR r TO RIGHT FRONT DOOR AUTOMATIC COLUMN ACCESSORY LAMP WIRING MAP LAMP 1 FLASHER 0 L E R FRONT DOOR AUTOMATI...

Page 343: ...OP _ _ I L 7 1 8 B K 09 18T L7A lBBK TO HEADLAMP BUZZER RELAY WIRING L1 16BK Q3 14R DlO 1BLGN D32 18R D4A 18W BATTERY FEED Q3 14R 7 FUSE BLOCK 8 127 I FOOT DIMMER SWITCH INSULATORS VIEWED FROM TERMINA...

Page 344: ...TOR EMERGENCY FLASHER X1 16R CIGAR LIGHTER RIGHT TURN SIGNAL LAMP TEMPERATURE GAUGE I 1 6 R a HEATER BLOWER MOTOR SWITCH 16DGN 16LGN 14BK A r I c OIL WARNING LAMP 4 RESISTANCE CABLE CIRCUIT V7 24BR lN...

Page 345: ...N SIGNAL LAMP FEED DlOA lBLGN HIGH BEAM LAMP FEED L R INSTRUMENT LAMPS FEED E2A 18 0 LEFT TURN SIGNAL LAMP RIGHT TURN SIGNAL LAMP FEED DPA 18T a E ATURE GAUGE SENDER G2 1 L WARNING SENDER CIRCUIT BREA...

Page 346: ...AMMETER VOLTAGE LIMITER RIGHT TURN SIGNAL LAMP 16BR LOW 16LGN HIGH 16DGN MEDIUM X12 18R HEATER BLOWER SWITCH 12BK r E2E 18 O 5 18P CIGAR LIGHTER I II rc I I G4 18DBL R6A 12 B K A G4 l BDBL El OA 1BBK...

Page 347: ...BK DlOA 18LGN V1 16P Q2 12BK D7 18BR 17 18BK D27 1BV D4 18W PANEL DIMMER SWITCH PANEL ACCESSORY J2 16 Q 2 1 2 B K A C C E S S O R R N G 0 0 DIAGRAM S2 1BY START STARTER AND I 1ILJ1 12R BATTERY IGNITIO...

Page 348: ...NG INDICATOR LAMP _ BRAKE SYSTEMS LAMP w INSTRUMENT LAMP THIS CIRCUIT NOT REQUIRED WIPERS RIGHT TURN SIGNAL LAMP FOR TWO SPEED LA V3 16BR WINDSHIELD WIPER AND WASHER SWITCH STARTER AND 1 IGNITION SWIT...

Page 349: ...STRUMENT LAMP HIGH BEAMINDICATOR LAMP AMMETER 4 LEFT TURN SIGNAL LAMP DlOA l8LGN HIGH BEAM LAMP 5 1 8 INSTRUMENT LAMPS E2 180 TEMPERATURE GAUGE SENDER LEFT TURN SIGNAL LAMP EMERGENCY FLASHER SWITCH D9...

Page 350: ...F PANEL MAIN HARNESS X1 16R M3H lbP M3G18P II Xl l6R PLUG TOGETHER WITHOUT GLOVE BOX LAMP W M 3 F 1 8 P b M2G 18BR CIGAR LIGHTER A M 3 E 1 6 P PART OF INSTRUMENT PANEL MAIN HARNESS M2H 18Y e M 2 J 1...

Page 351: ...FT BUCKET SEAT OR LEFT 50 50 SPLIT SEAT ADJUSTER LEGEND FEMALE INSULATORS VIEWED FROM TERMINAL SIDE Fig 25 Power Seats Wiring Diagram REAR WINDOW DEFOGGER OR REAR HEATER SWITCH C10 18LGN LEFT SEAT ADJ...

Page 352: ...inal compression ratio of 8 5 l for the 170 cu in engine and 8 4 l for the 225 cu in engine The lubrication system consists of an externally mounted rotor type pumd on the lower right side of the cyli...

Page 353: ...ions Faulty starter C Moisture on ignition wires and distrib d utor cap Faulty ignition cables e Faulty coil or condenser f Dirty or corrodeddistributor contacts g Incorrect spark plug gap h Incorrect...

Page 354: ...n wiring i Faulty coil or condenser j Incorrect tappet lash a Incorrect ignition timing b Worn or burned distributor rotor c Worn distributor shaft or cam d Dirty or incorrectly gapped spark e Dirt or...

Page 355: ...CONNECTING ROD NOISE a High or low oil level in crankcase b Thin or diluted oil c Low oil pressure d Dirt in tappets e Bent push rods f Worn rocker arms g Worn tappets h Worn valve guides i Excessive...

Page 356: ...Tune up 5 Valves and Valve Springs 9 Valve Timing 12 SERVICE PROCEDURES TUNE UP 1 Test battery specific gravity add water if nec essary clean and tighten battery connections 2 Test cranking voltage Se...

Page 357: ...9 Remove clutch torque shaft brake cables and 10 Remove speedometer cable and gear shift rods 11 Disconnect propeller shaft and tie up out of 12 Install engine support fixture Tool C 3487and 13 Remov...

Page 358: ...or rect Whenever an engine has been rebuilt and or a new camshaft and or tappets are installed one quart of engine supplement Chrysler Part Number 1879406 or equivalent should be added to the engine o...

Page 359: ...on system CYLINDER HEAD The chrome alloy cast iron cylinder head Fig 11 is held in place by 14 bolts Spark plugs are located at the wide edge of the combustion chambers and alum inum spark plug tubes...

Page 360: ...conical washers against manifolds Tighten nuts to 10foot pounds 8 Tighten 3 bolts holding intake manifold to ex haust manifold to 15foot pounds Sequence Tighten inner bolt first then the outer two bo...

Page 361: ...odate the oversize valve stem are as follows Reamer Reamer Valve Guide c 3433 005 in 379 380in C 3430 015 in 389 390in C 3427 030in 404 405 in 6 Slowly turn reamer by hand and clean guide thoroughly b...

Page 362: ...Place spring over the stud on table and lift the compressing lever to set the tone device Pull on torque wrench until ping is heard Take read ing on torque wrench at this instant Multiply this readin...

Page 363: ...oval 1 Drain cooling system 2 Remove radiator and fan 3 Install Tool C 3732Aand pull vibration damper assembly offend of crankshaft Fig 22 4 Loosen oil pans bolts to allow clearance and re move chain...

Page 364: ...p between the neoprene and flange of seal REMOVING AND INSTALLING PLATE CHAIN CASE COVER NYl61A Fig 26 Removing Oil Seal retainer 2 Place washer and nut on the remover screw Tighten nut forcing the bl...

Page 365: ...on the crankshaft Fig 30 CAMSHAFT The camshaft has an integral oil pump and dis FEELER GAUGE A Fig 29 Inspecting Seal for Proper Seating Fig 30 Indofling Vibration Damper Assembly tributor drive gear...

Page 366: ...ack of each bearing shell and drive out all bearing shells Fig 32 lnrtalling Camshaft Installation 1 Install new camshaft bearings with Tool C 3132A by sliding the new camshaft bearing shell over the...

Page 367: ...E R N NPW8 Fig 34 Cross Hatch Pottern cleaned again to remove all traces of abrasives CAUTION Be sure all abrasives are removed from engine parts after honing It is recommended that a solution of soap...

Page 368: ...pin Fig 37 1 Arrange Tool C 3724 parts for removal of 2 Install pilot on main screw 3 Install screw through piston pin 4 Install anvil over threaded end of main screw with small end of anvil against p...

Page 369: ...nstall a new connecting rod and repeat the installation and testing procedure If the connecting rod does not move under 15 foot pounds piston and connecting rod interference is satisfactory 14 Remove...

Page 370: ...rs on rod bolts the long protector should be installed on squirt hole side of connecting rod Rotate crankshaft so that connecting rod journal is on the center of cylinder bore 6 Insert rod and piston...

Page 371: ...ing or InstallingUpper Main Booring PART O F TOOL a SIDE SEAL GROOVES N Y Fig 46 installing R w r Main Bearing Oil Sod ing the bearing into position Remove Tool 7 3059 MEASURING MAIN BEARING CLEARANCE...

Page 372: ...into position until tool is seated 3 Trim off portion of seal that protrudes above cap Fig 47 4 Install two side seals in grooves in seal retainer 5 When installing seal retainer tighten screws to 30f...

Page 373: ...idler a r m ball joints to center link Tighten retaining nuts to 40 foot pounds and secure with cotter pins 3 Lower vehicle on hoist then lower the engine down into position Remove lifting fixture an...

Page 374: ...9inches replace outer rotor 4 If inner rotor length measures less than 649 inch Fig 53 replace inner rotor 5 Install outer rotor into pump body pressing to one side with fingers ahd measure clearance...

Page 375: ...an effective seal tighten filter by hand the additional number of turns indicated on the replacementfilter Start engine and inspect for leaks 3 Install the oil pump on engine Tighten attach EIGHT CYL...

Page 376: ...Control Valve Solvent Part Number 2525054 or equivalent to the bushing and shaft 12 Every 6 months remove air cleaner filter ele ment and blow out dirt gently with air hose Direct air frcm inside out...

Page 377: ...Engine R w r SuppoH Vufknt 6aruda HOUSING NU281 E L 3 C 90 FT LBS Fig 6 Engine Rear Support Satellite except with 4 Speed Transmission ENGINE ASSEMBLY Removal 1 Scribe outline of hinge brackets on the...

Page 378: ...been rebuilt and or a new camshaft and or tappets are installed one quart of engine supplement Chrysler Part Number 1879406 or equivalent should be added to the engine oil to aid in break in The oil m...

Page 379: ...er Hood lightening Sequence with 1316241 sealer or equivalent Install intake mani fold gaskets with the bead down and end seals locked in the tangs of head gasket Add a drop of sealer in the V notches...

Page 380: ...total dial indicator reading should not exceed 017 inch Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored 5 Service valves wi...

Page 381: ...gs Fig 17 1 Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested As an example the compression length of the springto be tested is 1 5 16 inch...

Page 382: ...h RETAINERR_ L SPRING INTAKEVALVE SEAL s I NK13 Sk I Fig 204ndalling Valve Cup Seal Spring and Retainer which when fed to the tappets causes them to lose length and allows valves to seat noisily Any l...

Page 383: ...unger and plunger from 3 Fill tappet body with kerosene and install 4 Unseat check valve with a brass rod to permit VAL RETAINER I TAPPET BODY CHECK VALVE SPRING PLUNGER CAP NR68 Fig 21 Hydroulic Tapp...

Page 384: ...irection of crankshaft rotation to take up slack 30 foot pounds with cylinder head installed or 15 foot pounds cylinder heads removed With a toque applied to the camshaft sprocket bolt crankshaft shou...

Page 385: ...s is im COVER Fig 27 Remover Blocks Expanded fo Puller Position REMOVING AND INSTALLING PLATE TOOL REMOVERSCREW TOOL CHAIN CASE COVER A ALEEVE A Fig 28 Removing 011 Seal portant remover is only positi...

Page 386: ...ig 34 With engine in repair stand C 3167 NU274 Fig 32 Installing Vibration Damper Assembly and adapter C 3662 Remove intake manifold cylinder head covers timing case cover and timing chain 1 Remove ro...

Page 387: ...h oil passages from the main bearings Also Number two bearing must index with the oil passage to the left cylinder head and Number four bearing must index with the oil passage to the right cylinder he...

Page 388: ...cylinder walls should be checked for out of round and taper with Tool C 119 If the cylinder bores show more than 005 out of round or a taper of more than OW or if the cylinder walls are badly scuffed...

Page 389: ...NU159 Fig 41 3 4 0 Cubic Inch Piston MwsunmenU following oversizes 005 020 040inch FiWing Pistons Piston and cylinder wall must be clean and dry Specified clearance between the piston and the cyl ind...

Page 390: ...Piston Ring Clearance Fig 43 Showing Location of InternalMarking of No 8 Counterweight rods are assembled to pistons correctly they are not interchangeablefrom one bank to another The bearing caps are...

Page 391: ...ecting rod bore must be installed t e ward crankshaftjournal fillet 8 Install rod caps tighten nuts to 45 foot pounds CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for ex cessive...

Page 392: ...e bearing is too large Fig 48 Installing Rear MainUpper OilSeal or crankshaft cannot be rotated bearing is too small and should be replaced with the correct size 4 Measure crankshaft end play 002 to 0...

Page 393: ...9 42 273 318 340 ENGINE A a h 9 cu p Z MyMopar com...

Page 394: ...h proper grade and quantity of motor oil connect battery ground OIL PUMP It is necessary to remove the oil pan and remove b RETAIN ER NF931B Pig 51 Relief Valve Spring and Retainer Removed the oil pum...

Page 395: ...oved with 400 grit wet or dry paper 10 The relief valve spring has a free length of 2 1 32to 2 3 64inch and should test 16 2 to 17 2 lbs when compressed to 1 11 32inch Discard springs that fails to me...

Page 396: ...iner cap is within the relief valve bore diameter as shown in Figure 59 In stall cotter pin INCH ENGINES Page Camshaft 56 Camshaft Bearings 57 Connecting Rods 62 Crankcase Ventilation System 84 Cranks...

Page 397: ...ing and shafts 12 Every 6 months remove filter element and blow out dirt gently with air hose Direct air from inside out and keep nozzle 2 inches away from ele ment to avoid damaging Fig 1 Clean the m...

Page 398: ...ing fixture to carburetor 7 Raise vehicle on a hoist and install engine s u p 8 Drain transmissionand torque converter 9 Disconnect exhaust pipes at manifolds propel ler shaft wires linkage cable and...

Page 399: ...nsmission linkages Road test vehicle ROCKER ARMS AND SHAFT ASSEMBLY The rocker arms are of stamped steel and are ar ranged on one rocker arm shaft per cylinder head The push rod angularity tends to fo...

Page 400: ...pounds in sequence Fig 10 Repeat the procedure tightening all head bolts to 70 foot pounds 5 Inspect push rods and replace any worn or bent rods 6 Install push rods in the tappets maintaining alignmen...

Page 401: ...t a right angle to the valve stem being measured Fig 1 4 6 Move valve to and from the indicator Total dial indicator reading should not exceed 017inch If the dial indicator reading is excessive or if...

Page 402: ...echanism includes a safety factor to allow for a limited amount of wear and the refacing of the valves and seats 7 To insure that limits have not been exceeded the dimension from valve spring seat in...

Page 403: ...ngine to correct tappet noise read the oil pressure at the gauge Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and check the oil level in the oil pan The press...

Page 404: ...marking stamped on the engine numbering pad indicates that some tappet bodies are 008 inch oversize CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve must always be f...

Page 405: ...pacer CAUTION Do not turn crankshaft any further clock wi as the valve spring might bottom and result in seriousdamage TIMING CHAIN COVER OIL SEAL AND CHAIN Cover Removal 1 Drain cooling system and re...

Page 406: ...ver shaft and up against sprocket flange away from sprocket Oil Seal Replacement Cover Removed 1 Position remover screw of Tool 2 3506 through case cover inside of case cover up Position remover block...

Page 407: ...damper retainer washer and bolt Tighten to 135 foot pounds 6 Slide belt pulley over shaft and attach with bolts and lockwashers Tighten bolts to 200 inch pounds CAMSHAFT The camshaft has an integral o...

Page 408: ...led drive out camshaft rear bearing welch plug 2 Install proper size adapters and horse shoe washers part of Tool C 3132A at the back of each bearing to be removed and drive out bearings Fig nsiallati...

Page 409: ...in the dis tributor cap 3 Place distributor gasket in position BUSH NG I Fig 3blnstalling Distributor Drke Shaft Bushlng Fig 37 Burnishing Dirtributor Drive Shaft Burhlng 4 Lower the distributor and...

Page 410: ...aight and round 20 to 60 strokes de pending on the bore condition will be sufficient to provide a satisfactory surface Inspect cylinder walls after each 20 strokes Use honing oil C 3501 3880 or a ligh...

Page 411: ...inch piston 6 For the two top rings use ring installer Tool FWingRings from bottom of cylinder bore in which it i s to be fitted An inverted piston can be used to push rings l Measure piston ring gap...

Page 412: ...ngrod 10 Remove tool and arrange tool parts and piston assembly in same manner Fig 42 11 Place assemblyin a vise Fig 4 6 12 Attach torque wrench to nut and tighten up to 15 foot pounds If the connecti...

Page 413: ...pounds 3 Turn crankshaft 1 4 turn in each direction A slight drag should be felt which indicates clearance i s satisfactory 383 engine with barrel carburetor correct clearance is from 0005 to 0015 in...

Page 414: ...marked at removal to insure correct assembly Bear ings are available in standard and the following undersizes 001 002 003 010 011 and 012 inch Do not install an undersize bearing that will reduce clea...

Page 415: ...til tool is seated in bearing bore 3 Hold the tool in this position and cut off portion of seal that extends above the block on both sides Lower Reur Muin S e d lnstullution trude Fig 52 1 Install a n...

Page 416: ...ade and quantity of oil OIL PUMP Removal Remove o i lpump attaching bolts and remove pump Disassembly 1 Remove filterbase and o i lseal ring 2 Remove pump rotor and shaft and lift out outer 3 Remove t...

Page 417: ...nce straightedge across the face between bolt holes Fig 60 If a feeler gauge of more than 004 inch can be inserted between the rotors and straightedge replace pump body 7 If the tip clearance between...

Page 418: ...dicated on the replacement filter Start engine and inspect for leaks 426 CUBIC INCH HEMI ENGINE INDEX Page Camshaft 76 Camshaft Bearings 77 Connecting Rods 80 Crankcase Ventilation System 84 Crankshaf...

