Chrysler Imperial 1957 Скачать руководство пользователя страница 1

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Содержание Imperial 1957

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Страница 2: ...pecified Extra copies of this Manual are available at 4 00 each under Part Number D 15899 Order from Chrysler Division P O Box 1658 Detroit 31 Michigan C H R Y S L E H D I V I S I O N Chrysler Corporation DETROIT 31 MICHIGAN Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its product without imposing any ob ligation upon itself to instal...

Страница 3: ...etroit 31 Michigan Detroit 31 Michigan Phone VAUey 2 4700 NOTE Please make certain to include the code WUX on all telegrams to either the Chrysler Division or Plymouth Division as this insures delivery direct to our Teleprinter Room thus eliminating delay Letters or telegrams should be confined to one subject only and should include the follow ing information Car Serial Number Owner s Name Date of...

Страница 4: ...Books Parts Price Lists Parts Bulletins etc should be forwarded direct to Chrysler Corporation Parts Division P O Box 1718 Detroit 31 Michigan Attention Parts Advertising Department Shortage o Accessories or Other Equipment on New Cars Before placing an order for missing accessories other parts or equipment on new cars received examine the vehicle for the presence of a back order notice which if p...

Страница 5: ...4 INTRODUCTION CH1YSLE1 SEBV1CE MANUAL Fig 1 Model C 75 1 Windsor 57x129 Fig 2 Model C 76 New Yorker Fig 3 Model Imperial MyMopar com ...

Страница 6: ...hicle number is stamped on a metal plate attached to the left front door body hinge post as shown in Figure 4 ENGINE NUMBER For L A built cars the vehicle will be re vised as follows Windsor Saratoga New Yorker L A Identification W57L1001 L57L1001 N57L1001 X 6 Is 5 1 x 1 7 Fig 5 Engine Number The engine number is stamped on a boss on the top side of the cylinder block just back of the water pump a...

Страница 7: ...218 9 224 2 Four Door hard top 219 2 219 2 219 2 224 2 Width with Four Door Sedan 78 8 78 8 78 8 81 2 Bumper Convertible Coupe 78 8 81 2 Two Door hard top 78 8 78 8 78 8 81 2 Town Country Wagon 78 8 78 8 Four Door hard top 78 8 78 8 78 8 81 2 Rear Axle Four Door Sedan 3 73 with Manual Convertible Coupe Transmission Two Door hard top 3 73 Town Country Wagon 3 73 Four Door hard top 3 73 Rear Axle Fo...

Страница 8: ... Diagnosis 22 DATA AND SPECIFICATIONS MANUAL STEERING Caster Camber Steering Axis Inclination Toe In H 0 H right l A H left 5 to 7 At 0 Camber y w Vs Preferred WITH POWER STEERING Caster Camber Steering Axis Inclination Toe In H H 0 U right H H left 5 to 7 At 0 Camber y 9 w V Preferred SPECIAL TOOLS C 3553 Remover and Installer Shock Absorber Lower Bushing C 3557 Installer Lower Control Arm Bushin...

Страница 9: ...trut to Lower Control Arm Mounting Bolts 65 Lower Control Arm Strut Bushing Nut 35 Shaft to Lower Control Arm Bushing Retaining Nut I n n e r 125 Upper Ball Joint Stud Nut 135 Lower Control Arm Shaft to Crossmember Mounting Nut 200 Upper Control Arm to Support Bracket Mounting Bolt Nuts 55 65 Control Arm Support Bracket to Frame Bolt 70 Steering Knuckle to Brake Support Bolt 55 Steering Knuckle to...

Страница 10: ... LOCK R I N G v JOINT UPPER sif CAhA f COTTERPIN I NUT 1 RETAINER WASHER NUT COTTERPIN BUSHING SEAT M BOLT TORSION BAR NNER OUTE1 RETAINER BUMPER STEERING KNUCKLE FLAT WASHER NUT COTTERPIN NUT FLAT WASHER COTTERPIN BOLT SEAL LOWER CONTROL ARM LOCKWASHERS BALL JOINT LOWER LUBE FITTING STRUT RETAINER RETAINER 57x70 Fig 2 Front Suspension Disassembled View Fig 3 Lower View Front Suspension Assembly M...

Страница 11: ...s of the road wheels have little effect on the steering linkage The new system also offers a number of other advantages in terms of longer part life and ease of servicing Lubrication The number of lubrication points has been re duced to 8 in the new suspension system The suspension points requiring lubrication are ef fectively sealed against entry of dust dirt water or other contaminants Rubber bu...

Страница 12: ... pin inclination procedures and the term Steering Axis Inclination will be used hereafter To prevent the possibility of any fore and aft movement of the lower control arms a strut is attached from frame crossmember to lower control arm as shown in Figure 6 The forward end of the struts are mounted in the front cross member with replaceable rubber bushings as shown in Figure 9 The sway bar shaft is...

Страница 13: ... BOLT k A D J U S T I N G C A M K I F R A M E CROSSMEMBER A N C H O R BRACKET j LOCK R I N G EFT H A N D SIDE T O R S I O N BAR CROSSMEMBER A T T A C H I N G BOLT 57x78 Fig 12 Torsion Bar Spring Rear Mounting SERVICE PROCEDURES 2 CHECKING FRONT SUSPENSION HEIGHT Front suspension height should be checked and if necessary reset whenever service work has been done on the torsion bars The vehicle shou...

Страница 14: ...age or load should be removed If a constant load is carried such as when a Fig 14 Measuring Front Spring Height at Control Arm Fig 15 Adjusting Torsion Bar Cam Bolt car is used by salesman for carrying samples etc car should be loaded with its normal amount of weight before checking front wheel alignment All factors of front wheel alignment are in terrelated but each angle has specific purpose Fou...

Страница 15: ...bent frame and rear spring U bolts for tightness or shifted axle housing SECONDARY SCREW PRIMARY SCREW x 25C Fig 18 Checking Caster Right Wheel CH1YSLEH SE1VICE MANUAL 54x249 Fig 19 Checking Camber Tool C 3409 Grasp the front and rear bumper at center and jounce car up and down several times This will place the torsion bar springs and shock absorbers in their normal unloaded position The car must ...

Страница 16: ... control arm as near to the front wheel as pos sible Raise car off floor Loosen upper control arm support bracket bolts and add or remove shims as required as shown in Figure 20 Re tighten bolts remove jack and bounce front of vehicle to allow car to assume its normal op erating position before checking wheel align ment The total thickness of the shim pack at either of the support brackets should ...

Страница 17: ...sary to check steering axis inclina tion To check axis inclination refer to Figs 16 and 17 and proceed as follows Inflate tires to recommended pressure place front wheels in straight ahead position on turn tables and set foot brakes Grasp front bumper at center and move front end of car up and down several times to permit front suspension parts to settle in normal unloaded position Assemble gauge ...

Страница 18: ...hing out front of frame b Installation Dip new bushing in water and with tapered portion toward rear of vehicle install in open ing in frame using a twisting motion until groove in bushing indexes properly with frame With cupped side out slide washer over threaded end of strut Push strut through bushing in frame Fig 9 Slide outer washer over end of strut cupped side in Install nut Tighten nut suff...

Страница 19: ...t of knuckle Remove tool and disengage ball joint from knuckle Remove ball joint dust cover and grease seal Remove lubrication fitting from top of ball joint using Tool C 356 as shown in Figure 27 unscrew ball joint from upper control arm b Installation oi Upper Ball Joint NOTE When installing new ball joint it is Fig 26 Removing Upper Ball Joint Removal Tool C 3564 Fig 27 Removing or Installing U...

Страница 20: ...from torsion bar by unscrewing the cam ad justing bolt partly out of swivel CAUTION To prevent swivel from falling into frame brack et do not loosen the swivel bolt all the way out until torsion bar is removed Remove the lock ring from rear of anchor Fig 12 Slide torsion bar rearward enough to disengage forward end of bar from lower control arm then forward to disengage torsion bar from cam Remove...

Страница 21: ... k Fig 29 Removing Upper Control Arm Bushing Fig 30 Installing Upper Control Arm Bushing NOTE Make definitely sure control arm is properly supported when removing bushings If hammer and drift are used extreme care must be exercised to avoid damaging bushing surface in the control arm When installing new bushings always make sure control arm is supported squarely at the point bushing is being press...

Страница 22: ...ock ring from end of bushing housing Support lower control arm assembly in an ar bor press and using a brass drift press shaft and bushing assembly from control arm Re move cotter pin nut and washer and slide bushing assembly from shaft SHAFT AND z I BUSHING LOWER t CONTROL 1 ARM T O L XI Fig 32 lnstalling Lower Control Arm Pivot Bushing b Assembly Position new bushing flanged end of bushing first...

Страница 23: ...brackets or replace bushings Loose or worn strut mounting bushings rub ber Tighten mounting nut to proper torque or replace bushing Worn ball joints or tie rod ends Replace as necessary Front shock absorber noisy Tighten mount ing nuts or replace bushing or shock absorber as required Sway eliminator noisy Check attaching bolts for tightness and rubber bushings for wear If rubber bushings are worn ...

Страница 24: ...neven tire pressure Inflate to proper pres sure Worn or loose front wheel bearings Replace or adjust as required Inoperative shock absorber Replace as re quired Worn ball joints or tie rod ends Replace as required Worn upper or lower control arm bushings Replace as required Loose or worn strut mounting bushings Tighten to proper torque or replace bushings Incorrect front end alignment Check and ad...

Страница 25: ... Axle Shaft End Play 42 Removing Broken Axle Drive Shaft 43 Rear Axle Housing A l i g n m e n t 43 Service Diagnosis 44 DATA AND SPECIFICATIONS Rear Axle C 5 C 76 IM 1 2 4 Type Gear Type Ring Gear Diameter Semi Floating Hypoid 8 75f Semi Floating Hypoid 8 75 Semi Floating Hypoid 8 75 Pinion Bearing Type Adjustment 2 Tapered Roller Shim Pack 2 Tapered Roller Shim Pack 2 Tapered Roller Shim Pack Dif...

Страница 26: ... Axle Shaft End Play 42 Removing Broken Axle Drive Shaft 43 Rear Axle Housing A l i g n m e n t 43 Service Diagnosis 44 DATA AND SPECIFICATIONS Rear Axle C 5 C 76 IM 1 2 4 Type Gear Type Ring Gear Diameter Semi Floating Hypoid 8 75f Semi Floating Hypoid 8 75 Semi Floating Hypoid 8 75 Pinion Bearing Type Adjustment 2 Tapered Roller Shim Pack 2 Tapered Roller Shim Pack 2 Tapered Roller Shim Pack Dif...

Страница 27: ...o Drive Gear No Drive Pinion Teeth With Torque Flite No Drive Gear Teeth No Drive Pinion Teeth Std T C Model Wgn 3 73 3 91 41 43 11 11 3 18 3 36 35 37 11 11 Std T C Wgn 3 18 3 36 35 37 11 11 Standard 3 18 35 11 Type Recommended Ex Press Hypoid Ex Press Hypoid Summer Winter Extreme Cold Capacity 9C 9 C 80 3MF 1 1 1 ints 90 90 80 3 2 Pints Wheel Bearings Type Adjustment Axle End Play Tapered Select ...

Страница 28: ...ver Axle Shaft Inner Oil Seal C 845 or C 319 Puller Universal Wheel and Hub C 3565 Driver Axle Shaft Outer Seal C 3566 Driver Axle Shaft Outer Seal End Brake Support DD 996 or DD 955 Installing Sleeve Pinion Bearing DD 914 8 Ring Medium Reducer use with DD 914 89 DD 921 Wrench Differential Case Cap Remover and Installer DD 993 Puller Pinion Oil Seal DD 999 Installing Tool Companion Flange or Yoke ...

Страница 29: ...BOLT AND LOCKWASHER LOCK BEARING CONE BEARING CONE ADJUSTER CUP SHIMS CARRIER FLANGE SEAL NUT CAP DRIVE GEAR AND PINION A V r f b o l t CUP T j i f W 1 ill j SIDE GEAR THRUST WASHER X THRUST BLOCK PINION THRUST WASHER i CUP PLUG C A P ADJUSTER LOCK i BEARING CONE x BOLT AND LOCKWASHER 4 BOLT WASHER GUARD SIDE GEAR THRUST WASHER ADJUSTING WASHER Fig 1 Rear Axle Exploded View 57x1 THRUST WASHER BEAR...

Страница 30: ...ving Axle Shaft and Bearing 2 EEMOVAL OF DIFFERENTIAL CARRIE ASSEMBLY All models Raise car off floor and block the brake pedal so pedal cannot be depressed Drain lubricant from differential housing Back off brake shoes with Tool C 845 Remove rear wheels hub and drum assemblies as shown in Figure 3 Dis connect the brake line at wheel cylinders Re move rear axle drive shaft keys install special slee...

Страница 31: ...OTE The caps must NOT be interchanged as they are line bored with the carrier housing at manufacture DRIVER TOOL 56x178 Fig 8 Removing Outer Axle Shaft Oil Seal with Tool C 839 I 57x21 Fig 9 Checking Drive Gear and Pinion Backlash 4 DISASSEMBLY AND INSPECTION OF DIFFERENTIAL DRIVE GEAR AND CAGE ASSEMBLY Place differential case and drive gear assembly in a suitable fixture and remove the drive gear...

Страница 32: ...off the differential bearings from case as shown in Figure 12 Remove differential pinion shaft lock pins by driving pin from case with a hammer and punch as shown in Figure 13 Drive the long differential pinion shaft out of differential case using a brass drift and hammer This shaft can be identified as having only one retaining pin Rotate one differential side gear until each pin ion appears at t...

Страница 33: ...oulders of differential case The thrust shoul Fig 16 Removing Companion Flange Fig 17 Removing Drive Pinion Bearing Oil Seal der on adjusters must be free from burrs so that bearing cups will seat properly Check dif ferential case for cracks fractures distortion or damage Install a new case if necessary The bearings should be immersed in clean solvent and rotated by hand until clean After cleaning...

Страница 34: ... in case from the pinion shaft side of the drive gear flange Position each differential bearing TOOL THRUST B E A R I N G V BLOCK in 57x11 57x19 Fig 20 Checking Drive Gear Runout cone on hub of case Fig 19 taper away from drive gear and with installing Tool DD 1005 install bearing cones Make certain that con tacting surfaces of drive gear and flange are clean and free from burrs Position drive gea...

Страница 35: ... torque wrench Pinion Bearing Pre load Adjustment The importance of correct pinion bearing pre load cannot be over emphasized The selection of adjusting washers to give the desired pre load should be carefully made When pinion bearings are installed without pre loading the cones are not drawn far enough into their cups to bring the rollers in full contact with thrust ribs on cones Bearings install...

Страница 36: ... 13 Pre loading the pinion and differential bear ing is important because it holds the drive pin ion and differential in place and prevents back and forth movement which would create incor rect gear and pinion tooth contact PINION LOCATING WASHER SP 528 NO WASHER OR SPACER FIRST SET UP TIGHTEN GAUGE TO 40 50 FOOT POUNDS AND DETERMINE PINION LOCATING WASHER ONLY PRE DETERMINED PINION LOCATING WASHE...

Страница 37: ...nge from 084 to 100 inch when making final adjustment If bearing cups are to be replaced place the bearing cups in position in carrier assembly drive cups in place with suitable drift After properly positioning bearing cups in carrier assemble drive pinion thrust washer cham fered side down toward gear on drive pin ion shaft Install rear bearing spacer if so equipped and shims on pinion shaft Inse...

Страница 38: ...ig 27 Installing Gauge Block on Main Body CHRYSLER SERVICE MANUAL Fig 28 Installing Arbor Center arbor in differential bearing pedestals of carrier Insert a piece of 002 inch shim stock between arbor and each cap and tighten caps to 10 foot pounds torque Select a pinion wash er of sufficient thickness so that it will just pass between gauge block end of setting tool and machined surface of arbor a...

Страница 39: ...l the selected shim pack Lubricate front and rear pinion bearing cone with heavy PRESS 52x382 Fig 30 Installing Pinion Bearing Cone on Pinion Shaft Fig 31 Installing Drive Pinion Oil Seal oil Insert new oil seal with driver Tool C 359 making sure it is seated all the way in carrier Fig 31 Install companion flange on pinion shaft with Tool C 496 Holding companion flange with Tool C 784 tighten nut ...

Страница 40: ...s 57x21 Fig 33 Checking Backlash Between Drive Gear and Pinion cups are properly seated as follows Using spanner wrench Tool C 406 as shown in Figure 32 turn right hand bearing adjusting nut in clockwise rotation until considerable backlash exists between ring gear and pinion Back off adjusting nut several turns Tighten lower pedestal bolts 85 to 90 foot pounds torque leav ing top bolts slightly l...

Страница 41: ...roperly meshed and quiet operation will result Fig 35 Heavy Face Contact REAR AXLE 39 Fig 36 Heavy Flank Contact 13 GEAR ADJUSTMENT FOB COIBECT TOOTH CONTACT Check tooth contact by means of gear marking compound applied to drive gear teeth as shown in Figure 34 Apply load against back face of drive gear with a round bar as drive pinion is rotated This leaves a bare area the size shape and location...

Страница 42: ... rear wheels and tighten rear axle shaft nuts to a minimum of 145 foot pounds torque Install new cotter pin Reinstall propeller shaft and fill rear axle differential with correct viscosity Hypoid Oil Refer to Lu brication Section XV of this manual 15 INSTALLATION OF AXLE SHAFTS NOTE New oil seals should be installed when Fig 38 Installation of Axle Shaft Inner Oil Seal with Tool C 839 DRIVER TOOL ...

Страница 43: ... and differential side gear splines align Install axle drive shaft outer bearing cup wth special driver Tool C 413 as 56x236 Fig 42 Checking Axle Shaft End Play shown in Figure 41 Install axle shaft shims in same manner as removed to maintain central position of axle shaft thrust block Install spe cial sleeve Tool C 757 in axle bearing outer oil seal before mounting brake support to axle housing F...

Страница 44: ... approximately centered on the differential pinion shaft Axle operation is not affected by mislocation of the thrust block unless the block bears against the differential pinion shaft in which case end play of the left and right axle shafts may be different and wheel thrust will be imposed upon differential bearings a condition that should be avoided With left bearing cup in its innermost posi tio...

Страница 45: ...ry to re move differential and carrier assembly I f break is more than eight inches from splined end of shaft it will be necessary to remove in ner oil seal and snare inner end of axle drive shaft out through housing with a hoop CAUTION To avoid damage to rear axle carrier assembly oil must be drained from differential housing and cleaned to remove chips and grit before installing new axle shaft R...

Страница 46: ...own in Figure 47 Amount of housing misalignment Fig 46 Squaring Axle for Vertical Alignment will be indicated by thickness of feeler gauge between square and end flange at top or bot tom A housing that checks more than 007 inch should be replaced To determine amount that axle is misaligned multiply thickness of feeler stock used by the ratio of 4 7 to 1 Fig 47 Checking Vertical Alignment SERVICE D...

