PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor
Page 1: ...A A 11111131 piV 11M ND PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor...
Page 2: ...10 61 10 Universal Joints and 6 Propeller Shaft 75 00 81 00 135 010 9 Transmission Overdrive 143 110 PowerFlite TorqueFlite 7 Steering Power Steering Q Frame Rear Springs Shock Absorbers SECTION Page...
Page 3: ...PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyMopar com...
Page 4: ...six million automotive vehicles in operation in the United States Every year as new vehicles are put into use new inexperienced drivers take the wheel increasing the problem of handling traffic on ou...
Page 5: ...e coil and distributor BODY NUMBER LOCATION The body number is stamped on a plate which is attached to the left side of the engine side of the dash GENERAL DATA AND SPECIFICATIONS Model 30 and LP 1 P...
Page 6: ...ice needs of the Plymouth car this manual con tains over 300 diagnosis procedures In most instances it is advisable to make a road test to verify the condition Throughout the manual service data and s...
Page 7: ...PPER BUSHING NUTS SHIM NUT BUMPER BUSHING WASHER CAM SEAT TORSION BAR SEAL INNER SEAL OUTER RETAINER BUMPER STEERING KNUCKLE FLAT WASHER NUT COTTERPIN NUT FLAT WASHER COTTERPIN BOLT SEAL LOWER CONTROL...
Page 8: ...ear ends of the bars engage adjustable anchor assemblies which are supported by brackets welded to the frame side rails as shown in Figure 2 The inner end of the upper control arm has two rubber bushi...
Page 9: ...LOWER CONTROL ARM BALL JOINT 57P68 Figure 6 Upper and Lower Control Arm Ball Joints Figure 7 Lower Control Arm Strut Mounting To maintain a fixed position in relation to fore and aft movement of the l...
Page 10: ...ower Control Arm Strut Bolt Nut 65 ft lbs Tie Rod Clamp Bolts 10 to 15 ft lbs Remove shock absorber lower eye mounting bolt and Remove the lower mounting bushing from the shock nut from mounting brack...
Page 11: ...per control arm 2 INSTALLATION When installing new ball joint it is very important that the ball joint threads engage those of the control arm squarely With the lubrication fitting removed screw ball...
Page 12: ...move from under car Remove wheel and tire as an assembly Disconnect shock absorber at lower control arm bracket then push shock absorber up into frame out of the way Remove TOOL BALL JOINT STEERING KN...
Page 13: ...f the vehicle as indi cated The part number of the bar is stamped on the opposite end This end is to be installed on the anchor end for identification purposes Turn bar until anchor cam is positioned...
Page 14: ...s to grease from soiling the lining arm as near to tire and drum prevent dirt or Remove the cotterpins nuts and lockwashers that at tach the steering arm and brake dust shield to the steer ing knuckle...
Page 15: ...anchor sufficiently to disengage forward end from lower control arm Now slide bar forward and down disengaging from anchor Remove from car The only parts of the torsion bar rear anchor that may requi...
Page 16: ...rk the front bumper up and down several times This will place the torsion bars and shock absorbers in their normal position The car must remain in a normal position while checking camber caster and st...
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Page 19: ...o check the steering axis inclination However if camber cannot be adjusted within the recommended limits steering axis inclination must be checked If the axis inclination is not within 51 2 to 7 check...
Page 20: ...originate in the steering gear or steering column disconnect the steering gear arm and turn the steering wheel to check for a bind in the steering column 1 STEERING WHEEL An improperly centered steer...
Page 21: ...SHIMS CONE AND ROLLER ADJUSTER 1 BOLT PINION Ck LOCKWASHER WASHER SCREW Figure 1 Rear Axle 6 Cylinder 8 A inch Ring Gear SPACER CUP SIDE GEAR THRUST WASHER PINION SIDE GEAR THRUST WASHER DRIVE GEAR AN...
Page 22: ...CAUTION Do not strike the end of axle shaft to loosen the hub otherwise possible damage to the axle shaft bearings and thrust block might result 21 NOTE Cleanliness and inspection are vital factors t...
Page 23: ...ts 31 2 pts TORQUE SPECIFICATIONS Axle Shaft Nuts 145 ft lbs min Rear Axle Ring Gear Bolt Nuts 40 ft lbs Differential Bearing Cap Screws 85 to 90 ft lbs Drive Pinion Flange Nut 240 to 280 ft lbs Figur...
Page 24: ...ap retain ing bolts and adjusting nuts to relieve the load on the bearings Remove the caps and adjusting nuts Lift the differential assembly out then remove the differential bearing cups from the bear...
Page 25: ...7 plates 6 cylinder Remove the differential pinion shaft lockpin by driv ing out of the case using a hammer and punch as shown in Figure 11 Drive the differential pinion shaft out of the differen tial...
Page 26: ...hen place locking tabs in position 6 cyl and install the gear retaining bolts Tighten the bolts from 35 to 40 foot pounds Place a differential bearing in position on the hub Using Tool DD 1005 to driv...
Page 27: ...ll the pinion oil seal during the pre load and pinion setting operations otherwise there will be an added drag on the pinion shaft which would give a false bearing pre load reading on the torque wrenc...
Page 28: ...sher while pinion marked use a thicker washer Pinion spacer washers are available in nine different sizes WASHER THICKNESS 084 in 086 in 088 in 090 in 092 in 094 in 096 in 098 in 100 in Fasten the gau...
Page 29: ...ing Tool DD 996 and an arbor press Slide the bearing spacer over pinion shaft followed by the shim pack selected during preload operation Insert the drive pinion bearing spacer and shim pack into the...
Page 30: ...Figure 26 Make certain that the indicator is properly positioned so that the plunger will accurately indicate the exact amount of backlash Check the backlash between the ring gear and pinion at 90 in...
Page 31: ...llows Refer to Figure 28 for Gear Nomenclature CENTER OF GEAR BACKLASH TO E CLEARANCE 45x416 H E E Figure 28 Gear Tooth Nomenclature FLAN K HEAVY FACE CONTACT If the tooth marking is across the length...
Page 32: ...y from pinion If necessary to re adjust backlash install thicker washer Install thinner washer be hind pinion If necessary to readjust backlash move ring gear toward pinion HEA HEEL r Figure 29 Gear T...
Page 33: ...n 10 AXLE SHAFT END PLAY Axle shaft bearings are adjusted by removing or in stalling shims which are available in various thick nesses One or more of these shims should be used as required to obtain p...
Page 34: ...angles to each other and loose fitting at their intersection Both ends of each shaft have two flat surfaces or ramps which mate with identical ramps in the differential case There is additional cleara...
Page 35: ...T AXLE DRIVE PINION CLUTCH PLATES DIFFERENTIAL CASE AXLE SHAFT DIFFERENTIAL SIDE GEAR V GROOVE DIFFERENTIAL PINION 58x262 Figure 36 Power Flow Axle Shafts Turning at Differential Speeds utr111 SCRIBE...
Page 36: ...inion gears Figure 42 Re move remaining side gear Figure 43 side gear retainer Figure 44 and clutch plates Figure 45 Remove axle shaft thrust spacer by pressing out lock pin SIDE GEAR AXLE SHAFT THRUS...
Page 37: ...es see Figure 39 Install clutch plates alternately with one thick plate with tang facing side gear retainer followed by an internal splined plate until 5 plates are installed PINION SHAFTS AXLE SHAFT...
Page 38: ...eased Loose tail pipe brackets or a bent tail pipe will cause rattling noise 4 CLUTCH Noise resulting from a faulty clutch disc unit may be heard when the car is accelerating at speeds of 25 to 30 mil...
Page 39: ...1 lbs i 1 16 in 29 to 32 lbs 4 97 in Brake Pedal Free Play at Pedal Manual Brakes Power Brakes 1 8 to in 1 16 to A in HAND BRAKE Type Internal Expanding PowerFlite TorqueFlite External Contracting 3 S...
Page 40: ...HEEL CONVENTIONAL BRAKE TOTAL CONTACT HEEL Figure 1 Total Contact and Conventional Brake Shoes 39 The total contact brake shoes have contoured webs see Figure 1 which allow greater flexibility of the...
Page 41: ...ner as the conventional cylinders but are mounted on the brake support plate Self energizing action is effective on all front brake shoes and the rear brake front shoe when the vehicle is traveling fo...
Page 42: ...n a machine having a cylindrical grinding wheel TOOL 57P240 Figure 8 Removing Shoes from Support Plates DRUM REFACING Measure the drum inside diameter with an accurate gauge Drum diameter service limi...
Page 43: ...dial indicator may be used to indicate movement in place of a scale Lubricate the brake shoe guide contacting areas on the shoes very lightly with lubriplate then install guides and retainers Refer t...
Page 44: ...oes not clean up at 002 inch should be discarded and a new cylinder installed Black stains on the cylinder walls are caused by the piston cups and will do no harm Before assembling the pistons and new...
Page 45: ...ntly opening and closing the valve about every four seconds This causes a whirl ing action in the cylinder which helps expel the air Continue this operation until brake fluid runs out of the bleeder h...
Page 46: ...meter of the cylinder bore is not increased more than 002 inch A master cylinder bore that does not clean up at 002 inch should be discarded and a new cylinder used Black stains on the cylinder wall a...
Page 47: ...o the clearance between the drum and the lining at the anchor bracket is 015 inch Lock anchor screw Turn guide bolt adjust ing nut 1 until the clerance between band and bottom of drum is 015 inch Then...
Page 48: ...ating lever and the stamped top facing up Work the shoe return spring under the grease shield spring and secure ends in proper holes in webs of shoes as shown in Figure 21 Spread the bottom of both sh...
Page 49: ...sitioned against the cable guide so that the brake operating lever is cen tered in its normal free play arc To lock this adjustment tighten the cable guide clamp and then tighten the hand brake cable...
Page 50: ...nkage When application of the brakes begins force is applied from the booster through the yoke assembly to the pedal assembly In this way the contraction of the bellows assists in applying the brakes...
Page 51: ...f pressure applied to the brake pedal As the pedal pressure is varied to suit braking re quirements the force supplied by the unit instantane ously varies in proportion If at any point during brake ap...
Page 52: ...pward Remove plate and lift out the return spring and spring retainer DISASSEMBLY OF VALVES Place unit on its side Remove the bolts and lockwash ers that attach the valve cover to valve Lift off valve...
Page 53: ...ew 0 rings and seal rings through out Be sure all seal and 0 rings are suitably covered with silicone grease Rings and seals are pre coated in parts kits 11 ASSEMBLY OF POWER BRAKE ASSEMBLY OF VALVE C...
Page 54: ...ely Remove assembly from holding fixture and invert unit Coat the guide lightly with silicone grease and install return spring as shown in Figure 40 Position the spring evenly around hub of valve hous...
Page 55: ...vehicle 1 PEDAL TRIGGER ADJUSTMENT Install gauge Tool C 3508 on power lever cross pin positioning center lines on gauge as shown in Figure 44 TO VACUU AIR IRLET OURCE AM VACUUM BELLOWS VALVE OPERATING...
Page 56: ...lay with linkage in this position by pushing lightly at the pad end of the brake pedal This should be from IA to 1 2 inch Lengthening or shortening of the push rod if necessary should be made at this...
Page 57: ...e pedal several times the following causes may be responsible 1 BRAKE FLUID Check the brake fluid level in the Master Cylinder reservoir Loss of brake fluid due to leakage is the most likely cause of...
Page 58: ...e If the unit is operating the brake pedal will move forward when engine vacuum power is added to the pedal pressure If the test shows unit is not operating I VACUUM TEST Check vacuum from manifold to...
Page 59: ...inch Disassembled LEVER SPRING PRESSURE SPRING RELEASE LEVER EYE BOLT PRESSURE PLATE STRUT PIVOT PIN DRIVE LUG DISC ASSEMBLY 55 P1047 s DRIVEN DISC DRIVE LUG OPENING Figure 2 Borg Beck Clutch 10 inch...
Page 60: ...requires replacement It can be adjusted and the com ponent parts can be replaced When working on the clutch assembly always check the clutch finger height adjustment and the pressure plate for paralle...
Page 61: ...2 in spec equip Number of Springs in Pressure Plate 91 4 in B B 6 springs 9 4 in Auburn 3 springs 10 in B B 9 springs 10 in B B 9 springs 101 2 in B B 9 springs 11 in B B 12 springs 350 cu in engine...
Page 62: ...nd the open end of the eye bolt are close together Also keep the eye bolt pin seated in the socket in the lever See Figure 7 g 34x 97 Figure 7 Removing or Installing Release Lever COVER SUPPORT PLATE...
Page 63: ...the release lever springs and place the pres sure springs over the bosses on the pressure plate Place the clutch cover over the pressure plate assembly and match up the punch marks so that these parts...
Page 64: ...Use a suitable lubricant such as Lubriplate on drive lugs and fingers CLUTCH RELEASE LEVER ADJUSTMENT AUBURN Install clutch cover plate assembly on fixture and make certain that the housing clamps li...
Page 65: ...TCH RELEASE BEARING Exercise care when installing a new clutch release bearing to avoid damaging the bearing race Never drive the bearing on the sleeve with a hammer Installation can be accomplished b...
Page 66: ...ct for bent or misaligned linkage 2 OVERCENTER SPRING Check adjustment of free play and overcenter spring if clutch pedal is hard to operate or the pedal will not return properly NOISES 1 RELEASE BEAR...
Page 67: ...l 5 Bolt Hole Circle dia 41 2 in Bolt Size 1 2 in No 20 65 ft lbs Torque cu e 1 Type Super Soft Cushion Tubeless Tire Size 7 50 x 14 in Std 8 00 x 14 Spec Equip Ply 4 Tread Twin Grip TIRE PRESSURE Pou...
Page 68: ...TH SPECIAL SERVICE TOOL Completely deflate tire by removing valve core Place tire and wheel over base of Tool C 715 then insert pry arm on the tire directly next to the rim of the wheel See Figure 1 H...