Page 419: ...inkage from bellcrank at rear of engine 2 Position fan to clear radiator top tank and hoses 3 Remove engine mount to frame bolts on the right side disconnect flexible line and fitting from fuel pump a...

Page 420: ...oil temperature and oil pressure sending units fuel line 9 Install carburetors linkage throttle cable and adjust 10 Install radiator connect heater hoses cooler lines and fill cooling system 11 Instal...

Page 421: ...s an assembly 6 Disconnect exhaust headers from cylinder heads and tie out of way 7 Remove the lower eight cylinder head bolts Fig 4 8 Remove the four stud nuts 9 16 inch hexagon from cylinder head st...

Page 422: ...inch pounds Repeat the tightening procedure in the sequence shown until all screws maintain their specified torque 9 Connect fuel line automatic choke intake mani fold heat tubes transmission throttle...

Page 423: ...ntake and exhaust valve seats and valve faces have a 45 degree angle 2 Inspect the remaining margin after the valves are refaced Fig 13 Valves with less than 3 64 inch margin should be discarded 3 Whe...

Page 424: ...If height is greater than 1 59 64 inch install a 1 16 inch spacer in head coun hrbore to bring spring height back to the normal 1 53 64 to 1 57 46 inches TAPPET ADJUSTMENT When adjusting tappets on t...

Page 425: ...Measuring Timing Chain Stretch Typical movement of the chain may be measured 2 Place a torque wrench and socket over camshaft sprocket attaching bolt and apply torque in the direc tion of crankshaft...

Page 426: ...uller Position and installingplate into the sleeve 4 Place flat washer and nut on the remover screw Hold center screw and tighten remover nut to remove the seal Fig 2 1 5 Insert remover screw through...

Page 427: ...lobe taper rE CHAIN L A X C U V t K RETAINER KR155B Fig 24 lnspeciing Soul for Propor S aring both tend to provide a rearward thrust Removal 1 With tappets and the timing chain and sprockets removed...

Page 428: ...cylinder block The oil holes in camshaft bearings and the cylinder block must be in exact register to insure proper lubrication The camshaft bearing index can be inspected after installation by inser...

Page 429: ...crankshaftcenter line Fig 294urnishing Distributor Drive Shaft 6urhing RANKSHAFT KR16 CENTER LiNE OF 5A Fig 30 Dirtriburor Drive bear Inrtalld Piston Removal 1 Remove top ridge of cylinder bores with...

Page 430: ...boresafter cleaning to prevent rusting PISTONS PINS AND RINGS Pistons The pistons are cam ground so that the diameter at the pin boss is less than its diameter across the thrust face This allows for e...

Page 431: ...ed so that the small formed tang fits into the machined grooves of the rods The end clearance should be from 009 to 017 inch tworods Limits of taper or out of round on any crankshaft journals should b...

Page 432: ...rrstall an undersize bearing that will reduce clearance below specifications Removal 1 Remove oil pan and identify bearing caps before removal 2 Remove bearing caps one at a time Remove upper half of...

Page 433: ...ends above the block on both sides Lower Rear Main Seal hstallation trude Fig 35 into position with Tool 2 3743until tool is seated above the cap Fig 36 1 Install a new seal in seal retainer so ends p...

Page 434: ...Fig 39 Medsuring Outer Rotor Thickness lnspection and Assembly 1 Clean all parts thoroughly The mating face of filter base oil pump cover should be smooth Replace filter base if it is scratched or gr...

Page 435: ...4easuring Clearance Over Rotors Fig 43 Measuring Cloaraneo Botwean Rotors lines 1 Using Tool C 3845unscrew the filter from the base on bottom side of engine and discard Fig 4 4 2 Wipe base clean nstal...

Page 436: ...epaired by the use of Heli Coils Essentially this repair consists of drilling out worn or damaged threads tapping the hole with a special Heli Coil Tap and installing a Heli Coil Insert into the tappe...

Page 437: ...learance Desired Maximum Allowable before Reconditioning Side Clearance Bearings for Service Piston Pin Bore Diameter Drive Bearings Number Thrust Taken by Clearance CAMSHAFT Maximum Allowable Before...

Page 438: ...Y 047 Oil Steel rails Cast Iron not available 015 062 Compression 0 0 1 5 004 Oil Steel rails Cast Iron not available O002 005 Oil Cast iron Service Rings RingGap RingSide Clearance VALVETIMING Intak...

Page 439: ...ive Shaft Bushing press fit in block Ream to Shaft to Bushing Clearance Pump Type Capacity qts Pump Drive Camshaft Operating Pressure at 1000RPM 45to 60Ibs Pressure Drop Resulting from Clogged Filter...

Page 440: ...tc indicating Crankshaftcounterweight No 2 3 main bearing journal and or R 14 etc indicating No 1 4 connecting rod journals MalteseCross and X M 10 indicates O W Crankshaft counterweight U S all main...

Page 441: ...ONS A m L a a E s a E g a e r 1 3 1 a a o z E 2 sac 9 m e r 0 1 a o o E 0 TJ si E Q c y ob 0 0 l z m u a o o m a 3 C w E n f O W 0 a a v g2Q o L 0 E E Q e 0 2 m v g 1 1 6 9 si 2 c m 0 E M c m 0 U ii m...

Page 442: ...A S PEC I Fl CAT1 0 N S 9 91 L o O h a s a n Z r r E b o d 0 I x CY 0 a s r 5 a m L 8 0 a s aE E 2 E M O a m E a 2 r 2 C v n 4 0 w 0 n n a Q t E a u m a Z 0 0 0 E E E v a 0 0 0 0 MyMopar com...

Page 443: ...PEC1 Fl CAT10 N S A M 0 L c F W i L 3 3 L m n 0 z a 0 v p x Q Q r a u nak us a m z c c b Q a F a m M 5 s d d d d d zzzzz r o u C 0 i g E p lv eo m m W W o m Z a K a X Z L n w d d d d d zzzzz c I MyMop...

Page 444: ...b m e 2 78 h 0l l S B v h u W v m E a E 0 h I E 3 s In v E 7 3 s I I n S h C C I I 0 0s z y I b S h c i q 7 3 s zy b S h P i q 0 n E 3 z y h E E B v m E E E E 2 g W v u W V m b 4s s8 N cv LL a a F e...

Page 445: ...PEC I FlCATl 0 NS A 3 r 0 e L s G m I I 2 b E z a g e a n a g L L n E p me E r a mL 3 Q E L I O C L O L o a 3 L 0 0 c6 3 d L U a LL 5 Y L L L L L L L 0 0 0 0 0 0 0 ei w 4 3 P i 1 L L a m e a E B MyMop...

Page 446: ...155psi Maximum variation between cylinders any one 130 165psi Engine 20 psi 25 psi TDC Manual TDC Firing Order 1 8 4 3 6 57 2 Automatic 7 1 2 BTC Basic Timing all with C A P Manual Power Pack 5 BTC CY...

Page 447: ...ance Desired Diametral Clearance Allowed Finish at Rear Oil Seal Surface CRANKSHAFT 383 440 O2lff 02Yf 023 030 0003ff 0013ff 0003ff 0013N 770 gms 857 5 gms 3 874 3 650 my rn 208 Std 005 Omf Wf Oversiz...

Page 448: ...ter Standard Stem to Guide Clearance Maximum Allowable Face Angle CONNECTING ROD JOURNALS CAMSHAFTJOURNALS CAMSHAFT BEARINGS TIMING CHAIN CYLINDER HEAD VALVE GUIDES 383 440 2 6245 262Wf 001 001 002 00...

Page 449: ...Spring Installed Height spring seat to retainer 1 070 1 090 A A 1 07 Y l O90 1 53 64ff 1 57 64 f 1 53 64 1 57 64 Use 1 16 Spacer to Reduce Spring Height Pump Type Rotary Full Rotary Full Pressure Pre...

Page 450: ...open throttle Maximum Variation between Cylinders any one engine Firing Order Basic Timing Left Bank Right Bank Cylinder Bore standard A Size E Size C Size D Size E Size Cylinder Bore Out of Round Max...

Page 451: ...ARINGS CRANKSHAFT Type Bearings Thrust Taken By End Play Maximum Allowable Clearance Desired Clearance Allowed Finish at Rear Oil Seal Surface Diameter Maximum Allowable Out of Round Maximum Allowable...

Page 452: ...thickness compressed Combustion Chamber Volumes with valves and plugs CAMSHAFT BEARINGS Diameter VALVE TIMING TIMING CHAIN TAPPETS CYLINDER HEAD VALVE GUIDES VALVES41ntake Type Guide Bore Diameter He...

Page 453: ...NGINE LUBRICATION 003 005 017 45 Std 005 015 0 3 Y Oversize Stem Diam 473 16 2 m 110 120 1 55 64 270 290 1318 1 070 1 0 9 0 1 16 1 53164 1 57 64 Rotary Full Pressure 6 U S or 5 Imperial Camshaft 15 ps...

Page 454: ...utor Clamp Bolt Engine Front Mounting to Frame Nut Engine Front Mounting to Block Nut Engine Rear Mount Bolts Exhaust Manifold Nut Exhaust Pipe Flange Nut Exhaust Pipe Clamp Bolt Exhaust Pipe Support...

Page 455: ...er Cylinder Head Cover Stud and Nut Distributor Clamp Bolt Exhaust Manifold Nut Exhaust Pipe Flange Nut Exhaust Pipe Clamp Bolt Exhaust Pipe Support Clamp Bolt Fan Attaching Bolt Flywheel to Crankshaf...

Page 456: ...el Cap Screw Clutch Cover to Flywheel Flywheel Pan Screws Flywheel Housing to Block Bolts Fuel Pump Attaching Bolt Intake Manifold Main Bearing Cap Bolt Main Bearing Cap Tie Bolt Oil Pan Bolt Oil Pan...

Page 457: ...langes Ball joint connections are used between the exhaust pipes and pipe extensions on Fury models with 383 and 440 cubic inch engines Figs 11 and 12 Page 12 426 Hemi Engine 12 6 Cylinder Engine 14 2...

Page 458: ...ail pipe c Remove restriction if possible or replace as necessary Loose heat tube connections d Replace gaskets as required Tighten stud nuts or bolts to specifications Burned or rusted out heat tubes...

Page 459: ...A EXHAUST 11 3 Fig 2 Exhaust System Val ant 273 318 Cu In Engines MyMopar com...

Page 460: ...11 4 EXHAUST A Fig 3 Exhaust System Ckrrrarcuda 340 383 Cu In Engines MyMopar com...

Page 461: ...A EXHAUST 11 5 MyMopar com...

Page 462: ...s time 4 Tighten all slip joint U bolt nuts to 150 inch pounds except exhaust pipe to extension slip joint on Valiant Barracuda and Belvedere with 273 318 or 383 2BBL which must use a heavier U bolt 3...

Page 463: ...A EXHAUST 11 7 MyMopar com...

Page 464: ...11 8 EXHAUST A LOCK WASHER 2 OCK WASHER 2 a STATION WAGON ONLY NR353 Fig 9 Exhaust System Fury 225 Cu In Engine PLAIN WASHER 2 Fig I0 Exhaust System fFu y 3 18 Cu In Engine MyMopar com...

Page 465: ...lide U bolt and saddle in place on extension tilator valve hose automatic choke rod and throttle linkage at carburetor and remove carburetor 3 Disconnect exhaust pipe at exhaust manifold 4 Remove nuts...

Page 466: ...11 10 EXHAUST A Fig 12 Dwl Exhaust System Fury 383 440 C u In Enaim MyMopar com...

Page 467: ...the carbon deposits 4 Install intake manifold using new gaskets Tighten manifold screwsto 35foot pounds EXHAUST CROSSOVER CARBURETOR MOUNTING FLANGE I Fig 14 Intake Manifold 273 Cu In Engine Typical E...

Page 468: ...ifolds in solvent and blow dry with 2 Inspect manifolds for cracks and distortion 3 On right hand manifold test manifold heat con trol valve for free operation If necessary to free up apply a suitable...

Page 469: ...ader and separate tube from header 5 Remove screws and washers attaching exhaust headers to cylinder heads Remove headers and gaskets from cylinder heads Cleaning andinspection 1 Clean gasket surfaces...

Page 470: ...ield in up ward position and insert lock in shaft slot Fig 20 4 Center counterweight on shaft and turn shaft counterclockwise until bumper passes stop pin 5 Press Counterweight on shaft until it is se...

Page 471: ...13 Install exhaust pipe to manifold no gasket used and tighten to 35 foot pounds 340 CUBIC INCH ENGINE Removal 1 Remove exhaust pipe from manifold 2 Remove exhaust manifold from engine 3 Position val...

Page 472: ...mo stat as it slides over edge of undercut on shaft 3 Move valve shaft back and forth and test opera tion If shaft is binding in manifold apply a suitable solvent to dissolve the deposits 4 If fabric...

Page 473: ...ostat into shaft and seat firmly 3 Wrap outer end of thermostat counterclock wise and engage under stop pin 4 Install counterweight on outer end of valve shaft with lock engaged in valve shaft slot an...

Page 474: ...proper operation during engine tune up and apply a suitable EXHAUST MANIFOLLJ NU447 Fig 30 Six Cylinder Exhaust and Heat Tube Cross Section TOP A Fig 31 Manifold and Heat Tube Assembly heat control va...

Page 475: ...er Ball Joint Bolt Nut 426 Hemi Exhaust Manifold Brace Bolt Nut 273 318 Cu In Exhaust Manifold to Cylinder Head Stud Nut 170 Engine Engines 225 Cu In Engines 273 Cu In Engine 318 340 383 440 Cu In Eng...

Page 476: ...d freezes on the throttle valve or valves This ice formation effectively blocks passage of air and the engine stalls To prevent ice formation and subsequent stalling a heat tube is installed in the ex...

Page 477: ...tors secure an accurate ignition tachometer and a Sun Electric Combustion VacuumUnit Model 80 Ex haust Condenser Model EC and Hose 669 14 or equivalent The above analyzer is recommended however other...

Page 478: ...setting by approxi mately 1 2 inch of mercury If valve cannot be ad justed to specifications described in Step No 9 re place valve Fig 2 11 Replace vacuum valve cover Reset carburetor dash pot if so...

Page 479: ...el f Loose main body to throttle body f Tighten main body to throttle body screws securely to prevent air leaks g Worn or corroded needle valve and g Clean and inspect needle valve and seat If found t...

Page 480: ...type e Excessive fuel pump pressure POOR PERFORMANCE MIXTURE TOO RICH place element CARBURETOR MIX TURES LEAN a Air leak bypassingcarburetor a ReDair ENGINE RUNS EXCESSIVELY RICH AFTER COLD START CHO...

Page 481: ...d Water temperature sub normal d Check thermostat BBS SERIES CARBURETOR INDEX Page Automatic Choke well type 2 Carburetor Adjustments 1 1 Accelerator Pump and Bowl Vent 1 1 Choke Vacuum Kick 12 Fast...

Page 482: ...1 or 2 4 Remove clip from choke operating link and disengage link from diaDhram plunger stem and v v 1 Place carburetor assembly on repair block Tool 2 Remove hairpin clip and disengage accelerator 3...

Page 483: ...m the seat must be maintained at installation Remove screw and spring from throttle body The carburetor now has been disassembled into three main units air horn main body and throttle body and the com...

Page 484: ...SFER PORT E 1 ADJUSTING CURB IDLE VENT HOLE NH272B Fig 8 Ports in Relation to Throttle Valve idle mixture control DO NOT USE A SCREW DRIV ER Turn screw lightly against its seat with the fingers Back o...

Page 485: ...ine and is stable over a wide range of temperatures The tip is flexibleenough to make a good seal on the needle seat The use of the new inlet needle requires a new procedure in adjusting the float set...

Page 486: ...ator Pump and Bowl Vent When assembling the accelerator pump to the air horn note that the hairpin clip which opens the bowl vent can be placed in any one of three positioning notches These notches co...

Page 487: ...i _ DRILL FOR ADJUSTMENT IGHT CLOSING RESSURE AGAINST FAST IDLE SPEED ADJUSTING SCREW ON THE SECOND HIGHEST STEP OF THE FAST N N n l A Fig 14 Fast Idle Cam Position Adjustment CLOSING PRESSURE AGAINS...

Page 488: ...stment to provide correct throttle closing torque Before adjusting idle and or fast idle speeds and mixtures make sure that the basic timing and the distributor control valve are correctly adjusted as...

Page 489: ...the bowl After being compressed the tip is very slow to recover its original shape It is very important that the float lip be perpen dicular to the needle or slanted not more than 10 degrees away from...

Page 490: ...assembly on repair stand Tool C 3866 and remove dashpot if so equipped 2 Remove vacuum hose between carburetor throt tle body fitting and vacuum diaphragm 3 Remove choke vacuum diaphragm link and bra...

Page 491: ...rns from the seat must be maintained at installation Remove screw and spring from throttle body Discard plastic cap 15 Remove fast idle and curb idle speed screws and spring from throttle lever The ca...

Page 492: ...then install in pump lever and secure with clip When installing link be sure link is in center hole of throt tle lever 6 Slide pump spring Fig 7 over pump dia phragm stem Install assembly in position...

Page 493: ...COND HIGHEST STEP OF FAST IDLE CAM NN756C Fig IO Fast Idle Cam Position Adjustment 2 Insert specified drill between choke valve and wall of air horn See Specifications at rear of Fuel System Group 3 I...