Страница 47: ...void ex cessive weight in or on car Replace broken case After checking for other possible causes examine gears and bearings for possible damage Avoid erratic use of clutch 24 DIFFERENTIAL SIDE GEAR BROKEN AT HUB a Replace damaged gears Examine other gears and bearings for possible damage Check Rear Axle Housing Alignment as outlined in Paragraph 19 in this section b Replace damaged gears Check axl...

Страница 48: ... 13 in this sec tion c Remove unmatched drive gear and pinion Replace with a new matched gear and pinion set Refer to Removal and Inspection of Differ ential Carrier Assembly Paragraph 2 in this section d Check teeth on drive gear and pinion for contact as outlined in Gear Adjustment for Correct Tooth Contact Paragraph 13 in this section I f necessary replace with new matched set e Adjust drive pi...

Страница 49: ...SPECIFICATIONS CENTER PLANE SERVICE BRAKES MODELS C 75 C 76 IM 1 2 and 4 T Y P E DRUM DIAMETER LINING Type Attachment Width Thickness BRAKE SHOE RETURN SPRING TENSION USING FISH SCALE HOOKED AT TOE OF SHOE BRAKE PEDAL FREE PLAY WHEEL CYLINDER BORE Front Upper and Lower Rear MASTER CYLINDER BORE PISTON CLEARANCE Center Plane Floating Shoe Hydraulic 12 in Moulded Asbestos Cyclebond 2X A in 1 in 35 t...

Страница 50: ...in to 020 in SPECIAL TOOLS Tool Number Tool Name C 3014 Installing Tool Hand Brake Adjusting Nut Spanner C 3015 Installing Tool Hand Brake Adjusting Nut Cable C 3080 Hone Brake Cylinder Surfacing C 3281 Wrench Brake Drum Holding C 3462 Wrench Brake Shoe Return Spring Remover and Installer C 3496 Tank Master Cylinder Refiller Air Pressure C 452 Puller Parking Brake Drum C 650 7 Hose Brake Bleeder C...

Страница 51: ...toured in depth so when brakes are ap plied equal pressures are applied to brake drums along entire length of lining The shoes are held in position by brake shoe return springs One end of each spring is hooked in loop of return spring links The other end en gages the brake shoe UPPER CYLINDER ASSEMBLY ADJUSTING CAM J X RETURN SPRING 14 COILS RETAINER ANCHOR X GUIDE SPRING A N C H O R S V SUPPORT P...

Страница 52: ...50 BRAKES CHRYSLER SERVICE MANUAL Fig 3 Front Brake Disassembled View S H O E ASSEMBLY 57x360 Fig 4 Rear Brake Disassembled View MyMopar com ...

Страница 53: ...using shoes to operate in opposition to each other Self en ergizing action is effective on rear brake front shoe when vehicle is traveling forward and ef fective on rear shoe when traveling in reverse SERVICE PROCEDURES 1 DISASSEMBLY OF FRONT BRAKE Block brake pedal to prevent downward move ment of pedal Back off adjusting cams Re move wheel and hub and drum assembly Using Tool C 3462 remove shoe ...

Страница 54: ... on brake shield and install cylinder mounting screw and lockwasher but do not tighten NOTE Be sure brake adjusting cam rubber dust washers are i n place and i n good condition before installing support plate assembly Install four support plate bolts lockwashers and nuts Tighten 35 foot pounds and wheel cylinder mounting screw 20 foot pounds torque Install wheel cylinder flexible brake hose and ti...

Страница 55: ...ve guide spring Fig 13 The lip on end of spring is for correct positioning on outer support plate Remove brake shoes 56x11B Fig 13 Removing or Installing Rear Brake Shoe Guide Spring 56x12 A Fig 14 Removing or Installing Rear Brake Shoe from Support Plate Fig 14 Disconnect brake line at wheel cyl inder Install Tool C 745 to protect axle shaft outer seal Fig 15 Remove five nuts and lockwashers that...

Страница 56: ...ylinder push rod NOTE Long end of brake return springs must be hooked in shoes Otherwise brake noise will be encountered due to coil springs contacting shoes Install brake shoe guide springs making sure positioning lip of spring engages hole in support plate Fig 13 Loosen adjusting cams and install hub drum and wheel assem bly Bleed brake system refill master cylinder to proper level and adjust br...

Страница 57: ...e rear wheel shoe adjusting cams are rotated in direction of reverse wheel ro tation Fig 19 L E F T FRONT R I G H T FRONT L E F T R E A R RIGHT REAR Fig 19 Adjusting Front and Rear Brake Shoes Orientation Diagram as Viewed Beneath Vehicle BRAKES 55 Fig 20 Master Cylinder Location and Linkage Typical 0 SERVICING THE WHEEL CYLINDERS Wheel cylinder pistons that are badly scored or corroded should be ...

Страница 58: ...e caused by pis ton cups and will do no harm CAUTION Use extreme care cleaning master cylinder af ter reconditioning Remove all dust or grit by flushing cylinder with alcohol Wipe dry with clean lintless cloth and clean second time with alcohol Dry master cylinder with air pressure and flush with clean brake fluid Be sure re lief port in master cylinder is open Before assembling piston cups and va...

Страница 59: ...hen it is installed in band Drill and counterbore four rivet holes two at each end of lining to coincide with holes at extreme ends of band These counterbores should be at least one half thickness of lining Rivet two extreme ends of lining to respec tive extreme ends of band Due to 4 inch ex cess length lining will now bulge slightly at center of band Snap this lining in against band to make an ev...

Страница 60: ...CHOR WASHER BRAKE SHOE A N C H O R BRAKE SUPPORT GREASE SHIELD BRAKE SUPPORT BRAKE SHOE OPERATING LEVER LINK BRAKE SHOE LINING ASSY SHAFT FLANGE BRAKE DRUM ASSY 0 S J fBRAKE SUPPORT It SPACER t BRAKE SUPPORT SPACER SLEEVE f I 4 BRAKE ADJUSTING SCREW COVER I BRAKE ADJUSTING SCREW COVER I SCREW BRAKE SHOE OPERATING LEVER SCREW SHAFT FLANGE WASHER SHAFT FLANGE NUT BRAKE SUPPORT GREASE SHIELD SPRING B...

Страница 61: ...ut lockwasher and bolt The brake is now disas sembled as necessary for replacement of worn or damaged parts b Assembly Assemble operating lever to right hand brake shoe Slide right and left hand brake shoes un der brake support grease shield spring and up against inner anchor shoe guide Spread shoes and insert operating lever strut with wide slot toward operating lever and word top facing up Repla...

Страница 62: ...e between operating lever brake shoe cable To lock adjustment tighten cable housing clamp securely and tighten cable adjusting nut against housing Never substitute cable adjustment for brake shoe adjustment 18 CYCLEBOND BRAKE LINING Pre cemented Cyclebond brake lining can be applied to either new or used shoes See in structions in MOPAR Shop Replacement Pack ages POWER BRAKE UNIT BELLOWS TYPE SERV...

Страница 63: ...move nuts that attach mounting plate to unit Slide plate off and away from unit Remove and discard mounting plate 0 ring Using an Allen wrench back out two set screws sufficiently to allow removal of yoke TO VACUUM SOURCE 4 57x475 Fig 28 Removing or Installing Power Brake Unit Bellows Type Shown Fig 31 Slide yoke off end of guide and away from unit Slightly compress bellows by hand for clearance w...

Страница 64: ...MyMopar com ...

Страница 65: ...ver to valve Lift off cover Fig 34 If it is necessary use a flat blade to separate cover plate from bellows flange Extreme care should be taken to avoid marking or scratching inner face of plate where it clamps to bellows flange A scratch on this surface could cause a leak Remove 0 ring from valve cover and dis VALVE COVER PLATE E 56x529 Fig 32 Removing or Installing Operating Rod Fig 33 Removing ...

Страница 66: ...er bore of valve housing The bellows type power brake now has been disassembled as much as necessary for cleaning and inspection Clean all parts except bellows bearing and air filter in solvent and blow dry GUIDE VALVE SEAL V A C U U M VALVE SPRING GUIDE SEAL VALVE HOUSING BOLTS 56x537 Fig 37 Removing or Installing Guide with compressed air Place cleaned parts on clean paper for reassembly I f nec...

Страница 67: ... guide down against valve body making certain tapered portion of vacuum valve enters seal evenly Press down on guide to seat and install bolts and lockwashers Tighten bolts evenly and se curely 56x543 Fig 41 Installing the Vacuum Seal Fig 43 Installing the Air Valve CAUTION Be sure countersunk holes at end of guide line up with long centerline of valve housing If new bellows are being installed po...

Страница 68: ...late Release bellows and bearing will ride up guide with plate into position Install bearing to mounting plate 0 ring and lower outer mounting plate down on as sembly The notch on edge of plate must be in line with arrow on bellows Install nuts and 56x547 Fig 46 Installing Guide Bearing draw down finger tight Slide new valve op erating rod seal ring over nylon bumper on end of rod and into groove ...

Страница 69: ...play adjust ment check should be made at no vacuum as follows NOTE Removing vacuum hose and pressing brake pedal several times will aid in obtaining a no vacuum condition Insert blade of screw driver between rubber collar of power brake trigger pivot and rear side of elongated hole in power brake lever forcing them apart NOTE If brake pedal and power brake lever are not wedged apart a false free p...

Страница 70: ...ing Check for restric tion in vacuum supply line restriction on air cleaner faulty pedal adjustments or faulty power unit operation Stop engine and again exhaust all vacuum in system Depress brake pedal and hold foot pressure on pedal I f pedal gradually falls away under foot pressure hy draulic system is leaking I f brake pedal trav els to within one inch of toe board brake shoes require re adjus...

Страница 71: ...dal binding loosen pedal across shaft 35 HARD PEDAL a Check brake shoe lining replace with proper lining b Check by pass port in master cylinder repair or replace as necessary c Check push rod make proper adjustments 36 WHEEL LOCKS a Check brake lining replace torn or loose lining b Check wheel bearings adjust to proper clearance c Check wheel cylinders repair or replace as necessary 37 BRAKE PEDA...

Страница 72: ...ter 10 inches Thickness Y inch Total Effective Area Sq In 100 5 Engagement Cushioning Method Springs Flat Crimped Torsional Damping Coil Spring Release Bearing Ball Sealed PRESSURE SPRINGS 12 Total Plate Pressure Lbs 2013 Individual Pressure Lbs 195 6 1 50 inches PEDAL FREE PLAY 1 inch CRANKSHAFT FLANGE DIAMETER RUNOUT 002 inch SPECIAL TOOLS Tool Number Tool Name C 3005 Wrench 100 Foot Pound Senso...

Страница 73: ...otal of six inch pedal travel 2 OVER CENTER SPRING ADJUSTMENT FIG 1 Remove spring washer that holds clutch pedal release rod to the clutch pedal and back off the over center spring adjusting nut until it is free of the C link With the clutch pedal depressed to the full six inch travel turn the adjusting nut until the nut just contacts the C link Tighten seven full turns from the finger tight posit...

Страница 74: ...72 CLUTCH CHRYSLER SERVICE MANUAL SPRING CLIP PULL BACK SPRING 57x395 Fig 1 Suspended Clutch Pedal and Linkage MyMopar com ...

Страница 75: ...ter into the torque shaft tube swing torque shaft down and pull it away from the frame side ball stud b Installation After cleaning all parts thoroughly and in specting for wear lubricate the pivots and pivot bearings with chassis lubricant Install pivot bearings over the pivot ball at frame and slide end of torque shaft over the bearings and down into position Place the two remaining Fig 2 Punch ...

Страница 76: ...ications d Clutch Cover Place clutch cover on a surface plate or on a new flywheel to check for damage or distortion e Release Levers Release levers that are badly worn on the re lease bearing contact face are an indication that the bearing is operating with insufficient free play and or a damaged clutch release bearing Replace eyebolts and adjusting nuts if threads are damaged Replace struts if t...

Страница 77: ...er lining up the punch marks Also make sure that the eyebolts and drive lugs are guided through the holes in the cover while compressing the assembly With the clutch compressed in fixture Tool C 585 A screw the adjusting nuts on the pro truding eyebolts until the nuts are flush with the tops of the eyebolts as shown in Figure 6 Slowly release pressure by unscrewing the fix ture compression nut Dep...

Страница 78: ... housing and tighten attaching bolts just snug enough so that the housing can be shifted by tapping with a mallet Install arbor Tool C 870 to the flywheel at taching studs as shown in Figure 1 Install in dicator Tool C 869 so that the point of the in dicator contacts bore of housing The bore of the clutch housing should not vary more than 005 inch Check the rear face of the housing as shown in Fig...

Страница 79: ...oot pounds torque Remove aligning arbor Tool C 360 Install clutch release bearing and collar carefully en gaging springs over the clutch fork fingers In stall the transmission Do not allow transmis sion to hang or damage to the clutch will re sult Support the transmission with a suitable jack slide it into place and bolt securely In stall the clutch housing cover Check and ad just clutch pedal fre...

Страница 80: ...pedal down usually indicates that the release bearing should be replaced b A rattling noise may develop when an uneven lever causes the release bearing to shuf fle on its sleeve c A high pitched noise occurring only with the engine running the transmission in GEAR and the clutch pedal down may indicate that the pilot bushing is tight worn or dry The noise is usually more evident in low or second g...

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Страница 82: ...4 inch Fin and Tube With Air Conditioning 2 4 inch Cellular 2x i inch Cellular Tubular Tubular A11 Models with Air Conditioning have a box type fan shroud six blade fan SPECIAL TOOLS Tool Number C 311 Flushing Gun C 3208 Remover Water Pump Shaft Bushing C 3476 Puller Plastic Water Pump Impeller Insert C 3468 Sleeve Water Pump Bearing and Shaft Installing C 551 Refacer Water Pump Housing Seat TIGHT...

Страница 83: ...s been designed to provide the neces sary driving force to maintain cooling at low speeds and to limit the top speed of the fan at higher engine speeds thus making more pow er available to the wheels and eliminating the fan noise encountered at higher engine speeds a Engine Overheating If the fan drive operates below its minimum design speed excessive engine heating may oc cur Check as follows 1 T...

Страница 84: ...ter pump body to housing and remove water pump b Disassembly Remove fan hub from shaft with puller Tool C 3208 Fig 3 Support pump body on hub PULLER TOOL BODY FAN PULLEY HUB 57x135 Fig 3 Removing Fan Hub with Puller using Tool C 3208 SI 57x136 Fig 4 Removing Plastic Impeller end and remove impeller by breaking the plas tic away from metal insert as shown in Figure 4 Remove impeller metal insert us...

Страница 85: ...to the end of shaft and not to the body Maintain 330 inch dimension as shown in Figure 6 d Installation on Car Fig 7 Install water pump body on housing using new gasket Tighten bolts to 30 foot pounds torque Install pulley spacer and fan On Air Condi tioning Models assemble the fan to the fluid fan drive and pulley and attach the assembly to the wafer pump Tighten nuts to 15 foot pounds torque Ins...

Страница 86: ...ket Refill cooling system b Radiator Drain cooling system and remove hoses from engine Install flushing gun Tool C 311 or other suitable flushing gun in radiator outlet house Fill radiator and turn on air in short blasts NOTE Do not apply excessive pressure when pressure flushing radiator as damage to radia tor may result Continue this procedure until water runs VARIABLE RESISTANCE VARIABLE FIELD ...

Страница 87: ... CIRCULATION a Check for low coolant level and refill to 1 4 inches below filler neck b Inspect and replace hoses if collapsed c Check for plugged radiator or cylinder block and reverse flush as necessary d Check for loose water pump impeller and repair as necessary e Check for loose or defective fan belt tighten or replace as necessary 3 OVERHEATING a Refer to Poor Circulation listed in Para grap...

Страница 88: ...cing the R e g u l a t o r 102 Removal and Installation of Distributor i 108 Checking Distributor Governor Advance 108 Servicing the Spark Plugs I l l Servicing the High Tension Cables 112 Headlight Aiming and Lighting System 113 Operation of Fuel Gauges 115 Ignition Starter Switch 118 Servicing the Horns 119 Servicing the Windshield Wipers 120 Servicing the Electric Window Lifts 122 Servicing the...

Страница 89: ... 28 6 to 32 9 Amps at 6 Volts Hold in Coil Draw 10 2 to 11 8 Amps at 6 Volts Pinion Adjustment Clearance Between Pinion and Stop with armature end play removed ELECTRICAL LIGHT BULBS Number Mazda CP or Chrysler Required Number Watts Part No Headlights Seal Beams 2 5400 50 40 W 1648133 Headlights 4 Seal Beams Inner High Beam Only 2 4001 37 W 1753435 Headlights 4 Seal Beams Outer High and Low Beam 2...

Страница 90: ...264 Rotation Clockwise at Drive End Clockwise at Drive End 12 12 Controlled by Vibrating Regulator Controlled by Vibrating Regulator Rated Current Output 30 Amperes 30 Amperes Bearings Standard Ball at drive end Ball at drive end Bushing at opposite end Bushing at opposite end With Air Conditioning Ball Both ends Ball Both ends Ground Polarity Negative Negative Poles 2 2 Brushes 2 2 Spring Tension...

Страница 91: ...Temperature 40 60 70 80 100 40 60 70 80 100 31 35 29 33 28 32 27 31 25 29 41 45 39 43 38 42 37 41 35 39 Cut Out Relay Voltage Winding Resistance Air Gap Contacts Open Measure Gap as near hinge as possible Contact Gap Minimum Contacts Close Volts Contacts Open After a charge of 10 amperes Discharge Amperes Volts 107 to 121 ohms 031 to 034 inch 015 inch 13 0 to 13 75 volts 0 to 6 amperes discharge 8...

Страница 92: ...nce ohms at 70 to 80 F 1 65 to 1 79 Ballast resistance ohms at 70 to 80 F 665 to 735 HORNS Make Auto Lite Spartan Jubilee Current draw at 12 4 volts 9 to 10 amps ELECTRIC WINDSHIELD WIPER Variable Speed Motor Rated Volts 12 Resistor ohms Variable speed wiper 17 40 Field Current Draw at 13 5 volts 1 4 to 2 amps Motor Current Draw with dry glass High Speed 1 4 amps at 66 to 75 rpm Low Speed 3 amps a...

Страница 93: ...0 in warm temperature and all cells reading even ly within 15 specific gravity points 015 of each other requires recharging A battery that has a specific gravity reading which varies more than 15 points between any two cells should be recharged and high rate discharge tester or other suitable method used to check battery before discarding battery as unsuitable for use b Voltage Tests 1 Battery Cel...

Страница 94: ...h 6 and 12 volt batteries on the same circuit Each 12 volt unit must be considered as equal to two 6 volt batteries and charging rate must be ad justed to suit the smallest 12 volt battery on the line Safe slow charging rates are deter mined by allowing one ampere per positive plate per cell The proper slow charging rate for an 11 plate battery is five amperes Connect positive charger lead to posi...

Страница 95: ... F or when open circuit voltage drops to 2 05 volts per cell Battery should be fully charged when installed WARNING When batteries are being charged an explosive gas mixture forms beneath cover of each cell Do not smoke near batteries on charge or which have recently been charged Do not break live circuits at terminals of batteries on charge A spark will occur where the live circuit is brok en Kee...