Page 69: ...ank When a test tank is not available apply a coating of soap solution with a paint brush or hand spray Cover surface of tire valve stem and the juncture of tire and rim flange Allow five minutes any...
Page 70: ...t into the hole in the tire with a firm and steady motion 57x27 Figure 9 Lubricating Puncture with Cement Push the needle and plug in until the short end of the plug snaps through the tire as shown in...
Page 71: ...driven due to pressure build up Never reduce this build up pressure When the tires are cold such as after standing over night the pressure will be less than when the tires are warm after driving Afte...
Page 72: ...DIRECTION OF FORCE SPINDLE CENTER LINE OF WEIGHT MASS AXIS OF ROTATION DIRECTION OF FORCE A STEERING KNUCKLE PIVOT B Figure 15 Dynamic Unbalance 54x393 A wheel and tire assembly which has been balance...
Page 73: ...s free to rotate but tight enough to prevent any wobble likewise the dial indicator should be known to be accurate and attached to a firm surface to assure that it will be held steady while taking the...
Page 74: ...rval of 3 000 miles 57x35 Figure 20 Under Inflation Wear 57 36 Figure 21 Over Inflation Wear EXCESSIVE TIRE WEAR In addition to normal wear other types of tire wear are classified as Spotty Wear Under...
Page 75: ...nd is rubbed over the face of the tread Toe out wear Figure 23 produces the same condition as toe in wear except that the feather like edge is formed on the outside edges of the tread ribs 5 CAMBER WE...
Page 76: ...d joint is designed to absorb GREASE COVER GASKET the thrust and torque of the drive line The cross and roller type universal joint consists of a yoke steel forged spider and four needle bearing assem...
Page 77: ...ft Flange Bolt in Front 35 ft lbs Propeller Shaft Flange Bolt in Rear 20 ft lbs 2 CHECKING PROPELLER SHAFT ALIGNMENT The included angle between the propeller shaft and the rear axle pinions in the ver...
Page 78: ...that the endwise location of the trunnion pin can affect the runout and balance of the propeller shaft The trunnion pin should be a very tight fit after assembling in the end of the propeller shaft Ea...
Page 79: ...use a needle like arrangement for forcing lubricant into the dust cover of the uni versal joint Excessive grease can be forced into the cover and cause the shaft to be thrown out of bal ance or the lu...
Page 80: ...N Vibration caused by an unbalanced propeller shaft or other chassis parts can usually be detected by driving at a speed slightly above the speed where the condition is most noticeable and shifting th...
Page 81: ...TAINER no Ilk HOUSING PIN CUP WASHER LUBE FITTING HOUSING SPRING SPRING SHIFT ROD WASHER SHIFT TUBE 11111Mi ADJUSTING SCREW ADJUSTING SCREW LOCKNUT Figure 1 Steering Gear 54x694 Figure 2 Roller Tooth...
Page 82: ...e a master serration to insure correct installation The high point is the point of least clearance between the worm and roller and is at the midpoint of the worm and roller travel An oil seal is insta...
Page 83: ...acket flange with the steering column jacket hori zontal Loosen the column jacket clamp and pull the jacket off the steering gear housing Remove the roller tooth shaft adjusting lock nut and plate and...
Page 84: ...ed scale reading should be from 1 8 to pound pull ADJUSTMENT OF ROLLER TOOTH AND WORM End play of steering arm shaft and mesh of the roller tooth with the steering worm may be adjusted either during a...
Page 85: ...ss of the bushing which would cause premature bushing failure and prevent lead to one side COLUMN JACKET DUST PAD INSTRUMENT PANEL BRACKET Figure 5 Steering Column Installed 57P336 5 COAXIAL POWER STE...
Page 86: ...e remove three horn ring screws and remove horn ring Remove front seat cushion Remove steering wheel nut and remove wheel with Tool C 612 Remove turn signal lever steering column to instrument panel b...
Page 87: ...K 0 RING CUP PIN RING PIN SEAL RETAINER CONNECTOR LOCK SNAP RING SEA BALL CLAMP 0 40 0 RING PISTON AND ROD NUT THRUST BEARING 0 RING HEAD GUIDE ROD UPPER WASHER WORM RACE WORM BEARING DOWEL WASHER BOL...
Page 88: ...6 inch alien wrench Drain the upper housing Bolt the holding fixture C 3323 to the power steering unit then mount the fixture in a vise see Figure 6 Remove the bolt and washer that attaches the coupl...
Page 89: ...s that show signs of wear REMOVAL OF WORM CONNECTOR AND VALVE CONTROL To remove the worm connector and valve control assembly refer to Figure 13 then proceed as follows Pry the worm connector nut lock...
Page 90: ...ve with crocus cloth spread over a flat surface The valve control spacer is serviced in two different lengths with a 001 inch differential The spacer must be exactly the same length as the spacer betw...
Page 91: ...l Seal COVER 0 SEAL RING NEEDLE BEARING ADJUSTING SCREW 57P356 57P355 GEAR _HOUSING GEARSHAFT Figure 20 Gearshaft Cover Removed ADJUSTING SCREW GEARSHAFT ft Figure 21 Removing the Gearshaft DISASSEMBL...
Page 92: ...ing Tool C 3229 pliers remove the adjusting screw retaining snap ring as shown in Figure 22 Slide adjust ing screw 0 seal ring and retaining washer from the end of gearshaft Remove thrust washer from...
Page 93: ...using a paper clip remove the valve rod 0 seal rings from each end of the upper rod See Figure 30 Remove and discard the 0 seal PISTON UPPER PISTON ROD 57x419 Figure 28 Removing Upper Piston Rod PAPER...
Page 94: ...Lower Piston Rod Bushing 5 inch pounds The piston 0 ring grooves should be free from nicks or burrs with no sharp edges around the piston pin hole DISASSEMBLY OF GEAR HOUSING Using a suitable blunt d...
Page 95: ...Coat seals and 0 seal rings with lubriplate at installation TOOL SEAL 57 x 251 Figure 38 Installing Lower Piston Rod Seal ASSEMBLY OF GEAR HOUSING Remove the garter spring from a new piston rod seal...
Page 96: ...n should be flush in piston Using pliers C 3106 install the retaining snap ring bevelled side out It may be necessary to tap the snap ring using a brass drift to be certain it is fully expanded in the...
Page 97: ...C 3401 over end of adjusting screw and slide down until seated Now slide new 0 seal ring over tool and into groove of adjusting screw as shown in Figure 47 This opera tion may be done before installi...
Page 98: ...nnector nut over piston rod with threaded end out Slide a new control spacer seal into spacer and install retainers as shown in Figure 52 Place seal protector Tool C 3329 over threads on upper rod Now...
Page 99: ...ith the tang side facing threads Slide the worm connector over the control spacer and screw the nut on to the connector by hand Hold the worm connector with Tool C 3321 then using Tool C 3326 tighten...
Page 100: ...the connector until the ball guide is directly down and rails are aligned Slide the worm housing over connector with the vent on top side Use care so as not to force the 0 seal ring off the housing h...
Page 101: ...oduce the same torque reading in both directions Torque reading must be equal and under 40 foot pounds If the torque reading is equal at less than 25 foot pounds a much more accurate adjustment can th...
Page 102: ...coaxial housing clamp Connect turn signal and horn wires Install steering column to instrument panel bracket and shroud Install steering wheel If clearance between steering column jacket and wheel is...
Page 103: ...right end of the power piston and across into the right reaction chamber Part of this oil is forced around the grooves of the wormshaft inside the piston and around the recir culating balls to the hol...
Page 104: ...ce instantaneously when ever the steering wheel is turned to the left as shown in Figure 64 In the reaction area of the steering unit another action takes place simultaneously as the wheel is turned t...
Page 105: ...steering gear Fasten the disconnected ends of hoses above oil level in reservoir Cap ends of hoses and fit tings on steering gear Remove steering arm nut and washer at steering gear shaft Slide Tool C...
Page 106: ...ay be used to remove small nicks or burrs provided it is used carefully When used on the steering gear valve use extreme care not to round off the sharp edge portions of the two lands located between...
Page 107: ...scharge of oil when shaft and cover are pulled from housing Turn worm shaft to full right position to compress parts and back off as necessary to align holes in column and worm shaft Enter a piece of...
Page 108: ...rm and piston assembly is furnished as a complete assembly only JACKET TUBE SUPPORT 00 411162 1 2 OIL SEAL TOOL SPANNER NUT 58x44 Figure 75 Installing Worm Shaft Upper Oil Seal With Tool C 3650 REACTI...
Page 109: ...spring retainer pin spring and pressure control valve piston Remove the two screws attaching the pressure control valve body to the steering valve and remove valve body Carefully shake out the valve...
Page 110: ...56 forcing it into seal until it has bot tomed in the seal Apply the two half rings and retainer over both portions of tool As hexagon nut is removed from the shaft the seal will be pulled from the ho...
Page 111: ...0 RINGS SEAL CYLINDER HEAD AND FERRULE RING BEARING SPACER SPRING REACTION RING CENTER RACE 7 BEARING SPACER 1 RACE SPACER ASSEMBLY REACTION RING SPRING REACTION RING NUT S 0 RING SUPPORT BEARING SEA...
Page 112: ...ter bearing race as shown in Figure 85 Place inner and outer reaction rings over center spacer and install upper reaction spring with cylinder head ferrule through hole in spring Install a new 0 ring...
Page 113: ...NTROL POWER STEERING TEST AND ADJUSTMENTS Remove oil reservoir cover and fill reservoir to level marks Connect test hoses C 3211 and C 3318 with proper adapters to hydraulic pump on car with pressure...
Page 114: ...ssure at the end of each turn Repeat this operation then system is properly bled Should the lack of steering assistance be encountered and other checks have been made refer to Service Diagnosis Chart...
Page 115: ...En u O Free Length 2 13 inch Working Length 1 20 inch Pressure at Working Length 14 11 2 lbs a a cO Free Length 1 51 inch Working Length 1 18 inch Force at Working Length 30 to 33 lbs TORQUE SPECIFIC...
Page 116: ...the pump until oil level covers filter Add oil if highest part of filter is not covered with oil LOCK RING Nli TOOL 41INIFT 57 371 Figure 90 Disassembly of Pressure Relief and Flow Control Valve Using...
Page 117: ...ROTOR RING COVER VALVE 4 RETAINER 4 BUSHING ADAPTER FLANGE COUPLING GASKET BOLT AND LOCKWASHER SCREW AND WASHER Figure 91 Rotor Type Steering Pump Disassembled 56P177 n col in PDF compression OCR web...
Page 118: ...as been threaded into bushing suffi ciently screw T handle section of tool into cover until it bottoms and continue turning to remove bushing Install bushing with Tool C 3233 as shown in Figure 93 PUM...
Page 119: ...from 15 to 20 foot pounds Tap coupling flange on pump shaft until it bottoms and install special square washer screw and lockwasher Using Tool C 3227 to hold coupling as shown in Figure 98 tighten sc...
Page 120: ...TE Whenever the pump is drained or removed for servicing the pump must be filled up to the full mark indicated on the filler neck of reservoir before and after the engine is started Use Automatic Tran...
Page 121: ...terior of pump Mount pump in a vise Remove cap screw and reservoir See Figure 101 Loosen four cap screws at the inlet end cap See Figure 102 Remove flow valve spring retainer fitting FILLER MARK BAFFL...
Page 122: ...retainer to prevent spring and fitting from escaping due to spring force Remove flow valve and spring Remove and dis assemble both end caps from inlet cap body and pump housing as shown in Figures 10...
Page 123: ...mh Amw 4 A BALL BALL SEAT Figure 108 Flow Spool Valve Press seal in until the shoulder stops against the bearing cap casting Care must be used to see that seal is properly aligned This operation shou...
Page 124: ...sition at the same time guiding cylinder block downward Continue this procedure to the 4 and 8 o clock positions until all the sleeves are aligned and engaged the block may then be pushed in all the w...
Page 125: ...the pump Continuous slipper con tact is assured by the spring loaded slippers against the eccentric inside diameter and by centrifugal action at higher speeds RESERVOIR SNAP RING SLIPPER ROTOR PRESSU...
Page 126: ...0 RING 58x225 TOOL SNAP RING PUMP OUTLET Figure 115 Removing Flow Control Valve Snap Ring TOOL 58x281 Figure 116 Removing Flow Control Valve Plug With Tool C 3655 If there was evidence of a malfuncti...
Page 127: ...Figure 118 far enough into bore to install snap ring then drive snap ring and plug with Tool C 3233 until snap ring seats in its groove in housing bore Install relief valve and gasket assembly Install...
Page 128: ...tion of the steering wheel If binding is evident the bearings are damaged or are adjusted too tightly Inspect the tube by turning the steering wheel from the extreme right to the extreme left If inter...
Page 129: ...of leak Special Service Tool C 3555 Dummy Flange Bulkhead Retainer has recently been released This tool is desirable in locating leaks in power steering unit Place chuck in holding fixture Tool C 332...
Page 130: ...w a pres sure between 70 100 psi If pressure is below 70 psi it is an indication that lower piston rod relief valve is not operating properly If pressure is considerably above 100 psi the plunger may...
Page 131: ...used by one of the following 1 Steering gear arm nut loose on gear shaft Tighten 120 foot pounds torque 2 Loose front wheel bearings Adjust 3 Steering linkage Check for worn or loose tie rod ends loos...
Page 132: ...g bolts to 70 foot pounds torque UNEQUAL STEERING EFFORT Severe Cases of Self Steering A condition whereby operator finds that it takes very little effort to turn steering wheel in one direction while...
Page 133: ...rol valve by peening Check for any movement between the two If movement exists re place control valve and rod Do not attempt to tighten by peening 4 Upper piston rod loose in piston Check for move men...
Page 134: ...P Loose torque to indicated specifications PUMP NOISE 1 CHECK OIL LEVEL IN RESERVOIR Oil level should be up to mark on filler neck when pump is at 175 F 2 AIR IN STEERING SYSTEM Check all connec tions...