Page 494: ...rmation at Front of Section SURFACE OF CARBURETOR 9 SURFACE OF FUEL BOWL VENT VALVE DRILL O R GAUGE VALVE SEAT Fig 14 Checking Bowl Vent Opening Fast Idle Speed Adjustment On Vehicle Fast idle engine...

Page 495: ...quipped with a manual or automatic transmission respectively and an Anti Icing Device The U S Ball and Ball Carburetor models BBD 46058 with Dash pot and BBD 4606s are used on the 273 cu in engine whe...

Page 496: ...5S BBD4608S and BBD 46 IOS Canadian VALVE ACCELERATOR PUMP ROD IN OUTER HOLE OF ROCKER ARM ACCELERATOR PUMP ROCKER ARM ACCELERATOR PUMP ROD FAST IDLE CAM THROlTLE LEVER CURB IDLE SPEED ADJUSTING SCREW...

Page 497: ...up Piston NN696B Fig 5 Removing or Installing Main Metering Jets 12 Remove main metering jets Fig 5 13 Remove venturi cluster screws then lift ven turi cluster and gaskets up and away from main body...

Page 498: ...es are elip IDLE TRANSFER PORTS i SPARK ADVANCE NN698A L VALVES Fig I Ports in Relationto Throttle Valves ACCELERATOR PUMP INTAKE CHECK B Fig 8 Installing Accelerator Pump Discharge Check Ball tical W...

Page 499: ...ake check ball so that weight of floats only is forcing needle against seat Hold finger against retainer to fully seat fulcrum pin 4 Using Tool T 109 282 or a T scale check the float Fig 11 There shou...

Page 500: ...es in the throttle lever Normally the bowl vent clip on the pump stem will be at the middle notch and the pump operating rod in the medium stroke hole The proper procedure is to adjust the amount of b...

Page 501: ...Position Adjustment ILL OR GAUGE LIGHT CLOSING PRESSURE ON CHOKE LEVER ps FAST IDLE SPEED 7 CONNECTOR d FAST IDLE i REW ON THE ON THROTTLE TO HOLD SPEED SCREW IN POSITION NN700A CAM T iEXERT SUFFICIEN...

Page 502: ...rew in clockwise direction leaner until there is a slight drop in r p m Now turn each screw out counterclockwise richer just enough to regain lost r p m This procedure will assure that idle has been s...

Page 503: ...ng Carburetor Parts 1 Closed Crankcase Vent System 2 Disassembling Carburetor 28 Inspection and Reassembly 29 Specifications 85 These carburetors are equipped with two idle limiter and one off idle mi...

Page 504: ...out accelerator pump discharge check ball and intake check ball Theintake check ball is the largest 15 Remove screws that attach throttle body to PISTON PISTON GASKET AT O F WELL NR379 Fig 2 Removing...

Page 505: ...They may have to be rotated slightly as the valves are eliptical When properly positioned tighten screws securely and stake using pliers 7 Turn idle mixture adjusting screw lightly against its seat wi...

Page 506: ...MUST MOVE FREELY NK617 GUIDE SIZE ROAD LOAD SYEP INTERMEDIATE POWER STAGED MIXTURE STEP Fig 7 Step up Rods Free Play FULCRUM PIN RETAINER IN POSITION FULCRUM PIN FLOAT GAUGE ONLY WEICGIT OF FLOATS NR3...

Page 507: ...ing Fast Idle Speed and Cam Position Adjustment The fast idle engine speed adjustment should be made on the vehicle as described in the Fast Idle Speed Adjustment On the Vehicle Paragraph How ever the...

Page 508: ...ssive choke enrichment can be cleared DRILL OR GAUGE AT WIDEST CHOKE OPENING DIAPHRAGM STEM PLUNGER RETRACTED BY VACUUM HOSETO VACUUM SUPPLY CHOKE DIAPHRAG HOSE FITTING Fig 1 I Checking Choke Vacuum K...

Page 509: ...icle 5 After float has been correctly set reassemble the air horn Fast Idle Speed Adjustment On Vehicle Fast idle engine speed is used to overcome cold engine friction stalls after cold starts and sta...

Page 510: ...self according to engine requirements The AVS air valve secondary carburetor con tains many features some of which are the locations for the step up rods and pistons The step up rods pistons and spri...

Page 511: ...p side be marked so that floats can be reinstalled in their respective positions 2 Remove two needle valves from their respective seats after marking one on pump side for identifica tion Using a wide...

Page 512: ...3 Removing or InstallingAceelerutor Pump Jet Housing CHECK ASSEM ACCELERATOR PUMP WELL MAIN METERING JET PRIMARY 2 NR515 Fig 4 Removing or InstallingMain Metering Jets shafts or valves unless wear or...

Page 513: ...Fig 4 Tighten jets se curely Install intake check 6 Install accelerator pump intake check ball using 7 Install hot idle compensator and gasket if so To01T 109 59 equipped Tighten screws securely Accel...

Page 514: ...OF CASTING 1 MINIMUM CLEARANCE WITHOUT BINDING Fig 8 Checking Float Alignment NR518 horn then install float fulcrum pins Be sure marked float is installed on pump side of the air horn See disassembly...

Page 515: ...ver and secure with hairpin clip lnstalling the Vacuum Diaphragm Inspect the diaphragm vacuum fitting to be sure that the passage is not plugged with foreign material Leak check the diaphragm to deter...

Page 516: ...UGE LIGHT CLOSING PRESSURE ON CHOKE LEVER BEND FAST IDLE CONNECTOR ROD AT THIS ANGLE FAST IDLE SPEED SCREW ON 2ND HIGHEST STEP OF CAM AND RIDING AGAINST FACE SCREW OF HIGHEST STEP AST IDLE SPEED Fig 1...

Page 517: ...rt Tool T 109 29 020 wire gauge between positive CURB IDLE SPEED ADJUSTING SCREW BACKED OFF TO FULLY SEAT ALLOW VALVES TO i NR524A FULLY CLOSED Fig I Checking Accelerator Pump Adjustment BEND ROD AT S...

Page 518: ...Vehicle Fast idle engine speed is used to overcome cold engine friction stalls after cold starts and stalls be cause of carburetor icing Set this adjustment after vehicle odometer indicates over 500 m...

Page 519: ...re equipped with the manual or automatic transmissions respectively Since the service procedures are identical on all Carter AFB carburetors the illustrations showing the various disassembly procedure...

Page 520: ...ol system The carburetors are equipped with a pair of veloc ity valves which control the secondary valve opera tion SERVICE PROCEDURES DISASSEMBLING CARBURETOR Fig 1 1 Place carburetor assembly on rep...

Page 521: ...air horn 6 Remove screws and retainer holding thermo static coil housing to choke housing Remove housing gasket and baffle plate To remove choke piston re move nut and washer then slide piston off sha...

Page 522: ...excessively worn that a new carburetor be installed However if the throttle valves have become nicked Fig Removing or Installing Secondary Venturi Cluster EIGHT 4K406 Fig 7 Removing or Installing Vel...

Page 523: ...y from the throt tle body Install a new check assembly then retest as described previously Discharge Check Needle 1 With discharge check needle installed insert a piece of drill rod down on needle Lig...

Page 524: ...rect drop setting has THESE SURFACES MUST HE PARALLEL WITH EDGE OF CASTING I h N l M U M CLEAKANCL WITHOUT IiINDIN NR518 Fig IO Checking Float Alignment FLOAT GASKET IN PLACE ENDOF FLOAT NR519 Fig 1 I...

Page 525: ...o assure that the speeds of each cam step occur at the proper time during engine warm up Adjust as follows 1 With fast idle speed adjusting screw contacting second highest speed step on fast idle cam...

Page 526: ...o wide open position to re lease the fast idle cam Back off the idle speed adjust ment screw curb idle until the throttle valves are seated in the bores Measure the distance from the top of the air ho...

Page 527: ...overcome cold talk after cold starts and stalls be tor icing Set this adjustment after indicates over 500 miles to in ne friction level Prepare engine by miles Connect a tachometer and set 1 I I 1 c...

Page 528: ...ype of metering provides for ade quate diagnosis and easier servicing The two primary bores have one choke valve con SECONDARY FUEL BOWL CHOKE LINK Page Idle Speed Curb Idle 69 Secondary Throttle 69 V...

Page 529: ...alibrated to deliver the proper mixture only when the fuel is at this level A float spring is incorporated under the float to keep the float in a stable position The float chamber is vented internally...

Page 530: ...ttle bore just below the throttle valve The air that is supplied to the curb idle system is supplied through two idle air bleed restrictions and by a curb idle air bleed adjusting screw This is the on...

Page 531: ...into the bottom of the main well The fuel moves up the main well past the main well air bleed hole in the side of the well Filtered air NR557A Fig Main Metering System enters through the high speed a...

Page 532: ...ed by a cam on the primary throttle shaft forces the pump diaphragm up As the dia phragm moves up the pressure forces the pump inlet check ball on its seat preventing fuel from flowing back into the f...

Page 533: ...el flows through the secondary metering restrictions into the idle well Fig 10 A secondary fixed curb idle discharge passage sup plies fuel directly to the intake manifold thus allow ing a smoother id...

Page 534: ...job 1 All parts should be carefully cleaned in a suit able solvent then inspected for damage or wear 2 Use air pressure only to clear the various ori fices and channels 3 Replace questionableparts wi...

Page 535: ...1460 FUEL SYSTEM HOLLEY A I L MyMopar com...

Page 536: ...ower Valve 48 Primary Jets 49 Needle Idle Adjusting Left Hand Thread 50 Spring Idle Needle 51 Screws Choke Valve 52 Choke Valve 53 Choke Shaft Lever Assembly 54 Discharge Nozzle Screw Pump 55 Gasket N...

Page 537: ...in Metering Body Primary 1 Using Tool C 3747 remove power valve assem bly from primary metering body Fig 7 2 Using Tool C 3748 remove main metering jets Fig 8 3 Remove idle adjusting needles and gaske...

Page 538: ...f possible damage INSPECTION AND REASSEMBLY Throttle Body If the throttle valves were removed because of damage install new valves as follows 1 Slide new primary throttle valves in position on throttl...

Page 539: ...ct clearancehas been obtained SECONDARY FUEL BOWL GASKET EI FUEL INLET NEEDLE Fig I I Float Needle Seat and Bafne Exploded View 2 Invert the secondary fuel bowl and using a 17 64 inch drill shank or g...

Page 540: ...y ven turi To test needle for sealing pour clean gasoline into primary fuel bowl through vent valve opening Push down on accelerator pump arm to expel air from the pump passages Using a small clean br...

Page 541: ...lip Slide spring and locknut between fuel pump lever and pump operating lever Open throttle valve and install adjusting screw Tighten 2 or 3 threads to hold The correct setting of the adjusting screw...

Page 542: ...rottle It is used to eliminate choke enrichment during cranking of an engine Engines which have been flooded or stalled by excessive choke enrichment can be cleared by use of the unloader Adjust the s...

Page 543: ...while the engine is running It positions the I LEVER LIGHT Fig 21 Fast ldle Cam Position Adjustment choke valve within the air horn by use of linkage be tween the choke shaft and the diaphragm The di...

Page 544: ...lost Start or crank engine and allow fuel bowls to fill The reading on level gauge should be 9 16 for Primary and 13 16 inch for Secondary with 5 pounds fuel pump pressure If an adjustment is necessa...

Page 545: ...PUMP LEAKS a Worn ruptured or torn diaphragm a Loose diaphragm mounting plates b C Loose inlet or outlet line fittings FUEL PUMP LEAKS a OIL Cracked or deteriorated pull rod oil a seal Loose rocker a...

Page 546: ...m reading should be at least 10 inches of vacuum at 500 r p m with the fuel line disconnected at the carburetor Volume Test minute or less at 500 r p m The fuel pump should supply 1 quart of fuel in 1...

Page 547: ...e diaphragm 4 Slide the rocker arm into the housing and en gage the diaphragm pull rod Align the pivot pin holes in the arm with those in the housing then in stall pivot pin Install new plug and drive...

Page 548: ...n peen pivot pin to retain 6 Place valve body on diaphragm Align then in stall attaching screws Draw down evenly 7 With pump held in vise compress rocker arm to its full travel Hold in this position t...

Page 549: ...installing a tank Page Removing Fuel Tank 74 78 Removing Fuel Tank Station Wagon 75 79 unit be sure the filter is pushed down on the pipe until seated The fuel tank on all 119 5 inch wheelbase Fury m...

Page 550: ...ghten Not over 50 inch pounds 3 Lubricate rubber grommet using a suitable rubber lubricant then slide filler tube down through dusi seal and into tank far enough to clear quarter panel Twist or rotate...

Page 551: ...d install a new grommet at reassembly Keystone clamp to outer filler tube elbow securely to avoid leaks Sedans Fig 4 Before installing the tank gauge unit check the condition of the filter on the end...

Page 552: ...oles in end of straps Install nuts but do not tighten 5 Guide button head of studs into slots in frame and down into position Tighten hold down strap at taching nuts securely 40 in lbs 6 Install fille...

Page 553: ...hing screws and tighten securely REMOVING GAUGE UNIT Sedans 119 5 W B MODELS The vehicle should be lifted with a frame type hoist to let the rear axle fall away from the body Remove REMOVING FUEL TANK...

Page 554: ...fully engage filler spout in opening 4 Hold fuel tank in this position and place hold down straps in position feeding attaching studs through holes in end of straps Install nuts but do not tighten 5 G...

Page 555: ...IP FUEL GAUGE I TUBE FUEL LINE WIRING FUEL GAU UBE FUEL GAUG CLIP FUEL GAUG GROUNDING d 1 STUD FUEL GAUGE STUD F UEL GAUGE UNIT TUBE FUEL GAUGE TANK UNIT NRl1 Fig 8 Fuel Tank Ground Strap PHILLIPS HIE...

Page 556: ...ver 4 Back off ferrule 2 1 4 inch to provide 1 4 inch cable slack at idle Tighten cable clamp nut to 45inch pounds 5 Connect choke rod or remove blocking fixture Manual Transmission Fig 3 With Hemi En...

Page 557: ...14 82 FUEL SYSTEM THROTTLE LINKAGE A NN974A Fig 3 Throttle Linkage Adjustment 426 Hem Engine MyMopar com...

Page 558: ...compartment Fiberglass reinforced thermosetting plastic pas sages attached to the hood inner panel extend out board from the air cleaner to the openings at the sides of the hood A rubber gasket forms...

Page 559: ...of Main Metering Jet ADJUSTMENTS Cam rpm Manual Trans Automatic Trans Type Control Setting CHOKE With Headlights ON BALL AND 225 1 9116 1 114 50 48 46 27 32 39 52 9 32 3 32 2 650 1700 1700 Single Thr...

Page 560: ...uri Main Metering Jets Standard One Step Lean Two Steps Lean Step up Wire Diameter 2 stage Float Setting at center of floats Bowl Vent Valve throttle closed Choke Unloader Idle Mixture Screws turned o...

Page 561: ...loader Vacuum Kick drill size Bowl Vent Valve Setting Fast Idle Speed r p m 1 Idle Speed r p m 1 Secondary Throttle Lever Adj Secondary Throttle Lockout Adj Float Setting Float Drop Idle Mixture Screw...

Page 562: ...2 65 035 089 092 65 031 101 095 65 035 65 031 16 160 7116 50 114 35 118 1700 700 21164 020 5116 112 2 16 165 16 176 7116 Y50 114 25 118 1700 700 11 32 020 16 545 7116 50 114 35 118 1700 650 318 020 71...

Page 563: ...Venturi Secondary Main Metering Jet Standard 1 Size Lean 2 Size Lean 5 000 10 000ft Idle Fuel Mixture Curb Idle Speed Fast Idle Speed No 5 Step Bowl Vent Valve Unloader Adjustment wide open throttle V...

Page 564: ...Hemi 440 Cu In H P Make Carter Carter Carter Carter Airtex Carter Model MS 4588s MS 4587s MS 4589S MS 4024S RD 267A MS 4434s Type Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Diaphragm Nurnber o...

Page 565: ...t universal joint Servicing of all four pro peller shafts are the same in all respects SERVICE DIAGNOSIS Condition Possible Cause Correction PROPELLER SHAFT VI BRATION a Undercoating or other foreign...

Page 566: ...re contacting propeller shaft Be sure arrow on gauge is pointing toward the front of car 6 Observe position of bubble in spirit level and compare the position with that shown on Chart Fig 13 for front...

Page 567: ...mper plate from differential and carrier housing and position gauge SP 5060on GAUGE SP 5060 ADAPTER DIFFERENTIAL ADAPTER DIFFERENTIAL C 4050 NR295 Fig 4 Propeller Shaft Angularitv Tool C 3976 the mach...

Page 568: ...ge 5 If bubble in spirit level is found outside the acceptable range indicated on Chart Fig 13 you will have to install a wedge type shim between both rear springs and the axle housing spring pads to...

Page 569: ...Fig 2 Be careful not to damage splines on output shaft or yoke Examine sliding yoke seal for evidence of leakage If no leak age is evident do not disturb the seal If necessary to replace the seal see...

Page 570: ...STALL THICK END O F WEDGE TO FRONT O F CAR VALIANT 108 W B 7 AXLE VALIANT 108 W B 8 AXLE BARRACUDA 108 W B 7 AXLE BARRACUDA 108 W B 8 AXLE I I BARRACUDA 108 W B 8 AXLE AND 383 C I ENG PLYMOUTH 116 W B...

Page 571: ...ARRACUDA Model Application PROPELLER SHAFT Length Inches Diameter Inches Type Tubular MANUAL TRANSMISSION 3 SPEED 170 225 273 C I Engine 7 1 4 Axle 51 43 318 C I Engine 8 3 4 Axle 49 27 273 318 340 38...