Страница 96: ...Fig 4 12 Volt Starter Motor MyMopar com ...

Страница 97: ... Stall Test Install starter motor in test bench Follow in structions of equipment manufacturer and check stall torque of starter against following specifications With applied battery voltage ad justed to 4 volts stall torque should be 6 0 foot pounds minimum with a current draw of 225 amperes 6 DISASSEMBLING THE STARTER FIG 4 Remove clevis pin from solenoid plunger link age Remove thru bolts and t...

Страница 98: ...rease starter efficiency and damage the armature core and windings 12 SERVICING THE BUSHINGS Inspect armature shaft bearing surfaces and bearings for wear by placing core in vise equipped with soft jaws Do not squeeze tightly Try commutator end plate and the drive end nose casting by placing them on shafts and checking for side play Replace commutator end plate assembly if bearing is worn Also rep...

Страница 99: ...r and flywheel mounting surfaces are free of dirt and oil These surfaces must be clean to make good electrical contact Install starter from beneath car Draw attaching bolts up tight and attach wires to solenoid switch Lower car to floor install battery cable and test operation of starter for proper engine cranking GENERATORS 17 REMOVAL The generator is mounted on a bracket at tached to engine and ...

Страница 100: ...FSg 7 12 Volt Generator Standard Equipment MyMopar com ...

Страница 101: ...ator brushes for excessive arcing and or bounce while high output is being de livered A rough burned or dirty commutator will cause arcing and bouncing at brushes 20 DISASSEMBLY To disassemble a standard type generator Fig 7 remove through bolts and pull end plate from field frame Slide armature and drive end frame assembly from generator field frame Place armature core in vise equipped with soft ...

Страница 102: ...WASHER 56x40A Fig 8 12 Volt Generator Air Conditioning Models MyMopar com ...

Страница 103: ...inal post and field frame I f lamp lights it indicates that either terminal post or brush holder is grounded Remove terminal post and retest brush holder I f lamp lights brush holder is grounded Replace defective parts It is necessary to replace field frame if insulated brush holder is grounded d Testing Field Current Draw Fig 9 Test field coils for short circuits between wind ings high resistance...

Страница 104: ... plate and through bolts Place felt and shield in commutator end plate and press bear ing on shaft applying pressure to inner race Install shield c Testing After Assembly The generator should be tested before it is in stalled on car I f proper bench test equipment is not available it is possible to motor test generator A generator that will motor freely with specified voltage applied will in most ...

Страница 105: ...malize regulator temperature REGULATOR 31 TESTING REGULATOR TEMPERATURE When testing regulator keep cover in place and make sure temperature at regulator is known The regulator armature hinges are temperature compensated and control will vary with temper ature changes To measure temperature at regulator hold an accurate Fahrenheit thermometer two inches from cover The correct voltage setting of re...

Страница 106: ... for voltage regulator When test of current reg ulator immediately follows voltage regulator test generator should be run at its rated out put of 30 amperes for 15 minutes in addition to voltage regulator 15 minute run before checking or adjusting current regulator Test as follows Install test equipment Fig 12 start en gine and increase speed to 2 000 r p m Adjust variable resistance across batter...

Страница 107: ...l knob to full resistance position Slowly rotate variable re sistance control knob toward no resistance position while carefully observing voltmeter Increase engine speed slowly The relay con tacts close when voltmeter hand jumps back slightly The closing voltage is highest reading in volts reached before hand jumps back and should be 13 to 13 75 volts Rotate variable re sistance control knob towa...

Страница 108: ...t point file Do not remove too much material Never use sandpaper emery cloth or dirty file to clean contact points as foreign material may become embedded in con tacts and result in arcing or burning The filing should be done parallel to length of armatures Cross filing will form grooves and result in contacts sticking and faulty op eration After contacts are clean and smooth wipe them with piece ...

Страница 109: ...With relay arma ture against upper stop 031 inch gauge should slide in freely but 034 inch gauge should be too tight Adjust air gap by bending upper stop up to increase air gap or down to decrease it d Cut Out Relay Contact Clearance Adjust contact clearance by expanding or con ARMATURE STOP STATIONARY CONTACT BRIDGE e m 51x621 Fig 17 Adjusting Cut Out Relay Contact Clearance tracting bridge Fig 1...

Страница 110: ... engine Install timing light and start engine Allow engine to warm up sufficiently to enable carburetor fast idle mechanism to position for Fig 19 Ignition Timing indicates a loose connection in circuit between voltmeter leads or poor contact in ignition switch Move key off and on while noting volt meter A reading that varies also indicates poor contact in switch Clean and tighten loose connection...

Страница 111: ...EAKER PLATE CAM SLEEVE WICK SNAP RING CAM ANTI RATTLE SPRING SPACER GOVERNOR WEIGHT SPRING SET SPRING CLIP AND BRACKET 1 S SHAFT THRUST WASHERS BUSHING LOCKWASHER PRIMARY LEAD SPRING CLIP AND BRACKET SCREW LOCKWASHER VACUUM CHAMBER ASSEMBLY SPRING GOVERNOR WEIGHTS BASE ASSEMBLY BUSHING WASHER WASHERS GASKET PLUG 57x315 Fig 21 Single Point C 75 Distributor Disassembled MyMopar com ...

Страница 112: ... inch 42 ADJUSTING CONTACT POINT CLEARANCE Measure clearance with feeler gauge dial in dicator or with a dwell meter 015 to 018 inch New contacts should always be adjusted to 018 inch This will allow rubbing block to wear into cam contour and still provides specified clear ance when shaped Where dwell meter is used to check clearance it is essential to adjust clearance with feeler gauge or dial in...

Страница 113: ...eater blower Loosen plug Fig 25 Installing Intermediate Bushing and slide new upper bushing over driver and down on adapter shoulder Insert bushing and driver into bore Fig 24 and press bushing into position The bushing when properly in stalled will measure 094 inch below top of bore Place adapter over driver with shoulder down and slide new upper bushing over driver and down on adapter shoulder I...

Страница 114: ...gly when installed Terminal clips should fit tight in cap towers li M 4 A J Fig 26 Spark Plugs a Spitfire b Firepower Fig 27 Removing and Installing Spark Plugs b Distributor Cap and Rotor Inspect cap for cracks and clean corrosion from towers Inspect electrodes for excessive burning Inspect rotor for cracks and burned tip Inspect brush spring for distortion and be sure carbon brush moves freely i...

Страница 115: ...o 5 inch Sealed Beams on each side of the front of the vehicle Fig 30 4 5 6 34x179 Fig 28 Pattern of Properly Aimed Headlight 1 Upper beam of right headlight 2 Upper beam of both headlights 3 Horizontal line 2 inches below headlight centers 4 Vertical line in line with center of left headlight 5 Vertical line in line with windshield center strip and radiator ornament 6 Vertical line in line with c...

Страница 116: ...red with lights burning and battery in fully charged condition Remove headlight rim and with Sealed Beam unit partially removed from its mounting seat attach leads of reliable voltmeter to prongs of Sealed Beam unit while it is still inserted in connector socket With Sealed Beam unit in its correct position top prong supplies current for low traffic beam One of the side prongs sup plies current fo...

Страница 117: ... wire of test lamp to SW ter minal on panel unit and connect other wire to a ground I f lamp lights when ignition switch is turned on this circuit is in good condition b Testing Panel and Tank Units lor Ground The panel unit and tank unit must have good grounds to operate properly Use jumper wire to temporarily ground each unit at case If gauge reading changes when temporary ground CONSTANT FIELD ...

Страница 118: ...failure unit should be replaced Fig 34 When in stalling unit in tank do not bend float arm Make sure that gasket is properly positioned and tighten lock ring 54 ELECTRIC TEMPERATURE GAUGE The electric or magnetic temperature gauge consists of two units dash unit and engine Fig 34 Removing and Installing Fuel Gauge Tank Unit VARIABLE FIELD AMMETER ENGINE UNIT 53x527A Fig 35 Electric Temperature Gau...

Страница 119: ...e result of leak in oil gauge tube or due to improper installation To correct this condition disconnect tubing at gauge and engine block and drain out oil Con nect tubing at gauge first and then at block Test for possible plugging by breaking con nection at gauge Hold gauge end of line over an empty clean container and start engine The oil should flow at a steady rate I f it does not flow steadily...

Страница 120: ...orque Flite transmission 60 REMOVAL AND INSTALLATION OF IGNITION LOCK CYLINDER NOTE Remove battery ground cable before removing ignition lock cylinder To remove ignition lock cylinder turn ignition key clockwise to on position and loosen set screw holding switch in instrument panel Pull switch assembly out from instrument panel toward firewall far enough to allow lock cylin der locking pin to clea...

Страница 121: ...RVICING THE HORNS a Adjusting the Sparton Horns Pry cover from horn Remove contact adapter turn adjusting nut counter clockwise Fig 37 until there is no vibration Turn adjusting nut clockwise approximately 4 turn or until tone has clear mellow sound b Adjusting the Auto Lite Horns Pry cover retaining clips up and remove cover Loosen lock nut and turn adjusting screw Fig 38 clockwise until vibratio...

Страница 122: ...oving the bracket back far enough to clear the studs and lowering unit down from under instrument panel NOTE Care should be taken not to bend the links and battery should be disconnected to eliminate the possibility of shorts I I Cars equipped with Heater and Defroster ducts Remove glove box and door If car is equipped with a radio that removes from front of instrument panel time will be saved by ...

Страница 123: ...o crank lever pivot in same manner locking in place with a clip instead of retaining bolt e Pivot Removal Remove the wiper arms and blades Remove two 2 front stud and washer bolts on the Imperial models the front of pivot is held in place by an exterior spanner nut bezel and sealing gasket Remove the back two 2 bolts The pivot can now be removed from inside of car f Installing New Pivot Install ne...

Страница 124: ...a Remove four regulator to door attaching cap screws and pivot guide retaining pin Lower motor and regulator assembly through opening in door If gear box is to be replaced remove regu lator counter balance spring before removing unit The counter balance spring has approx imately 360 degrees of wrap CAUTION Use large pair of pliers when removing Be sure to remove spring before disassembling gear bo...

Страница 125: ...rness should be clipped securely so wires will not be pinched when track is in extreme forward position The tracks are re placed only as an assembly and are not inter changeable from left to right Tracks cannot be adjusted The horizontal travel is five inches and horizontal plane of seat track is inclined 11 degrees Vertical travel is 2 inches at front and 2 inches at rear Available tilt is 7 de g...

Страница 126: ...n terminal on starter relay c Replace neutral switch TF trans only d Replace starter relay e Replace ignition starter switch f Recharge battery 76 RELAY OPERATES BUT SOLENOID DOES NOT a Replace open circuit wire between starter relay solenoid terminal and solenoid actuating terminal post b Check and clean up solenoid switch con tacts c Clean and tighten terminal connections on terminal bus bar bet...

Страница 127: ...lace regulator b Test for open circuit in field lead from generator to regulator c Test for grounded armature lead from generator to regulator 84 LOW UNSTEADY CHARGING RATE a Adjust or replace drive belt b Test charging circuit resistance cleaning and tightening all loose connections c Inspect generator brushes and commuta tor for wear grease or commutator out of round d Test car ammeter 85 EXCESS...

Страница 128: ...s are badly burned or pitted b Check battery polarity negative ground Remove field lead from regulator and touch battery lead to polarize generator after battery is properly installed c Install regulator of proper polarity A negative ground regulator has NEG stamped on base IGNITION 93 BURNED CONTACTS a File contacts that are not excessively burned Align contacts and adjust gap to speci fications ...

Страница 129: ...INTER DOES NOT MOVE TO FULL MARK FULL TANK a Clean and tighten loose connections in fuel system electrical circuit b Check tank unit for good ground connec tion c Check tank to frame ground connection d Check tank unit for open coil Replace tank unit e Replace dash unit 105 GAUGE POINTER FLICKERS a Clean and tighten all loose connections including ground b Check tank unit arm contact to rheostat 1...

Страница 130: ...rol switch b Replace master control switch c Replace broken wire at door containing master switch group 115 WINDOW DOES NOT OPERATE FROM EITHER MASTER OR INDIVIDUAL SWITCH a Replace burned out motor and check for grounded sticking or defective switch b Check voltage of circuit for broken wiring between circuit breaker and motor terminals c Replace circuit breaker if voltage is pres ent at terminal...

Страница 131: ...n of Valves and Valve Springs 141 Removal and Installation of Valve Guides 142 Testing Valve Springs 143 Hydraulic Tappets 144 Checking Valve Timing 146 Removal and Installation of Timing Gears and Chain 147 Camshaft Removal 150 Distributor Basic Timing 150 Removal and Installation of Camshaft Bearings 151 Cylinder Block 151 Connecting Rods 153 Crankshaft 154 Removal and Installation of Oil Pan 15...

Страница 132: ...ble in Standard and the Following Undersides CONNECTING RODS A N D BEARINGS T y p e Length Center to Center Weight less bearings shells V 90 8 3 94 3 63 354 cu in 9 25 to 1 140 to 170 lbs 20 lbs 1 8 4 3 6 5 7 2 1 3 5 7 2 4 6 8 Fully Counter Balanced Steel Backed Babbitt 2 4995 to 2 5005 2 249 to 2 250 001 5 005 to 0015 002 to 007 No 3 Main Bearing Diagonal Knurling Upper and Lower Nos 1 2 Upper an...

Страница 133: ...ve 0001 to 0004 Selective CAMSHAFT Drive Chain Chain Bearings Steel Backed Babbitt Steel Backed Babbitt Number 5 5 Thrust Taken By Thrust Plate Thrust Plate End Play 002 to 006 002 to 006 Maximum Allowable Before Reconditioning 010 010 Diametral Clearance 001 to 003 001 to 003 Maximum Allowable Before Reconditioning 005 005 CAMSHAFT BEARING JOURNALS Diameter and Length No 1 1 998 to 1 999 x 1 998 ...

Страница 134: ...ll RING SIDE CLEARANCE Compression Upper Hydraulic 0005 to 0015 9040 to 9045 Dry Lash 060 to 210 Horizontal Slot w steel strut Aluminum Alloy Tin Coated 028 to 033 y2 f from Bottom of Skirt 0005 to 0015 646 gm 3 99 in 200 200 194 Std 005 020 040 060 OS Full Floating 9841 to 9843 x 3 140 to 3 150 0000 to 0005 004 to 026 0001 to 0004 Std 003 008 OS Toward Right Side of Engine 3 2 1 0775 to 0780 1860...

Страница 135: ...Compressed to valve open Valve Springs I D CYLINDER HEAD Number Used Combustion Chamber Valve Seat Runout maximum Intake Valve Seat Angle Seat Width finished Exhaust Valve Seat A n g l e Seat Width finished 002 to 0035 001 to 0025 Silicon Chromium Steel i 372 to 373 001 to 003 004 45 None 388 002 to 0035 0010 to 0025 Silicon Chromium Steel 2 5 2 372 to 373 001 to 003 004 45 None 388 Nitrogen Treat...

Страница 136: ... and Gauge Piston Fitting C 741 Reamer Solid Valve Guide C 756 Cleaner Valve Guide C 863 Timing Light 6 and 12 Volt C 897 Driver Welch Plug Installer C 3005 Wrench Torque 100 Foot Pounds Sensory Type C 3012 Reamer Cylinder Bore Ridge C 3020 Tool Main Bearing Seal C 3024 Tool Rocker Arm and Spring Compressor C 3025 Sleeve Guide Wear Measuring Intake C 3026 Sleeve Guide Wear Measuring Exhaust C 3028...

Страница 137: ...ing SpitFire C 3430 Reamer Valve Guide 389 to 390 inch SpitFire C 3433 Reamer Valve Guide 379 to 380 inch SpitFire C 3436 Gauge Valve Stem Length SpitFire C 3466 Plate Engine Lifting C 3495 Tool Piston Ring Installer FirePower C 3501 Cylinder Bore Deglazing Hone C 3506 Removing and Installing Tool Chain Case Cover Oil Seal C 3509 Tool Camshaft Holding C 3511 Tool Rear Main Bearing Seal Installing ...

Страница 138: ...136 ENGINE CHRYSLER SERVICE MANUAL SSSSSSSSmZ 57x83 Fig 2 FirePower V 8 Engine End Sectional View MyMopar com ...

Страница 139: ...dary wires Service the Air Cleaner DO NOT WASH OR OIL Normal operation Remove filter cartridge every 15 000 miles Service more frequently under severe dusty conditions See Fig 3 Test fuel pump for pressure and vacuum and adjust carburetor Refer to Fuel and Exhaust System Section V I I Carburetor Adjust ments Check combustion analysis Check man ifold heat control valve Road test car as a final chec...

Страница 140: ... The oil mixture should be left in engine for a minimum of 500 miles It is not necessary however to drain the mixture before normal oil change is required nor is it necessary to use the oil additive at subsequent oil changes 57x219 Fig 4 Cylinder Head SpitFire Engine 57x221 Fig 5 Cylinder Head FirePower Engine Start engine warm up to 160 degrees F check timing and adjust carburetor as neces sary 5...

Страница 141: ... Push Rods Installed FirePower Fig 8 Tightening Cylinder Head Bolts SpitFire 7 Insert cylinder head bolts into rocker arm support brackets and place rocker arm assem blies in position on head lining up all push rods to their respective rocker arms Starting at top center tighten all cylinder head bolts to 60 80 foot pounds torque in sequence shown in Figure 8 and 9 Then repeat the procedure tighten...

Страница 142: ...nd install spark plug covers after carefully INTAKE VALVE ROCKERS DOWEL SLOT FOR CYLINDER HEAD BOLT INTAKE VALVE ROCKER EXHAUST VALVE ROCKERS SPRING 55x725A B R A C K E T V D O W E L Fig 11 Rocker Shaft Assembly Disassembled View SpitFire arranging spark plug cables Tighten screws securely Install generator Tighten generator bracket bolts to 50 foot pounds torque and generator mounting nut to 20 f...

Страница 143: ...move burrs from valve stem lock grooves to prevent damage to valve guide when valves are removed 10 VALVE INSPECTION Clean valves thoroughly and discard burned warped or cracked valves Check valve stems for wear Intake valve stems should measure 372 to 373 inch and exhaust valve stems should measure 371 and 372 inch I f wear ex ceeds 002 inch replace the valve Remove car bon and varnish deposits f...

Страница 144: ...RETAINER LOCK G R O O V E S EXHAUST VALVE 54x330A Fig 16 Intake and Exhaust Valve Nomenclature Fig 17 Checking Valve Stem Position SpitFire 380 inch Reamer Tool C 3427 404 to 405 inch Slowly turn reamer by hand and clean guide thoroughly before installing new valve CAUTION Do not attempt to ream valve guides from stand ard directly to 030 inch Use step procedure of 005 015 and 030 inch so the valv...

Страница 145: ...eat If tip exceeds maximum grind to approach but do not go below minimum allow able on gauge 13 TESTING VALVE SPRINGS Whenever valve springs are removed they should be tested with spring tester Tool C 647 Attach torque wrench check tension and mul tiply reading by 2 The valve springs should test 170 to 184 pounds when compressed to 1 6 inch Discard springs that do not meet these specifications Che...