Page 135: ...aged valve lever 5 Improper worm thrust bearing adjustment 6 Burrs or nicks in reaction ring grooves in cylinder head or 7 Defective or damaged cylinder head worm shaft seal ring 8 Dirt or chips in st...
Page 136: ...asurement with the distance between the points connected by line B See Figure 1 Compare all corresponding diagonals in this manner The distance between the points connected by any two corresponding di...
Page 137: ...ls P 30 LP 1 Except Convertible Coupe and Suburban 45 45 1 571 17 49 179 191 1941 4 TOP OF FRAME LINE Figure 3 Frame Dimensions All Models P 31 LP 2 Except Convertible Coupe and Suburban 57P16 PDF com...
Page 138: ...es 4 exc Sub 4 exc Sub 5 exc Sub 6 all Suburbans Heavy duty springs 6 leaves except Suburban 7 leaves Suburban Type Shackle Side strapped with rubber bushed bolts Type Pivot Front End Rubber Bushings...
Page 139: ...models are equipped with 4 leaf springs except the suburban models which are equipped with 6 leaf springs Refer to Specifications Tighten spring U bolt nuts to 70 foot pounds The spring shackles shoul...
Page 140: ...eneath the spring leaf sur face and slip out the old interliner after separating the spring leaf from the next longer spring leaf To effect this separation pry open the slight gap between the leaves w...
Page 141: ...stability which is particularly noticeable at high speeds or on rolling or rough roads The Oriflow shock absorbers permit the car s wheels to follow the road surfaces and the springs to flex without...
Page 142: ...mount of spring bottoming on certain types of uneven road surfaces such as a broad hump in the road is normal Rubber bumpers are provided to absorb the shock of bottoming Excessive bottoming on rough...
Page 143: ...ransmission Bearing Retainer Gasket Thickness 001 0165 inch 022 0275 inch Clutch Housing Run Out 003 inch maximum Clutch Housing Bore Run Out 003 inch maximum 0 g gg First 2 50 2 31 Second 1 68 1 55 T...
Page 144: ...ransmission Bearing Retainer Gasket Thickness 001 0165 inch 022 0275 inch Clutch Housing Run Out 003 inch maximum Clutch Housing Bore Run Out 003 inch maximum 0 g gg First 2 50 2 31 Second 1 68 1 55 T...
Page 145: ...neutral After removing lubrication fitting as shown in Figure 1 from the tube lever pin retainer rotate re tainer until gearshift tube cross pin is exposed as shown in Figure 2 STEERING COLUMN LOWER...
Page 146: ...inch pounds torque against the second direct control rod swivel block Be sure transmission remains in neutral Now loosen and back off adjusting nuts at low reverse gear shift control rod swivel see Fi...
Page 147: ...ately 8 inches square with holes drilled to receive the four studs of the brake drum and flange assembly To provide additional stability additional holes may be drilled in the mounting fixture for att...
Page 148: ...everse sliding gear should move smoothly and freely on mainshaft Remove synchronizer clutch gear snap ring using pliers Tool C 484 or Tool C 3301 Exercise care so as not to damage mainshaft or clutch...
Page 149: ...shers and replace if excessive wear is evident Inspect the clutch teeth of the drive pinion If they are excessively worn broken or chipped install a new pinion shaft Inspect mainshaft pilot rollers fo...
Page 150: ...CHRONIZER UNIT EXTENSION HOUSING Figure 11 Synchronizer Unit Assembled on Mainshaft ADAPTER ARBOR Figure 12 Installing Reverse Idler Gear REVERSE IDLER GEAR Insert adapter arbor as shown in Figure 12...
Page 151: ...ce of extension housing and install gasket Install transmission case to extension housing assembly See Figure 6 Install the extension housing to case studs and bolts and tighten finger tight only TAB...
Page 152: ...retaining pin Install interlock sleeve in its bore as shown in Figure 15 Place one of the interlock balls in sleeve followed by the interlock ball spring Place low and reverse gearshift lever shaft pa...
Page 153: ...been jumping out of gear check clutch housing face alignment with housing alignment arbor C 870 be fore installing transmission The rear of the engine must be supported under the rear face of the clu...
Page 154: ...ng When installing a new oil seal be sure to use special driver Tool C 3105 which automatically locates the seal in its proper position Reinstall brake drum and flange assembly Install washer convex s...
Page 155: ...oor When the kick down switch plunger is depressed two actions take place 1 Contact points A Figure 25 which are nor mally closed are opened breaking the circuit and de energizing the solenoid The sol...
Page 156: ...care when removing the unit from the transmission to prevent possible damage REMOVING OVERDRIVE MAINSHAFT Drive the tapered pin from the overdrive housing Pull the control shaft out as far as possibl...
Page 157: ...04 See Figure 29 Clean and inspect the bearing Install the rear bearing open end first with driver C 3204 Always use new snap rings Selectively fit both front and rear snap rings to eliminate end play...
Page 158: ...er tension on the control plate by hooking a pull scale on one finger of the balk ring Pull away from the opening and if less than 1 lb of pull is required to move the lubri cated balk ring around the...
Page 159: ...cage retaining clip Slide the assembly on the splines of the transmission mainshaft and install the clutch cam SHIFT RAIL 45x762 Figure 33 Installing Shift Rail and Sun Gear retaining clip Make sure...
Page 160: ...pped with a neutral starter safety switch which prevents starting the car in gear All normal driving can be done in the Drive range which acceler ates the car in low range and then automatically shift...
Page 161: ...5 iii 2 i 4 0 E 1 Direct Clutch Piston Retainer Thrust Washers 3 sizes 043 to 045 in thin 060 to 062 in medium 078 to 080 in thick Kickdown Planet Pinion Carrier Thrust Washer 060 to 062 inches Planet...
Page 162: ...carried along by the force of oil on the backs of the stator vanes because the stator is mounted on an overrunning clutch permitting it to rotate in the direction of the impeller During this time the...
Page 163: ...sison multiplied by the 2 6 to 1 torque multiplication of the torque converter provides an overall starting ratio of 4 47 to 1 at the trans mission output shaft DRIVE RANGE KICKDOWN Pressing the accel...
Page 164: ...LVE OOTTID TELLOW LOSE SPEEN IT5POTTLIII 140 PSI 55055 11105101505 014 PSI SERVO PRESS BLEED VALVE CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING 57P271 KICKDO VALVE THR PRESS DI CHECK VALVE DIRECT CLUTCH S...
Page 165: ...ide air The oil is directed under pressure from the torque converter to various parts of the transmission where lubrication is essential It then drops down into the transmission oil pan Circulation th...
Page 166: ...PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyMopar com...
Page 167: ...S REVERSE RVO OIL STRAINER REAR PUMP GOVERNOR NOTE A B C D E ARE METERING HOLES Figure 47 PowerFlite Oil Flow Diagram Low LEGEND RED REVERSE ISO PSI DOTTER SLUE PUMP SUCTION SHIFT YELLOW CONvERTER 110...
Page 168: ...serve to reduce throttle pressure to 75 p s i in order to prevent downshifting the transmission at too high a speed The excess oil is channeled through a vent into the transmis sion oil pan The 75 p s...
Page 169: ...hrough the hole in the servo pressure bleed valve pressure on this piston drops to a low valve while oil from the shuttle valve and from the shift valve build up pressure on the direct clutch and the...
Page 170: ...hrottle R P M Pressur D Applied Closed 450 14 p s i D Applied Wide open 1500 90 p s i DIRECT CLUTCH PRESSURE Before checking direct clutch pressure check line pressure since any deviation in line pres...
Page 171: ...the housing will enter the transmission case the proper distance preventing damage or possible displacement of the 0 ring if the housing was inserted too far Push the cable into the cable adaptor as f...
Page 172: ...re take off plug Ye inch pipe located between the reverse and kickdown servos on the right side of the transmission Connect 100 p s i throttle pressure gauge C 3292 There will be no oil pressure at th...
Page 173: ...an and refill transmission with type A automatic transmis sion fluid DISCONNECT THROTTLE ROD FROM THROTTLE LEVER air d 57P269 Figure 57 Adjusting Kickdown Band Using Wrench C 3380 0 57P381 Figure 58 A...
Page 174: ...nch screws are installed through the transfer plate cover on the valve body The three 1 s inch screws are installed through the transfer plate cover Tighten screws finger tight and then tighten to 12...
Page 175: ...ousing is removed Figure 62 is a plan for a tool which can be made to hold the gearset in position The holding tool is installed behind the rear edge of planet pinion carrier and is attached to the tr...
Page 176: ...t insulator to the crossmember leaving the insulator attached to the transmission Install engine support fixture tool C 3245 Inspect the hooks of the fixture into the holes in the frame sub side rail...
Page 177: ...utch piston retainer thrust washer If clearance is less than 026 inches install a thinner washer The thrust washer is selectively fit and is available in three sizes 6 1 Figure 65 Checking 45 0091 End...
Page 178: ...of Rear Oil Pump Piston Secondary weight should work freely in primary weight when parts are clean and dry Inspect spring for distortion Compare with a new one Remove the governor locating screw from...
Page 179: ...ove the direct clutch assem bly from the reaction shaft Remove the thrust washer from reaction shaft This washer is selectively fit and controls end play between the clutch assembly and carrier housin...
Page 180: ...ring grooves and worn gear on shaft Remove the thrust washer and inspect for wear KICKDOWN PLANET PINION CARRIER ASSY KICKDOWN ANNULUS GEAR PLANET PINION CARRIER HOUSING INPUT SHAFT REVERSE PLANET PI...
Page 181: ...83 Inspect sun gear for worn or broken teeth Lift direct clutch hub from retainer See Figure 84 In spect hub driving lugs and spline Invert the piston re tainer and remove the five steel clutch plates...
Page 182: ...PISTON RETAINER v ASSY 55P1256 Figure 89 Removal or Installation of Piston Retainer Seal Ring CAUTION Use care when releasing the tool The piston spring may require guiding past the snap ring grooves...
Page 183: ...t outer edge then all succeeding discs must be in stalled in this manner If first disc was krafelt at outer edge succeeding discs must also be installed See Figure 90 for proper sequence DIRECT CLUTCH...
Page 184: ...ump gears to aid during assembly Do not use a scribe to mark gears Remove the oil pump gear from the front pump hous ing Remove the large neoprene oil pump housing seal from the housing and inspect fo...
Page 185: ...he piston sleeve for scores and wear Make sure the two bleeder holes are open Install tool C 3289 or C 3529 on trans mission case and compress the reverse piston spring retainer Use a screwdriver to r...
Page 186: ...de of case Do not lock screw into position at this time TRANSMISSION CASE INSPECTION Inspect transmission case for cracks and holes and stripped threads Check for burrs on mating surfaces Blow compres...
Page 187: ...Make sure sleeve slides freely on piston by working it up and down Remove installing tool from transmission case 57P289 REGULATOR VALVE BODY INSTALLATION Figure 101 Installing Kickdown Piston Assembly...
Page 188: ...on shaft and slide into position over guide studs until oil pump housing seal is flush with transmission case Using new aluminum or copper washers on screws start five of the screws and draw housing d...
Page 189: ...erse annulus gear and the planet pinion carrier housing Coat output shaft splines with Lubriplate The driving lugs on carrier assembly must engage the slots in the planet pinion carrier housing See Fi...
Page 190: ...nger tight KICKDOWN BAND ASSY 0 w REVERSE BAND ASSY OUTPUT SHAFT SUPPORT OUTPUT SHAFT C 3283 GUIDE STUD TORQUE CONVERTER REACTION SHAFT Figure 107 Installation of Power Train in Transmission 453 2149...
Page 191: ...he end clearance must be 026 to 052 inches See Figure 65 If it does not fall within this specification then trans mission will have to be partially disassembled in the following manner to allow a dire...
Page 192: ...apter C 3284 press extension housing into position against output shaft support Start the seven transmission extension to case screws and lockwashers then drawn down evenly and torque from 25 to 30 fo...
Page 193: ...re check valve ball in the valve body See Figure 111 Remove both valves and place in a clean container Compress the throttle valve operating lever assembly against the throttle valve operating lever a...
Page 194: ...TTLE CONTROL CAM SHAFT CONTROL CABLE RETAINER LOCK SPRING or MANUAL VALVE LEVER CABLE RETAINER CLIP DRIVE SCREW REVERSE BLOCKER VALVE AND SPRING SHIFT VALVE AND SPRING PLUG SCREW 2 SPRING KICKDOWN ROD...
Page 195: ...y Using a screwdriver compress the detent ball and slide out manual valve lever until it is disengaged from detent ball VALVE BODY THROTTLE VALVE OPERATING LEVER ADJUSTING SCREW THROTTLE VALVE OPERATI...
Page 196: ...so that the transfer plate is not distorted Inspect valve body plate and make sure all ports are open Inspect the pump check valve and springs in the transfer plate See Figure 118 ASSEMBLY OF VALVE BO...
Page 197: ...etering hole should be toward rear of transmission Place the valve body plate flush into position on the transfer plate by compressing the pump check valve springs IMPORTANT Make sure that the pump ch...
Page 198: ...face with lubri plate and install in torque converter hub making sure driving lugs are properly engaged Note position of driving lugs on front oil pump drive sleeve then position front oil pump pinion...
Page 199: ...pe Centrifugal Clearance between Governor Valve and Body 0005 to 002 cn rn 41 g A E Input Shaft Thrust Washer 3 sizes 078 to 080 thin 097 to 099 medium 115 to 117 thick Front Clutch Snap Ring Rear Clu...
Page 200: ...LUTCH PISTON 7 REAR CLUTCH ASSEMBLY FRONT CLUTCH PRESSURE PLATE TORQUE CONVERTER REACTION SHAFT FRONT OIL PUMP TORQUE CONVERTER STATOR TORQUE CONVERTER TURBINE OIL STRAINER REVERSE SUN GEAR LOW REVERS...
Page 201: ...econd and 1 low See Figure 124 57P347 Figure 124 Arrangement of TorqueFlite Push Button UNLATCHED POSITION PUSH BUTTONS LOCK SPRINGS OPERATING SLIDES ATCHED POSITION CONTROL CABLE ACTUATOR TO TRANSMIS...