Page 572: ...2 22 Y V Y 000 zc s 0000 m m m m 9 9 9 9 L a 0 a U L a m m o m e o e 2 0 a m 5 3 c n a g wl c U r n I U e 2 2 L a I I c a a ui 2 0 I I M c m al 1 n r n h h 222 rnrnrn b b r n rnrnrn r n h h h h hrnDc...

Page 573: ...n 2 w m m cum h s 2 w m m N W 3s a 2 e n w 0 R o o o o m o 0 0 m m m m m m m m 9 9 9 9 9 9 9 a a X a 2 a a d a 2 q x 2 a X a ma zzz 2 2 2 w w w h 2 w m x a X a S x 6 I n N N ci m 03 m 0 U d oo m m M S...

Page 574: ...0 150 200 Pinion Flange Clamp Screw 7 1 4 3 4 Axle Pinion Flange Clamp Screw 9 1 4 9 3 4 Axle Rear Spring U Bolt Nut 7 1 4 Axle Rear Spring U Bolt Nut 8 3 4 9 1 4 9 3 4 Axle 40 45 Pinion Bumper Plate...

Page 575: ...hock absorber only if it is broken or leaking badly not just damp or has lost resistance in one or both direc tions due to internal damage Slight fluid seepage during cold weather operation resulting...

Page 576: ...bber bushing This bushing will take some set after it has been in service and should be replaced once it has been removed 5 If lower bushing requires replacement remove it from shock absorber using To...

Page 577: ...shock absorber using Tool C 3553 Fig 4 3 Test and expel air from shock absorber then compress to its shortest length Position washer on upper rod of shock absorber and insert rod through upper bushin...

Page 578: ...9 Rear Spring Satellite suspension height on both sides correct tire pres sures no passenger or luggage compartment load and a full tank of fuel 1 Jounce car several times front bumper first Release...

Page 579: ...on all other models Tighten shackle nuts 45 foot pounds Satellite and Fury 30 foot pounds Val iant 9 It is recommended that after a rear spring has been replaced that the vehicle be driven and the fro...

Page 580: ...b x NHl7lA Fig 12 Zinc fnterfeaf 10 Install new alignment clips On Fury station 11 Reinstall shock absorber on spring plate stud 12 Lower vehicle onto its wheels wagon models reinstall old clips and...

Page 581: ...Hanger Bolt 30 Shackle Nut Satellite 45 Valiant 30 Fury 45 U Bolt Nut Valiant SatelIite 7 1 4 Axle 40 REFERENCE Foot Pounds Valiant Satellite Fury 8 3 4 Axle Satellite Fury 9 1 4 9 3 4 Axle SHOCK ABSO...

Page 582: ...ient lubricant in the steering b Lubricate as necessary c Steering gear shaft adjusted too tight c Adjust according to instructions d Frontwheels out of line d Align the wheels See Front Sus e Steerin...

Page 583: ...EAR CLEARANCE ADJUSTING SCREW ALL BEARINGS Fig I Steering Gear Cross Section Replace worn parts and adjust ac cording to instructions Replace worn parts See Front Wheel Alignment Adjust according to i...

Page 584: ...g gear arm retaining nut and lock washer Remove arm with Tool C 3646 Fig 3 2 Remove steering shaft lower coupling to worm shaft roll pin 3 Disconnect shift linkage on all models equipped with column m...

Page 585: ...o rotate until stopped at the end of the worm 9 Carefully remove worm and ball nut assembly Fig 6 The ball nut and wormshaft are serviced as an as sembly only and are not to be disassembled Do not rem...

Page 586: ...ousing bearings Inspect fit of shaft pilot in cover bearing Make sure the wormshaft has not been bent or otherwise damaged 18 Cross shaft and wormshaft oil seals should be replaced when unit is recond...

Page 587: ...and level of lubricant will be at top of worm 33 Slide cross shaft adjusting screw and shim into slot in end of shaft 34 Test end clearance Fig 12 The screw must be free to turn with zero to 004 inch...

Page 588: ...t Install three mounting bolts and tighten to 100foot pounds 3 Align master spline on wormshaft with master spline in coupling and slide steering column assembly down far enough to engage coupling wit...

Page 589: ...ower Steering Pump c Loose pump belt c See Group 7 Cooling d Improper caster and camber d See Front Wheel Alignment Front Suspension Group 2 e Power steering output low e Pressure test pump f Steering...

Page 590: ...Diagnosis Hard Steering cor rection e h Gear malfunction h Adjust and repair as outlined under Hard Steering condition and cor rection g a Buzzing noise in neutral and stops a Noisy pump make pressure...

Page 591: ...een thumb and forefinger with a light grip Tighten adjusting screw until backlash just disappears Continue to tighten to 3 8 to 1 2 turn from this position and tighten lock nut to 50 foot pounds to ma...

Page 592: ...r with rela tive ease Use of force may damage the lever If they do not go together easily lift off valve assembly re align valve spool hole with lever opening in valve body and install valve body 16 I...

Page 593: ...tool adapter contacts gear housing 9 Place steering gear and front wheels in straight TOOL NH633 Fig 6 lnstalling Gear Shaft m e r Oil Seal ahead position and install steering gear arm and nut 10 Tigh...

Page 594: ...suitable jack raise left side of engine approximately 1 1 2 inches Separate insulator from engine mount and allow insulator to rest on frame Rotate steering gear wormshaft end up between cylinder hea...

Page 595: ...ain rollers in the cage with wheel bearing lubricant CAUTION If the wormshaft oil seal is to be replaced perform the operation with the housing head assem bled in the steeringgear housing 12 Remove la...

Page 596: ...A POW ER STEER I N G 19 1 5 MyMopar com...

Page 597: ...ton flange should not exceed 008inch when the end of the worm is lifted with a force of 1pound Fig 18 27 Inspect condition of rubber sealing ring lo cated under cast iron ring and replace if necessary...

Page 598: ...ring race Fig 20 Make a loop in one end of cord and hook loop of a distributor breaker arm spring scale Tool MTU 36 in cord loop Pulling cord will cause bearing race to rotate Re tighten worm bearing...

Page 599: ...ol C 3875 Press bearing into steering gear housing 1 32 inch below end of bearing bore to provide space for oil seal back up Fig 22 Readion Seal Ring in WormShaft Support washer and snap ring and cros...

Page 600: ...rm just disappears See Gear Shaft Adjustment If power train has been removed tighten 1 1 4 turns from this position and while holding adjusting screw in this position tighten lock nut Fig 25 This is a...

Page 601: ...gear in vehicle as follows Install steering gear on mounting bracket from Fig 27 lnstalftng Worm Shaft Of1Swl 5 With steering wheel centered lower steering column till column shaft coupling indexes wi...

Page 602: ...ess steel rollers against the inside sur face of the cam ring As the rollers follow the eccen tric pattern of the cam ring oil is drawn into the inlet OVAL SHAPED KEY Page 1 06 Model 29 Inspection 25...

Page 603: ...assemble pump and clean n Damaged or leaky pressure relief n Replace seat and ball 1 06 pump re place flow control valve 94 pump 0 Damaged housing bore 0 ring s1 or 0 Replace 0 rings p Scored pressure...

Page 604: ...gear and connect the free end of the hose to the gauge side of C 3309B Connect a second pressure hose from the valve side of C 3309B to the steering gear The valve must be installed on the outlet side...

Page 605: ...he pressure hose on these modelsis a right angle fitting 4 Tighten pump end hose fitting to 24 foot pounds and gear end fitting to 160inch pounds 5 Hoses must remain at least one inch away from all pu...

Page 606: ...d pressure plate 0 rings 11 Place pump body on flat surface and pry drive shaft oil seal out with a screw driver Fig 9 12 Inspect seal bore in housing for burrs nicks PUNCH RETAINER INSERTED IN O iG 1...

Page 607: ...y worn or scored Assembly 1 Place pump body on flat surface and drive new drive shaft seal into bore with a 7 8 or 15 16 inch socket till seal bottoms on shoulder Fig 1 2 7 16 INCH END WRENCH Fig I I...

Page 608: ...end cover lip edge UP over spring 12 Press end cover down below retaining ring groove with thumb and install ring making sure it is seated in groove Fig 19 This operation can be performed in an arbor...

Page 609: ...bled for cleaning if dirt has caused pump failure It is important that if the valve is disassembled for cleaning purposes the en tire pump should be disassembled and cleaned Disassembly 1 Remove press...

Page 610: ...th end of shaft This movement is necessary and will be mini mized by a thin cushion of oil between the rotor and end plates when pump is in operation 10 Install pump and adjust belt as outlined under...

Page 611: ...s recommended that all the Inspection interior parts be replaced 26 passages with compressed air and air dry all cleaned parts l Remove lean Out Plug with wrench Fig 5 Inspect pump body drive shaft bu...

Page 612: ...urface of installed cam ring it is not seated in index hole in housing 8 Install rotor and shaft in cam ring and carefully Fig 30 lnstalling Rollers in Rotor place 12 rollers in cavities of rotor Figs...

Page 613: ...ts tighten to 18foot pounds PRESSURE PLATE OIL PASSAGE SLOT l h IN SOCKET NU81 Fig 33 Seating Pressure Plate Fig 34 Pulley Installation 6 Cylinder Engines 18 Install drive pulley See Pulley Installati...

Page 614: ...DE PRESSU E RELIEF BALL NR327 Fig 36 Flow Control Valve Disassembled View 5 Clamp land of valve in a soft jawed vise and remove hex head ball seat and shim s Note number and gauge of shims on ball sea...

Page 615: ...the ward the driver column from being shifted toward the driver during The center section of the column jacket has dia impact It incorporates three break away capsules mond shaped perforations and is...

Page 616: ...ctors at steering col umn jacket 5 Remove horn ring ornament assembly by turn ing counterclockwise 6 Disconnect wire at horn switch Remove three screws attaching horn ring and switch to steering wheel...

Page 617: ...of the way 7 Remove two bolts holding lower bearing and support to lower end of column jacket Fig 5 Install steering shaft remover C 4044 Fig 6 and press shaft out of upper bearing Slide steering shaf...

Page 618: ...MyMopar com...

Page 619: ...n install roll pin 12 Bend turn signal wiring terminal tangs out ward slightly proper location TOOL 4 NP552A Fig 12 Pulling Shaft Through Bearing GEARSHIFT LEVER FEELER GAUGE NP12 Fig 13 Installing Ge...

Page 620: ...rrectly 8 Attach finish plate to bottom of instrument panel 9 Install turn signallever 10 Place steering wheel on steering shaft with master splines aligned Install retaining nut and washer tighten nu...

Page 621: ...pport in the column jacket Fig 6 slide support and bearing assembly out of jacket Remove low reverse lever and spacerfrom shift tube 8 Remove two lower shift tube bushing retaining screws at slotted h...

Page 622: ...Lubricate floor plate O ring with a soap solution or rubber lubricant and slide floor plate assembly on steering column The floor plate assembly must be installed before installing shift tube and lev...

Page 623: ...and cross over blade so it will be held in neutral position half way between the two shift levers Fig 9 10 Position gearshift lever and spring in housing so ball end with insulator ring engages hole i...

Page 624: ...g 13 Tight en the two bracket nuts to 140 inch pounds Valiant and Barracuda models with power steering have no gauge hole in the steering shaft Measure from top of coupling to weld on steering shaft A...

Page 625: ...t is therefore suggested that the removal and installa tion and the disassembly and reassembly procedures be carefully followed when servicing this assembly IMPORTANT Bumping jolting and hammeringof t...

Page 626: ...d screwdriver above and below the terminal to release the tangs Fig 3 6 Remove snap ring flat washer and wave washer INSTRUMENT PANEL PLASTIC RIVETS 2 BRACKET ASSY NUT AND BOLT ASSY NU492 Fig 2 Gearsh...

Page 627: ...damaged parts Inspect wiring insula tion for worn or bare spots Inspect steering shaft bearing for smooth opera tion and lubricate with Multi Purpose Chassis Lubri cant or similar lubricant If bearing...

Page 628: ...and rotate fully clock wise Fig 6 Tighten 3 retaining screws 30 to 40 inch pounds 8 Bend turn signal wire terminal tangs outward slightly Fig 11 9 Install wire terminals in proper locations in in sula...

Page 629: ...forward adjustable hanger to the instrument panel support Attach col umn bracket forward leg to the hanger and tighten to 140 inch pounds Then tighten the hanger to inrtru ment panel support bolt to...

Page 630: ...on nector Remove all wires in same manner 4 Carefully pry upward on one end of gearshift indicator bracket to remove it from gearshift tube Fig 4 5 Drive out gearshift lever pivot pin then remove leve...

Page 631: ...ench turn nut clockwise with a second wrench to withdraw pivot pin from the support COVER REMOVER SLiDE HAMMER NU570 J SPECIAL TOOL FOR 12 POINT LOCK NUT NU572 Fig 7 Removing or lnstalling Steering Sh...

Page 632: ...in Fig 14 flush with housing face for release lever pin clearance Drive out release lever pin from inside actuator housing remove lever and spring 21 Drive out lock shoe pin then remove lock shoes and...

Page 633: ...G ACTUATOR HOUSING NU575 Fig 1 Lock Shoes and Rele se Lever Disassembled keyway in tube with key in bowl 3 Push shift tube into bowl with hand pressure Insert lower end of main screw Tool C 4046 throu...

Page 634: ...sing install and tighten three retaining screws to 35inch pounds Fig 6 ACTUATOR COVER NU577 Fig 17 Installing Actuator Cover NPSSA Fig I 8 Spreading Tang on Wire Terminal 13 Lubricate and install uppe...

Page 635: ...SatelIite 94 pump 1 0 6 pump 94or 1 06 pump 318 383 or 440 C I D engine 1 0 6 pump 225C I D engine 1 0 6 pump 426C I D Hemi engine Fury all engines 94or 1 0 6 Pump Output 94pump 1 0 6 pump High level...

Page 636: ...llite 100 Fury Models 100 50 20 30 High Pressure Hose Fitting Foot Inch Pounds 140 200 200 Steering Arm Nut 175 Steering Column Support Nut Steering Shaft Coupling Bolts Valve Body End Plug Valve Body...

Page 637: ...A 745 When replacement of parts is required always refer to the Parts Catalog to make sure the correct part is being installed The three speed manual transmissions are of the synchromesh type with he...

Page 638: ...ce parts as neces sary Replace worn gears Replace worn bearing tral middle detent position 3 Adjust 2nd 3rd rod swivel so it will enter 2nd 3rd lever at transmission while the hand lever on steering c...

Page 639: ...rom transmission lever 2 Make sure transmission shift levers are in neu tral middle detent position STRG COL PI CROSS OVER BLADE I N NEUTRAL I _ _ _ I _ I I Fig 5 Holding Cross Over Blade in Neutral P...

Page 640: ...reverserod swivel by loosening lock nut and turning swivel so it will enter 1st reverse lever at steering column Install washers and clip scREw r EETAlLS AT TRANSMISSION NR23 Gearshift Linkage Tighte...

Page 641: ...ea on extension housing are perfectly clean Dirt or sand will cause mis alignment resulting in speedometer pinion gear damage 6 With proper gear tooth range number in 6 o clock position carefully pres...

Page 642: ...stalled ADA PTER RETAINER RING NN362 Fig IO Speedometer Pinion and Adaptor Disassembled 5 Fill transmission to level of fill plug Refer to Lubrication Section EXTENSION HOUSING YOKE SEAL Replacement 1...

Page 643: ...oles in the side frame members with support ends up against underside of oil pan flange Use Adapter Leg C 3806on 6cyl engines 5 Raise engine slightly with support fixture Dis connect transmission exte...

Page 644: ...taken before any further disassembly of transmission 3 The synchronizer float should be 060 to 117 inch when measured between synchronizerouter ring pin and opposite synchronizer outer ring Fig 20 Th...

Page 645: ...e mainshaft 2 Cock mainshaft then remove clutch sleeve outer synchronizer rings front inner ring and 2 3 shift fork Fig 23 or 24 3 Remove clutch gear retaining snap ring Fig 25 Slide clutch gear off e...

Page 646: ...d thrust washers out of the case Remove bearing rollers from gear Gearshiff Mechanism leaking shafts This operation need only be done if the seals are 1 Remove operating levers from their respective r...

Page 647: ...r service The front mating surface should be smooth if any burrs are present dress them off with a fine mill file If threads are stripped install Helicoil inserts CLUTCH GEAR SYNCHRONIZER INNER STOP R...

Page 648: ...r showing signs of ex LOW AND REVERSE CAM 2ND AND DIRECT CAM Fig 29 A 903 Shift Forks and Levers NY858A SECOND AND DIRECT FORK SECOND AND DIRECT LEVER LOW AND REVERSE FORK NB3 LOW AND REVERSE 6r LEVER...

Page 649: ...ves in the gear Install remaining rear thrust washer plate over arbor at rear of gear The washer plate must be installed so step on plate will engage on ledge inside rear of the case thus preventing p...

Page 650: ...ve and at same time entering mainshaft rear bearing in the case bore If synchronizer parts are not positioned as de scribed in steps 5 and 6 it will not be possibleto place them in position after main...

Page 651: ...shift rods and back up light switch wires 8 Carefully guide front universal joint yoke into extension housing and onto mainshaft splines Con nect propeller shaft to rear axle pinion yoke 9 Fill transm...

Page 652: ...in applicable Parts Catalog therefore be sure they are used when replacement is necessary SERVICE DIAGNOSIS Condition Possible Cause Correction HARD SHIFTING TRANSMlSSl0N SLIPS OUT OF GEAR TRANSMISSI...