Страница 146: ...gine should run at fast idle for sufficient time to allow all of air inside of tappets to be worked out b Tappet Noises To determine source of tappet noise run en gine at idle with cylinder head covers removed Feel each valve spring to detect the noisy tappet NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets I f such is the case noise may be dampened by ap plying si...

Страница 147: ...in their original locations NOTE Do not disassemble a tappet on a dirty work bench The plunger and tappet bodies are not interchangeable The plunger and valve must always be fitted to the original body It is advisable to work on one tappet at a time to avoid mixing parts Mixed parts are not usable d Disassembly Fig 25 Pry out plunger retainer spring clip Clean varnish deposits from inside of tappe...

Страница 148: ...at pointer con tacts valve spring seat as nearly at a right angle as possible Wait until seat stops moving This indicates that oil has bled out of hydraulic tappet and plunger has bottomed giving in af fect a solid tappet Set dial indicator on zero and turn crankshaft clockwise normal running direction until dial indicator shows that valve has lifted 020 inch SpitFire and 024 inch FirePower The ti...

Страница 149: ...c attaching bolt cup washer and eccentric Remove timing chain with crankshaft and camshaft sprockets Remove the camshaft and crankshaft gear keys from their respective slots C R A N K S H A F T SPROCKET I V K T I M I N G X M A R K S C A M S H A F T S P R O C K E T m RETAINER WASHER 6x556 A Fig 28 Installing Fuel Pump Eccentric 19 INSTALLATION OF TIMING GEARS AND CHAIN a Installation Place both cam...

Страница 150: ...ed to prevent rotation I f chain is satisfactory slide crankshaft oil slinger over shaft and up against gear flange away from gear 20 TIMING CHAIN CASE COVER OIL SEAL REPLACEMENT a Removing Oil Seal Position puller screw of Tool C 3506 through PULLER r crr UP O F SEAL DETAINER 56X221 K L l M B i B Fig 30 Puller Blocks Expanded to Correct Pulling Position 56X222 Fig 31 Removing Oil Seal case cover ...

Страница 151: ...nger c Installing Chain Case Cover Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs Using a new gasket slide chain case cov er over locating dowels and tighten bolts 15 foot pounds torque 21 INSTALLING VIBRATION DAMPER Fig 35 Place damper hub key in slot in crankshaft FEE G UGf S E A L 222 Fig 34 Checking to Determine if Seal is Properly Seated DAMPER 0 ...

Страница 152: ...aft Holding Tool C 3509 24 CAMSHAFT INSTALLATION Install Tool C 3509 in place of distributor drive gear and stub shaft Fig 39 Hold tool in position with distributor lock plate screw This tool will restrict the camshaft from being pushed in too far and prevent knocking out the Welch plug and should remain installed until camshaft and crankshaft sprockets and timing chain have been installed Lubrica...

Страница 153: ...block must be in exact align ment to insure proper lubrication Fig 40 Camshaft bearing index can be checked after installation by inserting a pencil flashlight in bearing shell The complete circumference of camshaft bearing hole should be visible by look ing through main bearing drilled oil passage Another oil hole in cam bearings should be visible by looking down the left bank oil hole above and ...

Страница 154: ...d be withdrawn clean the bore is clean c Cylinder Walls Cylinder walls which are badly scored scuffed scratched or worn beyond specified limits should be rebored Whatever type of boring equipment is used boring operation should be closely co ordinated with the fitting of pistons and rings in order that specifications may be maintained Fig 41 Fitting Piston to Cylinder Bore FirePower Typical of Spi...

Страница 155: ...ool C 3418 NOTE Be sure the mark Top on eadh com pression ring is to the top of piston when ring is installed Fitting Pins The piston pin should be a tight thumb press fit in connecting rod Fig 44 and in piston Fig 45 at normal room temperature 70 F I f proper fit cannot be obtained with standard pins ream piston and connecting rod and in stall oversize piston pin Piston pins are sup plied in stan...

Страница 156: ...the connecting rod cap wipe off oil from the journal and inserts Place the Plastigage on bearing parallel with crankshaft Reinstall cap and tighten attaching nuts alternately to speci fied torque Remove cap and measure the width of the compressed material with the graduated scale to determine bearing clearance Allowable clear ance is from 0005 to 0015 inches I f taper of compressed material is evi...

Страница 157: ...er Shell bearing Always use the smaller diameter bear ing half as the upper housing half Never use a new bearing with used bearing and never use an upper bearing half more than 001 inch smaller than the lower bearing half c Installation NOTE When installing a new upper bearing shell slightly chamfer the sharp edge from plain side Start bearing in place and insert Tool C 3059 in oil hole of cranksh...

Страница 158: ...rt bracket and allow linkage to settle away from bottom of pan Remove bolts that hold pan to cylinder block and remove pan b Installation Clean pan thoroughly and install new seals and gaskets End seals should be bottomed in their PUMP BODY STRAIGHT EDGE PLUG PLUNGER SPRING RELIEF VALVE PLUNGER COVER PLUG COVER BOlT R ROTOR J SHAFT LOCKWASHER FEELER STOCK 57x 24 Fig 51 Checking Oil Pump Cover groo...

Страница 159: ...n 012 inch replace oil pump body I f clearance between pump rotor and outer rotor Fig 56 is more than 010 inch replace pump rotor and outer rotor Check PUMP B C D V FEELER STOCK 57x126 Fig 55 Measuring Clearance between Outer Rotor and Oil Pump Body oil pump relief valve plunger for scoring and for free operation in its bore I f plunger is scored replace plunger The spring should con form to Speci...

Страница 160: ...AR MAIN BEARING OIL SEAL Crankshaft removed Remove old oil seals from cylinder block and bearing cap Install a new rear main bearing oil seal in block so that both ends protrude Tap seal down into position using Tool C 3574 on the FirePower Engines and Tool C 3020 on the SpitFire Engines until tool is seated in bearing bore Hold tool in this position and cut off portion of seal that extends above ...

Страница 161: ...or Adjustments 186 Service Diagnosis 190 Servicing the Intake and Exhaust Manifolds 192 Manifold Heat Control Valve 194 Service Diagnosis 195 DATA AND SPECIFICATIONS Model C 75 1 C 75 2 C 76 1M 1 2 4 FUEL PUMP Make Carter Carter Model M 2503 S M 2503 S Type Mechanical Diaphragm Mechanical Diaphragm Driven By Camshaft Camshaft Pump Pressure pounds 6 to 7 6 to 7 CARBURETOR Make Type Model Nominal Si...

Страница 162: ... Setting 1 Notch Integral Automatic Rich SPECIAL TOOLS FUEL PUMP C 483 Gauge T 109 210 Rivet Extractor SPECIAL TOOLS CARBURETOR C 3225 Stand Carburetor Repair C 3400 Stand Carburetor Repair T 109 22 Bend Tool Fast Idle Cam Adjustment T 109 28 Gauge Unloader inch T 109 29 Gauge Wire Cam 020 inch T 109 31 Gauge Unloader 34 inch T 109 41 Bending Tool T 109 44 Wire Gauge Fast Idle 015 to 018 inch T 10...

Страница 163: ...l leak at this point indicates presence of a deterio rated or damaged oil seal on the diaphragm pull rod In either case the diaphragm assem bly should be replaced c Fuel Pump Pressure If leakage is not apparent at fuel pump breath er hole test fuel pump pressure by inserting T fitting into fuel line at carburetor Con nect pressure gauge Tool C 483 to T fitting and check fuel pump pressure while ro...

Страница 164: ...f inlet and outlet valves are not available for service I f new valves are required install new valve housing assembly 5 ASSEMBLING THE FUEL PUMP FIG 1 NOTE When reassembling the fuel pump do not use shellac or other adhesive on either of the two diaphragms Install strainer screen in position in valve body Place rubber diaphragm over air dome with the cut out position over strainer Be sure the inl...

Страница 165: ... idle and main metering systems and are supplemented by the float accelerating and power systems 10 CARBURETOR MODEL EDBNTTIFICATION On each BBD series carburetor model number INTEGRAL AUTOMATIC CHOKE ROCKER ARM ACCELERATOR PUMP PLUNGER rutl INLET NEEDLE VALVE A N D SEAT M A I N BODY IDLE MIXTURE ADJUSTING NEEDLES i2 THROTTLE BODY is stamped on metal tag attached to air horn Do not remove or destr...

Страница 166: ...CHARGE CHECK S A I L FULCRUM PIN NEEDLE VALVE AND SEAT THROTTLE BODY MIXTURE SCREWS A N D SPRINGS s r SCREW MAIN BODY FAST IDLE C A M S C R E W P THROTTLE VALVES IDLE SPEED S C R E W FAST IDLE SCREW LOOSE LEVER THROTTLE SHAFT HAIRPIN CLIP PUMP ROD 56xl92B Fig 3 Carburetor Assembly BBD 2527S Disassembled View MyMopar com ...

Страница 167: ...S 12 CARBURETOR DISASSEMBLY FIG 3 Place carburetor assembly on repair stand Tool C 3225 if available This Tool is used to protect throttle valves from damage and provide a suitable base for working Remove hair pin clips that retain fast idle and pump connector rods disengage from choke and throttle levers as shown in Figure 4 Remove air horn and integral automatic choke as shown in Figure 5 discar...

Страница 168: ...FICE I j p N K 5 AND MAIN J U VENT TUBES 56x193 Fig 9 Removing or Installing Venturi Cluster ACCELERATOR PUMP ROCKER ARM lij PUMP PLUNGER 56x264 Fig 10 Removing or Installing Accelerator Pump Plunger Remove idle mixture adjusting needles and springs from throttle body Invert carburetor and remove screws that attach throttle to main body Separate bodies and discard gasket Disengage accelerator pump...

Страница 169: ...graph 14 13 CLEANING CARBURETOR PARTS The recommended solvent for gum deposits is denatured alcohol There are other commercial CHOKF SHAH SCREW m C H C K E SHAFT L O O S E LEVER W A S H E R C H O K E SHAFT LEVER 56x194 A PISTON WELL P I S T O N 7 56x267 Fig 14 Removing or Installing Choke Shaft Piston solvents or cleaners however such as Metal clene or equivalent which may be used with satisfactor...

Страница 170: ...raight and LOCATING NOTCH AND MATING LUG H GH S DE OF VA1V 5 NEW SCV V IDlc SPEED ADJUSTING SCR V BACKED OT Fig 16 Removing or Installing Throttle Valves HOUSING 57x324 THERMOSTATIC COIL AND HEAT RETAINING PLATE Fig 17 Installing Heat Retainer Plate smooth I f tapered portion is grooved or ridged a new idle mixture adjusting needle should be installed to insure having correct idle mixture control ...

Страница 171: ...nug screws down do not tighten at this time Place discharge check ball on its seat test acclerator pump action as fellows Remove ac celerator pump plunger from jar of gasoline Flare back leather several times slide into pump cylinder Pour clean gasoline into float chamber approximately 2 inch deep Raise plunger and press lightly on end of plunger shaft forcing plunger down into cyl CENTER INDEX MA...

Страница 172: ...d I f one float is lower than the other equalize by bend ing float arm If Tool T 109 282 is not available use a steel scale and measure distance from crown of float in the center to top of fuel bowl This meas urement should be 1 4 inch Remove accelerator pump plunger from jar of gasoline slide spring and cup washer over shaft Slide assembly up through air horn and engage with rocker arm CHOKE VALV...

Страница 173: ...cam screw should rest on high step of fast idle cam as shown in Figure 24 Insert wire gauge Tool THROTTLE VALVES HELD CLOSED WIRE GAUGE 015 INCH 56x278 Fig 26 Checking Choke Unloader Adjustment T 109 44 015 inch between throttle valve and side of bore opposite ports as shown in Figure 25 Adjust fast idle screw to give a slight drag on gauge as it is being withdrawn c Choke Unloader Adjustment To m...

Страница 174: ...OSED 56x280 iNSIDE KOLF B C A E C JT IP hFNDIMG TOOL Fig 28 Checking Accelerator Pump Travel 56x281 Fig 29 Bending Pump Rod for Correct Pump Travel leads engine ignition timing and manifold heat control valve operating properly If it was not made during assembly of car buretor make preliminary setting of idle mix ture adjusting needles by turning them clock wise until seated Back out one full turn...

Страница 175: ...j MIXTURE ADJ SJNG NEEDLE 2 VACUUM PASSAGE THRO 30DY THROTTLE SHAFT FLEX DOG 57x341 Fig 30 Carburetor Assembly WCFI 2589S or 2590S v C A P CHOKE CONNECTOR ROD 1 ACJUM DIAPHRAGM THROTTLE OPERATING ROD CARBURETOR J3NT F CATION TAG DO NOT DESTROY IDLE SPEED ADJUSTING SCREW THROTTLE LEVER FAST IDLE ADJUSTING SCREW SECONDARY THROTTLE SHAFT FAST IDLE CAM SECONDARY LOCKOUT LEVER 57x342 Fig 31 Carburetor ...

Страница 176: ...ket The carburetor must be disassembled and all parts carefully cleaned in solvent such as Met aclene or equivalent Inspect all parts re moved from carburetor and replace as neces sary 18 CA1BUBETOR DISASSEMBLY CFIGS 30 3L 32 and 33 Place carburetor assembly on repair stand Tool C 3400 i f available This tool is used to pro tect throttle valves from damage and to pro vide a suitable base for worki...

Страница 177: ...VICE MANUAL FUEL AND EXHAUST SYSTEM 175 WASHER SCREW SPRING DIAPHRAGM GASKET LINK WASHER LEVER DOG WASHER SPRING PLUG THROTTLE BODY SCREW 56x202A Fig 33 Carburetor WCFB 2589S or 2590S Disassembled View MyMopar com ...

Страница 178: ... soft and pliable Install new pump plunger i f any of these conditions are apparent Place accelerator pump plunger in j a r of clean gasoline to prevent leather from drying out Remove air horn gasket Remove primary and secondary fuel inlet plugs gaskets and screens Loosen metering rod arm and accelerator pump arm screws Remove bowl vent arm attaching screw Lift out arm Slide accelerator pump shaft...

Страница 179: ...ts cylinder as shown in Figure 40 As choke pis ton clears cylinder withdraw choke shaft and piston out of air horn Using suitable tool push out piston pin and separate piston front link See Fig 41 Re move screws that hold choke housing to air horn Remove housing discard gasket N E W SCREWS i C H O K E VALVE l r 1 C H O K E P I S T O N C H O K E VALVE A T T A C H I N G SCREWS 4 56x293 Fig 40 Removi...

Страница 180: ...ROTTLE J IDLE MIXTURE ADJUSTING NEEDLES 1 OPERATING LINK HAIRPIN CLIP WASHERS FLEX DOG 56x204 SCREW WASHER 1 Fig 45 Removing or Installing Throttle Flex Dog ing link to primary and secondary operating levers Slide link out and away from levers as shown in Figure 44 Don t lose washers Dis engage throttle flex spring from tang on throttle flex dog and slide flex dog off primary shaft as shown in Fig...

Страница 181: ...e from which it was removed The screws that at tach the throttle valves are staked on opposite IDLE DISCHARGE PORTS SPARK ADVANCE PORT m THROTTLE SHAFT AND LEVER SCREWS SECONDARY THROTTLE SHAFT THROTTLE VALVES 55x223B Fig 49 Removing or Installing Primary Throttle Shaft Lever side and care should be used in removal so as not to break screws i n throttle shafts Remove screws that hold primary throt...

Страница 182: ...ssible under extremely dusty con ditions that fine particles of dirt may be found deposited on various choke parts A heavy S P R I N G v Fig 52 Removing or Installing Idle Mixture Adjusting Fig 53 Vacuum Diaphragm Assembly Disassembled View black hard carbon deposit on choke parts in dicates possibility of leak in heat tube Check tube in exhaust manifold and repair as required Examine all choke pa...

Страница 183: ... SCREWS Wtmn H NEW SCREWS Fig 55 Installing Secondary Throttle Valves NEW S O r W S NEW SCREWS HUHH 1 1 i 56x305A Fig 56 Installing Primary Throttle Valves If tapered portion is grooved or ridged a new idle mixture adjusting screw should be installed to insure having correct idle mixture control DO NOT USE A SCREWDRIVER The adjust ment should be made with the fingers Turn needles lightly against t...

Страница 184: ...celerator Pump Test stalled on primary side Invert carburetor and mount in repair stand assemble main body as follows b Main Body Assembly Install accelerator pump discharge check needle in discharge passage as shown in Figure 58 Install primary and secondary idle jets Refer to Fig 43 Tighten securely using Tool T 109 58 Remove accelerator pump plunger from jar of gasoline and flex leather several...

Страница 185: ... center and locate valve Tighten screws securely Re fer to Fig 39 With valve in open position stake screws using pliers Do Not Lubricate any choke operating parts Hold air horn in an up right position and close choke valve The valve should open freely of its own weight Install choke baffle plate and gasket Hold choke coil housing against gasket with index mark in down position Turn choke coil hous...

Страница 186: ...n position FLOAT GAUGE PRIMARY F L O A T S and install fulcrum in pin Check float setting as follows Be sure each needle is installed i n its original seat g Float Level Adjustment When m a k i n g float level adjustment be sure air horn gasket is removed The primary and sec ondary floats are set at different heights using two separate gauges Place primary float level gauge Tool T 109 236 2 inch i...

Страница 187: ...e accelerator pump plunger from jar of gasoline and flex leather several times Check to see if leather is hard cracked or worn If any afore mentioned conditions exist install new accelerator pump plunger Slide accelerator pump plunger spring over plunger shaft fol lowed by spring seat shoulder on seat toward spring With spring compressed slide shaft end into opening in air horn With pressure on bo...

Страница 188: ...VES IN CLOSED POSITION 57x348 Fig 71 Positioning Meter Rods ing toward pump shaft arm Back off idle speed adjusting screw i f not previously done until primary throttle valves are fully seated in their bores Make sure fast Idle adjusting screw is off fast idle cam Hold straight edge across top of dust cover boss as shown in Figure 69 and adjust length of connector rod until flat on top of pump arm...

Страница 189: ...oader Adjustment With primary throttle valves held in wide open position insert a 6 inch drill or unloader gauge Tool T 109 28 between upper edge of choke valve and inner dividing wall of air horn Fig 75 Checking Secondary Throttle Lockout Release as shown in Figure 73 With finger pressing lightly against upper part of choke valve a slight drag should be felt on gauge as it is being withdrawn I f ...

Страница 190: ...INSERT GAUGE NEXT TO IDLE PORT PRIMARY VALVES HELD AT WIDE OPEN POSITION CHOKE VALVE SLOCKED OPEN 56x184A Fig 79 Checking Opening of Secondary Throttle Valves Step 1 arm To decrease lift press down on cap until correct lift has been obtained h Throttle Linkage Adjustment To check throttle linkage for correct opening or positioning of secondary throttle valves in re lation to primary throttle valve...