Page 202: ...on shafts in the planet pinion SUN GEAR HELD s3x97 Figure 127 Planetary Gear Set Sun Gear Held Gear Reduction carrier The sun gear rotates inside and is also meshed with the planet pinions PLANETARY G...
Page 203: ...ear Set Reverse Planet Pinion Carrier Held ANNULUS GEAR AND SUN GEAR LOCKED TOGETHER 53x98 Figure 129 Planetary Gear Set Direct Annulus and Sun Gear Locked the transmission will not downshift to low i...
Page 204: ...on carrier together with the reverse annulus gear both of which are splined to the output shaft drive housing The reverse planet pinion carrier is attached to and prevented from turning backward by an...
Page 205: ...ge D Drive position breakaway D Drive position second speed 2 Second position second speed D Drive position direct R Reverse position 1 Low position low speed N Neutral Ratio Element Applied 2 45 Fron...
Page 206: ...position breakaway or 2 second position breakaway with one exception the low reverse band is applied locking the overrunning clutch to provide engine braking See Figure 133 R REVERSE POSITION The rear...
Page 207: ...hose functions are interrelated In a general way the components of any automatic control system may be grouped into the following basic components or units Refer to Figures 135 through 141 1 The press...
Page 208: ...op the required capacity a system of levers 4 is used to actuate the clutch apply plate Although no pressure is applied to the front clutch piston in reverse or neutral oil is present in the clutch pi...
Page 209: ...the kickdown piston spring is sufficient to overcome the forces of line pressure and throttle com pensator pressure acting on the apply side of the kick down piston Application of the kickdown piston...
Page 210: ...sure front clutch which is acting on the small area of the accumulator piston This action cushions the application of the kickdown band PRESSURE REGULATING VALVES The regulator valve controls line pre...
Page 211: ...converter Oil is fed from the regulator valve through a restricting hole in the regulator valve body to the torque converter The oil flows through the torque converter and returns to the regulator val...
Page 212: ...oximately 25 M P H the primary weight moves outward against the preload of the spring and bottoms against the snap ring leaving only the secondary weight active Small variations in vehicle speed above...
Page 213: ...ning The throttle valve allows oil to flow from the line pressure port to the throttle pressure port which is con nected by a passage to the reaction area of the throttle valve Throttle pressure will...
Page 214: ...D drive button is pushed in the manual valve is positioned to route line pressure to the follow ing places 1 The secondary reaction area of the regulator valve making line pressure 90 P S I 2 The line...
Page 215: ...shifted When the valve is upshifted throttle pressure is cut off so that normal downshifts are not throttle sensitive 2 3 SHIFT VALVE This shift valve automatically shifts the transmission from interm...
Page 216: ...or kickdowns below 30 M P H oil is fed to the line pressure area of the kickdown servo through both the hole in the servo pressure bleed valve and the line pressure and servo pressure ports of the shu...
Page 217: ...nning clutch Line pressure from low port of the man ual valve is fed to the low port of the 1 2 shift valve governor plug where it is blocked until compensated governor pressure drops sufficiently so...
Page 218: ...damaged seal ing washers 4 Front oil pump housing oil seal 5 Front oil pump housing seal located on outside diameter of front oil pump housing 6 Torque converter Leaks at these locations may be correc...
Page 219: ...age the N neutral button and check for drag ging up to an engine speed of 800 R P M 2 Push in the R reverse button and note the shift time and smoothness of the shift Back the car up and check for dra...
Page 220: ...position with engine at 800 R P M and wheels free to turn GOVERNOR PRESSURE Remove the pipe plug from the governor pressure takeoff hole located on the lower left side of the output shaft support See...
Page 221: ...rpin clip securing cable end to actuator Remove the two screws holding cable assembly bracket to push button control unit then remove cable assembly See Figure 147 PUSH BUTTON CONTROL UNIT INSTALLATIO...
Page 222: ...and seat properly in regu lator valve body Then install regulator valve spring sleeve cup gasket and retainer and tighten to a torque of 45 to 50 foot pounds Check and adjust line pressure if necessa...
Page 223: ...nd torque from 14 to 16 foot pounds NOTE Dished type washers are used to prevent cutting or chipping of soft metals and should be installed on screws with dished portion facing away from head Install...
Page 224: ...sembly into case With piston properly centered so as not to damage rings tap lightly and bottom piston into transmission case Slide piston spring over kickdown piston rod assembly and install in pisto...
Page 225: ...per level Refer to Lubrication section EXTENSION REMOVAL Raise vehicle off floor Drain approxi mately two quarts of fluid from transmission then reconnect filler tube at connector Disconnect front uni...
Page 226: ...nd brake sup port Connect front universal joint and torque nuts from 33 to 37 foot pounds GOVERNOR BODY AND SUPPORT 0 GUIDE STUD 56x6d Figure 157 Removal and Installation of Governor Body and Support...
Page 227: ...using INSTALLATION Slide governor support and body assembly into position in rear oil pump housing Com press governor support seal rings as support enters oil pump housing Do not force Place rear oil...
Page 228: ...uds and into position against converter housing Make sure driving lugs on front oil pump drive sleeve properly engages the torque converter To avoid damage to front oil pump do not attempt to use tran...
Page 229: ...mbly in stand Tool C 3280 and invert as shown in Figure 158 Remove the oil pan bolts and remove the oil pan and gasket as shown in Figure 159 Note the construction of oil pan bolts washers used are pa...
Page 230: ...ve screwdriver and with dial indicator point contacting edge of front clutch retainer set dial indicator to zero Now pry front clutch assembly rear ward against rear clutch remove screwdriver and take...
Page 231: ...NSION REMOVAL Remove the speedometer drive pinion and sleeve assembly as shown in Figure 167 Inspect the output shaft rear bearing oil seal and remove if necessary using puller Tool C 748 Remove the s...
Page 232: ...t shaft rear support assembly and gasket from transmission case as shown in Figure 175 If rear support is stuck to transmission case it can be loosened by tapping lightly with a soft ham mer Remove gu...
Page 233: ...l Pump Pinion 56x612 Figure 175 Removal and Installation of Output Shaft Support UNIT NO 1 56x613 Figure 176 Removal and Installation of Unit No 1 56x614 Figure 177 Removal and Installation of Interme...
Page 234: ...removing to prevent damage to seal rings on input shaft and sealing surfaces in reaction shaft aluminum LOW REVERSE BAND ASSEMBLY REMOVAL Mark the low reverse band assembly for installation purposes...
Page 235: ...remove Spring retainer may require guiding out of transmission case Remove the spring retainer spring and servo piston assembly KICKDOWN SERVO REMOVAL Reinstall Tool C 3529 or C 3289 modified as show...
Page 236: ...rive sleeve if installed then remove the transmission regulator valve spring retainer gasket cup spring sleeve and valve as shown in Figures 188 189 and 190 Remove the torque converter control valve s...
Page 237: ...ULATOR VALVE BODY 56x628 Figure 192 Removing Regulator Valve Body FRONT AND REAR PUMP CHECK VALVE 14 56x651 TORQUE CONVERTER CONTROL VALVE dr REGULATOR VALVE Figure 193 Regulator Valve Body and Valves...
Page 238: ...fumes and expansion of oil caused by heat Clean output shaft rear bearing and dry with com pressed air Do not spin bearing with air pressure In spect bearing for rough spots Do not remove bearing fro...
Page 239: ...GHT SNAP RING OUTER WEIGHT SNAP RING VALVE SHAFT 41 INNER WEIGHT BODY TO SUPPORT SCREW AND LOCKWASH ER 4 VALVE SHAFT SNAP RING WEIGHT SPRING OUTER WEIGHT 0 BODY SUPPORT 0 s VALVE I1 VALVE SHAFT SNAP R...
Page 240: ...assembly Inspect interlocking seal rings K L on output shaft J for wear or broken locks and make sure they turn freely in the grooves Do not remove rings unless condi tion warrants When replacing rin...
Page 241: ...r and make sure pinions are free to rotate on shafts Make sure shaft lock pins are installed Do not replace carrier assembly unless inspection re veals it is necessary The planet pinion carrier and pi...
Page 242: ...ler gauge check the clearance under the kickdown annulus gear snap ring as shown in Figure 203 Clearance limits are as close to zero as possible Snap rings are available in the following two thickness...
Page 243: ...8 Removal and Installation of Intermediate Support and Cam Assembly from Overrunning Clutch Hub LOW AND REVERSE BAND DRUM OVERRUNNING CLUTCH HUB 56x640 Figure 209 Removal and Installation of Overrunni...
Page 244: ...PECTION Inspect driving discs for evidence of burning glazing and flaking off of facing material Check discs by scratching facings with finger nail if material collects under nail replace all of drivi...
Page 245: ...roken teeth 2 Inspect steel back bronze type bushing for scoring or excessive wear Bushing and reverse sun gear serviced as an assembly 3 Inspect intermediate support bearing surface of gear for wear...
Page 246: ...al Ring Outer S Front Clutch Piston Cushion Spring T Front Clutch Piston Cushion Spring Retaining Plate LOW AND REVERSE BAND DRUM INSPECTION Inspect the band contacting surface for deep scratches and...
Page 247: ...ing B and input shaft the front clutch assembly must be placed in an arbor press With the rear of retainer resting on a suitable support press the input shaft only far enough into retainer to permit r...
Page 248: ...kup on hub of retainer and inspect seal ring groove for nicks or burrs Inspect steel clutch plate contacting surfaces for scores or brinelling Make sure clutch driving lugs on steel plates travel free...
Page 249: ...t improper installation LEVER ASSEMBLIES Inspect levers J and K for being cracked or worn and make sure they are free to turn on shaft and have side clearance when installed Inspect lever shaft I for...
Page 250: ...Tool C 3278 to drive seal until tool bottoms on face of housing as shown in Figure 218 Inspect drive sleeve seal ring contacting surface in housing for wear and scratches Inspect steel back bronze ty...
Page 251: ...e for proper seating on both surfaces Check metering hole for a plugged condition and be sure hole is free of foreign matter If necessary to remove valve use a pair of long nose pliers When installing...
Page 252: ...e if oil pump gears turn freely main body of driving sleeve 57P417 Figure 222 Installing Front Oil Pump Drive Sleeve SEAL RING DRIVE SLEEVE DRIVE SLEEVE 57x148 Figure 223 Front Pump Drive Sleeve Insta...
Page 253: ...retainer over spring Install Tool C 3529 or C 3489 modified for low reverse servo piston in stallation TOOL LOW REVERSE SERVO SPRING RETAINER SPRING 56x623 Figure 225 Compressing Low and Reverse Servo...
Page 254: ...and tighten from 25 to 30 foot pounds Use extreme care when installing the locating bolt inside of case to prevent loss of lockwasher as shown in Figure 177 Check input shaft and sun gear for free ro...
Page 255: ...rnor valve shaft slide shaft into governor body as shown in Figure 170 through the output shaft and governor weight assembly at the same time position valve into body Install the governor valve shaft...
Page 256: ...crewdriver between the front and rear clutch Remove screwdriver and with dial indicator point con tacting edge of front clutch retainer set dial indicator to zero Then pry front clutch assembly rearwa...
Page 257: ...ify location of adjusting screw in relation to transmission case then back ad justing screw out 3 2 turns While holding adjusting screw stationary tighten lock nut from 35 to 40 foot pounds VALVE BODI...
Page 258: ...oval and Installation of Transmission REMOVING THE VALVE BODIES LOWER VALVE BODY If valve bodies and transfer plate are being serviced with transmission in vehicle refer to Valve Bodies and Transfer P...
Page 259: ...all passages are free from obstructions When inspecting also check for porous castings Inspect all mating sur faces for burrs nicks and grooves Small ones may be removed with crocus cloth otherwise d...
Page 260: ...valve ball M and seat L Remove throttle compensator valve spring N and valve 0 Refer to Figure 237 and assemble as follows Place valve body in an upright position and install throttle compensator valv...
Page 261: ...ring E on pilot Place the 1 2 shift valve kickdown plug C over the 1 2 valve spring G Place kickdown plug cover over 3 1 relay valve spring and 1 2 kickdown plug Compress springs and guide the 1 2 kic...
Page 262: ...Blocker Valve P Reverse Blocker Valve Spring Q Throttle Valve Lever Shaft Pin R Throttle Valve Lever Shaft S Manual Valve Lever Assembly T Manual Valve Lever Detent Ball U Manual Valve Detent Ball Sp...
Page 263: ...band support throttle lever shaft on wooden block Install shaft pin using a small punch and ham mer as shown in Figure 243 Remove rubber band With reverse blocker valve spring in position in valve 0 a...
Page 264: ...make sure it oper ates freely as shown in Figure 246 Place transfer plate and valve bodies assembly in transmission case Refer to Valve Bodies and Transfer Plate Installation Install transmission as...
Page 265: ...igh gear at a speed where the noise is more apparent and then shifting into neutral shutting off the engine and coasting This action stops the operation of the pinion bearing and then any noise in eit...
Page 266: ...ring and mainshaft bearing synchronizer clutch teeth second speed gear clutch teeth shifter rail detents shifter forks or shifter fork set screws for wear c End Play Inspect the pinion shaft countersh...
Page 267: ...ol circuit is grounded 2 ELECTRICAL CIRCUITS Pull the control handle out and turn the key ON again If a click is still heard in the relay the ground is between the horn relay and the rail lockout swit...
Page 268: ...piston and clutch check valve ball 5 REVERSE Check reverse band adjustment In spect transmission case to valve body mating surfaces for evidence of oil leakage Inspect reverse servo assem bly for wea...
Page 269: ...pect manual valve and lever Inspect the kickdown valve ball and rod 12 NO KICKDOWN Adjust throttle linkage Inspect valve body to transmission case mating surfaces for parallelism Inspect throttle valv...