Page 653: ...NT FINISH PLATE WASHER 2 I i I 2 Install shift rods washers and clips 3 See next paragraph for adjustment procedure 4 Push Shift lever down into shift unit far enough for spring to click and lock leve...

Page 654: ...connected carefully work 3 4 SHIFT ROD ASSEMBLY Fig 7 Gearshift Linkage Adjustment Fig 8 Speedometer Pinion and Adapter Installed adapter and pinion out of extension housing 4 If transmission fluid is...

Page 655: ...haust Systems Section 11 6 Install engine support fixture C 3487 engaging the hooks in holes in frame side member Be sure support ends are up against underside of oil pan flange 7 Raise engine slight...

Page 656: ...ts that attach extension housing to synchronizer sleeves and clutches before disassem transmission case bling mainshaft 3 Slide third and fourth synchronizer sleeve 5 Remove snap ring Fig 21 that reta...

Page 657: ...housing Fig 23 HEAVY DUTY MODEL Fig 24 has snap ring in outer race of bearing Use snap ring pliers to expand and hold this ring while removing mainshaft and bearing from extension housing 9 Remove sn...

Page 658: ...21 22 TRANSMlSSlONA SPEED MANUAL A NH740D Fig 17 A 833 transmission Disassembled MyMopar com...

Page 659: ...ch Sleeve 42 3rd Speed Gear 63 Reverse Idler Gear Shaft 88 1st and 2nd Lever 64 Bushing Reverse Idler Gear 89 3rd and 4th Speed Fork 43 Mainshaft Output 65 Gear Reverse Idler 90 1st and 2nd Speed Fork...

Page 660: ...RING GROOVE NH745 I MAINSHAFT EXTENSION HOUSING Fig 23 Removing or Installing Mainshaft SNAP RING REMAINS IN SNAP EXTENSION HOUSING GROOVE RING PLIERS GROOVE IN BEARING NU40 Fig 24 Removing or Install...

Page 661: ...rse Idler Gear Shaft A 833 age the case bore then carefully push reverse gear shift lever shaft inward and remove it from case Fig 32 Lift out detent bal1from bottom of case Remove shift fork from sha...

Page 662: ...llers and Spacers Inspect all bearing rollers for flat spots or brinel ling Inspect all bearing roller spacers for signs of wear or galling Install new parts as required Gears Inspect gear teeth on sy...

Page 663: ...ng in bearing groove HEAVY DUTY MODEL Fig 33 be cause of larger bearing can be installed through front of case 9 Using Tool 2 3789 or C 3801 for heavy duty model Fig 37 install a new oil seal in retai...

Page 664: ...ft with synchronizer cone toward front followed by third gear stop ring Fig 21 8 Install third and fourth speed synchronizer clutch gear assembly including sleeve shift struts and springs on mainshaft...

Page 665: ...transmission on a suitable jack slide as sembly under vehicle 2 Raise transmission until drive pinion is centered in clutch housing bore 3 Roll transmission slowly forward until pinion shaft enters c...

Page 666: ...ehicle and engine combinationand Page Fluid Leakage 66 Recondition Sub Assemblies 69 Accumulator Piston and Spring 73 Extension Housing Bushing and Oil Seal 73 Front Clutch A 904 77 Front Clutch A 727...

Page 667: ...s sion fully automatic and has four important functions to perform In a general way the components of any automatic control system may be grouped into the following basic groups The pressure supply sy...

Page 668: ...e runaway 11 I I 3r THROTTLE P R E S S U R E J Fig Par ThrottleDownshift Hydraulic Circuit Gearshift and Parking Lock Controls The transmission is controlled by a lever type gearshift incorporated wit...

Page 669: ...mbled until a careful diagnosis is made the definite cause determined and all possible external corrections performed In diagnosing any abnormal shift condi tion always make the hydraulic pressure tes...

Page 670: ...as re quired i Kickdown servo band or linkage i Inspect servo for sticking broken malfunctions seal rings binding linkage or faulty band lining Repairas required j Worn or faulty front clutch j Disass...

Page 671: ...emove and clean governor Replace parts if necessary g Oil filter clogged g Replace oil filter h Valve body malfunction or leakage h Perform pressure tests to determine cause and correct as required i...

Page 672: ...body malfunction or leakage c Perform pressure tests to determine cause and correct as required Faulty oil pump d Perform hydraulic pressure tests ad just or repair as required Clutches or servos stic...

Page 673: ...and lining Repair as required d Front and or rear clutch faulty d Disassemble and inspect clutch Re pair or replace as required e Planetary gear sets broken or seized e Inspect condition of planetary...

Page 674: ...determine the cause of slippage STALL SPEED BELOW SPECIFICATION Low stall speeds with a properly tuned engine indi cate torque converter stator clutch problems A road test will be necessary to identi...

Page 675: ...ice Hemi Engine Vehicles The factory fill fluid should be changed after the first 24 000 miles or 24 months whichever occurs first and periodically thereafter every 12 000 miles or 12 months The filte...

Page 676: ...nt 3 With control lever on transmission in park position detent and selector lever in PARK position Fig Hearshift Llnkage tighten swivelclamp screw to 100inch pounds CONSOLE GEARSHIFT Removal 1 Discon...

Page 677: ...llite and Fury Models U NN560 Fig IO Removing or Installing Console Valiant and Barracuda Models tions Install and tighten console retaining screws 3 With gearshift lever in NEUTRAL thread but ton spr...

Page 678: ...turning in the transmissioncase 2 Using wrench Tool C 3380 with adapter C 3705 tighten band adjusting screw 47 to 50 inch pounds If Fig IP Neutral Park Starting Switch and Back up Light Switch LOW AND...

Page 679: ...tion of cable housing ferrule 6 in the clamp so that all slack A TORQUEFLITE TRANSMISSION 21 53 is removed from the cable with carburetor at curb idle To remove slack from cable move ferrule 6 in the...

Page 680: ...TRANSMISSI ON TO RQUEFLlTE A Fig 15 Throttle Linkage Adjustment valiant or Barracuda with 273 318or 340 Cu In Engine V NR343A Fig 16 Throttle Linkage Adiustment Barracuda with 383 Cu In Engine MyMopa...

Page 681: ...A TORQUEFLITE TR ANSMI SSI0N 21 55 Fig I7 Throttle Linkage Adjustment Satellite 8 Cylinder Engine NU347 Fig I8 Throttle Linkage Adjustment Fury 8 Cylinder Engine MyMopar com...

Page 682: ...Tighten cable clamp nut 4 to 45 inch pounds 11 Connect choke 8 rod or remove blocking fix ture Models With426 Cu In Eng Fig 19 1 Follow detailed instructions in Lubrication Sec tion for linkage lubric...

Page 683: ...e pressurized in direct Re duce engine speed slowly to 1 000 rpm Line pressure at this time 1 000 rpm must be 54 60 psi and front servo release pressure must not be more than 3 psi below the line pres...

Page 684: ...r screws and repositioning the spring retainer The regulator valve may cock and hang up in its bore if spring retainer is out of position If line pressure is not correct it will be necessary to remove...

Page 685: ...units clutches bands and servos can be located through a series of tests by sub stituting air pressure for fluid pressure Fig 25 The front and rear clutches kickdown servo and low reverse servo may be...

Page 686: ...a on extension housing are perfectly clean Dirt or sand will cause misalignment resulting in speed ADA PTER OIL SEAL B O L T AND WASHER RETAINER RING NN362 Fig 27 Speedometer Drive A D A P T E R L O C...

Page 687: ...e on output shaft Install a new bearing on shaft with outer race ring groove toward front Fig 32 then install rear snap ring To replace the extension hous ing bushing refer to INDEX hsfallation 1 Plac...

Page 688: ...k straps over bolt heads 3 Assemble governor weights and spring and secure with snap ring inside of large governor weight Place weight assembly in governor body and install snap ring 4 Place governor...

Page 689: ...witch has been removed If parking lock rod was re moved insert it through opening in rear of case with knob positioned against the plug and sprag Move front end of rod toward center of transmission wh...

Page 690: ...is sion lever Remove the gearshift torque shaft from transmission housing and left side rail Console Shift Remove two bolts securing gearshift torque shaft lower bracket to the extension housing Swing...

Page 691: ...ter front cover being careful to place as nearly as possible same amount of weld material in exactly same loca tion as was used in original weld This is necessary in order to maintain proper balance o...

Page 692: ...k If no leak is found proceed to step 5 5 Service Transmission Converter Housing Area a Replace torque converter hub seal inspect torque converter hub for roughness or damage b Check pump housing bolt...

Page 693: ...h a dial indicator to transmission bell housing with its plunger seated against end of input shaft Fig 43 Move input shaft in and out to obtain end play reading End play specifications are 030 to 089...

Page 694: ...ide valve and shaft assembly out of the governor body 2 Remove snap ring from behind governor body then slide governor body and support assembly off the output shaft Oil Pump and ReactionShahSupport 1...

Page 695: ...ement for most all bushings in the TorqueFlite transmission The two bushings in sun gear are not serviced because of the low cost of sun gear assembly If bushings are found worn or scored they should...

Page 696: ...s Carefully lift transfer plate and steel separator plate assembly off the valve body 6 Invert transfer plate assembly and remove the NU367 Fig 52 Steel Ball Location stiffener plate Remove remaining...

Page 697: ...i i i 1 2 SHIFT VALVE I SHIFT V A L E END PLATE 8 6 CYL ONLY 8 CYL ONLY NP146 Fig 55 Valve Body Shift Valve Side Disassembled throttle valve spring and throttle valve Fig 5 4 14 Remove governor plug...

Page 698: ...valve spring and shuttle valve throttle plug Install governor plug end plate and tighten the five retaining screws to 28 inch pounds 3 Install Eclip on end of shuttle valve Fig 54 Install shuttle valv...

Page 699: ...nspect sprag and control rod springs for distortion and tension Inspect square lug on sprag for broken edges also lugs on parking gear for damage Inspect knob on end of control rod for nicks burrs and...

Page 700: ...5 to 010 inch Clearance between outer rotor and its bore in oil pump body should be 004 to 008 inch Pump Bushing Replacement A 904 1 Place pump housing seal face down on a smooth f i r m surface 2 Pla...

Page 701: ...s 8 Thoroughly clean reaction shaft support assem bly before installation Assembly 1 Place reaction shaft support in assembling Tool C 3759 with hub of support and tool resting on a smooth flat surfac...

Page 702: ...h Clearance between outer rotor and its bore in oil pump body should be 004to 008inch Pump Bushing Replacement A 727 1 Place pump housing on a clean smooth surface with rotor cavity down 2 Place remov...

Page 703: ...facing inward using Tool C 3860 drive seal into housing until tool bottoms FRONT CLUTCH A 904 Disassembly Figure 67 shows a disassembled view of the front clutch assembly 1 Remove large selective sna...

Page 704: ...th surface Slide a new bushing on installing head Tool SP 3626 and start them in clutch retainer bore Fig 69 4 Install handle Tool SP 3549in installing head Drive bushing into clutch retainer until to...

Page 705: ...res pressure plate in clutch piston retainer Lift pressure plate and clutch plates out of the retainer 2 Install compressor Tool C 3863 over piston spring retainer Fig 72 Compress springs and re move...

Page 706: ...ner before assem bly and installation A 727 Assembly 1 Lubricate and install inner seal on hub of clutch FRONT CLUTCH CHART A 727 Engine Clutch Plate Piston Type Disc Clearance Springs 225 Cu In 3 036...

Page 707: ...facing material on all driving discs Replace discs that are charred glazed or heavily pitted Discs should also be replaced if they show evidence of ma terial flaking off or if facing material can be s...

Page 708: ...gressively push or tap spring into place mak ing sure it is fully seated in the groove 5 Install inner pressure plate in clutch retainer WAVE SPRING SPACER RING Fig 79 Installing Roar Clutch Spring Sp...

Page 709: ...grooves Note ball check in the piston make sure ball moves freely Inspect seal surfaces in clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of neoprene seals...

Page 710: ...re rear clutch plate clearance by having an assistant press downward firmly on outer pressure plate then insert a feeler gauge between the plate and snap ring Fig 80 The clearance should be be tween 0...

Page 711: ...iving gear teeth for damage Replace distorted lock rings Assembly Refer to Figure 84 for parts reference 1 Place rear annulus gear support in annulus gear and install snap ring 2 Position rear planeta...

Page 712: ...r burrs and remove with a sharp edged stone Make sure all oil passages in shaft are open and clean Inspect bushings in sun gear for wear or scores replace sun gear assembly if bushings are damaged Ins...

Page 713: ...Center punch the rivets exactly in center of each rivet head Fig 87 3 Drill through each rivet head with a 3 8 inch drill Be careful not to drill into the transmission care Chip off rivet heads with...

Page 714: ...d block and hammer 3 Clean all burrs and chips from cam area in the case Fig 90 Rernovlng Overunning Clutch Cam A 727 NN130 Fig 9I Instolling Output Shaft Support IA 727 4 Place spring retainer on the...

Page 715: ...the band If lining is worn so grooves are not visible at ends or any portion of the band replace the band Inspect band for distortion or cracked ends Assembly the piston and secure with snap ring 1 Lu...

Page 716: ...N PIN NR171 Fig 98 Double Wrap Band Linkage lnstulled A 904 LA Transmission only clutch and band 4 Install operating lever with pivot pin flush in case and adjusting screw touching center lug on band...

Page 717: ...e assembly in position on the rear clutch Make sure front clutch plate splines are fully engaged on rear clutch splines 5 Align rear clutch plate inner splines grasp in put shaft and lower the two clu...

Page 718: ...accumulator piston in transmission case and place piston spring on the accumulator piston Fig 102 Make sure Back up Light and Neutral Start Switch has been removed 3 Insert parking lock rod through o...

Page 719: ...is in position install bell housing bolts and tighten to 28foot pounds 8 Install and tighten the two lower drive plate to converter bolts to 270inch pounds 9 Install starting motor and connect batter...

Page 720: ...switch 17 Install cover plate in front of the converter assembly 18 Install the transmission case to cylinder block brace The converter cover plate must be between case and brace The oil line bracket...

Page 721: ...ts Lubricant Type Gear Type Tolerances Second Speed Gear End Play Countershaft Gear End Play Clutch Housing Face Squareness Clutch Housing Bore Run Out Synchronizer Float A 903 A 745 A 745 A 745 3 22...

Page 722: ...of No of Size Teeth Teeth Teeth Teeth Teeth Teeth Teeth Teeth Teeth Teeth 2 71 l 2 76 l 2 93 l 2 94 l 3 23 l 3 31 l 3 54 l 3 55 l 3 91 l 4 1 0 l 6 50 x 13 30 32 35 39 43 7 00 x 13 29 31 34 38 41 070...

Page 723: ...ving Shell Front Planetary Gear to Annulus Gear Front Annulus Gear to Driving Shell Front Clutch to Rear Clutch Rear Planetary Gear to Annulus Gear 3 170 225 Cu In Eng 4 273 318 Cu In Eng 3 170 225 Cu...

Page 724: ...o Case Bolts 50 Transmission Drain Plug 25 Gearshift Operating Lever Nuts 18 Pounds Torqueflik A 904 and A 727 Foot Inch Cooler Line Fitting 110 Cooler Line Nut 85 Converter Drain Plug 110 Converter D...

Page 725: ...e most important to the owner are Superior ride and hand ling improved fuel economy and improved high speed durability because of cooler operating temper atures Tire wear and vehicle stability are aff...

Page 726: ...s cold if possible It is normal for tire air pressure to increase 24 psi due to temperature increases caused by tire flexing Under no circum stances should inflation pressure of warm tires be reduced...

Page 727: ...ard 70 Series wide tread or extra wide tread bias breaker again radial not recom mended tires is acceptable on your vehicle if the size is listed in the above charts The use of oversize tires of this...

Page 728: ...the four tires with all tires inflated to normal pressure Tire roughness is rec ognized as a low frequency rumble or vibration and is very similar to driveline vibration Positive sepa ration of the tw...

Page 729: ...e wheel until the car can be brought to a safe stop TIRE WHEEL BALANCE The need for tire and wheel assembly balancing is Fig 7 Safety Type Rim indicated by heavy vibration of the steering wheel when d...

Page 730: ...stem hole The covers are structurally stronger at the outer circum ference to withstand the force required for removal and installation Use a rubber end mallet when in stalling the covers FRONT WHEEL...

Page 731: ...nt see Lubrication Group 0 Lubricant should be even with inner diameter of bear 3 Force lubricant between bearing cone rollers or repack using a suitable bearing packer 4 Install inner cone and a new...

Page 732: ...s 170 225 273 318 6 50 13 6 50 13 7 00 13 7 00 13 7 00 13 7 00 13 7 00 13 6 95 14 6 95 14 6 9514 6 9514 Disc Brakes and Air Conditioning Trailer Towing I MaximumTire Size Do Not Exceed I 6 95 14 D70 1...

Page 733: ...G78 15 F70 15 btandard 14 Wheel on Station Wagon 15 Wheel on Station Wagon ir Conditioned ir Conditioned k railer Towing 8 55 14 H78 14 8 25 15 G78 15 Sedan Hardtop Convertible Vehicle Maximum Camacit...

Page 734: ...kat Or 3rd Seat Total k a t kat Or 3rd S w t Total 3 Passengors 200 Lbs 1100 Lbs 2 Passengers 3 Passengers Maximum Maximum Maximum Maximum Maximum 0 750 Lbr TIRE PRESSURE CHART Front 32 32 28 32 MINI...