Страница 191: ...ep 3 A possible to insert Tool T 109 31 i 4 inch unloader gauge between upper edge of pri mary throttle valve and bore next to idle port as shown in Figure 81 In this posi tion secondary throttle valves should just crack open If an adjustment is necessary bend tang on throttle shaft dog using Tool T 109 214 as shown in Figure 82 until inner arm of flex spring just contacts inner lug of sec ondary ...

Страница 192: ...jet b Install new accelerator pump c Clean accelerator pump discharge cluster d Clean vacuum piston and cylinder e Install new accelerator pump inlet check valve f Check and reset float level g Install new needle valve and seat h Install new throttle linkage i Check and readjust choke 24 CARBURETOR FLOODS OR LEAKS a Install new main body i f required b Install new air horn to main body gasket c Ch...

Страница 193: ...YSLER SERVICE MANUAL FUEL AND EXHAUST SYSTEM 191 Fig 87 Exhaust System Single Rocker Shaft Engine BRACKETS AND SUPPORTS X N U T EXHAUST PIPE 57x391 Fig 88 Dual Exhaust System Models C 75 2 C 76 MyMopar com ...

Страница 194: ...the Intake Manifold Remove air cleaner drain radiator Remove generator and disconnect carburetor linkage Disconnect power brake vacuum line at mani fold i f so equipped Disconnect distributor vacuum advance line and fuel line at carburetor Disconnect automatic choke heat tube at car buretor Disconnect wires at coil Remove bolts COIL MOUNTING BOSSES i GENERA OR MOUNTING PAD w y j 4 r f BRAKE BOOSTE...

Страница 195: ...for further service Particular attention should be given to Hot spot chamber in intake manifold I f chamber is coated with hard black carbon i t must be scraped or sand blasted to remove deposit The layers of carbon act as an insulator and retard heating action of exhaust gases on hot spot chamber which in turn affects vaporization rate of fuel passing through intake manifold Fig 92 Exhoust Manifo...

Страница 196: ...xceptions I n dual exhaust system cross over and Y exhaust pipes are not used there is an individ ual exhaust pipe muffler and exhaust extension pipe and tail pipe for each cylinder bank Refer to Fig 88 33 ALIGNMENT OF EXHAUST SYSTEMS Figs 87 88 and 89 illustrate various types of supports insulators and clamps with procedures as follows Tighten exhaust manifold flange studs and nuts evenly 40 foot...

Страница 197: ...l minutes Loosen by turning shaft clock wise or counter clockwise depending on frozen position until shaft is free Work shaft from closed to open position several times until shaft can be turned very easily with fingers b Assembly Before installing heat control valve on engine lubricate valve shaft with graphite paste Posi tion valve shaft in extreme counter clockwise position Place new coil sprin...

Страница 198: ... tail pipes i f needed Check alignment of exhaust pipes muf fler and tail pipe Align as necessary e Remove manifold and install new gaskets if necessary after carefully inspecting both cyl inder head and manifold mating surfaces Tighten manifold nuts and bolts evenly work ing from center to outer ends of manifold f Check for bent or pinched exhaust or tail pipes Such conditions will retard the flo...

Страница 199: ...rliners 202 Shock Absorbers 203 Servicing the Oriflow Shock Absorbers 204 DATA AND SPECIFICATIONS FRAME Models C 75 C 76 I M 1 2 4 TYPE Welded Double Channel Box Section Side Rails DIMENSIONS See Figures 1 2 and 3 REAR SPRINGS TYPE Semi Elliptic NO OF LEAVES SEDANS TOWN COUNTRY WAGON W I D T H 2 5 2 5 LENGTH 58 58 58 SHACKLE Silent Block Rubber Bushings HANGER Side Strapped with Rubber Bushed Holt...

Страница 200: ...Foot Pounds REAR SPRING S I L E N T BLOCK N U T 100 W UPPER 60 SHOCK ABSORBER STUD N U T He LOWER 70 REAR SPRING U CLIP BOLT NUTS 70 REAR SPRING SHACKLE NUTS Jf6 50 SHOCK ABSORBER M O U N T N U T REAR 60 E S S E N T I A L T O O L S C 3413 Remover and Installer Shock Absorber Lower Mounting Assembly GAUGE HOLE IN EACH SIDE OF FRAME 57x231 Fig 1 Frame Dimensions Windsor and New Yorker MyMopar com ...

Страница 201: ... rear axle control strut is continued for the I m perial Models See Paragraph 8 Universal Joint Section X I I for adjustment proce dures 1 CHECKING FBAME DIMENSIONS In case of collision frame members can often be satisfactorily straightened to the required dimensional limits I n case of serious damage or fracture to front crossmembers upper and lower control arms and steering knuckle the component...

Страница 202: ...easily checked for alignment by measur ing diagonals as shown i n Figure 3 with tram mels or steel tape and check dimensions given in Figs 1 2 and 3 Measurements may be taken without removing body from chassis by using plumb bob and chalk line on level floor Attach line of plumb bob to one of rear body bolts The plumb bob should be suspended slightly above floor When plumb bob comes to rest mark f...

Страница 203: ...spring The width of spring leaves are 21 2 inches refer to Data and Specifications Thus with outboard mounted rear springs rear end Fig 5 Rear Springs Front Mounting roll is greatly reduced and car stability on curves or sharp turns is maintained NOTE Cars equipped with air conditioning units are equipped with a heavier rear spring Should i t become necessary to install new springs or silent block...

Страница 204: ...ication that one of rear springs may need to be replaced This condition could also be due to a bent frame kick up or an incorrectly welded spring saddle c m m M X f m imfr4 t M m if wf m 57x506 Fig 8 Rear Interliner Fig 9 Positioning New Interliners CAUTION Care should be taken when replacing rear spring on Imperial Models to see that the rear axle housing to frame struts are shimmed properly so a...

Страница 205: ...eaf Remove tapered bar which has remained be tween leaves during these operations The bar may be withdrawn while a screwdriver is placed alongside Then the screwdriver may be pulled out reversing operation which was used to in sert bar in position A faster method for with drawing bar is to insert end of a bar with a short tapered hook alongside the tapered bar After tapered bar has been withdrawn ...

Страница 206: ...r to Fig 12 and proceed as follows From the engine compartment remove dirt and grit from around shock absorber piston rod and upper retainer housing Remove piston rod nut and retainer washer Place jack i n center of engine front crossmember and raise vehicle off floor Remove shock absorber to lower control arm bracket attaching nut bolt and washer Disengage shock absorber eye from control arm brac...

Страница 207: ...acer 10 REPLACING LOWER SHOCK ABSORBER EYE BUSHING Remove the lower shock absorber bushing sleeve Fig 14 Rear Shock Absorber Installed in vise or arbor press as shown i n Figure 13 NOTE To avoid damaging bushings when in stalling bushings press against the steel sleeve 11 R E M O V A L A N D I N S T A L L A T I O N O F REAR SHOCK ABSORBERS FIG 14 To remove rear shock absorber remove nuts from shoc...

Страница 208: ...eaks 230 Adjusting the Power Steering Units 231 Power Steering Pump Removal 233 Power Steering Pump Assembly 237 Service Diagnosis 238 DATA AND SPECIFICATIONS M O D E L S C 75 1 C 75 2 C 76 IM 1 2 4 Steering Type Manual Worm and Three Tooth Roller None None None Rack and Gear Sector Recirculating Ball Nut Ratio Manual 20 4 None Power 16 3 16 3 16 3 16 3 Turning Radius Curb to Curb 45 4 45 4 49 5 N...

Страница 209: ... degree Steering Knuckle T y p e Rail and Socket Front Wheel Rearing Type Tapered Roller Rearing Inner Rearing Size 1 25 1 25 1 25 1 375 Outer Rearing S i z e 75 75 75 844 Spindle Thread Size M 16 NF Steering Linkage T y p e Symmetric Idler Arm Equal Length Tie Rods Caster should be equalized as near as possible on Left and Right wheel COAXIAL POWER STEERING MODELS C 75f C 76f I M 1 2 4 Fluid Capa...

Страница 210: ...nch Working Length 3 inch Force at Working Length 12 5 to 14 lbs SPECIAL TOOLS MANUAL STEERING Tool Number Tool Name C 3402 Pitman Arm Puller C 3428 Steering Wheel Puller COAXIAL POWER STEERING Tool N u m b e r Tool Name C 3128 Pliers Snap Ring C 3211 Hose High Pressure C 3229 Pliers Gear Shaft Adjusting Screw Snap Ring C 3309B Gauge Pressure Check C 3318 Hose Low Pressure C 3319 Holding Nut Worm ...

Страница 211: ...ar Shaft Rearing C 3333 Driver Gearshaft Bearing C 3350 Remover and Installer Gear Shaft Seal C 3392 Wedge Coupling Removing C 3554 Protector Lower Piston Rod Seal C 3401 Thimble Gear Shaft Adjusting Screw O Ring Installing C 3402 Pitman Arm Puller C 3428 Puller Steering Wheel C 3445 Rod Control Valve Centering C 3555 Flange Oil Leak Testing TIGHTENING REFERENCE MANUAL STEERING Foot Pounds Steerin...

Страница 212: ...haft Nut Steering Linkage Ball Stud N u t Steering Wheel to Steering Shaft Nut Tie Rod Clamp Bolt and Nut Pump Flow Control and Relief Valve Adapter Retaining Upper Piston Rod Nut Gear Shaft Cover Screws Thread Size x 2 0 y x i s H x 20 X A x 20 x 2 0 Foot Pounds to Turn or 15 to Y2 Turn or 30 20 10 50 120 40 40 150 In Pounds 50 30 25 Worm Housing to Gear Housing Screws 25 Gear Shaft Adjusting Scr...

Страница 213: ... d y PUMP Thread Size Foot Pounds Pump Assembly Bolt x 18 15 Hose Connector Outlet y8 x 18 30 Flow Divider Valve Plug x 14 20 NUT PLATE SCREW SHIMS BUSHINGV S E A L CAGE AND ROLLERS CUP CAGE AND ROLLERS BUSHINGS NUT l i t X LOCKWASHER HOUSING SEAL SHAFT X T U B E X NUT SCREW WASHER PLUG SCREW 57x366 Fig 1 Steering Gear Assembly Disassembled View MyMopar com ...

Страница 214: ...ing gear shaft Correct backlash can be obtained by turning adjusting screw in or out as required The steering wheel and arm are splined to the steering tube and steering gear shaft re spectively Both steering wheel and steering Fig 2 Removing or Installing Steering Wheel Ornament gear arm have master serrations to insure correct installation The high point is the point of least clearance between t...

Страница 215: ... tube to be sure no bind exists Final tightening of cover screws cause end play to disappear with torque of to pound required to rotate the tube when measured with the pull applied at rim of steering wheel Add or remove shims in event a bind or excessive end play occurs Shims are available in 003 006 011 and 025 inch Install gear shaft Before installing cover turn adjusting screw all the way out P...

Страница 216: ... shims of necessary thickness to eliminate a binding condition I f any tightness exists too many shims have been removed or the steering as sembly is out of alignment See Steering Gear Alignment Paragraph 3 b Adjustments of Roller Tooth and Worm In Car Disconnect steering gear arm at link Rotate steering wheel to mid position and check for backlash by attempting to move steering gear arm back and ...

Страница 217: ... inch no preload to 003 inch bearing free play measured axially It is important to remove any burrs or nicks on the spindle thread to insure accurate readings COAXIAL POWER STEERING The new 1957 Chrysler Coaxial Power Steer ing Unit Fig 6 incorporates two basic gear mechanisms a worm and worm connector and rack and sector gear The hydraulic system of power steering gear consists of a double acting...

Страница 218: ...MP NUT CONNECTOR LOCK 1 THRUST BEARING GUIDE SNAP RING ROD BODY SPRING PLUNGER PISTON RING C 5 R I N G SNAP RING SEAL O RING PISTON AND ROD O RING HEAD ROD UPPER W A S H E R HOUSING WORM RACE WORM BEARING DOWEL t s O RING THRUST BEARING O RING COUPLING BOLT WASHER 57x363 Fig 6 Coaxial Power Steering Unit Exploded View MyMopar com ...

Страница 219: ...w instrument panel With front wheels in straight ahead position install steering wheel and steering wheel nut Tighten nut 40 foot pounds torque NOTE Check to make certain that cancelling dogs on steering wheel actuate the directional switch Move column jacket up or down to ob tain proper steering wheel to column jacket clearances and for proper operation of direc tional switch Fig 7 Removing or In...

Страница 220: ...ubber dust pad Seal and floor Fig 10 Removing Turn Signal Switch and Bracket Fig 11 Installing Turn Signal Switch panel Opening Cover Disengage drag link from steering gear arm and pull steering gear arm with Tool C 3402 Loosen three gear housing to frame attach ing bolts Disconnect pressure and return hoses Cap fittings at steering gear and fasten dis connected ends of hoses above oil level in re...

Страница 221: ...GEAR H O U S I N G H O L D I N G FIXTURE GEAR SHAFT t j 57x399 Fig 13 Steering Unit Mounted in Holding Fixture T O O L COUPLING v H 57x400 Fig 14 Removing Coupling Tool C 3392 down between housing and coup ling rap sharply with hammer forcing coup ling off end of the shaft as shown in Figure 14 Insert a screw driver under lip of worm housing oil seal gently pry seal out away from housing and slide...

Страница 222: ...llers of bear ings should be smooth highly polished and free to turn in their retainers The needle bearing rollers in lower spacer should also be free to BEARING RACE BEARING SPACER THRUST BEARING 57x403 Fig 17 Removing or Installing Bearing Race Bearing and Spacer HEAD WORM CONNECTOR WORM H O U S I N G S C i l O C K N U T L O C K NU O SEAL RING O SEAL R I N G G E A R H O U S I N G 57x404 Fig 18 R...

Страница 223: ...should be smooth and housing head HOUSING HEAD CONNECTOR NUT TOOL PISTON ROD NUT 57x407 Fig 22 Removing or Installing Piston Rod Nut CONNECTOR NUT 4 57x408 Fig 23 Removing Spacer Seal and Nut should be free from nicks or burrs The inner bore of valve control spacer should show little or no wear from the retainers and edges should be smooth free from nicks or burrs I f nicks or burrs are present re...

Страница 224: ...f gear shaft and down against seal Install nut on threaded portion of shaft Turn complete tool until the tool has entered seal Install half collars and retainer to lock tool together Back off on nut and pull seal out of housing as shown i n Figure 25 Remove tool Remove bolts and washers that attach gearshaft adjusting cover to housing Two TOOL SEAL o f GEAR HOUSING Jill w l OIL SEAL LOCK RING 57x4...

Страница 225: ...hown in Figure 30 Carefully work the lower rod out of piston to expose piston valve as shown in Figure 31 Remove and discard the rod 0 seal ring Slide piston valve out of piston as shown in Figure 32 Use care so as not to bend the valve rod during or after removal Support pis ton assembly in order to protect seal ring land using a soft wood block drive piston UPPER PISTON ROD GEAR PISTON HOUSING I...

Страница 226: ... R O D O R I N G 5 3 x 8 2 3 Fig 36 Removing Valve Rod O Seal Rings Clamp head of bolt in a vise rap on end of rod using a fibre hammer Slide valve out of rod as shown in Figure 37 To disassemble valve insert a stiff wire paper clip into pin hole and push out retaining pin Remove plung er and spring The restrictor valve plunger should slide freely in valve body and show no signs of sticking The lo...

Страница 227: ... Removing Lower Piston Rod Oil Seal cylinder side Do not remove plug by punch ing hole and flipping out This method will damage aluminum housing Using a thin blade screw driver pry out lower piston rod thrust pad from gear housing Fig 40 Remove lower piston rod oil seal from housing using Tool C 3450 To remove seal insert disc end of tool through opening in end of housing locating disc between sea...

Страница 228: ...Tool C 3331 L i p of seal toward driver Slide pilot SP 1927 through seal and into driver until bottomed Insert assembly into housing keeping tool centered i n bore as shown i n Figure 44 Drive seal into position remove tool Carefully work garter spring into seal w i t h the aid of two long shank screw drivers I f Tool C 3331 A is used it will not be necessary to remove garter spring Slide gearshaf...

Страница 229: ...sing pliers Tool C 3106 in UPPER PISTON ROD Fig 48 lnstalling Upper Valve Rod O Seal Ring UPPER PISTON ROD Fig 49 lnstalling Valve Rod Lower O Seal Ring stall retaining snap ring bevelled side out Be sure that ends of snap ring do not obstruct an oil passage as shown in Figure 50 Any ob struction at this point will affect steering per formance I t may be necessary to tap the snap ring using a bras...

Страница 230: ...g GEAR SHAFT ADJUSTING SCREW 3 x 8 6 7 Fig 54 Installing Gearshaft Adjusting Screw O Seal Ring new O seal ring over tool and into groove of adjusting screw as shown in Figure 54 This operation may be done before installing screw Install sector gear to mesh with rack as shown i n Figure 55 Seat shaft to mesh teeth Check gear timing using steering gear arm to rotate gearshaft Full piston travel must...

Страница 231: ...seals in inside holes and tighten to 30 foot pounds torque Install ad justing screw locknut but do not tighten at this time Place a new welsh plug in position at bottom of housing and drive into position 25 INSTALLING THE VALVE CONTROL SPACER Remove garter spring from a new upper piston 57x259 Fig 57 Removing Oil Seal Protector Sleeve TOOL 4 HOUSING HEAD i z 5 3 x 8 3 4 Fig 58 Installing Upper Pis...

Страница 232: ...ing them gently using rubber end of pencil and at same time oscillating worm as shown in Figure 62 When 30 balls have been inserted they should be visible in the hole Place remaining 10 balls in either half of ball guide Grease balls to help hold them in place then place the other half over balls Insert guide and ball assembly into holes i n connector Fig 62 Install clamp lock wash ers and bolts T...

Страница 233: ...h connector rails then seat against gear hous ing Worm housing must meet gear housing with hand pressure only Install attaching bolts and washers Tighten 30 foot pounds torque TOOL X V TOOL 57x238 Fig 63 Testing Steering Gear for Leaks HOLD 57x239 Fig 64 Adjusting Worm Housing Bearings Outer Slide bearing spacer over worm shaft shoulder towards worm and seat in housing Slide bearing race radial be...

Страница 234: ...re Remove tools 32 GEAR LASH ADJUSTMENT With engine running and steering gear at nor mal operating temperature turn steering gear to straight ahead position Using a very light finger tip touch at end of steering gear arm turn gear shaft adjusting screw clockwise until all gear lash has been eliminated Turn ad justing screw turn tighter clockwise and tighten lock nut Stop engine Install worm housin...

Страница 235: ...7 LUBRICATION Proper lubrication of steering gear and front suspension is very important on vehicles equipped with Power Steering Lubrication of tie rods remain the same as specified for man ual steering 38 TIE RODS Whenever i t becomes necessary to install new tie rods and or tie rod ends make definitely sure when adjusting toe in that both tie rod end tubes are turned an equal amount and are of ...

Страница 236: ...Thoroughly clean exterior of pump Mount pump in a vise Remove cap screw and reser voir Fig 68 Loosen four cap screws at the inlet end cap Fig 69 Remove flow valve spring retainer fitting LLER CAP l O i L LEVEL MARk i g 57x560 Fig 67 Sleeve Type Power Steering Pump Installed CAUTION Flow and plunger springs are under pressure Use care when removing cap and retainer to prevent spring and fitting fro...