Page 270: ...l Inspect the input shaft seal rings for excessive wear or broken ends and reaction shaft bore for scoring Inspect all parts of the direct clutch assembly OIL PRESSURE 1 NO GOVERNOR PRESSURE Governor...
Page 271: ...il pressure to partially engage the direct clutch A slight surge which is not continuous is normal 3 CAR MOVES BACKWARD IN NEUTRAL Read just gearshift linkage and inspect manual valve and valve lever...
Page 272: ...Breather EllEMEIMM 111111 111111 1111MM OEM M Output Shaft Rear Bearing S R iiiiimmimmEn am iii N K D Servo Band Linkage IIIIIIIIIIMMIIIIIIMMINE1111 0 L R Servo Band Linkage 1111101111111111111111E11...
Page 273: ...tor be sure to cover accumu lator piston bore to prevent piston from being blown out Protect from oil spray by holding a clean lintless cloth cardboard or some other shield against the bot tom of the...
Page 274: ...diate shaft No 1 2 and 3 seal rings 7 Front clutch oil feed tube 8 Front clutch piston inner and outer seal ring 9 Front clutch check valve ball d REAR CLUTCH Clean and inspect discs plates return spr...
Page 275: ...ELECTRICAL ENGINES IGNITION SYSTEM STARTING SYSTEM GENERATING SYSTEM COOLING SYSTEM FUEL AND EXHAUST SYSTEM PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFComp...
Page 276: ...V 8 Engine 58P86 58P88 58P89 Golden Commando 350 Cubic Inch Engine Power Flow 6 230 Cubic Inch Engine Fury V 800 Typical of 301 and 318 Cubic Inch Engine PDF compression OCR web optimization using a w...
Page 277: ...les are punched out and that sealing ridges are not creased This is important to insure a positive seal around each opening Coat the new gasket on both sides with a light application of a suitable sea...
Page 278: ...il normal operating temperature is reached Then recheck all cylinder head bolts and tighten to specified torque V 8 Engine 350 cu in 70 ft lbs V 8 Engine 277 301 318 cu in 85 ft lbs 6 Cylinder Engine...
Page 279: ...n 020 inch the bores should be rebored and new pistons fitted HONING CYLINDER BORES To remove light scratches scoring or scuffing cylinder bores can be satisfactorily honed Honing limits should not ex...
Page 280: ...ned to the same weight in grams regardless of oversize to maintain piston balance For cylinder bores which have been honed or rebored pistons are available in standard and the following oversizes 005...
Page 281: ...on diameter should be measured at the top of the skirt 90 to the piston pin axis The cylinder bores should be measured halfway down the cylinder bore and crosswise to the centerline of the engine The...
Page 282: ...speed of 150 RPM plugs removed and wide open throttle 120 150 P S I 125 165 P S I 150 180 P S I Maximum Variation Between Cylinders 10 P S I 15 P S I 25 P S I Cylinder Numbering From Front of Engine 1...
Page 283: ...istons to the connecting rods on the right hand cylinder bank Nos 2 4 6 and 8 with the indent on the top of the piston on the side opposite to the large cham fer at the insert end of the connecting ro...
Page 284: ...in 13 46 in x 15 16 in 2 in 16 4 in 131 32 in 161 64 in 1 in No 5 1 C Adjustment None Number of Links 48 68 50 Width 1 02 in 875 in DI a As 0 41 Stem Diameter 340 in to 341 in 372 in x 373 in Std Head...
Page 285: ...e Then position the rod over the pilot Insert main screw and pin assembly through piston and install puller nut Install assembly in press and press pin into piston until it bottoms on the pilot See Fi...
Page 286: ...Cam Ground Slotted Cam Ground with Steel Belt Material Aluminum Alloy Clearance 5 10 Pounds Pull 002 x 1 2 in Feeler Stock With 0015 in x 1 2 in feeler stock 5 10 pounds pull Hand Fit Weight ounces 15...
Page 287: ...rings be installed correctly as shown in Figure 25 MAIN BEARING CAPS V 8 ENGINE Main bearing caps Nos 1 2 3 and 4 are marked at the bottom Make sure they are installed correctly and in their proper p...
Page 288: ...n up by the number four rear main bearing on 6 cylinder engines and the number three main bearing on V 8 engines 9 CRANKSHAFT BEARINGS REPLACEMENT BEARINGS When 001 inch thicker wall undersize cranksh...
Page 289: ...thod consists of compressing a plastic like material between the crankshaft journal and bearing insert The flattened material is then measured by a graduated scale on the packing envelope thus indicat...
Page 290: ...ain Bearing Oil Seal 277 301 and 318 Cubic Inch V 8 Engine halves of bearings 1 2 and 4 are interchangeable The lower halves of bearing 1 2 and 4 are also interchange able On 1957 and some 1958 engine...
Page 291: ...eplacing the rear oil seal replace both the upper and lower halves With the cap removed the upper seal can easily be removed with a pair of long nose pliers Clean the groove in the block of any foreig...
Page 292: ...alf When fitting bearings do not file the connecting rod or cap to fit bearings but use the proper size insert When an engine is com pletely overhauled the shim method can be used to advantage The Pla...
Page 293: ...alve side of the engine 57P82 PISTON RING COMPRESSING TOOL Figure 39 Installing Piston Ring and Connecting Rod Assembly V 8 Engine Typical of 6 Cylinder Engine TAPPET 57P90 Figure 40 Removing Mechanic...
Page 294: ...dial indicator to the block with the plunger of the indicator resting on the back of cam nearest a bearing Pry the shaft to and from the indicator so that the movement will be shown on the indicator...
Page 295: ...ving Camshaft Bearings 6 Cylinder Engine To check after each bearing shell has been installed insert light in shell The complete circumference of the camshaft bearing oil hole should be visible by loo...
Page 296: ...he crankshaft See Figures 49 and 50 A straight edge should be used to check the accuracy of this alignment CENTERLINE MARK ON CAMSHAFT SPROCKET MARK ON CRANKSHAFT SPROCKET 56P105 Figure 51 Timing Mark...
Page 297: ...Turn crankshaft clockwise so that the top span of chain is tight If the amount of deflection in the lower span of chain is greater than 3 4 inch from a straight line replace the timing chain 14 VALVE...
Page 298: ...to BEARING 0 BEARING SCREW TROUGH BUSHING OIL SEAL CHAIN SCREW WASHER KEY SPROCKET CRANKSHAFT BEARING CAP WASHER SCREW CAP WASHER SCREW BEARING NUT CAP BEARIN BY PASS SLEEVE BEARING OIL SEAL CAP SCREW...
Page 299: ...valve stems are avail able for service when it is necessary to ream guides REFACING VALVES AND VALVE SEATS When refacing a valve remove only enough metal to insure a smooth accurate surface of the val...
Page 300: ...MINIMUM MEASUREMENT MAXIMUM MEASUREMENT 58x144 Figure 61 Testing Valve Springs Figure 64 Checking Installed Height of Valve 350 Cubic Inch Engine 1 16 57P92 Figure 62 Checking Trueness of Valve Spring...
Page 301: ...r head Measure to spring seat surface of retainer If the height on a 277 301 or 318 cubic inch engine is over 111A6 inch install a 1 16 inch spacer in the head counterbore to bring the spring height b...
Page 302: ...ACKAGE RETAINER SCREW CAP SCREW RING SET PISTON BOLT 1 BOLTI WASHER BUSHING PIN BEARING ROD BEARING KEY CAP CAP CAP SCREW SCREW CAP SERVICED IN ROD NUT CAP CRANKSHAFT SPROCKET OIL SLINGER Figure 69 Cr...
Page 303: ...intake manifold when removing the hydraulic tappets ROCKER ARM TAPPET ADJUSTMENT SCREW FEELER GAUGE 56P235 Figure 71 Adjusting Mechanical Tappets 277 301 and 318 Cubic Inch Engine HYDRAULIC TAPPET CY...
Page 304: ...KEY SPROCKET BEARING NO 2 CAP NO 2 CAP NO 3 BEARING No CAP DOWE PLUG TAPPET ASSEMBLY SEAL CAP NO 4 GASKET SCREW AND WASHER CAMSHAFT BEARING KEY SCREW AND WASHER PLATE SEAL Figure 74 Crankshaft and Re...
Page 305: ...ctual clearance between the valve stem and the guide Check for scuffed valve stems which might damage new valve guides Install new valves if necessary REFACING VALVES Replace valves that are badly bur...
Page 306: ...take 001 to 003 inch Exhaust 003 to 005 inch For intake valves install the valve guides with the counterbored ends downward For exhaust valves in stall the valve guides with the counterbored ends upwa...
Page 307: ...ocking See Figure 78 16 FLYWHEEL To remove the flywheel remove the propeller shaft the transmission the clutch housing pan the clutch assembly and the oil pan Remove the flywheel nuts and the two lowe...
Page 308: ...xhaust Manifold Bolt Nut 25 ft lbs Fan to Hub Bolt 17 ft lbs 15 18 ft lbs Flywheel Nut 60 ft lbs Exhaust Pipe Flange Nut 40 ft lbs Fuel Pump Mounting Bolt 30 ft lbs Intake Manifold Bolt 30 ft lbs Inta...
Page 309: ...on its own power This is necessary to provide initial lubrication Clean and inspect or replace the spark plugs Clean the distributor breaker points and reset the gap if necessary Test distributor in...
Page 310: ...e inner surface of the cover and try to insert a feeler gauge between the straight edge and inner surface of the cover See Figure 84 If clear ance is in excess of limit shown below replace the pump co...
Page 311: ...EAD OIL FROM RIM TO SYSTEM OIL BY PASS VALVE ASSEMBLY Of BY PASS AND CHECK VALVE OR TO AMR OIL GALLERIES CRANKSHAFT LATER MODE PASSAGE TO CYUNOER HEAD OIL OAUFRY OIL PASSAGE ORIFICE OIL PUMP OIL FILTE...
Page 312: ...UST FACE OF CAMSHAFT PUMP 0 U N T T E I K A T E TUBE LUBRICATING TIMING CHAIN AND SPROCKETS OIL GROOVE ANNULUS CARRIES CONTINUOUS FLOW Of OIL FROM MAIN BEARING OIL PASSAGE TO CRANKSHAFT OIL PASSAGES P...
Page 313: ...ANCE Move rotors to one side and measure the clearance outer rotor and pump body with a feeler gauge as shown in Figure 90 If clearance is in excess of limits shown below replace the pump body V 8 Eng...
Page 314: ...SPECIFICATIONS MODEL 6 Cylinder Engine V 8 Engine 230 cu in 301 318 cu in 350 cu in Engine Lubrication Type Pressure Oil Pump Type Rotary Oil Pump Driven By Camshaft Oil Pressure 40 50 lbs at 1500 r p...
Page 315: ...1 piston was accidentally changed while the oil pump was removed take out the spark plug Rotate the crankshaft and check the com pression of the No 1 cylinder Do this by holding the thumb tightly ove...
Page 316: ...he filter These fittings can be used when installing a new filter When installing a new filter tighten all connections firmly Start the engine and inspect the oil line connections for possible leaks O...
Page 317: ...ormation for performing each step in the tune up procedures will be found in the section of this manual covering the unit involved MINOR TUNE UP BATTERY Test for weak or discharged battery In spect ca...
Page 318: ...low With poor compression the needle will be low and unsteady This is because compression pressure will vary between cylinders Vacuum will vary also because the same leaks which cause low compression...
Page 319: ...ng on the 350 cubic inch engine is dow eled and bolted directly to the engine block Figure 101 Checking Converter Hub Runout 57P252 FRONT OF CAR we Figure 102 Correcting Converter Hub Runout Do not ha...
Page 320: ...and heat for approxi mately 8 minutes after the water starts to boil 57P234 TOO 57P232 DOWEL Figure 105 Removing Dowel Pin r 7 ADAPTER TOOL Figure 106 Checking Converter Housing Face Runout 3 STEAM W...
Page 321: ...runout well within the allowable limit of 005 inch or 008 007 offset pin 001 inch runout To install the offset dowel pins remove the housing and remove both dowel pins See Figure 105 Install the offse...
Page 322: ...rn or leaking valves worn piston rings or leaking cylinder head gasket 2 HARD STARTING NON MECHANICAL CAUSES Dampness When high humidity prevails moisture may collect in the distributor cap on the spa...
Page 323: ...am aged b Drain Plug Inspect the oil pan drain plug for tightness c Rear Main Bearing Oil Seal Inspect the under side of the clutch housing for traces of oil Oil at this point usually indicates leakag...
Page 324: ...sticking valves or for a binding condition of the rocker arm on the shaft If valve noise is evident check valve tappet clearance Valve tappet noise cannot be controlled by setting the clear ance less...
Page 325: ...t requires more fuel per mile to operate car at 70 miles an hour than at 35 miles an hour At 70 miles an hour the engine develops about 60 horsepower and only approximately 10 horse power at 35 miles...
Page 326: ...SCREW L 4 LOCK CLIP WASHER WASHER FELT WASHER BREAKER POINT SET ASHER BREAKER PLATE CAM SNAP SL E R I NG 12 WICK SPRING CLIP AND BRACKET__ THRUST WASHERS BUSHING SPRING CLIP AND BRACKET r lx OILER BAS...
Page 327: ...ce and operation depends on the condition and setting of the contacts Too little contact gap can cause contact burning and too wide a gap can 325 result in high speed misfire Contacts should be clean...
Page 328: ...advance ignition timing 57P118 Figure 4 Timing Engine with Timing Light TIMING LIGHT Place a chalk mark on vibration damper or pulley at the specified number of degrees advance Start engine and allow...
Page 329: ...ming As engine load or thottle opening decreases the vacuum increases and overcomes the pressure spring advanc ing the ignition timing Remove vacuum from distributor vacuum control unit and operate di...
Page 330: ...Ballast None 665 735 CONDENSER Capacity microfarads 25 to 285 SPARK PLUGS Models P 30 LP 1 P 31 LP 2 Golden Commando Type AR 51 AR 52 AR 32 Fury AR 42 AR 32 Fury AR 32 Resistor Size 14mm Gap 035 in DI...