Page 735: ...m vehicle capacity pressures under all load conditions All tires and especially the wide tread 70 Series bias breaker and radial types must be rotated no later than every second oil change and should...

Page 736: ...NG REFERENCE A TIGHTENING REFERENCE Pounds Pounds Foot Inch Foot Inch Wheel Bearing Nut with Wheel Spinning Valiant Ba rracuda SateIIite Fury Wheel Stud Nut 70 90 VaIiant Ba rracuda 55 Sate11ite Fury...

Page 737: ...nt and is bolted to the Unibody MAINTENANCE AND CARE INDEX Page ACRYLIC FINISHES POL1 SHING 4 BRIGHT METALS PO LISHING 4 CONVERT1BLE Backlight 2 Boot 2 Top 1 Well 2 GLASS 5 INTERIOR TRIM Cargo Area St...

Page 738: ...wder from surface Repeat operation should any stain remain Entire Inwrt Cleaning Only Waterspots dirt food stains coffee and other water borne stains Vacuum or brush off as much of the staining materi...

Page 739: ...lution Shoe PolishCcrub area with a cloth saturated with cold water Remove wax base polishes by sponging with spot remover Grease Oil Lipstick and Related Stains Use spot remover to avoid leaving a ri...

Page 740: ...ced personnel Dyes or tints can be applied when stains persist after clean ing or a change in color is desired The instructions for mixing and applying the color must be followed precisely Use only th...

Page 741: ...in fluids from the well area LUBRICATION To maintain ease of operation the hood door deck lid and tail gate hinges should be lubricated with the recommended lubricants at the recommended intervals Ref...

Page 742: ...m opening flange and held to brackets on the base of the duct with screws Fig 1 0 WITHOU HEATER RIGHT DUCT Fig I Fresh Air bud NR165 The left duct assembly is attached directly to the plenum by positi...

Page 743: ...and raising hood fully 2 Disengage left hand torsion bar roller from hood hinge BUMPER c I BUMPE ADJUSTMENT SCREW COWL BRACKET FENDER N P 79 Fig 3 Hood Leveling Adjustment 3 Remove hood assembly 4 Re...

Page 744: ...at cowl side area and align fender with mounting holes in radiator yoke Install all mounting screws and retainer nuts 3 With fender correctly positioned tighten all screws and nuts securely making cer...

Page 745: ...face of the fenders at the outer Refer to Figs 10 11 12 and 13 for bumper edges to avoid stressing or fracturing the die cast attaching points metal DOORS The service procedures for internal door comp...

Page 746: ...ime Raising outer end of door moves upper part of door into door opening Lowering outer end of door moves lower part of door into door opening LATCH AND STRIKER PIN The front door cannot be locked unt...

Page 747: ...or trim and hardware REAR DOOR All Models Removal door near the hinges 1 Open rear door and place a padded jack under 2 Remove door interior trim and hardware 3 Scribe aligning marks around hinge plat...

Page 748: ...ar inner end and base can be separated and if necessary the pad may be recovered TRIM PANELS Replacement The remote control handle Fig 18 is attached to 1 Remove inside handles and armrests ARM RESTS...

Page 749: ...oor opening and con 3 Install attaching screw and test operation of nect link to the control lever control LOCK REPLACEMENT Removal from lock by pulling link outward at lock from lock assembly 1 Disco...

Page 750: ...oor and r e lnstallation nuts connector on handle 1 Position handle in door and install mounting 2 Depress handle button and position link over 3 Install retainer over link and connector WEATHERSTRIPS...

Page 751: ...justment Fig 25 of the upper end is accomplished by moving vent wing up or down The assembly moves forward and downward to relieve a binding condition of the door glass and rearward and upward to remo...

Page 752: ...nch expandable ends of rivet together and push rivet out of glass lnstallation install rivet and plug channel 1 Position lift bracket and gasket on glass and Before installing glass lubricate regulato...

Page 753: ...e division channel attaching screws at upper and lower ends Fig 28 and remove channel 2 Move the glass and weatherstrip assembly for ward and out of window opening 3 Inspect the weatherstrip Fig 27 Re...

Page 754: ...nd disengage regulator arm from glass lift bracket and remove from door 7 Invert vent wing and door glass assembly and remove adjusting stud rod and retainer from vent wing Fig 31 ANTI RATTLE ADJUSTIN...

Page 755: ...ioned and held in place to assure satisfactory alignment Do not over tighten the mounting screws or the moulding will become damaged at the screw hole area TRIM PANELS The rear seat cushion and back m...

Page 756: ...7 Quarter Glass Assembly Sedan SCF EW NP642 Fig 38 Regulator Assembly Sedan inner panel with screw and washer assemblies In spect rollers on regulator studs and apply lubricant to the slide area of th...

Page 757: ...ide and roller from glass frame rear track and roller assemblies from tracks in front sec tion Fig 43 lnstallation 1 Position roller assemblies and slide to front and rear tracks of glass lower frame...

Page 758: ...just pivot brack et so glass is parallel to rear edge of door glass and rear roof rail weatherstrip effecting a proper seal 5 Adjust rear stabilizer and front track lower at tachments outboard until u...

Page 759: ...tached to the inner panel at the top end and to a support at the lower end The upper attachment permits in and out ad justment and the lower end permits fore and aft and in and out adjustments ANTI RA...

Page 760: ...indow until top of glass is even with quarter outside panel 8 Adjust lower end of rear guide sleeve nut so rear end of glass lightly touches outer belt weather strip 9 Position stop on regulator plate...

Page 761: ...8 Position regulator rear arm roller in rear slot and move rearward 9 Spring regulator arms inboard to allow studs to enter rollers 10 Install spring nuts on studs 11 Install quarter glass and up sto...

Page 762: ...e deck lid is attached to the hinges by two screws Fig 61 Outer Belt Weatherstrips Fastback 1 NU152 BEZEL AND GASKET cLllg3 Fig 62 Quarter Panel Side Reflector Valiant Fig 63 Quarter Panel Side Ref le...

Page 763: ...e deck lid in various open positions and test 6 Adjust torsion bars progressively until deck lid arm adjusting slot tension of torsion bars stays in open position Lock Replacement The deck lid lock as...

Page 764: ...e locking SHEET METAL DOORS COWL PANELS INDEX SATELLITE Page BUMPERS 34 COWL PANELS Fresh Air Ducts 30 Fresh Air Inlets 29 Attachment 29 Control Cable Routing 29 Alignment 54 Hinge 55 Cylinder 55 DECK...

Page 765: ...52 Opening 52 Window Washer System 48 Hardtop Sedan Station Wagon RADIATOR YOKE SUPPORT SERVICE PROCEDURES COWL PANELS FRESH AIR INLETS Control Cable vent door is used On air conditioned equipped veh...

Page 766: ...ontrol Cable Adjustment Without Heater The fresh air duct assemblies are attached to the plenum opening The right duct is retained by two hook type rods positioned over the plenum opening flange and h...

Page 767: ...d on hinges and 2 Align scribe markings on hood with hinge and 3 Close hood and inspect hood alignment 4 Adjust the alignment Figs 6 and 7 as neces sary and tighten the hood to hinge bolts 180 inch po...

Page 768: ...hinge mounting screws prop the hood into the wide opening position The prop should be positioned so the hood cannot move rearward STRIKER SAFETY CATCH NR538 Fig 8 Hood Lock and Striker CARBURETOR FRES...

Page 769: ...Alignment should be made at bottom of floor sill panel front of hood and door outer panel upper edge REPLACEMENT Removal 1 Disconnect battery ground strap 2 Tape leading edge of front door and cowl t...

Page 770: ...or hoses fill cooling system and inspect for leaks AIR SHIELD AND CROSS BAR ing points Refer to Fig 12 for air shield and cross bar attach BUMPERS ATTACHMENT Refer to Fig 13 for bumper attaching point...

Page 771: ...t have been performed ALIGNMENT up and Down Adjustment of the door can be made at either the Fore and Aft Adjustment is made at the door hinge half Adjust only one hinge at a time Raising outer end of...

Page 772: ...y 3 Adjust jack to align hinge plate scribe marks and tighten attaching screws 4 Complete door aligning procedure and install door interior trim and hardware REAR DOOR All Models Removal On vehicles w...

Page 773: ...screws 8 Install escutcheon washer handles and arm rest LOCK ASSEMBLY Remote Control Manual Removal 1 Raise door glass 2 Remove screws attaching remote control base to 3 Remove link from remote contro...

Page 774: ...2 door models connect cylinder link to cyl inder position link bracket on door face and install attaching screws Connect lock link to lock OUTSIDE HANDLE FRONT DOOR Removal 1 With door glass in up po...

Page 775: ...al and install screws 3 Install weatherstrip on door indexing at top of door at belt line with two fasteners Roof Rail Weatherstrip Refer to Figure 24 for the attaching points and methods of cementing...

Page 776: ...oward rear of door and pull assembly out of door nstallation lower assembly into door tion channel on lower support 1 Tilt top of vent wing toward rear of door and 2 Move vent frame channel over glass...

Page 777: ...hrough the large access opening REAR DOORS SEDAN MODELS Adjusfments screw Fig 30 and lower window half way Refer to the Electrical Section for tests and wiring 1 Loosen the division channel lower brac...

Page 778: ...roup for tests and wiring Motor Replacement When removing the motor from the regulator it is imperative the regulator linkage be locked in position o prevent the mounting bracket from moving around th...

Page 779: ...n channel door face Fig 33 3 Disengage support on bottom of channel from door panel and remove channel Installation 1 Position run channel and support into door as sembly and install upper attaching s...

Page 780: ...o lower raise bracket 6 Move upper front track attachment forward and tighten when quarter window weatherstrip is against front door window 7 Tighten pivot bracket nuts 8 Loosen and position front and...

Page 781: ...ests and wiring diagrams Front Track and Brace Removal 1 Remove screws and washers attaching front track brace Fig 41 to inner panel and front track and remove brace 2 Remove nut and washer attaching...

Page 782: ...m stud retainers and studs YP STOP NN497 Fig 43 Quarter Window Adjustments Convertible d NN548 Fig 44 Quarter Window Stabilizer Convertible 3 Removeroller from glass frame center slot 4 Raise glass an...

Page 783: ...race attaching screws run 8 Adjust quarter window tion assembly in panel ing hole in inner panel in loosely Stabilizer The quarter window stabilizer Fig 44 is attachcd to the inner panel at the upper...

Page 784: ...her electrical leads 1 Remove check arm and torsion bar guide from pillar guide plates 2 Support tail gate on jacks or stands 3 Loosen hinge pivot pin locking screws Fig 50 4 Use a pencil and outline...

Page 785: ...djustment must be made on both sides Regulator Handle With tail gate handle in unlocked position remove tail gate inner panel and remove nuts attaching han dle to door Fig 51 To remove a handle which...

Page 786: ...acket 6 Install link into release regulator mechanism and upper left latch remote lever clip 7 Install link into lock remote lever 8 Take up all play in latch remote lever and re LEFT SIDE I I P GLASS...

Page 787: ...ition tail gate glass on weatherstrip and lower frame and install the washers spacers and re taining screws 3 Apply lubricant to regulator arm studs and to glass lower frame studs GLASS AND FRAME NK94...

Page 788: ...ert torsion bar into tail gate 3 Position hinge to tail gate and install mounting screws Tighten screws 30 foot pounds 4 Install bearing and bearing retainer on torsion bar Fig 59 Tighten retainer nut...

Page 789: ...install retainer screw 3 Using a new glass run retainer seal start at lower edge of upper pillar and apply seal up and across roof header and down opposite pillar HEADLINING REAR HEADLINING REAR RETAI...

Page 790: ...screws 2 Install screw attaching lower end of retainer V NRl9l Fig 65 Deck Lid Hinge Replacement over lower opening weatherstrip 3 Starting at center line of roof rear header glass run retainer instal...

Page 791: ...insert end of bar into first 5 Place deck lid in various open positions and test 6 Adjust torsion bars progressively until deck lid adjusting slot tension of torsion bars stays in open position Lock...

Page 792: ...ent 81 Adjustments 69 Lift Bracket 71 Pivot Bracket 72 Rear Track 71 Regulators Arms 72 Motor 72 Lift Switch 72 Replacement 70 Adjustments 73 Assembly 75 Lift Bracket 76 Regulators Motor 76 Lift Switc...

Page 793: ...rews and at the rear lower edge under the floor sill step plate A silencer pad is used between the trim panel and cowl panel Build Up and lnstallation 1 Position cowl side trim panel extension under R...

Page 794: ...Air Vents REPLACEMENT Removal 1 Place a protective covering over cowl and fender area 2 Mark outline of hinges on hood to aid in instal lation 3 Use extreme care not to permit hood to slide rearward...

Page 795: ...e REPLACEMENT Removal 1 Disconnect battery ground strap 2 Tape leading edge of front door and cowl to 3 Remove front bumper assembly 4 Disconnect head lamp wires and remove grille extension to fender...

Page 796: ...r tight to support screws finger tight only progressively with plastic straps and inspect for leaks 1 Position yoke support on frame and install 2 From under the fenders install splash shield 3 When a...

Page 797: ...A BODY AND FRAME 23 61 STEP PAD STATION WAGON r L A l e GUARD CUSHION REAR BUMPERS BUMPER Fig 9 Front and Rear Bumpers MyMopar com...

Page 798: ...23 62 BODY AND FRAME A Fig I0 Grille Appliccrtion Fury 1 11 111 FENDER 1 GRILLE BEZEL V t K I l L A L W J t W K l NU80 Fig II Grille Appliccrtton Sport Fury VIP MyMopar com...

Page 799: ...rubber isolation of the round striker pin on the door frame and those surfaces acting as stops inside the latch The latch assembly is built into a sheet metal pocket on the door face The striker pin i...

Page 800: ...ndles are retained on the shaft with an allen set screw Fig 14 The handles should be placed in approximately a horizontal position with the knobs facing forward on the doors and rearward on the quarte...

Page 801: ...plate to sliding and contact areas 2 Install assembly through door opening and con Removal 1 With window in up position disconnect cylinder 3 Install attaching Screw and test Operation Or link Fig 18...

Page 802: ...sole 4 Tighten solenoid to mounting bracket screws REPLACEMENT Removal 1 Disconnect solenoid link at solenoid Fig 20 2 Remove solenoid lead wires 3 Remove solenoid to mounting bracket screws and remov...

Page 803: ...nd install mounting 2 Depress handle button and position link over 3 Install retainer over link and connector WEATHERSTRIPS AND WINDCORDS Door Weathersirips Make sure all old weatherstrip particles an...

Page 804: ...tall seal W n ords Refer to Figure 23 for windcord starting points and GLASS ADJUSTMENTS 3 Make Sure lip Of weatherstrip dovetails The circled numben shown on the glass adjustment grooveOf door upper...

Page 805: ...per bracket at belt line 4 Move pivot bracket fore or aft and set glass Fig 25 stop in rear frame merit screw weatherstrip Parallelism of Glassto Primary Seal In Out and Secondary Seal tive glass to w...

Page 806: ...fasteners and up stop from glass Fig 28 lnstallcrtion upward 1 Place glass on table with outside of glass facing 2 Install fasteners and upstop in glass Fig 28 3 Position track guide over fasteners an...

Page 807: ...EAR TRACK SECTION A A SUPPC SCREW NU311 I face and install screw loosely slot of lower support bracket and install nut loosely track screw and nut after adjusting glass 3 Insert track bottom bracket a...

Page 808: ...ric operated regulators Pivot Bracket The pivot bracket and support assembly Fig 33 is NU310 Fig 334ivot Brocket secured with screws to the electric regulator idler arm slide and to the door inner pan...

Page 809: ...dge of glass parallel to line up bead on 5 Snug secure vent wing screw on hinge at belt weatherstrip 13 Snug secure nut assembly and screws loosen to perform adjustment 14 Loosen rear channel upper br...

Page 810: ...EW IN CIRCLE A NU568 Fig 36 lift Bracket 4 Remove lift channel to door glass fastener 5 Tilt top of glass inward and remove door glass screws Fig 36 and vent wing assembly bisassernbly forcement Fig 3...

Page 811: ...Insert lowest point of front leg and adjusting stud and lower assembly into door with the pivot as sembly mounting plate between the spacer bracket 2 DOOR and door outside panel reinforcement 4 Posit...

Page 812: ...Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot Window Lift Switch Slide a thin blade behind the switch housing front and back to depress retaining cli...

Page 813: ...g frame to door frame screws 5 Remove lift channel to door glass fastener 6 Lift vent wing and door glass out of panel screws lnstallation 1 Inspect seal on vent wing upper surface 2 With regulator ar...

Page 814: ...e linkage be securely clamped in a vise to lock it in place Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot Window Lift Switch Slide a thin blade behind...

Page 815: ...ront edge of glass forward and down engaging glass ends into the front and rear glass runs 4 Align glass fasteners with holes in lift channel and secure with screws Glass Run The rear door glass run F...

Page 816: ...Install rear door glass to lift bracket screws Regulators The manual and electric operated regulators Fig 50 are attached to the door inner panel with screws Refer to the Electrical Group for test pro...

Page 817: ...faces plastic up stop bumpers on glass Tighten callouts 14 through 18 securely GLASS REPLACEMENT The rear door incorporates a track panel assembly to which the door glass is attached When necessary t...

Page 818: ...arward approximately four inches to al low clearance for the U nuts 5 Slide track panel off of glass until upstops on glass find clearance to enter door opening 6 Slowly lower track panel completely t...