Страница 237: ...unger spring Remove ball bearing retainer ring from housing using snap ring pliers Tool C 3106 Fig 72 Remove shaft and bearing Fig 73 40 CLEANING AND INSPECTION Wipe bearing and shaft assembly with clean lint free cloths Do not soak in cleaning solvent the lubricants sealed into the ball bearing may become diluted by the solvent Fig 70 Removing or Installing Pump Body from Housing Fig 71 Removing ...

Страница 238: ...LOW SPOOL SPRING BALL RETAINER BALL BALL SEAT 57x568 Fig 75 Flow Spool Valve liner move flow spool back and forth to in spect On each pass rotate spool slightly The spool must slide freely I f spool sticks or drags remove i t from liner Remove dirt nicks and burrs using above caution and check by re peating above procedure Examine shaft seal in bearing cap I f worn or damaged replace seal NOTE T h...

Страница 239: ...re as shown in Fig ure 76 and place driven cylinder block with out spline or serration on assembly fixture Lubricate SAE 10W and insert plunger spring plunger and seven sleeves in drive block as shown in Figure 77 Place the pump body square end down over the cylinder drive block and fixture locating pins use a pointed probe to align the sleeves to a uniform spacing and Install the two other remain...

Страница 240: ...ap Lubricate O ring for ease in assembling reservoir Align reservoir so that the indentation on back will mate w i t h angu lar boss on suction end cap NOTE Reservoir alignment may be achieved by sighting thru the 9 32 inch hole i n the back of the reservoir Push the reservoir Into place applying force around its outside diameter Replace the copper gasket between the head of the inch hex head cap ...

Страница 241: ...short time against each wheel stop CAUTION Do not exceed 1 400 engine r p m or hold against stops longer than 15 seconds as it is possible to damage power units fan belt and or oil pump I f there was no emission of oil from vent during this test the condition existing was one of seepage or all of oil has been lost from upper housing due to neoprene plug missing from vent passage inside housing 44 ...

Страница 242: ...spect mating sur faces of cover and housing for nicks burrs etc b Around cover attaching screws Two of these screws have neoprene seals the two ad jacent to engine do not Make sure seals are installed properly or replace with new ones i f needed c Around threads of gear shaft adjusting screw Due to damaged O ring Remove cover and replace adjusting screw O ring Check for porosity of housing Can be ...

Страница 243: ... condition can be caused by any one or more of following items each of which should be checked in following sequence a Steering gear arm nut loose on gear shaft Tighten 120 foot pounds torque b Loose front wheel bearing Adjust bear ings c Gear shaft adjusted too loose Adjust gear shaft d Steering tube coupling screw loose Tight en screw e Worm bearing preload adjustment too loose Adjust to proper ...

Страница 244: ...s checked c Steering wheel to column jacket interfer ence Adjust to give necessary clearance d Steering column jacket bearing Remove steering wheel with puller Tool C 3428 jac ket and shroud assembly and steering tube Re check torque i f reading is 40 foot pounds or below the difficulty is caused by steering col umn jacket bearings replace bearings I f read ing was not below 40 foot pounds proceed...

Страница 245: ...has been set then refer to I N A B I L I T Y TO M A I N T A I N CONTROL V A L V E ADJUST MENT Paragraph 71 63 UPPER PISTON ROD MOVEMENT IN PISTON Check fit of snap ring which retains upper piston rod in piston by attempting to rotate it I f snap ring can be rotated it will allow upper piston rod to move axially with respect to piston thus displacing control valve in re lation to valve body This ca...

Страница 246: ...fer to Unequal Steering Effort for method of establishing Lack of assist in one direction usually is found to be caused by one of following a Piston Ring Neoprene Check for dam aged neoprene piston ring b Housing Head Oil Seal Upper Piston Rod A damaged or improperly seated housing head oil seal will cause lack of assist when turning to left and will also be accompanied by loss of oil out vent in ...

Страница 247: ...iller neck when pump is at 175 P b A i r in steering system check all connec tions to make certain that they are tight c Discharge and return line hoses the hoses must not touch any part of the body or frame except where they are attached to the pump or steering column d Loose pulley e Water in oil 76 HARD OR IERKY STEERING TOWARD END OF FULL LEFT OR RIGHT TURN a Loose drive belt tighten drive bel...

Страница 248: ...nd Tests 278 Manual Control Cable Adjustment 279 Throttle Linkage Adjustment 279 Transmission Bands 280 Trouble Diagnosis Chart 283 Servicing Transmission in Vehicle 288 Regulator Valve Assembly 289 Torque Converter Control Valve Assembly 289 Valve Bodies and Transfer Plate Assembly 289 Kickdown Piston 290 Governor 293 Rear Oil Pump 294 Removal of Transmission From Vehicle 295 Reconditioning Trans...

Страница 249: ...ngs or other damage caused by pounding on the wrench Re move flange nut and washer Disconnect hand brake cable Remove brake drum and flange as HOUSING BACK UP LIGHT S W I T C H M O U N T I N G HOLE INTERLOCK BALLS l mMn INTERLOCK S L E E V E j W J S P R I N G L O W A N D REVERSE T P I N S E C O N D A N D GEARSHIFT LEVER X C C A f DIRECT GEARSHIFT SEAL rp LEVER X R I N G S UL R E T A I N I N G P I ...

Страница 250: ...r and pick out rollers d Mainshaft Remove extension housing to transmission case bolts Place a nut 0 2 to inch in thickness between synchronizer clutch gear sleeve and inner stop ring assembly as shown i n Figure 3 The nut will serve to minimize any interfer ence from synchronizer clutch gear sleeve when transmission case is removed from extension housing assembly CASE SYNCHRONIZER CLUTCH GEAR SLE...

Страница 251: ...haft splines for galling or scor ing Inspect bearing mounting surfaces and snap ring grooves Slight nicks or burrs can be stoned off Replace damaged parts Inspect the gear teeth and threads on inner and outer synchronizer stop rings Check gear teeth on clutch gear sleeve I f there is evidence of chipped or excessively worn gear teeth replace the part Make sure synchronizer clutch sleeve slides fre...

Страница 252: ...x333 Fig 6 Positioning Bearing for Installation BEARING EXTENSION H O U S I N G MAINSHAFT 57x168 Fig 7 Installing Mainshaft in Extension Housing NOTE Lightly grease threads on stop ring to provide lubrication during initial application of synchronizer assembly Install synchronizer clutch gear on mainshaft and secure in place with one of four available snap rings to eliminate all end play at clutch...

Страница 253: ...ion case to edge of bench to permit adapter arbor to be pushed with the finger into countershaft hole in front of trans mission case Rotate case 180 degrees and in stall remaining large thrust washer in like manner Make sure tab engages groove in case Using cluster gear shaft push adapter arbor from cluster gear until shaft key can be in serted Continue to drive shaft into case until it is approxi...

Страница 254: ...nut and draw Fig 12 Installing Interlock Sleeve LOW AND REVERSE GEARSHIFT LEVER 57 X 4 9 6 l J Fig 13 Depressing Interlock Ball Using Suggested Tool nut up snug against washer Install lubricant drain plug and tighten 20 foot pounds torque e Gearshift Housing Refer to Fig 1 Place gearshift housing in vise equipped with soft jaws Fig 12 Place 0 ring seal on second and direct gearshift lever shaft an...

Страница 255: ... is not equipped with back up light switch install plug and tight en to 15 foot pounds torque 4 INSTALLATION If transmission has been jumping out of gear check clutch housing bore and face alignment with housing aligning arbor Tool C 870 be fore installing transmission in car Refer to Clutch Section I V of this manual for proced ures outlining clutch housing alignment Installing Transmission Inser...

Страница 256: ... lever hub as shown i n Figure 18 an adjustment at STEERING COLUMN LOWER SUPPORT SCREW FIRST AND REVERSE SHIFT LEVER GEARSHIFT TUBE TRANSMISSION GEARSHIFT HOUSINC LOW AND REVERSE CONTROL ROD SECOND AND HIGH SHIFT LEVER i t LOW AND REVERSE OPERATING LEVER SECOND AND HIGH CONTROL ROD LUBRICATION FITTING TUBE LEVER PIN RETAINER GEARSHIFT TUBE LOWER SUPPORT 57x108 GEARSHIFT TUBE LOWER SUPPORT SECOND A...

Страница 257: ... and two planetary gear sets to provide three forward ratios and a reverse ratio With the front or forward clutch engaged and low gear reaction transferred through the transmission overrunning clutch assembly a low ratio of 2 45 to 1 is obtained Engagement of kickdown or second speed band will shift the transmission to second speed ratio of 1 45 to 1 Disengagement of the kickdown band and engageme...

Страница 258: ...ND INTERMEDIATE SUPPORT ASSEMBLY OVERRUNNING CLUTCH ASSEMBLY LOW REVERSE BAND j LOW REVERSE BAND DRUM REAR OIL PUMP EXTENSION GOVERNOR ASSEMBLY SPEEDOMETER PINION TORQUE CONVERTER STATOR TORQUE CONVERTER TURBINE5 OIL STRAINER REVERSE SUN GEAR LOW REVERSE PLANET PINION CARRIER ASSEMBLY VALVE BODIES AND TRANSFER PLATE ASSEMBLY INTERMEDIATE SHAFT ASSEMBLY Fig 20 TorqueFlite Transmission and Torque Co...

Страница 259: ... the first button from the restraint of the spring lock The first button is then free to return under spring force to its original position A back up light switch when so equipped is incorporated in the gearshift control housing and is operated by the R reverse push but ton slide A motor starting switch is also incorporated into the gearshift control housing Fig 22 The car is started by turning ig...

Страница 260: ...p when making a push button selection a D drive All normal forward driving will be done i n this range The vehicle w i l l have a slight tendency to creep after pushing the button from N neu tral to D drive at idle This can be prevented by applying the foot brake lightly As soon as the accelerator is depressed the vehicle will move forward i n the drive breakaway range A t a speed of approximately...

Страница 261: ...transmission will automatically upshift into direct i f the accelerator is partially re leased or a speed of approximately 75 m p h is reached I f vehicle is accelerated in 2 sec ond position to wide open throttle upshift speed an upshift to direct will occur thus eliminating overspeeding the engine in second gear f Kickdown forced downshift At speeds between 30 to 65 m p h approxi mately in D dri...

Страница 262: ... be transmitted This provides neutral op eration bN OUR HEif CARRiER HELD Fig 25 Planetary G e a r Set Planet Pinion Carrier Held Reverse 15 OVERRUNNING CLUTCH The overrunning clutch consists of a cam cam rollers cam springs and a clutch hub The cam which provides the ramps is riveted to the intermediate support so that i t is prevented from turning The overrunning clutch hub is splined in the low...

Страница 263: ...inion carrier together with the reverse annulus gear both of which are splined to the output shaft drive housing FRONT CLUTCH APPLIED The reverse planet pinion carrier is attached to and prevented from turning backward by an overrunning clutch and becomes stationary in forward drive overruns on coast There fore the reverse carrier pinions are forced to rotate in a forward direction and force the r...

Страница 264: ...arrier which is splined to the output shaft drive housing moves at a slower speed than the annulus gear thus providing a gear ratio of 1 45 to 1 c D Drive Position Direct Fig 29 The power flow from the torque converter goes directly through the transmission because the planetary elements of the gear train are locked up by two multiple disc clutches and both bands are released The torque converter ...

Страница 265: ...s held stationary by the low re verse band therefore the set acts as a simple reverse train through the reverse planet pinr ions to the reverse annulus which is splined to the output shaft drive housing and provides a reverse ratio of 2 20 to 1 h N Neutral Position All friction elements are released Hence there is no drive connection between the engine and the rear wheels i Power Flow Summary The ...

Страница 266: ...MyMopar com ...

Страница 267: ...ND BLUE LINE 90 P S I BLUE DOT PUMP SUCTION 0 5 P S I YELLOW CONVERTER 30 P S I YELLOW DOT LUBE 10 30 P S I GREEN THROTTLE 0 90 P S I BROWN GOVERNOR 0 90 P S I BROWN DOT GOVERNOR COMPENSATOR 0 90 P S I 56X70JA o m m K w tr w m w m m o m 3 Fig 33 Hydraulic Circuit D Drive Breakaway 2 CO w w I I O CD MyMopar com ...

Страница 268: ... BLUE LINE 90 P S I BLUE DOT PUMP SUCTION 0 5 P S I YELLOW CONVERTER 30 P S I YELLOW DOT LUBE 10 30 P S I GREEN THROTTLE 0 90 P S I GREEN DOT THROTTLE COMPENSATOR 30 90 P S I BROWN GOVERNOR 0 90 P S I BROWN DOT GOVERNOR COMPENSATOR 0 90 P S I 56X702A to CD CD 3 w m i i o Fig 34 Hydraulic Circuit D Drive Second o x hC w f M 50 CO m w 0 m 1 MyMopar com ...

Страница 269: ...CHRYSLER SERVICE MANUAL TRANSMISSION 267 MyMopar com ...

Страница 270: ...268 TRANSMISSION CHRYSLER SERVICE MANUAL MyMopar com ...

Страница 271: ...W 74 M RH LEGEND BLUE LINE 90 P S I BLUE DOT PUMP SUCTION 0 5 P S L YELLOW CONVERTER 30 P S I YELLOW DOT LUBE 10 30 P S I GREEN THROTTLE 0 90 P S I GREEN DOT THROTTLE COMPENSATOR 30 90 P S I BROWN GOVERNOR 0 90 P S I BROWN DOT GOVERNOR COMPENSATOR 0 90 P S I 56X705A O W C O m w CO M SO o m c Fig 37 Hydraulic Circuit 2 Second Second Ul Ul ui i i o CD CD MyMopar com ...

Страница 272: ...Fig 38 Hydraulic Circuit R Reverse MyMopar com ...

Страница 273: ...n spring when feed of the control pressure is discontinued In order to develop 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 i n reverse or neutral oil is present in the clutch piston chamber With high ro tative speeds of the clutch retainer in reverse or neutral it is possible to build up sufficient ...

Страница 274: ...sufficient to overcome the force of line pressure front clutch which is acting on the small area of the accumulator piston This action cushions the application of the kickdown band 20 PRESSURE REGULATING VALVES a Regulator Valve The regulator valve controls line pressure at a value of approximately 90 p s i for all oper ating conditions except reverse Line pressure which is supplied by the front p...

Страница 275: ...t with the result that small changes in vehicle speed re sult in comparatively large changes in centrif ugal force and governor pressure Above ap proximately 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 approximately 25 m p h therefore result in only sma...

Страница 276: ...s arrangement makes i t possible to more closely obtain the variations required for the 1 2 and 2 3 shifts Throttle compensator pres sure is routed to the throttle compensator pres sure area of the kickdown servo 21 FLOW CONTROL VALVES a Front and Rear Pump Check Valves The front pump check valve prevents back flow from line pressure into the pressure side of the pump when the pump is either stati...

Страница 277: ...of the kickdown servo 6 The accumulator 7 Line pressure port of the 1 2 shift valve kickdown plug The kickdown piston and accumulator are so designed that the value of the balance pres sure is sufficient to complete a smooth band application during the time required to stop the rear clutch retainer After completion of the 1 2 shift the servo apply pressure rises further to the value of line pressu...

Страница 278: ... position and on the gov ernor plug end of the 2 3 shift valve holding the 2 3 shift valve in the upshift position re gardless of governor pressure As car speed decreases and governor com pensator pressure can no longer overcome the force of the 1 2 shift valve spring the two shift valves will downshift at the same time resulting in a smooth 3 1 downshift f Kickdown Valve The kickdown valve makes ...

Страница 279: ...ck down band is applied A t this time the kick down piston can no longer force oil into the clutch and the pressure is allowed to fall to zero For kickdowns at higher vehicle speeds gov ernor pressure attains a sufficient value to move the shuttle valve toward the shuttle valve plug cutting off the feed of line pressure to the shut le valve Oil must then flow to the apply pres sure area of the kic...

Страница 280: ...lug so the transmission will not upshift out of low gear while the 1 low button is engaged Pushing in the N neutral button moves the manual valve to a position which shuts off oil flow to the valve bodies The torque conver ter and lubrication system remain pressurized Pushing in the R reverse button of the control unit positions the manual valve so that oil pressure is directed to apply the rear c...

Страница 281: ...roper adjustment push the various push buttons return to neutral each time while checking the starter operation En gine should start only when the N neutral push button is depressed to limit of travel A test light attached to the neutral starter switch may be used instead of the starter for checking proper adjustment Refill transmission with Automatic Transmission Fluid Type A to proper level Refe...

Страница 282: ...dels and should not be used for making the throttle linkage adjust ment 29 TRANSMISSION BANDS a Kickdown Band Front The kickdown band adjusting screw is located on the left side of the transmission case as shown in Figure 40 Using a inch wrench loosen the locknut Check the freeness of the b Low Reverse Rear Band The low reverse band adjusting screw is located on the right side of the transmission ...

Страница 283: ...heck the quality of the shift Accelerate the car in kickdown second gear at wide open throttle until the transmission up shift The shift should occur at approximately 70 mph Check the quality of the shift Slow the car down to 25 to 32 mph and engage the 2 second button The transmission should downshift to second gear Check for gear noise Slow the car to 15 mph and depress the accel erator pedal qu...

Страница 284: ...ply pressure take off hole located on the output shaft support Fig 40 Install gauge Tool C 3293 300 psi as shown i n Figure 43 The rear clutch circuit is pressurized in D drive position direct and in the R reverse position The rear clutch circuit pressure should be check ed simultaneously with line pressure The rear clutch apply pressure should not be less than a value of 15 psi lower than line pr...

Страница 285: ...switches Check wire connec tions and switch Check clearance of N neu tral push button slide to motor starting switch contact clearance Fig 48 I Handbrake Check for excessive drag Refer to Brakes Section for method of adjust ing hand brake J Regulator valve spring The regulator valve may be removed by removing the regu lator valve spring retainer which is on the right side of the transmission case ...

Страница 286: ...ition 1 Slips in L R Only Slips in All Positions No Drive in Any Position No Drive in Forward Ranges E OW 2 O Q P 2 Drags or j Locks Grating Scraping Etc Noises j Buzzing Noises 1 Trans Hard to F i l l Oil Blows Out Fill Tube 1 Trans f Overheats Impossible to Push Starter Won t Energize A Oil Level 0 m 0 m m 0 0 0 0 0 0 0 B Throttle Link Adj 0 0 m 0 m C Gearshift Control Cable Adj B m 0 0 D Pressu...

Страница 287: ...ear clutch is operating Also check for excessive oil leaks Apply the air pressure to the kickdown ap ply line pressure passage toward the cen ter of the transmission case and to the front of the kickdown servo Observe the operation of the kickdown servo lever and band when air pressure is applied Apply air pressure to kickdown apply compensated throttle pressure passage to ward the center of the t...