Page 331: ...hing with Tool C 3041 DRIVER TOOL 4 ADAPTOR 57P293 Figure 10 Installing Upper Bushing Using Tool C 3041 BUSHING TOOL 57P294 Figure 11 Installing Lower Bushing in Distributor Remove felt wick and snap...
Page 332: ...11 at 2000 R P M Distributor Model Number Vacuum Advance Dist utor Degrees and Inches of Mercury Start 8 10 12 Maximum 1BR 4001 00 5 6 in hg 1 4 3 2 3 50_5 50 5 5 7 5 8 5 10 5 at 16 in hg 1BP 4003 0...
Page 333: ...available ream bushings from 4995 to 5000 inches Remove any burrs from inside of bushings and make certain oil passages are clean Install upper thrust washers on the distributor shaft and insert shaft...
Page 334: ...kshaft until num ber 1 piston is at top dead center on the compression stroke Timing indicator pointer should be pointing to the dead center mark on vibration damper Check com pression stroke by holdi...
Page 335: ...tor cap Hold the end of the cable about 1 4 of an inch away from the cylinder head and crank the engine with the ignition key turned on If the spark jumps the 1 4 inch gap the coil should be satisfact...
Page 336: ...rk streaks up the side of the insulator top This condition may also cause burning of the insulator and the electrodes INSUFFICIENT HEAT An excessively rich fuel mix ture excessive oil consumption or p...
Page 337: ...PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyMopar com...
Page 338: ...ommutator run out and bent shaft must be made with the starter drive removed GROWLER Figure 3 Testing Armature for Short 57P306 Place the armature shaft ends in Vee blocks and check commutator run out...
Page 339: ...7P309 Figure 6 Testing Field Coils for Ground Inspect the field coils terminal leads and brush leads for broken frayed chafed insulation or loose connec tions Resolder all loose connections and repair...
Page 340: ...57P311 Figure 7 Cleaning Starter Drive Assembly To remove the drive assembly from armature shaft loosen the set screw at the end of the drive spring and slide unit from shaft IMPORTANT Do not immerse...
Page 341: ...k when energized with a jumper wire install a new solenoid 3 STARTER MOTOR If test indicates that the starter motor is at fault it should be removed and inspected for repair A heavy arc appearing when...
Page 342: ...2 250 GJC 7012A 1770754 Battery Voltage 12 Battery Terminal Grounded Negative GENERATOR REGULATOR DATA AND SPECIFICATIONS Models P 30 LP 1 P 31 LP 2 Model Number Stamped on Regulator Name Plate Auto L...
Page 343: ...DIMENT SPACE 56P142 Figure 1 Battery The reading of the hy drometer will vary with the temperature of the electro lyte An ordinary dairy thermometer may be used to take electrolyte tempera ture readin...
Page 344: ...d negative plate material Liquid may be forced from the cells resulting in cor rosion of cables battery support and other vital elec trical or engine parts Severe warping or buckling of the positive p...
Page 345: ...side of Battery Post 2 GENERATOR PERFORMANCE TESTS OUTPOST TEST Connect a test lamp between the armature terminal on the generator and ground Be sure to clean the armature terminal to remove any oxida...
Page 346: ...he armature on a growler Turn the armature slowly and hold a hack saw blade or thin strip of steel over each segment of the core 57P315 Figure 7 Testing Armature for Short I Figure 8 Refacing Commutat...
Page 347: ...ds for broken frayed chafed insulation or loose connec tions Resolder all loose connections and repair any frayed or chafed insulation provided the wire has not been damaged If the wire has been damag...
Page 348: ...under the brushes Repeat operation until the brushes seat at least 75 per cent over the entire contact face Excessive use of sandpaper will shorten life of the brushes and should be avoided Blow out a...
Page 349: ...s charging and opens the circuit when the generator is not charging This prevents the battery discharging back through the generator THE CURRENT REGULATOR limits the maximum cur rent output of the gen...
Page 350: ...s open as noted on the voltmeter Points should open at 8 2 9 3 volts with a 0 6 amps discharge If adjustment is necessary remove the regulator cover and inspect the contact points of all three units I...
Page 351: ...eck the gen erator output and be sure the regulator is the correct unit for use with the particular generator Be sure reg ulator is properly grounded 57P318 Figure 15 Refacing Regulator Contact Points...
Page 352: ...m 031 to 034 inch Insert the gauge between the armature and magnet core See Figure 18 Place the gauge as near to the hinge as possible 0 M1 ARMATURE STOP STATIONARY CONTACT BRIDGE 57P316 Figure 19 Adj...
Page 353: ...rrosion 3 FAN BELT Make sure fan belt is tight and in good condition 4 WIRING Inspect wiring for frayed or worn insu lation in the generating circuit 5 REGULATOR With the engine at fast idle con nect...
Page 354: ...tio Fan To Crankshaft R P M 95 to 1 Thermostat Type Choke Pellet actuated BELT TENSION SPECIFICATIONS Type of Accessories New Belt in Used Belt in Location 5 co d co Standard 5 32 1 4 between generato...
Page 355: ...oling system cleaner In areas where the water contains a high percentage of minerals the cooling system should be cleaned at regu lar intervals otherwise it may be necessary to remove the top or botto...
Page 356: ...Figure 3 Reverse Flushing Cylinder Block the block If the tube is not removed the sediment in the block may plug the tube or its slots which direct the flow of water toward the valve ports On older ca...
Page 357: ...ter of the type that will accurately test the particular type anti freeze solution used 1 4 INCH DEFLECTION AT FIVE POUNDS APPLIED FORCE ADJUSTING STRAP BOLT 57P3 Figure 4 Checking Belt Tension with S...
Page 358: ...TION TUBE The water distribution tube used only on 6 cylinder engines should be replaced whenever the engine is completely overhauled If the tube becomes rusted or corroded overheating of the engine m...
Page 359: ...t with emery cloth discs SP 1527 to obtain a smooth seal seat Place the discs under the teeth of the refacing tool and perform the final lapping operation by rotating tool until all cutter marks are r...
Page 360: ...gures 14 15 and 16 Use drill fixture C 783 on pinned hubs to insure a straight hole through the shaft and hub Drive new pin in until it is below surface of hub 8 TEMPERATURE GAUGE The temperature gaug...
Page 361: ...and the fan pulley hub If the pump is leaking it should be removed and re conditioned LOSS OF WATER WITHOUT APPARENT LEAKAGE I RADIATOR Restriction of the passages in the radiator core due to sediment...
Page 362: ...scaping water should ex tend 5 to 6 inches above the lower connection Use an air hose on the back of the radiator core to blow out dead bugs leaves and other particles of dirt that would restrict the...
Page 363: ...team is used when cleaning a fuel tank drain the tank thoroughly Then using compressed air blow air through the filter element holding the air hose at the fuel line 2 FUEL PUMP The fuel pump is operat...
Page 364: ...ve the press fit pivot pin plug and slide out pin Disengage the rocker arm from the diaphragm push rod Separate valve body from main body after remov ing attaching screws The valves are press fit in t...
Page 365: ...is closed the trip lever rides on the high part of the cam and holds the throttle valve at a greater open ing than that provided by the idle speed adjusting CHOKE PISTON LINK FAST IDLE LINK CHOKE LEV...
Page 366: ...he choke to open At the same time the vacuum operated choke piston connected by a rod to the valve keeps a constant pull on the valve against the tension of the spring See Figure 9 This is true as lon...
Page 367: ...1 2 in 2 in Fast Idle 016 in 020 in 014 in 5 V2 turns 3A6 in drill 015 in 7 Vz turns 4 in drill Unloader 9A4 in 3 in 1 y64 in drill 1 4 in 1 4 in drill Idle Mixture 1 2 1 2 turns 3A 1 4 turns 11 4 tur...
Page 368: ...le and to aid in warm engine starting It is impor tant that floats are properly adjusted and needle valve assembly is in good condition Equally important is a good seal between the air horn and main b...
Page 369: ...ean A clogged tube may cause excessively rich mixtures Leakage of air at the gaskets will decrease or destroy the vacuum and the step up piston will remain up resulting in excess fuel consumption PUMP...
Page 370: ...LY POWERFLITE TRANSMISSION ONLY DISCHARGE AIR HORN GASKET CUP WASHER PUMP SPRING r ACCELERATOR PUMP PLUNGER STEP UP PISTON SPRING FLOAT FULCRUM PIN RETAINER STEP UP PISTON GASKET FLOAT BALL 4 FLOAT FU...
Page 371: ...his carefully roll the leather back turn it inside out and return it to its normal posi tion and reshape by rolling between the thumb and forefinger This should also be done before installing a new pi...
Page 372: ...ERING JETS STEP UP PISTON STEP UP PISTON SPRING STEP UP ROD STEP UP PISTON zi z2 RETAINING SCREW 55P I 214 Figure 20 Removing or Installing Step up Piston V 8 Engine the step up piston spring both ste...
Page 373: ...WS GASKET CLUSTER GASKET PISTON JET SPRING RETAINER PIN NEEDLE GASKET GASKET VALVE 57P394 SPRING SCREW ay SPRING INLET BALL RETAINER FLOAT BODY 410 ROD SPRING SCREW LEVER FLANGE SCREW ARM Figure 23 V...
Page 374: ...sed air If hot water is used remove all traces of water with kerosene mineral solvents or gasoline Water in the carburetor can cause die cast parts to corrode and form an oatmeal like mash which will...
Page 375: ...of the main body Each float must be adjusted to this setting It is important that the floats do not touch the sides of the bowl AIR HORN AND THROTTLE BODY 6 Cylinder En gine Carburetor Place a new gas...
Page 376: ...13 The unloader adjustment must be made after the fast idle adjustment is performed Hold the throttle valve wide open and close the choke valve as far as possible without forcing Clearance is measured...
Page 377: ...retors Adjust the engine idle speed at about 450 to 500 revolutions per minute with the engine at normal operating temperature Turn the idle mixture adjusting screw two on V 8 Engine Carburetors until...
Page 378: ...This mixture of air and fuel is then discharged into the air stream through the auxiliary venturi tubes The main body and main discharge jets are designed to prevent percola AUXILIARY VENTURI TUBE MAI...
Page 379: ...REWS 2 PUMP OPERATING ROD REPAIR STAND 57P64 56P199 AIR HORN CHOKE VALVE FAST IDLE LEVER FAST IDLE ROD FAST IDLE CAM WIDE OPEN KICK LEVER FAST IDLE ADJUSTING SCREW THROTTLE LEVER Figure 41 Carburetor...
Page 380: ...Then lift out float CHOKE VENT SCREW DISCHARGE CLUSTER GASKET em Figure 45 Removing or Installing Accelerator Pump Discharge Cluster owe POWER BY PASS JET 57P46 Figure 46 Removing or Installing Power...
Page 381: ...SEAT AND GASKET PLUGS MAIN DISCHARGE JETS TUBES GASKET CLUSTER SCREW GASKET DISCHARGE CLUSTER GASKET r DISCHARGE CHECK BALL IDLE TUBES MAIN BODY FAST IDLE CAM MAIN METERING JETS GASKETS MAIN JET PLUGS...
Page 382: ...gure 47 Then install gasket and plug Install power by pass jet and gasket TESTING ACCELERATOR PUMP Install the accelerator pump inlet check ball 3 l6 inch diameter in the check ball seat at the bottom...
Page 383: ...IDLE ROD BEND AS REQUIRED FAST IDLE STOP ADJUSTING SCREW FAST IDLE IDLE SPEED CAM ADJUSTING SCREW 57P56 THROTTLE LEVER TANG Figure 55 Fast Idle Adjustment plunger to be sure no binding exists If the p...
Page 384: ...and wall of the carburetor See Data and Specifications See Figure 58 Bend the piston lever ear if necessary ACCELERATOR PUMP SETTING Hold carburetor in vertical position and operate pump to permit th...
Page 385: ...62 Rear Choke Control Cross over Typc Automatic Set at Center Index Mark Integral Automatic Set 1 mark lean 0 4 o a Accelerator Pump Adjustment Top of pump plunger arm parallel to dust cover boss Mete...
Page 386: ...cluster tubes which prevents air being drawn into the pump system when the pump plunger is raised FLOAT SYSTEMS The float systems maintain an adequate supply of fuel at the proper level for use by th...
Page 387: ...Invert main body and remove the pump dis charge check needle Remove main metering jets pri mary side as shown in Figure 66 Then remove the secondary side main metering jets Primary main meter ing jets...
Page 388: ...0 Then 0 IDLE MIXTURE ADJUSTING SCREWS AND SPRINGS 54x515 Figure 69 Idle Mixture Adjustment Screws slide the fast idle cam trip lever over the shoulder on screw guiding the tang between the fast idle...
Page 389: ...coil housing and retainer ring Install retaining screws Position the index mark of the coil housing to match the center index mark of the choke housing Do not tighten retaining screws excessively PRI...
Page 390: ...e They can be bent inward for correct adjustment Adjust the secondary float in same manner Float Drop Adjustment After performing the float lever adjustment invert air horn assembly and note distance...
Page 391: ...NDARY FLOAT PRIMARY FLOAT PUMP JET HOUSING SCREW so PUMP JET HOUSING PRIMARY IDLE JETS PRIMARY MAIN JETS ACCELERATOR PUMP PASSAGE PLUG PUMP JET HOUSING GASKET SECONDARY MAIN JETS SECONDARY IDLE JETS B...
Page 392: ...n screw See Figure 82 Fast Idle Adjustment Insert a wire gauge between the primary throttle valves and side of bore opposite the idle ports Refer to Data and Specifications for correct size wire gauge...
Page 393: ...and throttle bore Refer to Data and Specifications for correct setting Re connect secondary throttle operating rod Secondary Throttle Lever Adjustment The stop lug on both primary and secondary throt...
Page 394: ...osition a clearance of 017 022 in must be between the positive closing shoes on primary and secondary throttle levers See Figure 89 This adjustment is made by bending shoe on primary lever Interconnec...