Page 819: ...se to lock it in place Failure to do this allows the assist spring to drive the mounting bracket around the lift pivot Window Lift Switch Slide 2 thin blade behind the switch housing front I and back...

Page 820: ...eatherstrip 2 Raise glass fully so top of glass is seated fully against roof rail weatherstrip and flushing front of glass with top of front door glass 3 Adjust upper front track attachment so front o...

Page 821: ...lower 2 Install grommets on glass retaining screws 3 Align glass lower frame attaching holes with access openings in quarter inner panel 4 Lower glass into quarter panel align openings In glass with...

Page 822: ...roller and guide assemblies on track 2 Insert track assembly in quarter panel 3 Position roller assemblies into slots of glass lower frame Fig 66 4 Insert sleeve nut on upper end of track into hole of...

Page 823: ...se rear of lower frame and remove from quarter 5 Remove roller and guide assemblies from lower frame lnstallation 1 Inspect glass lower frame to be sure grommets are installed at the upper outer holes...

Page 824: ...ainst stop on sector and snug tighten locknut 7 Test operation and inspect alignment of glass Tighten Callouts 8 9 and 10 securely GLASS REPLACEMENT Removal glass fasteners screws Fig 71 1 Lower glass...

Page 825: ...to lower end of roof rail weather strip to create a seal 11 Press securely into retainer for full length 12 Install quarter window assembly index to front corner and tab of retainer over bottom leg be...

Page 826: ...side of vehicle insert bottom of glass into weatherstrip and using a fiber stick pull lip of weatherstrip over glass Fig 78 6 Seat glass in weatherstrip using hand pressure 7 Apply rubber lubricant to...

Page 827: ...g 77 Weatherstrip Replacement TAIL GATE Station Wagon Models are equipped with a two way tail gate that can be opened as a swingout type door or in the conventional tail gate manner The sequence of ad...

Page 828: ...ttach torsion bar bracket to pillar post 6 Open tail gate and tighten locking screws on 7 Connect electrical leads and install trim panel 8 Operate tail gate window and inspect alignment hinge pivot p...

Page 829: ...ectly fitted to its opening the inner belt weatherstrip installed and all glass and related hardware compo nent attaching screws and nuts loosened 1 With tail gate opened in tail gate position push gl...

Page 830: ...asten ers and secure with screws x Q I NU459 Glass Lie Channels To replace the glass lift channels Fig 86 it is necessary to first remove the glass assembly The channels are positioned over sliding bl...

Page 831: ...Fig 88 in inner panel lnstallation 1 Position channel assembly into tail gate and align to upper and lower holes in tail gate pillar 2 Secure channel to pillar with screws 3 Install glass assembly TO...

Page 832: ...hes it to the retainer The outer weatherstrip and clip assembly is held in position in the retainer by the weatherstrip clips Index top edge of outer weather strip flush with top edge of inner weather...

Page 833: ...DECK LID LOCKS The lock cylinder is retained by a spring steel U The vacuum actuated deck lid lock release system NU192 RETAINER A NU192 Fig 94 Deck Lid Lock Cylinder Fig 95 consists of a vacuum tank...

Page 834: ...t 3 Wind bar and insert end into center adjusting 4 Place lid in various open positions and test 5 Adjust bars until deck lid stays in open position slot tension WEATHERSTRIPS Removal a load Release l...

Page 835: ...of both front and rear floor covers The rear floor covering is positioned under the front covering To remove the rear floor covering it is necessary to re move the front seat assembly and the rear sea...

Page 836: ...sun visor mounting bracket screw holes in header and cut holes in headlining slightly larger than attaching screws 10 Install sun visors and tuck in corners of head lining at top of windshield posts...

Page 837: ...th semi flexibletype plastic mould ings Figs 12 and 13 forced over the retainer sections of the roof bows Starting at either outer end remove end cap and pry the moulding off retainer When installing...

Page 838: ...o seat it in side re 3 Align edges of section with moulding retainer 4 Install mouldings on bow retainers and caps NR347 w NU291 Glove Box 15 and 16 The glove box is a one piece folded type Figs 14 Re...

Page 839: ...DOOR HARDTOP VIEW ARROW A 4 DOOR MODELS SUPPORT LISTING WIRE SECTION C C SECTION B B HEADLINING u SECTION A A NU293 Fig 8 Headlining Application Fury LISTING WIRE VIEW A LISTING WIRE NR497 Fig 9 Headl...

Page 840: ...r window side 3 Loosen cemented end edges of trim panel 4 Raise trim panel at front and remove retainers 5 Slide trim panel forward and up to remove 6 Raise front edge of silencer pad and using a putt...

Page 841: ...aise or lower the front seat Figs 20 21 and 22 Y 7 TEREO CROSSOVER a SCREW NR498 Fig 16 Glove Box Fury SCREW Fig 17 Glove Box Door Valiant Barracuda loosen the adjuster mounting bolt nuts under the fl...

Page 842: ...back forward move the latch assembly Fig 23 until clearance is obtained at the pivot pin ALLEN SCREW Removal pin latch assembly 1 Remove snap ring and flat washer from pivot 2 Remove end of spring fr...

Page 843: ...e handle shaft from inside through hole in seat back installation end of spring in pivot groove outer end of spring in notch on latch latch assembly 1 Position spring on pivot and align inner 2 Instal...

Page 844: ...t use hole for adjuster rod 3 Position adjuster clevis end in bracket on seat back and secure with spring pin 4 Position seat back on cushion with shoulder SEAT BACK SPRING WASHE Fig 25 Reclining Seat...

Page 845: ...ssary Second Seat Cushion Removal 1 Raise rear floor hinged panel at rear of seat cushion assembly Fig 28 to expose seat cushion to floor pan attaching screws 2 Remove screws attaching cushion to floo...

Page 846: ...ig 30 is at tached to the seat back frame and over end of the release rod The cam bearing is positioned on release rod and into lower hole in hinge assembly The cam is pressed into the release bearing...

Page 847: ...ack panel with screws Cover Material Installation Prior to installing the original or new cover make certain the spring pad where used and pad cover are centered on the spring and are firmly attached...

Page 848: ...SCREW VIEW IN DIRECTION OF ARROW Y Fig 32 Front Sour Shoulder Belts Except Convertible Satellhe NU26 SHOULDER BELT ANTI RATTLE WASHER SHOULDERBELT WASHER C T C D U L I VIEW IN CIRCLE Y NU18 REAR LAP B...

Page 849: ...A BODY AND FRAME 23 113 3RD SEAT NU20 Fig 34 Rear and third Seat Lap Belts Satellite Fig 35 Front Seat Shoulder Belts Except Convertible Valiant Barracuda MyMopar com...

Page 850: ...LENCER PAD SHOULDER BELT VIEW IN CIRCLE X EINFORCEMENT WHEELHOUSE W VIEW IN CIRCLE Z OUTER LAP BELT VIEW IN CIRCLE Y STATION WAGON SEDAN HARDKP FASTBACK NU23 Fig 36 Rear Seat Shoulder 6elts Satell te...

Page 851: ...A BODY AND FRAME 23 115 SHOULDER BELT I ANT RATTLE WASHER NU25 Fig 38 Front Seat Shoulder Belts Convertible Barracuda Fig 39 Front Seat l a p Belts Fury MyMopar com...

Page 852: ...RATTLE WASHER FLOOR PAN IN DIRECTION OF ARROW Z VIEW IN CIRCLE Y NU19 Fig 40 Rear Seat Lap Belts Vallant Barracudu VIEW IN DIRECTION I STUD OF ARROW Y NU470 VIEW IN CIRCLE Z Fig 41 Front Seat Shoulder...

Page 853: ...23 117 STOWAGE BRACKETS OF ARROW Z 2ND SEAT ONLY SHOUL SPACER ANTI RATTLE VIEW IN CIRCLE X SECOND SEAT INBOARD INSTALLATION THIRD SEAT WASHER VIEW IN CIRCLE Y NU472 Fig 42 Rear and 3rd Seat Lap Belts...

Page 854: ...LACEMENT Removal 1 Place protective coverings over the areas adja cent to the glass being replaced 2 Remove window exterior mouldings using Tool C 4009and inner garnish mouldings 3 Secure one end of a...

Page 855: ...ss is installed tape on glass can be aligned with tape on body 8 Remove glass from opening and place on a protected surface with inside surface up 9 Primer solution will damage any paint or trim it co...

Page 856: ...fibre wedge and Fig 7 Windshield Weatherstrip Satellite with a slight twist to wedge unlock weatherstrip by moving tool around weatherstrip 5 Carefully loosen weatherstrip from glass inner and outer s...

Page 857: ...s Removal 1 Cover cowl hood and fender area with a protec tive covering 2 Release top locking mechanisms and push header from windshield frame to expose moulding re tainer screws 3 Remove wiper arms a...

Page 858: ...ne of the up per corners and remove glass from weatherstrip 4 Place glass on a cloth covered bench 5 Remove weatherstrip from fence lnstalIation clean smooth and straight 1 Inspect weatherstrip fence...

Page 859: ...ion fluid until fluid runs out of filler hole FOLDING TOP MECHANISM The electric hydraulic top folding mechanism Fig 1 consists of two cylinders a piping system an elec trict motor a pump and reservoi...

Page 860: ...gs door glass and quarter glass must be properly aligned Misalignmentin any of these areas make it impossible to obtain satisfactory results from top adjustments alone Glassup stop adjustments should...

Page 861: ...locking effort Inspect clearance for uniformity The nylon wedges control the fore and aft position of the folding top header To eliminate interference between the header and finish moulding rotate th...

Page 862: ...o loosen any paint bond between cam and linkage On Fury models the cams are adjusted in 45 de gree increments only Stack Height Do not move mounting plate positions until control links have been adjus...

Page 863: ...eliminated by a tube type weatherstrip Figs 12 and 13 secured to the underside of the top header The forward edge of weatherstrip contacts the wind shield header outside moulding On Satellite Barra c...

Page 864: ...Remove front screws from front roof rail weatherstrip retainers and remove top material lock ing flaps Fig 17 from between retainer and roof rail TOP ASSEMBLY TOP e C l m C CTDlD ASSEMBLY wm VlFW 7 _...

Page 865: ...r line of cover and header in alignment tack one half of cover to the header STAPLES SEC NU478 Fig 18 Tacking Cover at No 3 Roof Bow Space tacks approximately one inch apart 18 Install a drive nail at...

Page 866: ...4 Station Wagon Rear Areas 136 Cowl Dash Panel Floor Pan Areas 138 Deck Lid and Tail Light Areas 139 Door Frames and Drain Troughs 133 Floor Pan Areas 140 Pillar and Drain Trough Areas 137 Quarter Inn...

Page 867: ...the weatherstrip will transfer to the A post when the door is closed if a good contact exists SEALERS AND COMPOUNDS Super Rubber Cement May be used where a strong bonding of rubber parts to painted or...

Page 868: ...23 132 BODY AND FRAME A Underbody Areu Fury MyMopar com...

Page 869: ...m m L ALL MODYLS ALL MODELS VIEW IN DIRECTION O F ARROW D SEAL 4 DOOR VIEW IN DIRECTION OF ARROW X EXCEPT SEDAN VIEW IN DIRECTION O F ARROW Z DOOR PANEL SEALER PILLAR i VIEW IN DIRECTION VIEW IN DIRE...

Page 870: ...ION VIEW IN DIRECTION OF ARROWC DIRECTION OF ARROW A VIEW IN DIRECTION 2 DOOR SEDAN LOWER O F ARROW D OF ARROW B ALL MODELS QUARTERPANEL VIEW IN DIRECTION OF ARROW E 2 DOOR SEDAN VIEW IN DIRECTION OF...

Page 871: ...APPLICATION IN CIRCLE A SE QUARTER PANEL EXTENSION I WHEELHOUSE I OF ARROW B I SEALER REAR FLOOR PAN EXCEPT STATION WAGON SE VIEW INCIRCLE T VIEW IN DIRECTION OF ARROW V JLlI J SEALER FLOOR PAN STATI...

Page 872: ...CTION OF ARROW G FLOOR PAN AR FLOOR PAN IDE EXTENSION VIEW IN DIRECTION OFARROW I TIRE WELL AREA QUARTER PANEL VIEW IN DIRECTION O F ARROW A ILLAR DIRECTION OF ARROW E WHEELBASE PANEL TAILGATE AND REA...

Page 873: ...OF ARROW Z TIRE WELL SEA Tire Well and Floor Pan Station Wagon Fury SEAFR SEALER V A m INCH SEALER BALLS b NU362 QUARTER PANEL SEI V M IN DIRECTION OF ARROW A 2 DOOR 4Y E ILL BARRACUDA Pillar and Drai...

Page 874: ...LOOR FRAME NU127 Cowl Dash Panel Floor Pan Area Valtant Barracuda EALER QUARTER PANEL SIDE I SILL EXCEPT CONVERTIBLE CONVERTIBLE BELT BAR AND QUARTER PANEL NU123 Belt Bar Area Satellite WHEFLHOUSE SEA...

Page 875: ...B Deck Lid Tail Light Areas Satellite RTER ePANEL NU124 QUARTER PANEL DECK UPPER PANEL ALL EXCEPT FASTBACK OPENING FILLER QUARTER VIEW IN CIRCLE Y OUTER PANEL DECK LOWER PANEL EXTENSION DIRECTION OF...

Page 876: ...Fig 2 6 When the cement becomes tacky position cover on roof panel 7 Repeat steps 5 and 6 for the opposite side 8 Using a new paint roller pressurize cover to the roof working from center area toward...

Page 877: ...8 inch above lower edge of flange Fig 6 19 Locate and drill index hole for front pillar moulding upper locating boss Fig 5 original instal lation only NK985A Fig 3 Positioning Cover in Window Reveals...

Page 878: ...over to metal surface starting from one side of bubble and work ing toward opposite side until it conforms to metal surfaces and all raised surfaces disappear 9 Keep car from hot sunlight and other di...

Page 879: ...ditions a slight jerking motion will aid in paper backing removal Thoroughly wet application surfaces of body and the adhesive surface of the overlay with the wetting Flat Surfaces Use a plastic squee...

Page 880: ...nch rubber roller to be sure that overlay is well adhered to the painted metal surface Contoured Areas 1 Warm the unapplied overlay with a heat lamp working on an area no more than 1 2inch larger than...

Page 881: ...le and lower frame assembly out of vehicle as follows 1 Remove battery and air cleaner drain cooling system remove radiator and shroud disconnect heat er hoses from engine and disconnect battery tray...

Page 882: ...or support 2 Install body to frame bolts nuts and washers and tighten to 75 foot pounds 3 Install nuts and washers on studs at radiator support lower flanges 1 I a Fig Body to Crossmember Mounting 4 R...

Page 883: ...147 A 2 1 3 5 53 33 1 57 98 I 52 41 STATION WAGON 60 90 STATION WAGON 5 22 STATION WAGON NK1166B Fig I Body Frame Dimensions Fury BOTTOM VIEW SIDE VIEW Fig 2 Body Frame Dimensions Satellite 0 LINE NK...

Page 884: ...LE This means one coat overlapping to give complete coverage COAT DOUBLE A double coat means to first spray a single coat in 1 4 inch In making any body opening measurements always compare the matchin...

Page 885: ...er possible sanding should be done with a block as it distributes the pressures and gives a more uniform surface SURFACING The function of a surfacer is to prepare a smooth surface for the color coats...

Page 886: ...This operation is the backbone or foundation for the finish color It primes the metal to insure adhe sion and fills minor surface imperfections Use one of the recommended lacquer primer surfacers 8 Ap...

Page 887: ...ack Brite Blue Green Brite Red Corporate White Corporate Blue Single Tone X9 X9 Two Tone X9 Wl VALIANT BARRACUDA SATELLITE FURY Chrysler Silver Metallic AY2EA4 Ice Blue Metallic AY2EB3 Blue Fire Metal...

Page 888: ...1685 L O W GLOSS FINISH COLORS Jewel Black AB5TX9 9028 Front Seat Manual Adjuster Console Jewel Black semi gloss AB3TX9 9293 Optional for Front Seat Manual Adjuster Majesty Blue AB5EB9 13686 Console O...

Page 889: ...Bayou Green Metallic AC39EF8 43925 Regatta Red AC38ER8 71688 INTERIOR COLORS SATELLITE EXTERIOR GLOSS FINISH COLORS Console only Optional for Front Seat Manual Adjuster Console only Console only Cons...

Page 890: ...embly Adjuster Jewel Black AB3TX9 9293 Alternate for Adjuster Jewel Black AB5TX9 9028 a Baltic Blue Metallic AB6EB7 13670 a Desert Tan AB5ET1 23079 a Bayou Green Metallic AB6EF8 43929 a SUEDE FINISH C...

Page 891: ...d air is controlled by the Heat Defrost lever on the instru ment panel The blower switch determines the speed of the Page Heater Core 7 Heater Doors 8 InstaIlation 5 Fury V 1 P Blower Motor 7 Blower M...

Page 892: ...E H O U E 6 CRANK HEAT SHUT OFF DOOR CRANK TO DEFROSTER HEAT DEFROST DOOR CRANK PASSENGER SIDE HOUSING BLOWER MOTOR TUN SCREW RESISTOR BLOCK HEAT DISTRIBUTION DUCT LOCATING SCREW ENGINE SIDE HOUSING N...

Page 893: ...LE ADJUSTMENTS 2 With control assembly removed from instru ment panel position the three control cables so the cable housing is flush with edge of the cable mount ing bracket Fig 5 Install new clips 3...

Page 894: ...CHAMBER MOUNTING NUT 3 NP265 Fig 4 Fresh Air Duct Driver s Side ment panel position the three control cables so the cable housing is flush with edge of the cable mount ing bracket Fig 5 Install cable...