Страница 288: ...plates return spring and piston Check the fol lowing rear clutch circuit leakage possibilities 1 Valve body and valve body to case mating surface 2 Output shaft support to case mating sur face 3 Output shaft small and large seal rings 4 Intermediate shaft No 4 5 and 6 seal rings 5 Rear clutch oil feed tube 6 Sun gear rear clutch seal rings 7 Rear clutch piston inner and outer seal rings 8 Rear clu...

Страница 289: ... is equipped with back up light switch exercise care during positioning of plate in instrument panel to avoid damaging switch Adjust gear shift control cable as outlined in Maintenance Adjustments and Tests Paragraph 24 c Removing Gearshift Control Cable Engage L low button to place spring lock Fig 47 Releasing Manual Control Cable Spring Lock in line with control cable adapter plug hole in transm...

Страница 290: ...h Button Operating Slide to Starting Motor Switch Clearance to starting motor switch clearance is obtained by depressing the N neutral push button to the neutral position only and depressing only far enough beyond this point to remove all free movement from the actuator Clearance be tween slide and motor starting switch contact should then be between 010 015 inch Fig 48 I f clearance is not within...

Страница 291: ...ner and tighten to 40 foot pounds torque 37 OIL PAN a Removal Drain transmission by disconnecting filler tube connector at oil pan I t may be necessary to loosen filler tube support bracket screw Re move the oil pan screws and washers and re move the oil pan and gasket from transmission case b Installation Using a new oil pan gasket place oil pan into position on transmission case Install oil pan ...

Страница 292: ...in piston Install accumu lator cover three screws and washers draw down evenly Place oil strainer in position on transfer plate assembly Install the four screws and washers Draw down evenly and tighten strainer and accumulator cover screw to 16 foot pounds torque Install oil pan Install man ual valve control lever locking screw to rear on manual valve lever shaft Position lever on shaft so there i...

Страница 293: ...slightly binds on transmission case Work seal ring into position and gradually compress spring until seal ring enters case and snap ring can be installed Fig 53 Install kickdown pis ton rod guide snap ring making sure it is properly seated Loosen compressing portion of tool and remove tool from transmission case Place kickdown band strut in position in band and lever and compress band end sufficie...

Страница 294: ... torque Connect front uni versal joint and tighten nuts to 37 foot pounds torque Refill transmission i f necessary with A u tomatic Transmission Fluid Type A to prop er level 42 EXTENSION a Removal Raise vehicle off floor Drain approximately two quarts of fluid from transmission then reconnect filler tube at connector Disconnect front universal joint and secure propeller shaft out of the way Apply...

Страница 295: ...nsmission and at the same time align mounting studs in in Fig 56 Removal and Installation of Governor Valve Shaft and Valve Fig 57 Removal and Installation of Governor Body and Support Assembly sulator with holes i n crossmember Install two nuts and lockwashers that hold the rear engine support insulator and tighten to 35 foot pounds torque Engage ball end of hand brake cable in operating lever an...

Страница 296: ...aft snap ring from weight assembly end Remove gov ernor valve shaft and valve from governor valve body assembly Using Tool C 3229 re move governor weight assembly snap ring large one and remove governor weight as sembly from governor body Remove governor locating screw from governor support Remove the five rear oil pump housing to output shaft support screws and washers and install guide studs Too...

Страница 297: ... support fix ture Tool C 3487 insert hooks of fixture firm ly into holes in side of frame member with support ends up against the underside of oil pan flange Adjust fixture to support the weight of the engine Raise engine slightly remove crossmember to torsion bar bracket bolts and remove crossmember CAUTION When using fixture Tool C 3487 do not lower engine more than three inches from floor pan t...

Страница 298: ...on w i t h Automatic Transmission Fluid Type A Adjust throttle linkage RECONDITIONING O F TRANSMISSION 46 REMOVAL OF COMPONENTS The following precautions should be observed during disassembly of transmission Cleanli ness through the entire disassembly and as sembly cannot be over emphasized Unit should be thoroughly cleaned when removed from ve hicle preferably by steam When disassem bling each pa...

Страница 299: ...t and rear oil pumps Loosen to relieve spring load the three accumulator cov er bolts with washers and remove cover and spring from transfer plate as shown in Fig ure 62 Remove three transfer plate bolts and OIL STRAINER Fig 61 Removing Oil Strainer Assembly Fig 62 Removal and Installation of Accumulator Cover washers Remove valve bodies and transfer plate assembly from transmission case as shown ...

Страница 300: ... 65 Attach puller Tool C 452 i f necessary and remove propeller shaft flange and drum assembly I n spect oil seal surfaces Inspect lining contact surfaces on brake drum assembly for scoring and inspect brake lining for wear Remove transmission brake support grease shield spring This spring has two purposes BRAKE ANCHOR SHOE GUIDE BRAKE ANCHOR WASHER BRAKE SUPPORT GREASE SHIELD BRAKE SHOE OPERATING...

Страница 301: ... plate for deteriora tion and note the steel sleeve used between neoprene spacer and extension EXTENSION Fig 68 Removal of Extension Fig 69 Removal and Installation of Governor Valve Shaft Snap Ring 51 TRANSMISSION EXTENSION REMOVAL Remove speedometer drive pinion and sleeve assembly as shown in Figure 67 Nylon gear can be easily damaged i f extension is removed without first removing the speedome...

Страница 302: ...t shaft as shown in Figure Fig 72 Removal and Installation of Governor Weight Assembly GOVERNOR AND REAR OIL PUMP HOUSING ASSEMBLIES Fig 73 Removal and Installation of Governor and Rear Oil Pump Housing Assemblies 73 Use dye and mark face of pump gear in relation to pump housing Do not use scribe Oil pump pinion is keyed to output shaft by a small ball Use care when removing pinion so as not to lo...

Страница 303: ... support to corre spond with the threaded locating hole inside of case for installation purposes F i g 1 2 7 Keep unit centered as much as possible to prevent binding of intermediate support and remove assembly from transmission case as 56x613 Fig 76 Removal and Installation of Unit No 1 Fig 77 Removal and Installation of Intermediate Support Locating Screw shown in Figure 78 Make sure f r o n t c...

Страница 304: ... made to reline them The kickdown band is wider and has different lin ing material 56x617 Fig 80 Removal and Installation of Low Reverse Band KICKDOWN BAND ADJUSTING SCREW 56x618 Fig 81 Removal and Installation of Kickdown Band Strut 59 LOW REVERSE AND KICKDOWN BAND LEVER ASSEMBLIES REMOVAL Remove kickdown and reverse lever shaft stop plug at rear of transmission case Using pliers remove kickdown ...

Страница 305: ...n compressing portion of tool and remove from transmission case Remove piston rod guide piston spring and piston rod Using pliers Tool C 484 remove the kickdown piston from the transmission case Using pliers Tool C 484 remove the accumulator piston from transmis sion ease as shown in Figure 87 62 FRONT OIL PUMP REMOVAL Remove front oil pump drive sleeve if in installed Remove the transmission regu...

Страница 306: ...ump Housing Assembly constructed that i t will not drop into front housing during removal Remove the seven front oil pump housing to transmission case bolts and washers Sealing washers used under bolts are made from alu minum discard i f damaged Remove oil pump housing assembly from transmission case by tapping housing lightly with a soft hammer as shown i n Figure 91 Using dye mark pump gears in ...

Страница 307: ...ts Where lubrication is required use Automatic Trans mission Fluid Type A Do not use a sealing material on any gasket or mating surface al ways use new gaskets Torque all bolts and nuts to correct specifications Where snap rings are used always make sure they are seated prop erly I f mating parts do not go together prop erly always check reason Do not force parts unnecessarily 66 TORQUE CONVERTER ...

Страница 308: ...5 DRIVER l OUTPUT SHAFT REAR BEARING 2 OIL SEAL REAR EXTENSION 3 5 3 x 2 5 A Fig 97 Installing Output Shaft Rear Bearing Oil Seal ring Inspect ring for distortion Using driver Tool C 3275 drive output shaft rear bearing out of rear extension as shown i n Figure 95 70 OUTPUT SHAFT REAR BEARING AND OIL SEAL INSTALLATION Using driver Tool C 3204 install the output shaft rear bearing in extension as s...

Страница 309: ...PECTION Inspect oil pump housing machined surfaces for nicks and burrs and housing plug for leaks Inspect oil pump gears for scoring or pitting With gears cleaned and installed in pump hous ing as marked and using straight edge Tool C 3335 and feeler gauge check clearance be tween pump housing face and face of gears as shown in Figure 99 Clearance limits are from 001 to 0025 73 GOVERNOR ASSEMBLY R...

Страница 310: ...st washer D located inside of housing Remove kickdown planet pinion carrier assem bly E from intermediate shaft assembly C The kickdown planet pinion carrier assembly used in this unit is identical to the low reverse planet pinion carrier assembly used in Unit No 2 but should not be interchanged Remove kick down carrier thrust washer F from carrier assembly E Remove sun gear roller thrust washer G...

Страница 311: ... wear 79 REVERSE AND KICKDOWN ANNULUS GEARS INSPECTION Inspect for worn cracked or broken gear teeth 80 UNIT NO 1 OUTPUT SHAFT KICKDOWN PLANET PINION CARRIER AND INTERMEDIATE SHAFT ASSEMBLIES ASSEMBLY To aid in the assembly of Unit No 1 use the propeller shaft flange and brake drum assembly which was removed from the transmission With output shaft assembly J in the upright position lubricate outpu...

Страница 312: ...ssembly as shown in Figure 107 Remove intermediate support and cam as sembly from overrunning clutch hub Fig 108 Using a screw driver remove snap ring D from low and reverse band drum assembly G Remove the low and reverse planet pinion carrier assembly E from reverse band drum Remove overrunning clutch hub assembly from reverse band drum as shown in Figure 109 Remove o v e r r u n n i n g clutch c...

Страница 313: ... and remove OVERRUNNING 56x639 Fig 108 Removal and Installation of Intermediate Support and Cam Assembly from Overrunning Clutch Hub LOW AND REVERSE BAND DRUM OVERRUNNING CLUTGH HUB Fig 109 Removal and Installation of Overrunning Clutch Hub in Low and Reverse Band Drum the clutch return spring retainer P and spring Q from clutch piston retainer assem bly Spring retainer may require guiding past sn...

Страница 314: ...EMBLY Lubricate and install inner piston seal ring T on hub of clutch retainer Make definitely sure that lip of seal is facing down and seal is prop erly seated in groove Lubricate and install out er seal ring S on clutch piston lip of seal facing away from flange Place piston assem bly R in clutch retainer U and with a twist ing motion seat piston in bottom of retainer Install piston return sprin...

Страница 315: ...r scoring and excessive wear Bushing and hub serviced as an assembly Inspect lubricating hole and make sure it is free from foreign matter by cleaning with com pressed air Inspect reverse band drum snap ring select fit for being distorted TRANSMISSION 313 92 UNIT NO 2 ASSEMBLY Install overrunning clutch hub assembly hub first into snap ring side of the low and reverse band drum Fig 109 Place low a...

Страница 316: ...snap ring 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 removal of the snap ring with a screw driver If an arbor press is not available two large C clamps may be used by placing them 180 apart and applying equal pressure If C clamps are used make sure...

Страница 317: ...cs by scratching facings with finger nail i f material collects under nail replace all of driving discs Replace driving discs i f splines have become damaged Inspect the steel clutch plates E cushion spring retaining plate T and pressure plate F surface for evidence of burning scoring and damaged lugs replace i f necessary Inspect cushion spring S for dis tortion and evidence of scoring Inspect le...

Страница 318: ...ton Spring Retaining Plate 57x336 Fig 116 Identification of Front Clutch Cushion Spring clutch retainer followed by a steel plate E Repeat this procedure until all driving discs and steel plates have been installed 99 CHECKING FOR PROPER TRAVEL OF CLUTCH PRESSURE PLATE I t is very important that the front clutch pres sure plate has the proper amount of travel where levers are used for applying add...

Страница 319: ...identi fied to prevent improper installation 101 LEVER ASSEMBLIES INSPECTION 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 excessive wear 102 REVERSE SERVO PISTON ASSEMBLY INSPECTION Inspect lever contacting surface on plug L for excessive wear Remove and inspect re verse servo piston s...

Страница 320: ...8 to drive seal until tool bottoms on face of housing as shown in Figure 118 Inspect drive sleeve seal ring contacting surface in housing for wear and scratches I n spect steel back bronze type bushing i n hub for scratches or scoring and excessive wear Bush ing and housing are serviced as an assembly Remove oil pump gears and inspect gear con tacting surfaces for scratches burrs or groov ing pump...

Страница 321: ...TORQUE CONVERTER REACTION SHAFT INSTALLATION Using heat lamps heat front of transmission case to approximately 170 to 190 degrees F Install guide studs Tool C 3283 in front face of reaction shaft flange Lubricate portion of reaction shaft that presses into case with Au tomatic Transmission Fluid Type A Posi tion torque converter reaction shaft into front of transmission case so that guide studs in...

Страница 322: ...ve pump and check for foreign matter between pump gears and housing Install the torque converter control valve spring retainer and gasket Tighten to 40 foot pounds torque Reinstall the transmission regulator valve spring sleeve cup gasket and retainer with adjusting screw and lock nut installed Tighten 50 foot pounds torque 111 ACCUMULATOR PISTON INSTALLATION Lubricate seal rings and place accumul...

Страница 323: ... to install snap ring Spring retainer may require guiding into case Make sure snap ring seats properly Loosen compressing portion of tool and remove from transmission case v 6W REVERSE SERVOl W SPRING RETAINER Fig 125 Compressing Low and Reverse Servo Spring and Retainer SPRING 56x623 114 IICKDOWN BAND INSTALLATION Install the kickdown band assembly by rotating band ends over center support in tra...

Страница 324: ...olts lockwashers and tighten to 30 foot pounds Use extreme care when installing the locating bolt inside of case to prevent loss of lock washer as shown i n Figure 77 Check input shaft and sun gear for free rotation 119 UNIT NO 1 OUTPUT SHAFT KICK DOWN PLANET PINION CARRIER AND INTERMEDIATE SHAFT ASSEMBLIES INSTALLATION Be sure reverse sun gear thrust washer roller type is i n position in planet p...

Страница 325: ...e used for vents Make definitely sure that no attempt is made to install bolts in these holes Check each threaded hole before installing bolts Install the five rear oil pump housing to output shaft support bolts and washers Dished type washers are used to prevent cut ting or chipping of soft metals and should be installed on bolts with dished portion facing away from bolt head Draw down evenly tig...

Страница 326: ...PORT BRAKE SHOE fsliU y GASKET GUIDE STUDS EXTENSION UNIT No 1 OUTPUT SHAFT SUPPORT Fig 130 Internal Expanding Handbrake Drum Removed 56x656 Fig 131 Removal of Output Shaft Support Extension Handbrake Assembly and Unit No 1 as an Assembly tension far enough to permit Installation of spring Install the brake support grease shield spring opening in spring toward adjusting sleeve Make sure spring is ...

Страница 327: ...kwise direction to center bands on retainers prior to making band adjustments 127 LOW REVERSE REAR BAND Using wrench Tool C 3380 and with lock nut loose tighten low reverse band adjusting screw to 75 inch pounds torque as shown in Figure 132 Refer to Maintenance Adjustments and Test Paragraph 24 Fig 132 Adjusting Low Reverse Band Using a colored pencil identify adjusting screw location in relation...

Страница 328: ...rely A 7 32 inch drill can be used for ob taining proper clearance Fig 5 1 Place con trol cable adapter with spring lock i n position i n lever and install pin Place manual valve control lever in reverse position and install gasket control cable housing and three bolts and washers Draw down evenly and tighten to 16 foot pounds torque Install felt washer flat washer and throttle valve lever assembl...

Страница 329: ...r plate assembly and replace on stand Tool C 3428 133 FRONT VALVE BODY REMOVAL Remove the two front valve body to transfer plate bolts and lockwashers and separate front valve body from transfer plate assembly as shown in Figure 136 Do not disturb throttle valve stop screw setting Remove upper valve body plate from transfer plate 134 CLEANING AND INSPECTION Place all parts in clean solvent wash th...

Страница 330: ...prevent loss of the two check valve balls D and seats C remove cover Invert valve body and remove governor compensator valve E and valve spring P While holding throttle compensator valve cover K i n place spring loaded remove the three bolts and lockwashers J Use care when removing cover to prevent loss of check valve ball M and seat L Remove throttle compensator valve spring N and valve O 136 LOW...

Страница 331: ...o valve body Place the 2 3 shift valve J spring pilot facing out into position in valve body Position the 1 2 and 2 3 shift valve springs G and I in valves Place the 2 3 shift valve kickdown plug D identified by larger pilot over 2 3 shift valve spring I Compress spring sufficiently to seat plug in valve body and secure by placing a thin piece of metal 6 scale behind plug as shown in Figure 139 In...

Страница 332: ...330 TRANSMISSION CHRYSLER SERVICE MANUAL MyMopar com ...

Страница 333: ...lly it isn t necessary to remove the throt tle valve lever shaft R manual valve lever assembly S or manual valve V I f condi tion warrants however such as damage proceed as follows MANUAL VALVE FRONT VALVE BODY ASSY SHUTTLE VALVE N SHUTTLE VALVE SPRING SHUTTLE VALVE PLUG 5 6 x 6 6 7 A Fig 141 Removal and Installation of Shuttle Valve Plug Spring and Valve ALVE BOD KICKDOWN VALVE THROTTLE VALVE SPR...

Страница 334: ...rs in position in valve body with rubber band support throttle lever shaft on wooden block Install shaft pin using a small punch and hammer as shown in Figure 143 Remove rubber band W i t h reverse blocker valve spring in position in valve O and w i t h slots in valve aligned with pin install reverse blocker valve in valve body Install reverse blocker valve plug N and compress spring sufficiently ...

Страница 335: ...ase Remove stand Tool C 3280 Install transmission as outlined under Re moval and Installation of Transmission Par agraph 45 TORQUE CONVERTER SERVICE PROCEDURES 147 REMOVAL AND INSTALLATION OF TORQUE CONVERTER a Removal Remove transmission Remove the torque con verter housing to adapter screws and lockwash ers Remove torque converter housing I f torque converter is being removed because of excessiv...

Страница 336: ...rly the spot will become red within a few seconds I f sparks are noted it is an indication that torch is too close and metal is starting to burn move back slight ly Care should be taken to remove the torch the instant selected spot becomes a dull red to avoid over correction or damage to unit The area is then quenched as rapidly as possible w i t h cold water hose or wet rags I t is suggested this...

Страница 337: ...the entire diameter Reweld ring gear to torque converter using extreme care to place as nearly as possible the same amount of metal in exactly the same location as original assembly This is necessary in order to maintain proper balance of unit Place welds alternately on opposite sides of the converter to minimize distortion The following suggestions are offered as an aid in making the weld a Use a...

Страница 338: ...07 014 021 Determine amount and direction of bore run out Loosen intake manifold bolt which holds throttle linkage bracket in position Before proceeding further i t is essential that the torque converter impeller hub runout be with in 004 inch total indicator reading Correct i f necessary Remove two dowel pins from adapter plate that align housing Removal can be made w i t h vise grips and prying ...