Page 395: ...in Body Remove the accelerator pump jet housing and invert carburetor to remove discharge check needle Remove primary and secondary main meter ing jets Refer to Figure 92 Primary jets are not inter ch...
Page 396: ...179S 7 32 in 2744S 21 188S 1 4 in Carburetor Float Setting 2652S 21 179S 2 in 2652S 21 188S in 2653S 21 179S 7 32 in 2653S 21 188S 5 16 in Float Drop 2 2 2 4 Zn Fast Idle on Car 1400 R P M 1450 R P M...
Page 397: ...OR Main Body Install the two idle mixture adjusting screws and springs in the throttle body portion of the casting The tapered portion must be straight and smooth If the tapered portion is grooved or...
Page 398: ...ry to reclean the passage or install a new check ball Fuel leakage at the discharge check needle indi cates the presence of dirt or a damaged check needle Clean again and then install a new check need...
Page 399: ...tor rod if so equipped Fast Idle Adjustment With the choke valve held tightly closed tighten the fast idle adjusting screw on the high step of the fast idle cam until wire gauge can be inserted betwee...
Page 400: ...d contact the bosses on the flange at the same time If an adjustment is necessary bend the secondary throttle operating rod at the angle using Tool T109 213 until correct adjustment has been obtained...
Page 401: ...throttle of rear carburetor to wide open position Adjust intercon necting rod so that front carburetor is in wide open posi tion Then tighten lock nut 9 MANIFOLD HEAT CONTROL The purpose of the manif...
Page 402: ...aust VALVE SHAFT manifolds for evidence of cracks or distortion DIRECTION OF WRAP Inspect the exhaust crossover passage in the intake 57P390 manifold and in the cylinder heads See Figure 113 If engine...
Page 403: ...should be cut off as close to the front 56PI 25 EXHAUST CROSSOVER PASSAGE 2 WELL FOR AUTOMATIC CHOKE 4 6 8 TEMPERATURE SENDING UNIT EXHAUST CROSS OVER PASSAGE CARBURETOR MOUNTING FLANGE Figure 113 Int...
Page 404: ...ER BRACKET WASHER NUT WASHER PIPE NUT STUD BOLT WASHER WASHER BOLT SUPPORT I BRACKET WASHER NUT BOLT WASHER NUT o WASHER AR SADDLE PACKAGE NUT Figure 115 Dual Exhaust System CLAMP WASHER NUT 58P96 m 0...
Page 405: ...E BODY BODY ACCESSORIES AIR CONDITIONING INSTRUMENTS GAUGES HORN WINDSHIELD WIPERS LIGHTING SYSTEM PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyM...
Page 406: ...404 BODY PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyMopar com...
Page 407: ...ool between washer and handle as shown in Figure 2 Push tool from left to right and at the same time pull outward on handle Procedure is the same for removing inside door handles When installing the h...
Page 408: ...door Keep tool close to fasteners to prevent pulling the fasteners out of the trim panel See Figure 6 FRONT DOOR GARNISH MOULDING Remove the screws attaching the garnish moulding to the door Unlock a...
Page 409: ...RELEASE PUSH TOWARD FRONT OF CAR TO LOCK 57P138 Figure 10 Sliding Latch Plate To Remove or Install Lock Cylinder To install lock cylinder turn the key to the unlocked position With the latch in the r...
Page 410: ...be connected to the lock rivet Install the door lock attaching screws and the remote control hose screws Install the door link cylinder and outside door handle and adjusting link Reassemble door trim...
Page 411: ...e door hardware FOUR DOOR SPORT SEDAN REAR DOOR GLASS AND REGULATOR REMOVAL Remove the door inside hardware and trim panel roll the door glass to the half raised position Remove the front channel atta...
Page 412: ...ner either side push the glass out of the weatherstrip Work across the bottom and up the sides until the glass can be lifted from the weather strip Use of gloves will protect hands against possible sh...
Page 413: ...p channel while holding the bottom of the glass against the weatherstrip Do not attempt to push the glass into the corners at this time See Figure 20 NOTE Make certain that the glass is properly cente...
Page 414: ...n Figure 24 4 57P151 Figure 25 Positioning Rear Window in Weatherstrip 57P152 Figure 26 Working Rear Window Glass into Weatherstrip Releasing the locking lip will allow the rear window glass to be rem...
Page 415: ...ing regulator handle and trim panel Roll the quarter window glass to the half raised position Remove the front channel attaching screws as shown in Figure 28 NOTE If the car is equipped with electric...
Page 416: ...weatherstrip over the stationary glass Apply sealing compound under the outer lip of the weather strip Carefully place the assembly in the body opening With the use of a fiber wedge carefully work th...
Page 417: ...piece of 3 t inch pipe 12 inches long to the end of the bumper jack as shown in Figure 32 TOP REAR EDGE OF FENDER TOO CLOSE TO COWL Figure 33 Raise the hood and loosen the top fender bolt Pry up the f...
Page 418: ...alignment of the fender is obtained retighten the fender to cowl attaching bolts and remove the jack GAP BETWEEN REAR EDGE OF FENDER AND SILL PANEL SPACING CORRECT AT UPPER SECTION Loosen the bottom...
Page 419: ...be checked REAR CORNER OF HOOD TOO HIGH AT COWL Figure 41 Loosen the two hood hinge to bracket rear stud nuts These can be reached underneath the instru ment panel Loosen the hood hinge to bracket fro...
Page 420: ...OF HOOD TOO CLOSE TO COWL Figure 45 Scribe a line on the hood flange so that the hood movement can be checked Loosen the hood to hinge stud nuts and pull the hood forward until the proper spacing bet...
Page 421: ...the parting line between the forward edge of the front flange and the line formed by the rear edge of the fender and cowl After the front door is correctly posi tioned align the rear door with the re...
Page 422: ...to move the upper half of the door away from the pillar See Figure 57 Then re tighten the hinge screws Loosen the lower hinge screws and pull down on the upper rear corner of the door to move the lowe...
Page 423: ...he body see Figure 62 Then re tighten the hinge screws REAR DOOR TOO LOW IN OPENING Figure 63 Place a floor jack under the center of the door Protect the bottom edge of the door with a cloth pad Loose...
Page 424: ...id A tool to perform this operation can be made as shown in Figure 67 58P10 Figure 66 Rear Corner Binds at Lower Rear Corner 45x2228 MATERIAL STEEL Figure 67 Torsion Bar Tool Dimensions The torsion ba...
Page 425: ...salignment UPPER CORNER OF DECK LID BINDING AT UPPER PANEL Figure 69 Loosen the hinge to deck lid attach 57P191 Figure 70 Loosen Deck Lid to Hinge Attaching Screws 57P192 Figure 71 Upper Corner of Dec...
Page 426: ...and rear seat cushion assembly as well as the sun visor and upper windshield garnish moulding On Club Sedan models it will be necessary to remove quarter window garnish mouldings After rear glass has...
Page 427: ...shown in Figure 79 A 55P1020 Figure 78 Mark Clip Hole When Removing Bow From Roof Rail 55P1021 Figure 79 Bending Locking Tab Up To Remove Clip From Bow End to permit removal of the bow from the listin...
Page 428: ...ed in place Cut the listing from the end up to the clip After listings are cut start at the front and trim the 55P1025 Figure 83 Trimming Excess Material At Wind Cord 55P1026 Figure 84 Tucking Headlin...
Page 429: ...material in place at the quarter panel where it is to be cemented REAR WINDOW WEATHERSTRIP 57P204 Figure 88 Plastic Mouldings Removed From Retainers Install the remaining portion of the headlining at...
Page 430: ...d trim panel Disconnect the wires from motor Remove REGULATOR ATTACHING SCREWS 4 I 4 57P205 Figure 90 Window Regulator Attaching Screws the attaching nuts that hold the motor to the gear box pull moto...
Page 431: ...NT DOOR MOTOR RIGHT REAR DOOR OR QUARTER WINDOW LIFT SWITCH DK GREEN GRAY WHITE RED ORANGE BLACK LEFT REAR DOOR OR QUARTER WINDOW LIFT SWITCH UP 0 ORANGE 4OWN RED RIGHT REAR DOOR OR QUARTER WINDOW LIF...
Page 432: ...UID LEVEL Insufficient fluid or air in the system may cause the top to raise slowly or the pump and motor may be noisy during the operation Check the fluid level in the reservoir If low check for a le...
Page 433: ...gnment this should be done before attempting to make adjustments of the top fabric Figure 94 illustrates how to correct a door fit which is tight at the top and open at the bottom If the door fit were...
Page 434: ...er window VERTICAL PROP LINK VERTICAL PROP LINK Can be adjusted up or down to obtain proper leveling and centering of the top POWER LINK Can be adjusted toward front or rear to control for ward travel...
Page 435: ...JUSTMENT When the vent is ad justed to fit tight against the side rail weatherstrip the upper front corner of the door glass will also fit tight against the weatherstrip The upper rear corner of the d...
Page 436: ...align ment of door glass and channels 4 FRONT CHANNEL ATTACHING SCREWS Adjust attaching screws to move channel up or down 5 QUARTER WINDOW UPPER STOP Adjust screw to limit forward travel of glass Fig...
Page 437: ...necessary to replace the gaskets 57P213 Figure 98 Checking Windshield for Water Leaks 57P214 Figure 99 Apply Sealer Between Weatherstrip and Windshield FRESH AIR INTAKE Openings in the seals or seams...
Page 438: ...W HINGE IN PARTICULAR A POST TO BODY SILL 14 BOTTOM OF A POST 8 BODY PANEL TO FILLER NECK TUBE 4 FLOOR PAN TO WHEEL HOUSE 3 BODY SILL TO WHEEL HOUSE 1 BODY SILL JOINT 2 COACH JOINTS BOTH SIDES UPPER A...
Page 439: ...eatherstrip can be shimmed outward by putting a strip of body elastic tape on the door and using weather strip cement To replace the entire weatherstrip free the old weatherstrip from the door with so...
Page 440: ...ners of the window as shown in Figure 106 To aid in the installation of the moulding mark the clip holes by placing balls of sealer to the rear of each moulding hole This helps align the trim moulding...
Page 441: ...the quarter windows These areas can be sealed by applying semi fluid sealer between SEAL ENT RE LENGTH OF ROOF SEAM AND WELD JOINTS _ Figure 110 Sealing Tail Gate Area the weatherstrip and the body a...
Page 442: ...tin Grey 22 8269 8269 DQE 31390 DAL 31390 Canary Yellow 22 8292 8292 DQE 80905 DAL 80905 Silver Charcoal 22 8270 8270 DQE 31387 DAL 31387 INTERIOR COLORS Seat Frames Berry Bros Ditzler Steering Column...
Page 443: ...8480 11 8480 DQE 21501 DAL 21501 Copper Glow Met NNN 22 8479 8479 11 8479 DQE 21446 DAL 21446 Toreador Red Light 000 22 8477 8477 11 8477 DQE 70773 DAL 70773 Royal Red Dark PPP 22 8462 8462 11 8462 DQ...
Page 444: ...D NO SIGNAL INPUT ALL MEASUREMENTS ARE FROM POINT INDICATED TO CHASSIS UNLESS OTHERWISE SPECIFIED OSCILLATOR GRID VOLTAM WAS MEASURED WITH AN ELECTRONIC VOLTMETER HAVING A ONE WOODS PROSE ISOLATING RE...
Page 445: ...AL ON TEMP GAUGE 443 have all been eliminated by the use of the transistor There is only one transistor in each receiver the balance of the circuit functions being performed by tubes operat ing direct...
Page 446: ...tely 1400 kilocycles the volume at full and the antenna fully extended adjust the antenna trimmer for the maximum volume of a weak station or background noise between stations SETTING PUSH BUTTONS Pus...
Page 447: ...T CAPACITY 401 12F SERIES 40141F SHUNT 128L6 12AD6 RF AMPL 33 CONVERTER 12C06 IF AMPL 100 Ina TRIGGER 1 2120L8 DETECTOR 1STKuDIO DETECTOR I F 262 5KC 1201 8 DRIVER AR9121 POSH PILL OUTPUT I O TI r 2 1...
Page 448: ...op pavements at both low and high car speeds with antenna extended to operating position with radio at full volume and tuned off station If tire static noise is encountered inject Tire Static Suppress...
Page 449: ...heater and adjustment of controls are furnished with each heater package VALVE GASKET t RETAINER SCREW VALVE TO HEATER HOSE HEATER MOTOR BLACK WHITE I STRIPE HEATER o SWITCH c ea FUEL GAUGE Figure 9...
Page 450: ...before an attempt is made to elimi nate the interference 1 EXTERNAL INTERFERENCE This type is due to street cars neon lights power lines buses other auto mobiles high tension lines etc This interferen...
Page 451: ...condenser be sure not to connect it with the field terminal otherwise damage to the voltage regulator may result For proper installation see Figure 12 VOLTAGE REGULATOR A condenser which filters out...
Page 452: ...ntered the system and may have become trapped limiting the circulation of the hot water To correct condition by forcing out the trapped air loosen heater outlet hose with the engine running Be sure th...
Page 453: ...the dash area and provides temperature control for all weather driving Temperature control is obtained through a reheating process For summer operation the air is dehumidified and cooled as it passes...
Page 454: ...trol lever operates WARMER flA OFF COLD COOLING HEATING COWL VENT DOOR OPEN BLOWER the water temperature valve through a control cable the fresh air and recirculating door through two electric switche...
Page 455: ...nozzle TWO WAY SOLENOID VALVE CHECK VALVE TO PREVENT LOSS OF OIL PRESSURE DURING ENGINE IDLE AUXILIARY DRAIN TUBE FOR AIR AND OIL LEAKAGE PAST PISTON ROM HIGH y 7 TO LOW PRESSURE PRESSURE k POINT IN...
Page 456: ...esh air door opens and recirculating door closes due to de energization of the solenoid valve 2 Full fresh air cooling obtained 3 Lever mechanism picks up the cable controlling the water temperature c...