Page 895: ...e remov ing the heater as follows a From inside console storage compartment re move two console mounting bolts and two metal screws from the front sides in carpeting b Remove two shift indicator bezel...

Page 896: ...7 Remove bottom retaining nut from support bracket and swing bracket up out of the way 8 In engine compartment remove four retaining nuts from studs on engine side housing 9 Remove locating bolt from...

Page 897: ...ld connect heater hoses to core tubes 5 Fill cooling system and connect battery negative cable 6 Start engine operate heater and bleed air from system BLOWER MOTOR Fury and V I P Models The blower mot...

Page 898: ...nting Valiant and Barracuda Models Fig IO Heater Hose Connections 273 Cu In Engines Valiant and Barracudu Models 5 Connect heater hoses to heaters Fig 10 6 On passenger compartment side connect heater...

Page 899: ...ONING INDEX Page General Information 11 Vacuum Circuits Fury and VIP 13 Air Flow for Each Push Button SatelIite 16 Fury and VIP 13 Valiant 21 Anti Freeze Recommendations 37 Blower Motor Fury and VIP 4...

Page 900: ...EXISTING STUD IN PLENUM FRONT HOUSING d A C DOOR ACTUATOR w TIME DELAY RELAY FRESHIRECIRCULATING SUPPORT BRACKET BLOWER MOTOR A y AIR DOOR ACTUATOR R E S I S T O R BLOCK RECIRCULATING AIR DOOR HOUSIN...

Page 901: ...s and mechanical linkages The blower is turned on by any of four push buttons The second option is the Automatic Temperature Control System which automatically controls the heat ing and air conditioni...

Page 902: ...intains any SOLID LINE INDICATES VACUUM VACUUM SOLID LINE INDICATES VACUUM VACUUM Fig 4 Vacuum Circuit Heat Poshion desired temperature by sliding the lever right or left when operating either the hea...

Page 903: ...eft of the column controls the air inlet on the left side of the car and the right hand knob controls the right side The amount of air intake is regulated by the distance the knobs are pulled out Push...

Page 904: ...operation of the electrical and vacuum controls The Push Button Control Chart summarizes the actions that should take place when each button is for Each Push Button Position If all the controls operat...

Page 905: ...fore it can be blown onto the windshield Should it become necessary to replace the vacuum hose leading to the heater door actuators the correct restrictor should be used SATELLITE The air conditioner...

Page 906: ...tton position Figs 8 through 11 and Push Button Control Chart page 15 0FF The OFF button turns the system off Vacuum ap FRESH AIR ACTUATOR NU141 Fig IO Hear Position plication and door positions are t...

Page 907: ...G OPERATION The air conditioning refrigeration system operates at full capacity constantly when either the MAX A C or A C button is pushed Full capacity mean ing maximum refrigeration according to the...

Page 908: ...for a period of 2 to 10 minutes If the system is shut down for less than ten min utes no delay will occur upon restarting The relay will reset automatically after ten minutes shut down Restrictors Sat...

Page 909: ...housing Remove the radiator cap to minimize pressure in the car s cooling system Move the temperature control slide lever on the instrument panel to the extreme Warm position Push the Max A C button...

Page 910: ...se the control cable housing may be shortened or lengthened by rotating the turnbuckle remove glove box on To adjust the temperature control cable place the water valve in the full open position and p...

Page 911: ...s off the entire system Max A C maximum air conditioning A C fresh air air conditioning Heat for heater use only Def windshield defrosting Temperature Control Slide Lever Maintains any desired tempera...

Page 912: ...r manifold Since the heater defroster door is raised the full flow of heated air goes through the heater outlets except for a small amount that bleeds off through the defroster outlets DEFROST When th...

Page 913: ...nual have been ar ranged in a logical sequence that has proved to be the surest and shortest route to accurate diagnosis It is recommended that they be followed and per formed in the order in which th...

Page 914: ...ressor Clutch Off On On Off Off operating at idle speed vacuum will be high and vacuum actuators should operate quickly If actuator operation is slow check the source hose connection at engine manifol...

Page 915: ...ed comfort by pushing the A C button and adjusting the fan switch to change fan blower speed If less cooling is desired move the fan switch lever to Low speed and re adjust the cooling outlets for ind...

Page 916: ...em of the valve in the service port is depressed opening the service port valve Discharge Pressure Gauge at the center of the manifold set is calibrated to register 0 to 300 psi For all tests this gau...

Page 917: ...ormal temperatures and pressures The vapor is heavier than air non flammable and nonexplosive It is nonpoisonous except when it is in direct contact with open flame It is noncorrosive except when com...

Page 918: ...g refrigerant on any surface Refrigerant in combination with moisture is very cor rosive and can cause great damage to all metal sur faces TEST 1 TEST SYSTEM PRESSURE Enginenot Running Install the gau...

Page 919: ...nd when adding to the charge The sight glass is an integral part of the receiver strainer drier The outlet line liquid from the con denser must be attached to the connection marked IN The word IN is s...

Page 920: ...side of the system to escape TEST 4 CORRECTING LOW REFRIGERANT LEVEL Since the refrigeration system is completely sealed refrigerant level will not be low unless there is a leak in the system or refri...

Page 921: ...be used so that exactly 1 2 pound of refrigerant is added after foam clears inthe sight glass NK1439B d Close dispensing manifold valve Remove test hoses and adapters from the service ports of compres...

Page 922: ...1600 and Satellite 8 Cyl 1300 VaIiant 6 Cyl 1250 8 Cyl lo00 iSSOR INLET PORT NK1440A move fan switch to high Open grille outlets Adjust engine RPM as outlined in the following chart Arrange gauge set...

Page 923: ...nt unit off by pushing the OFF button Connect a jumper from the positive terminal of the battery to the compressor so that the refrigeration part of the entire system can be operated without air flowt...

Page 924: ...discharge pressure within these l i m i t s registered on the psychrometer To increase the discharge pressure restrict the air Observe and record Discharge A i r Temperature f l o w across the conden...

Page 925: ...air conditioning controls for Max A C high blower and temperature control lever to full reheat position Set RPM s at EQUALIZER TUBE CAPILLARY SENSING TUBE NU204 Fig 34 Expansion Valve Details Typical...

Page 926: ...or less If the compressor inlet pressure is higher than 17 psi the EPR valve should be replaced If the expansion valve passes Tests A through F then the compressor valve plate should be removed and th...

Page 927: ...system will not be left open any longer than necessary Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture All lines and compo nents in parts sto...

Page 928: ...radiator pressure cap using Tool C 4080 Fig 38 Before assembling adapter and radiator pressure cap to the pump dip radiator cap and both ends of adapter into clean water to assure a tight seal NY303A...

Page 929: ...m tester gauge needle will drop until the actu ator has operated and then will return to 8 inches Note how much the vacuum drops below 8 inches Continue to push buttons Off Max A C A C Defrost and Hea...

Page 930: ...give the maximum possible opening when the fresh air door is complete ly closed Push in the A C Air Conditioning but ton and inspect to see that the recirculating door has moved to its fully closed p...

Page 931: ...osed 2 Defroster Door Open 3 Fresh Air Door Open 4 Defroster Door Closed TEST 1 Test System Pressure If vacuum drop is still in excess of 3 4 inch remove connector plug from switch Insert the vacuum t...

Page 932: ...assembly on the base of compressor bearing housing Make sure coil assembly is positioned so lead wire points to left of compressor as viewed from the front Install the three mounting screws and tighte...

Page 933: ...R TOOL SUPPORT NB 63 Fig 53 Removing Bearing From the Pulley Assembly TOOL BEARING NB62 Fig 54 Installing a New Bearing in the Pulley Assembly fTypical frigerant oil level in the compressor before the...

Page 934: ...Install new 0 ring on the EPR Valve 2 Lubricate 0 ring with refrigerant oil and in stall EPR Valve in the compressor with Tool C 3822 while rotating the valve counterclockwise 3 Install compressor suc...

Page 935: ...e refrigerant has been released from the system 1 Operate the system for 15 minutes at 1000 engine rpm for eight cylinder engines and 1100 en gine rpm for six cylinder engines These engine set tings w...

Page 936: ...ts to insure reassembly inthe original position 6 Remove rod caps remove piston and rod as sembly from cylinder Inspeetion Inspect piston and rings for score marks Inspect rod bearing for pits and for...

Page 937: ...Fig 62 Removing Crankshaft Bearing Housing CARBON SEAL I COIL SPRING SPRING TANGS SARTRIDGE TYPE UNITIZED TYPE NU8 Fig 63 Gas Seal Identification lnstallation 1 Immerse the new seal seat in clean ref...

Page 938: ...kshaft 2 Install crankshaft making sure the thrust v Fig 64 Measuring Crankshaft Axial Movement washer is on the rear bearing journal before placing crankshaft in the crankcase 3 Rotate crankshaft to...

Page 939: ...cket up out of the way carefully roll front cover and heater core out from under instru ment panel Installation 1 Place heater core in front cover and position core and cover on evaporator housing Hol...

Page 940: ...h glove box opening remove retaining nut from housing end of support bracket and swing bracket up out of the way 9 Carefully roll housing out from under instru ment panel 10 Place unit on bench discon...

Page 941: ...ctuator on left side of housing 11 Install steering column cover FRONT COVER NU383 Fig 70 Evaporator RemovedFromFront Cover 12 Install left spot cooler duct 13 Connect suction line and expansion valve...

Page 942: ...NG DOOR HOUSING DISTRIBUTION TEMPERATURE HOUSING CONTROL VALVE CAPILLARY WELL NK1395 A fresh air recirculating door housing assembly F ig 76 6 Remove defroster hoses disconnect electrical connections...

Page 943: ...By Pass Valve Link Attaching Screw stripe to the rod side and install the fresh air recircu lating door housing Connect floor air actuator rod to the linkage with the retainer clip 7 Install fresh ai...

Page 944: ...m hose cluster at control switch and at Tee source connector 7 Disconnect electrical connections at resistor block 8 Remove right hand spot cooler duct and spot cooler held by two button head spring c...

Page 945: ...fittings Use two wrenches to prevent rotation and twisting of the lines 8 Connect the heater hoses Figs 79 thru 81 9 Install the Ranco valve sensing tube 10 Install the right hand spot cooler and duc...

Page 946: ...move mounting plate blower motor and fan 3 Test operation of blower as an assembly EXPANSION VALVE Valiant installation If the blower was removed from the mounting plate be sure the mounting grommets...

Page 947: ...he Fig 85 Expansion Valve Details evaporator suction line 3 With a rubber seal on the capillary sensing tube carefully install the tube in the well located in the suction line as far as it will go app...

Page 948: ...ct heater housing support rod from the fresh air duct Fig 87 7 Remove heater assembly 8 Removefresh air recirculating door actuator 9 Remove operating link between bellcrank and I BOWDEN CABLE NKlUU r...

Page 949: ...nd wire 12 Install right defroster tubing glove box as sembly and air outlet assembly 13 Install heater hoses Figs 89 and go fill cool ing system connect battery terminal and install air cleaner 14 St...

Page 950: ...ER DRIER ASSEMBLY SUCTION MUFFLER ASSEMBLY CONDENSER ASSEMBLY LIQUID TUBE ASSEMBLY NP672 Fig 90 Air Conditioning and HewerPlumbing Valiant 273 Cu In Engine these connections Cap all the refrigerant op...

Page 951: ...tud nuts that attach the assembly to dash panel 6 Install blower motor wires and air tube suction line Use two wrenches to prevent rotation 7 Use new 0 rings with clean refrigerant oil on all connecti...

Page 952: ...d be replaced and the system evacuated using a vacuum pump to remove all air and moisture The system should be charged with the proper amount of refrigerant Detailed instruction for performing these o...

Page 953: ...t manifold valves and open the gauge set manifold needle valve 2 Attach the free end of the long hose used for discharging to the refrigerant dispensing manifold 3 Attach a single can of Refrigerant 1...

Page 954: ...oon as the reaction plate seen through the window in the burner shield becomes red hot the tester is ready for use 2 Examine all the tube connectors and other pos sible leak points by moving the end o...

Page 955: ...vacuum If system is tight and pump in good condi tion vacuum will go as low as 28 inches 4 Allow vacuum pump to operate with the suction gauge registering 26 to 28 inches of vacuum for a minimum of f...

Page 956: ...sure at the discharge service port should read between 140 and 210 psi before starting the test expansion valve thermo bulb in well c Place the sensing element thermo bulb of the rear unit expansion v...

Page 957: ...s the heating and air conditioning operation of the vehicle to maintain a selected interior temperature In cold weather the system provides heat In warm weather the system provides cool dehumidified a...

Page 958: ...CONDITIONING DEFROSTER DUCT RECIRCULATING AIR DOOR TRANSFER SWITCH CONTROL UNIT PASSENGER SIDE HOUSING BLOWER MOTOR COMPRESSOR AMBIENT SWITCH NU520 ENGINE SIDE HOUSING Fig I AWo Tornp HoudngAssemblkr...

Page 959: ...This control is located above the push buttons in the control head It allows the operator to select any interior comfort setting from 65 to 85 Movement of the thumbwheel controls a resistance potenti...

Page 960: ...24 70 AIR CONDITIONING A H t al C 0 E c d Y MyMopar com...

Page 961: ...wer servo amplifier and transducer If the unit is found defective it is to be replaced as an assembly and no attempt shall be made to service it internally SERVICE DIAGNOSIS Condition Possible Cause C...

Page 962: ...Inspect lines BLOWER AND COMPRES SOR WILL NOT OPERATE AND SYSTEM WILL NOT GO INTO SELECTED MODE partment sible replace if necessary vacuum reservoir BLOWER WILL NOT OPERATE ON ANY MODE a Blower motor...

Page 963: ...uum lines to mode and defrost a Route properly actuators completely crossed FROST OR AIR CONDI a Doors binding or linkage bent or mis a Repair or adjust linkage OR HI AUTO EVEN WITH of unit a Air hose...

Page 964: ...high resistance corn by replacing switch with a jumper pressor switch wire replace switch if necessary f Fresh air door stuck in 100 fresh air f Inspect spring test vacuum transfer position broken ret...

Page 965: ...cal connection at sensors a Inspect connections b Loose electrical connection or other b Test control unit replace if necessary or at control unit fault in control unit PERATURE AND POS SYSTEM DOES NO...

Page 966: ...Tap gauge and re cord this reading Continue to increase vacuum to Maximum then slowly rotate control dial back to Calibrate Tap gauge Reading must be within 1 inch Hg of the recorded reading indicatin...

Page 967: ...lots No air should be coming out of A C outlets 3 The air temperature should have remained es 4 Blower speed increases sentially the same as in Auto Hi Defrost Push Hi Defrost button and observe the f...

Page 968: ...Closed Hi V J HI AUTO Minimum 0 Hg 20 Open Closed Closed Hi knob from 3 5 100 Open Closed Closed M3 Slowly rotate vacuum control minimum to maximum 20 Open Closed Closed Hi to M3 4 100 Open Closed Cl...

Page 969: ...stat There should be no increase in discharge air temperature 4 Increase vacuum to water valve to 4 5 inches Hg and observe a slight increase in discharge air This increase should be about 10 F 5 Fina...

Page 970: ...jump er the switch should be replaced COMPRESSOR VACUUM SWITCH This switch is vacuum operated and turns on the compressor if the ambient switch is closed It is iden tical to the blower master switch e...

Page 971: ...ge Compressor Test Suction Pressure Inlet light Gauge Gauge Gauge OFF 22 180 30 ON 30 150 0 or below Head pressure may vary but a 25 to 30 pound pressure differential will show during switching ac tio...

Page 972: ...efrigerant leaks 14 Reconnect 12 V D C lead from anti freeze switch to ETR valve at the terminal gasket Check system for proper operation TEMPERATURE CONTROL DIAL The control dial allows the operator...

Page 973: ...SWITCH 16V 16V 16LGN M2 DEFROSTER _ _ _ 16T HIGH DEFROSTER I 1 2 D G N d TO BLOWER MOTOR MOLDEDGROMMET LEGEND e l B FEMALE 5 3 MALE 1w1w MALE FEMALE INSULATORS VIEWED I FROM TERMINAL SIDE Fig 8 Auto...

Page 974: ...the system if it is suspected ASPIRATOR The aspirator is a tube shaped device connected to the passenger side housing in such a manner that air flowing through the housing creates a slight vacuum in t...

Page 975: ...ves which are found faulty and check out sys tem to see if malfunction has been corrected It should be noted that the most severe test on a check valve is below freezing weather It is possible that a...

Page 976: ...onnect Auto Temp Tester as shown in Figure 3 Place system in minimum vacuum position System should be in the maximum cooling position air con ditioning 20 F A and Hi blower Put freshhecirculating door...

Page 977: ...A AIR CONDITIONING 1 I I 24 87 a i 6 3 I Y 2 5 Z MyMopar com...

Page 978: ...A 24 88 AIR CONDITIONING t r L t E 2 9 VI L MyMopar com...

Page 979: ...A AIR CONDITIONING 24 89 f P Z c 5 c t L u MyMopar com...

Page 980: ...24 90 AIR CONDITIONING A L W 4 J MyMopar com...

Page 981: ...A AIR CONDITIONING 24 91 L w X I sv 8 JJ L U MyMopar com...

Page 982: ...essure increase air flow across condenser with external floor fans Observe and record both the Inlet D r y Bulb Tem perature and Inlet Wet Bulb Temperature as registered on the psychometer Observe and...

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Plymouth Barracuda 1969, Service Manual

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