Page 457: ...n will be approximately 40 F This shift in the temperature range is accomplished by the heating of the valve s temperature sensitive secondary capillary tube with a resistance heating coil wound aroun...
Page 458: ...left hand shut off valve on manifold remove hose from center connection of gauge set Attach capac ity test cap Tool SP 2922 to center connection of gauge set manifold Disconnect manifold hose from su...
Page 459: ...s from both service valves then replace valve stem and service port caps and both service valves Adjust fan belt and check both cylinder head to compressor attaching bolts for tightness 3 PRECAUTIONS...
Page 460: ...ling Gauge Set Manifold and Charging System but eliminate those steps involving scale Start engine and operate at 1200 r p m Turn blower control switch to high position and temperature switch to Cold...
Page 461: ...er In order to be certain the moisture content of Re frigerant 12 is kept out of the freeze up range acid producing and corrosion range the moisture content should not exceed 10 PPM The progressive re...
Page 462: ...evel to Cold position and blower switch to High Slowly turn the valve stem of the suction service valve two full turns and check sight glass for flow of refrigerant liquid through glass After approxim...
Page 463: ...efrigerant shut off valve and open refrigerant valve Purge air from drier by opening refrigerant tank shut off valve for a few seconds Install 1 4 inch cap on outer end of valve and tighten cap secure...
Page 464: ...suction pressure fluctuate down below 10 psi and then release clutch it is indicated the thermal switch sensing tube is not making a good contact with evaporator fin and coils Should suction pressure...
Page 465: ...ne end of lead to solenoid valve terminal and the other to ground Start engine and adjust engine speed to 1200 r p m Turn toggle switch to Cool position Move air con ditioning control lever to Off pos...
Page 466: ...n service valves Close both valves by turning valve stems clockwise with Tool C 3361A until valves are seated firmly The engine should never be started with the discharge or suction service valve clos...
Page 467: ...pounds of Refrigerant 12 19 REPLACEMENT OF RECEIVER STRAINER DRIER FUSIBLE PLUG WITHOUT REMOVAL FROM CAR Replacement of damaged fusible plug can be made without removal of unit from bracket assembly D...
Page 468: ...st its thermal charge The valve should therefore give satisfactory performance If the expan sion valve fails to pass the test procedure it should be replaced NOTE Be sure the expansion valve thermal b...
Page 469: ...ge extends to cylinder bores replace compressor If compressor is not damaged clean the surfaces of cylinder block valve plate and head thoroughly Use care to remove all shreds of old gasket from plate...
Page 470: ...e plate hub squarely into inner bearing race Place a brass drift against the drive plate inner hub and tap plate hub into bearing by tapping on brass drift with a hammer while supporting the inside ra...
Page 471: ...in later test Start engine adjust to 1200 rpm Check clutch should be de energized If clutch is energized and solenoid valve circuit is open see wiring diagram black wire on switch No 2 and white wire...
Page 472: ...ng sound takes place trace circuit through selector switch to the opening in the wiring circuit Check fresh air door It should be closed and the recirculating door open Check circuit to solenoid valve...
Page 473: ...utch white wire connection If hot open circuit in thermal switch circuit as indicated If cold reach No 1 micro switch by hand switch nearest Off position With the control lever in the Cold position mo...
Page 474: ...or cap to relieve pressure be fore removing heater hose Check water valve fooler circuit It should be ener gized but test light will still be dim If light remains out trace open circuit back to rheost...
Page 475: ...9 50 50 50 50 51 51 52 53 54 55 56 56 57 58 59 60 61 62 63 64 66 67 68 69 70 71 72 73 74 92 93 X X 47 47 48 48 48 48 49 49 49 50 50 50 50 50 50 50 51 51 51 52 52 52 52 53 54 55 55 56 56 56 56 57 57 58...
Page 476: ...see if there is any water leakage If necessary seal the evaporator housing on the inside of housing at the point of leakage After sealing the housing recheck for leaks NOTE Discharge and suction press...
Page 477: ...p o 8 CD 0 0 cu a 0 75 p i 173 a Ey u g t 0 o a g 0 01 1 cg 0 1 4 a En 5 m 7 15 4 0 1nm 2 t 17 0 d 0000 c0Wlib a 4 CA x a a g 0 yo t9 cti a t 0 15 0 40 6 Z a 0 0 C 7 u 0 a rq woo 0 u 2 a ty 0 c nouE...
Page 478: ...C 3358 C 3361A C 3473 C 3645 C 3128 Special Tools C 3363 C 3429 C 3355 1 4Vnwwas o ivoo 1111N1Mj C 3420 C 3362 C 3421 l se C 3623 C 3478 58x188 4 1Ot co 0 a PDF compression OCR web optimization using...
Page 479: ...ed by using a special Tool C 3582 when it is necessary to service the tank unit See Figure 2 and 3 TESTING ELECTRO MAGNETIC GAUGE TESTING WIRE FROM STARTER IGNITION SWITCH TO PANEL UNIT Turn switch to...
Page 480: ...ClIC11 1 Circuit Breaker Location Constant Speed Built into Switch Variable Speed Attached to Switch CIRCUIT BREAKER AND FUSE CHART MODELS LP1 P 30 LP2 P31 Headlamps 20 amp C B in switch Radio 71 2 am...
Page 481: ...ts on the gauge inspect the wires of the tempera ture gauge circuit for worn frayed or broken wires Clean terminals at the panel unit and engine sending unit Check the battery voltage Remove the sendi...
Page 482: ...PS NINIMMINIF Figure 4 Removing Horn Cover 57P29 SPEEDOMETER DRIVE PINION OIL SEAL The seal on the speedometer pinion may wear causing transmis sion lubricant to be pumped into speedometer cable housi...
Page 483: ...accessible under neath the steering wheel see Figure 7 To remove the horn blowing bar on Belvedere models rotate the center ornament counter clockwise until it disengages from the bar 3 ELECTRIC WINDS...
Page 484: ...er motor is sufficient to cause serious personal injury 16 BLACK VARIABLE SPEED WINDSHIELD WIPER FUEL GAUGE RED 16 YELLOW F VARIABLE SPEED WINDSHIELD WIPER MOTOR SWITCH 16 BLACK CIRCUIT BREAKER 58P15...
Page 485: ...able Speed 57P426 mutator Replace worn or oil soaked brushes Check the armature and crankshaft in their respective bush ings and replace worn parts if any looseness is detected End play in the armatur...
Page 486: ...free from oil or grease A dirty greasy commutator will cause a high resistance and greatly impair the efficiency of the wiper Assemble the frame armature and head being care ful to raise the brushes...
Page 487: ...st lamp between the battery negative terminal and the B terminal of the switch Lamp should light when switch is turned on and gradu ally dim as switch is rotated clockwise Lamp should go out when swit...
Page 488: ...d Variable Speed Motor vents slippage in the running direction and allows 180 slippage on the pin when the motor reverse to park the blades When assembling right linkage install link spring trip to en...
Page 489: ...ch plate Further adjustment may be necessary at the pivots to even up blade position 2 SWITCH Make certain that lead wires are tight in switch and are installed in proper socket 3 CONTACT POINTS Clean...
Page 490: ...957 5400 1958 Inboard 4001 Outboard 4002 Parking and Turn Signal Lamp 32 4 1034 Tail and Stop Lamp 32 4 1034 Direction Indicator Tell Tale 2 57 License Plate Lamp 3 67 Back Up Lamp 21 1141 Headlamp Be...
Page 491: ...ch end of the wire A wire showing a voltage drop of more than 1 10 volt should be replaced If any wire in the lighting circuit has been replaced with other than stan dard equipment wire it may lack co...
Page 492: ...n flickering lights due to vibration when driving over rough roads Inspect the connections and sockets at the taillamp panel lamps license lamps and parking lamps for poor ground dirt corrosion or loo...
Page 493: ...of the headlights Draw vertical lines on the screen to represent the vertical centerline of the inner and outer headlights A center vertical line should be equal distance from the outer lines which re...
Page 494: ...est for low output or high resis tance in generator brushes ONE LIGHT FAILS 1 BULB OR SEALED BEAM UNIT Inspect for cor rosion at socket terminals loose connections at sockets or for a defective bulb 2...
Page 495: ...PART FOUR MISCELLANEOUS LUBRICATION MAINTENANCE WIRING DIAGRAM ALPHABETICAL INDEX PDF compression OCR web optimization using a watermarked evaluation copy of CVISION PDFCompressor MyMopar com...
Page 496: ...djustment Check Clutch Adjustment Engine Tune up Minor Engine Tune up Major U Clean Carburetor Air Cleaner Cartridge Replace Oil Filter Repack Front Wheel Bearings 0 0 Lubricate Speedometer and Cable...
Page 497: ...is warm When checking the oil level Make sure the car is level If the oil level is checked immediately after the car has been driven some oil will remain in the oil passageways and the level will not...
Page 498: ...e A Crankcase Outlet Air Cleaner Spec Equip SAE 50 Engine Oil Oil Filler Pipe Cap Air Cleaner SAE 50 Engine Oil Speedometer Head MoPar Speedometer Oil Speedometer Cable MoPar Speedometer Cable Lubrica...
Page 499: ...name diluents as is the practice with SAE 10 W engine oil in order to secure better starting in cold weather will lower its viscosity below that required for ade quate lubrication NEW CARS Engine oil...
Page 500: ...aking in mileage has been covered Here is a suggested breaking in plan THE FIRST 300 MILES During this period the car should be driven at moderate speeds when accelerating in first and second and whil...
Page 501: ...ion Fluid Type A Apply parking brake Run engine at idle speed Operate all push buttons pausing momentarily at each position and ending with the N Neutral button pushed in Check oil level at transmis s...
Page 502: ...Flite should be with Auto matic Transmission Fluid Type A CAUTION To prevent dirt from entering the transmission make sure the oil level indicator cap is seated properly on the filler tube DISTRIBUTOR...
Page 503: ...push buttons paus ing momentarily in each position and ending with the N Neutral button pushed in Add sufficient fluid to bring the oil level to the L mark and 1 2 inch below the L mark approximately...
Page 504: ...ONS If the temperature drops below 32 F protect the cooling system with a good quality anti freeze CAUTION Anti freeze solutions containing sodium chloride common table salt calcium chloride or any in...
Page 505: ...POLISHING If the finish has become oxidized through neglect or exposure to severe climatic condi tions it may be difficult to restore the original luster by washing Removal of natural oxidation and a...
Page 506: ...ome plated parts can be removed with a chrome cleaner After cleaning car wipe the bumpers occa sionally with a cloth to which a little oil has been added STAINLESS STEEL PARTS Under certain conditions...
Page 507: ...wick with oil CABLE Disconnect at speedometer housing and coat shah with speedometer cable lubricant GEAR SHIFT CONTROL ROD rr Chassis lubricant Manual transmission only One fining on manual con trot...
Page 508: ...TOR REGULATOR 18 RED 14 BLACK OIL PRESSURE WARNING LAMP 18 ORANGE 20 DK BLUE WHITE ACC IGN GENERATOR LOW CHARGE WARNING LAMP 12 RED ST WHITE 18 LT BLUE STARTER SOLENOID FUEL GAUGE TANK UNIT STARTER AN...
Page 509: ...HEADLAMP SWITCH WITH 15 AMP BACK UP CIRCUIT BREAKER LAMP SWITCH STOP LAMP 18 PINK 20 ORANGE BLACK 0 rill ORANGE 18 18 WHITE toGLOVE BOX LAMP AND SWITCH FLASHER SOCKET 78 PINK 18 WHITE 18 BLACK RIGHT...
Page 510: ...ACK DOME LAMP FOUR DR SEDAN FOR OTHER MODELS SEE PAGE 510 GLOVE BOX LAMP SWITCH FUEL GAUGE LAMP SPEEDOMETER LAMP TEMP GAUGE LAMP PUSH BUTTON GEAR SHIFT IND LAMP P FLITE AND T FLITE ONI 18 WHITE 18 ORA...
Page 511: ...ISTRIBUTOR IGNITION COIL NEUTRAL SAFETY SWITCH P F ONLY STARTER MOTOR RADIO CONDENSER COIL RESISTOR 1957 MODELS 14 BLACK CD O U CO 14 BLACK 18 YELLOW STARTER SOLENOID 12 RED ST COIL RESISTOR 1958 MODE...
Page 512: ...RAL MANUAL SWITCH TWO DOOR HARD TOP FOUR DOOR HARD TOP 18 YELLOW HEADLAMP SWITCH AUXILIARY TERMINAL PINK I MAP LAMP WITH INTEGRAL MANUAL SWITCH A POST AUTOMATIC DOOR SW A POST AUTOMATIC DOOR SWITCH AF...
Page 513: ...Springs 63 Testing Thermal Switch 462 Release Bearing 64 Anti Freese Solutions 354 Release Lever Adjustment Auburn 63 Automatic Choke 362 377 Release Lever Adjustment Borg and Beck 62 Axle Shaft End...
Page 514: ...tion 365 383 394 Fuel Pump 361 G Generator Data and Specifications 340 Indicator Lamp 477 Inspection and Bench Tests 343 Performance Tests 343 Generator Regulator 347 Data and Specifications 341 Perfo...
Page 515: ...0 Semi Finished Pistons 278 Governor Pressure Chart 168 Service Brakes 38 Hydraulic Operation 163 Shock Absorbers 140 Hydraulic Pressure Tests 167 Sliding and Stationary Glass Suburban 414 Kickdown Ba...
Page 516: ...y 357 Line Pressure Chart 218 Wheel and Tire Run Out 71 Low and Reverse Planet Pinion Carrier Assembly 243 Wheel Balance 71 Low Reverse Rear Band 255 Wheel Bearing Adjustment 72 Lower Valve Body 261 W...
Page 517: ...ering Power Chuckle Noise Connector Nut Control Valve Adjustment Control Valve Loose on Rod Control Valve Rod Upper 0 Ring Creaking Noises on Turns Gear Shaft Cover Gear Shaft Oil Seal Hard or Jerky S...