Страница 339: ...for Indicating Face Runout should be inserted into adapter plate on an angle corresponding to direction of housing bore centerline and crankshaft centerline Use extreme care in selecting the dowel to be used to correct runout in two directions Install housing making sure mating faces are clean and free from dirt and nicks Tighten bolts Check bore concentricity i f necessary loosen bolts and adjust...

Страница 340: ...a l I n d i c a t o r H o u s i n g Face Location of Reading Observed T o t a l S h i m Low Point S h i m on H o u s i n g Face Thickness Near one of the lower Place shim on bolt 1 005 to 010 1 013 trans to housing bolt which will enter 2 010 to 015 2 020 holes this hole 3 015 to 020 3 026 Near one of the upper Place shim on bolt 1 005 to 010 1 014 trans to housing bolt which will enter 2 010 to 0...

Страница 341: ...Shaft Angles 347 Service Diagnosis 347 DATA AND SPECIFICATIONS Models C 75 C 76 I M 1 2 and 4 Town Country C 75 C 76 Propeller Shaft Number Used 1 1 2 1 1 Diameter With Standard Transmission With TorqueFlite Transmission 3 5 in 3 0 in 3 0 in 2 75 in 3 5 in 3 25 in 3 25 in Diameter with Air Conditioning And Standard Transmission And TorqueFlite Transmission 3 25 in 3 25 in 2 75 in 3 5 in 3 25 in 3 ...

Страница 342: ...SERVICE MANUAL 55x767 Fig 1 Rear Universal Joint Cross Type Disassembled View CENTERING BUhG N BUTTON SPRING Q SHAFT BGIT 2 BUTTON SPRING CENTERING BUTTON 5 4 x 4 9 Fig 2 Front Universal Joint Bali a n d Trunnion Type Disassembled View MyMopar com ...

Страница 343: ...r shaft and is covered by the joint body The pin with balls needle bearings thrust washers centering button and button spring at each end extends through the propeller shaft ball head and rides in ball channels in the body of the joint assembly This balanced installation is designed to absorb thrust and torque of the drive line This type of joint is used in Models C 75 C 76 at front universal join...

Страница 344: ...nd trunnion type universal joints will only be necessary when excessive backlash exists between balls and trunnion I n some instances it will be found that universal joint body has worn and it will be necessary to replace all parts including body pin thrust washers and centering buttons Worn rollers should also be replaced 3 UNIVERSAL IOMT MAINTENANCE BALL AND TRUNNION The universal joints propell...

Страница 345: ...ust cover into body With one hand grip end of dust cover protruding through back end of body With other hand pump body back and forth as shown in Figure 6 until entire dust cover has passed through body Dur ing operation cone may have reversed itself in side dust cover Pull i t out to its normal posi tion Insert 2 ounces of heavy fiber universal joint grease in joint of C 76 2 ounces in the C 75 a...

Страница 346: ... form an assembly These parts are not serviced separately After disassembly clean and inspect parts and replace those worn or damaged as necessary c Assembly Lubricate all parts before assembling I f splined joint at rear of front propeller shaft has been disassembled fill cavity with one ounce by weight of MS 1124 The center bearing is a sealed bearing and does not require lubrica tion Install du...

Страница 347: ...ng a shudder con dition make sure engine has been tuned and is operating smoothly with no hesitation or stum ble on accelerator NOTE A rough engine can aggravate or pro duce a shudder With fuel tank approximately half full de termine under what speed and passenger load a shudder is present and i f shudder is light FRONT PROPELLER SHAFT ASSEMBLY SEAL NUT LOCK Fig 8 Center Bearing Installed Fig 9 Re...

Страница 348: ... Since adjacent shafts are pointing i n dif ferent directions up or down whan viewed in same direction from front to rear of car the working angles are obtained by adding the angles below horizontal Therefore the mid dle joint working angle as shown i n Figure 10 is 2 and the rear joint working angle is 3 I f the adjacent shafts were pointing in the same direction then the angles below horizontal ...

Страница 349: ...nd remove undercoating material i f present with solvent b Check transmission flange nuts and rear axle differential flange nuts for looseness Tighten to Data and Specifications c Check alignment of balance arrows on both shaft and front universal joint These ar rows must be exactly in line I f not reposition splines so that arrows are properly aligned 9 UNIVERSAL IOINTS NOISY a Check universal jo...

Страница 350: ...ded Tire Pressures 352 Tire Rotation 353 Service Diagnosis 353 DATA AND SPECIFICATIONS Models C 75 C 76 IM 1 2 4 WHEELS y T y p e Size No of Nuts to Attach Wheel Stud Hole Circle diameter Stud Size 14 x 6 in K 5 m y2 2o Stee Drop Center 14 x 63 in K 5 m M 20 1 Disc Safety Wheel 14 x 7 in L 5 18 TIRES Type Cord Material Super Soft Cushion Tubeless 8 50 x 14 Rayon Nylon Supei Tul 9 00 x 14 Nylon Sof...

Страница 351: ...e amount on wheel I f radial runout of wheel exceeds 045 inch replace the wheel 11 M f Fig 1 Safety Type Rim NOTE Do not check runout on outside of wheel r i m since this method can easily give a false reading 4 CHECKING WHEEL FOR WOBBLE LATERAL RUNOUT Before checking a wheel for wobble lateral runout make sure tire is properly mounted Mount a dial indicator on firm base with an vil of indicator r...

Страница 352: ... the speed ometer The balance is correct i f the cloth or towel does not vibrate I f wheel and tire assembly is out of balance check with wheel balancing equipment and attach weights as needed TIRES 6 TUBELESS TIRES The Tubeless Tires provide longer life and added protection against blowouts and punc tures A puncture can be repaired by using the repair plugs and other materials in the Tube less Ti...

Страница 353: ...y an accumula tion of soap bubbles 10 REPAIRING PUNCTURES a Tire on Wheel Outside Method Simple punctures can usually be repaired with tire mounted on wheel using items in repair kit The operation can best be performed when tire is flat I t can also be accomplished while tire is inflated Remove the puncturing object Dip needle in serting tool in the cement provided in repair kit and carefully prob...

Страница 354: ...btain a good adhesion Two types of equipment are available for curing inside patches the Electric and the Match Patch The Electric type has a fuse plug that automatically cuts off the power when the curing Js completed The Match Patch or powder burning type depends upon the heat resulting from a slow fire C clamps are used with both types of equipment to apply pressure during the curing process Al...

Страница 355: ...eld area with soap solution and check for pin hole leak I f leak is evident repair or replace wheel as necessary DO NOT WELD RIM Heavy Rim Weld A slow leak may result if rim weld has not been dressed down Use a flat file to smooth off the weld in the flange area Apply MOPAR Rubber Cement in the area to help make the seal Cracked Rim A rim seldom cracks unless it has been welded or badly overloaded...

Страница 356: ...354 WHEELS AND TIRES CHRYSLER SERVICE MANUAL MyMopar com ...

Страница 357: ...inner and outer shoulder ribs Wear occurs at center of tread when tire is driven over inflated a Spotty Wear Fig 10 usually becomes evident on front tires when tires are not rotated every 3 000 miles b Excessive toe in or toe out Figs 11 and 12 of front wheels affects the rate of tire wear more than any other factor c Refer to Fig 13 Excessive positive camber will develop noticeable wear on the ou...

Страница 358: ...ow Regulator Handles 374 Door Trim Panel 374 Removal and Installation of Door Glass 377 Removal and Installation of Quarter Window Glass 378 Removal and Installation of Window Glass 380 Removal and Installation of Rear Window 382 Removal and Installation of Front Fenders 387 Removal and Installation of Radiator Grill and Bumper 387 Headlining 398 Cleaning of Interior Upholstery 391 Operating Conve...

Страница 359: ...CHRYSLER SERVICE MANUAL BODY AND SHEET METAL 357 DIAGONAL BRACES Fig 1 Basic Body Construction C 75 C 76 COWL PANEL 57X573 Fig 2 Basic Body Construction Imperial MyMopar com ...

Страница 360: ...round rain deflector panel to fresh air door cover 5 Through fresh air opening to cowl top seams 6 One bead between weatherstrip a n d glass O n e bead between weatherstrip a n d fence around entire opening Also seal rear w i n d o w 7 Underbody seams 8 Center pillar seams 9 Roof rain trough seams 10 Around deck lid weatherstrip trough deck opening 11 Apply 2 VB inch diameter beads of sealer aroun...

Страница 361: ...r rattles the trouble is probably caused by misalignment in such cases follow align ment and adjustment procedures Anti squeak material slipping out of position may also cause squeak and rattles Relocating and cementing material in position will elim inate this difficulty 2 TESTING CAH FOB WATEH OH DUST LEAKS Figures 3 and 4 illustrate various locations where sealers were used in the manufacture o...

Страница 362: ...p to check for other possible points of leakage After a complete test is made i t is essential that area be properly sealed with MOPAR Sealer Before testing deck lid make certain that deck l i d is properly fitted Test from bottom of deck lid and work slowly toward top on each side Then work across top of lid I f leakage occurs at seam between weatherstrip trough and deck upper panel and rear quar...

Страница 363: ...ES Surfaces to be sealed or cemented should be cleaned of all dirt grease and other compounds preferably with clean unleaded gasoline or cleaner s naphtha a Front Vent Wing Pivot Pins Seal openings around these pins with heavy sealing putty I t may be necessary to properly position weatherstrip at top and around vent wing To do this insert a shim between retainer and weatherstrip to obtain a bette...

Страница 364: ...CROSS BAR TO YOKE BRACE RADIATOR CROSS BAR TO DUST SHIELD 57x740 RADIATOR CROSS BAR CATCH SPRING LEVER SAFETY SPRING BUMPER BOLT JAM NUT WASHER WASHER Fig 7 H o o d Disassembled View C 75 C 76 WINDSHIELD WASHER JET SEAL HINGES SPRINGS STRIKER SPRING NUT HOOD LOCK ASSEMBLY ADJUSTABLE BUMPER RADIATOR CROSS BAR ORNAMENT MOULDING ADJUSTABLE BUMPER BRACE WASHER Fig 8 Hood Disassembled View Imperial MyM...

Страница 365: ...ith seam sealer g Cowl Panel loint Clean the seamed area thoroughly and apply heavy sealing putty or body seam sealer Be sure to apply sealer over hood hinge bracket and along seam to rear end of front fender h Cowl Quarter and Hood Ledge Seam Inspect various openings in cowl for possible leakage Check for openings and cracks in seal along seam in engine compartment Seal with heavy sealing putty a...

Страница 366: ...n installing use helper to assist i n mount ing hood to hinges Install attaching washers and nuts align hinges with aligning marks Tighten nuts a little more than finger tight Close hood align and adjust as follows Seal top of hood hinge bracket to dash panel w i t h sealing putty c Adjustment Hood Fits Cowl Loosely If one side of hood Fig 9 Hood Attachment BOLT I Fig 10 Diagonal Strainers is rais...

Страница 367: ...f fender and leading edge of front door When correct hood to fender fit is obtained tighten fender to cowl bolts securely Remove jack Front of Hood is Higher Than Fenders Check rear edge of hood to see i f hood fits correctly at cowl I f fit at cowl is correct check hood striker and latch assembly I f striker plate is lowered front of hood will be drawn down The front hood bumper on grille panel s...

Страница 368: ...tained After making any adjustment that requires shift ing of hood or fender always check hood strik er for proper length and lock plate assembly for alignment After hood has been centered i n opening and hinge bolts have been tightened check hood for ease of opening and closing Move striker plate in or out up or down as necessary until hood opens and closes easily and fits snugly against weathers...

Страница 369: ...er pull or push upper portion of door in desired direction Tighten hinge strap bolt and check fit To move lower portion of door ahead or back trim pan el removed loosen lower hinge strap bolts and c Fitting Front Door Flush with Adjacent Panels If door is not flush with adjacent panels cor rect by loosening four hinge strap screws on front doors or three hinge strap screws on rear doors It should ...

Страница 370: ... be aligned to roofline See Fig 21 The door weatherstrip seal can be checked by holding a heavy piece of paper similar to a shipping tag Fig 22 against lock pillar and closing door A slight drag should be felt as paper is being pulled out I f no drag is felt move striker plate in closer This paper test should be made all around door at about six inch intervals I f no drag is felt on paper make nec...

Страница 371: ... and anchored to support bracket at other See Fig 24 A roller sleeve on free end operates against a cam Contour on back face of hinge As deck lid is raised action of rollers against hinges cause bars to twist exerting a torsional spring resistance that balances lid To permit adjustment of tor sion bar tension four slots are located in each support plate on Imperial Models and three TORSION BARS r ...

Страница 372: ...ch hinge that attach l i d to hinge arm Leave remaining two bolts finger loose Brace deck lid i n such a manner so as to hold lid i n position while removing last two bolts This w i l l keep l i d from sliding down and damaging rear deck Remove last two bolts and lift deck lid up and away from rear of car When installing deck lid observe same pre caution L i f t l i d and slide down into position ...

Страница 373: ...ed a slight amount by bending but when doing so space across top of lid is also increased or decreased For instance i f contour were increased lid would become shorter whereas i f contour were decreased lid would become longer Each time lid contour is changed in all probability lid would have to be relocated on hinges L To Increase the Deck Lid Contour Insert rubber mallet between lid and quarter ...

Страница 374: ...f papers fit snug all along edges of lid as they are pulled out a good seal is evident I f paper fits loosely on one side and tight on other deck lid should be aligned 10 BODY ALIGNMENT When checking alignment of body that is badly X 57x712 Fig 30 Adjusting Rear Deck Lid Latch Imperial SHIPPING TAGS s M B 3 j Fig 31 Checking Seal of Deck Lid damaged frame should be inspected and nec essary repairs...

Страница 375: ...rear door binds near top of lock pillar and spacing is correct at hinge pillar shim at Num ber four body bolts Add shims until spacing between lock pillar and rear door is same as between door and hinge pillar Check adjust ment by opening and closing door to determine if interference is eliminated I f several shims are added it may be necessary to add shims at Number Three body bolt I f rear door ...

Страница 376: ...lied so that final metal finish will compare with original body fender or panel contour without Indentations and prepare for painting The same procedure can be followed when replacing other sections of body 13 REMOVAL AND INSTALLATION OF DOOR AND WINDOW REGULATOR HANDLES Cars without Electric Window Lift The door and window regulator handles are attached to regulator with a spring type clip Refer ...

Страница 377: ...rs without Electric Window Lift Remove garnish moulding remote control han Fig 38 Removing or Installing Rear Door Regulator Fig 39 Replacing Glass Run Channel dies arm rest and door trim panel assembly Remove trim panel and weatherproof lining Avoid tearing weatherproof lining Remove door glass and window regulator attaching screws see Fig 38 and slide regulator as sembly out through large openin...

Страница 378: ...lass and engage lower end of run in channel Tighten garnish moulding screws and reinstall t r i m panel and arm rest assembly DOOR G L A S S FRAME ATTACHING BOLTS 57x716 Fig 43 Removing Ventilator NOTE To replace glass r u n channel front ventilator assembly and window glass refer to Figure 42 Remove frame to door attaching screws and frame and glass assembly 17 REMOVAL AND INSTALLATION OF DOOR VE...

Страница 379: ... glass clears to raise window until the other regulator arm pivot roller clears door Disengage pivot arm and remove window glass When installing new window glass be sure that slots in bottom of channel frame are coated with MOPAR Lubriplate and that the pivot rollers are free After installing window glass adjust division bar so that the vertical sliding glass does not bind when window is raised or...

Страница 380: ...hannel is installed REAR GLASS RUN f FRONT GLASS RUN Fig 46 Rear Quarter Window Adjustment Club and Convertible Coupe DOOR HANDLE SPRING 1 EACH SIDE Fig 47 Removing or Installing Door Handle Refer to c below for adjustment of rear quar ter window Install t r i m panel and the other components that were removed b Convertible Coupe Lower top position quarter window and re move retainer and washer th...

Страница 381: ...ING _ _ L p f UPPER MOULDING LOWER MOULDING RIGHT WEATHERSTRIP WINDSHIELD GLASS LOWER MOULDING CENTER LOWER MOULDING LEFT 57x772 Fig 49 Windshield and Moulding Assembly C 75 C 76 WEATHERSTRIP MOULDING UPPER RIGHT I MOULDING j RIGHT t PILLAR MOULDING CAP UPPER MOULDING UPPER LEFT MOULDING LEFT PILLAR MOULDING CAP LOWER MOULDING LOWER RIGHT MOULDING LOWER LEFT WINDSHIELD GLASS 57x762 22 Fig 50 Winds...

Страница 382: ...ion Remove upper right and left garnish moulding from A post Remove windshield header t r i m and garnish moulding from weath erstrip ATTACHING STUDS Fig 53 Remoying or Installing Horizontal Moulding Fig 54 Removing or Installing Upper and Lower Moulding Clips Imperial Models a Removing Mouldings Protect hood and other necessary components of car with protective covering to avoid dam aging finish ...

Страница 383: ...lass When removing glass from weatherstrip it may be necessary to wear gloves to protect hands With helper assisting OWE V CULD NG RETAINING C PS BODY Fig 59 Windshield Weatherstrip and Moulding Sides on outside of car remove glass from inside of car by exerting pressure at either corner to force glass out of the weatherstrip SCREW OUTSIDE MOULDING 57x753 Fig 58 Locating Moulding Retaining Clips o...

Страница 384: ...as shown in Figure 62 Hold glass i n position and insert wedge in weatherstrip groove as shown i n Figure 63 strip glass into weather strip Pound glass into place with palm of hand The weatherstrip will slip under lip of mould ing with a slight popping noise CAUTION Make sure glass is locked into weatherstrip properly all around glass c Installation of Mouldings On I M models equipped with bolted ...

Страница 385: ...k pillar and rear deck panel with clips Remove clips then remove belt moulding After remov ing belt moulding center cap and stud nuts it may be possible to raise the moulding at center opening and slide moulding out of rear lock pil lar moulding cap without loosening clip nut in passenger compartment If this cannot be done remove headlining at door pillar post so rear lock pillar moulding clip nut...

Страница 386: ... WEATHERSTRIP OUTSIDE MOULDING 4 BODY FENCE NUT AND WASHER 57x755 Fig 74 Lower Rear Window Weatherstrip and Moulding cord inserted in moulding slot of weatherstrip Coat moulding slot with naptha solution be fore installing moulding Install upper mould ing lower left and right mouldings and upper corner caps as shown i n Figures 72 73 and 74 for C 75 and C 76 Models Install belt mould ing On Imperi...

Страница 387: ...CHRYSLER SERVICE MANUAL BODY AND SHEET METAL 385 Fig 76 Front Fender Assembly Models C 75 C 76 Fig 77 Front Fender Assembly Imperial MyMopar com ...

Страница 388: ...386 BODY AND SHEET METAL CHRYSLER SERVICE MANUAL Fig 78 Bumper ond Grill Assembly C 75 C 76 SUPPORTS BUMPER Fig 79 Bumper and Grill Assembly Imperial 57x77 MyMopar com ...

Страница 389: ...ery unclip the wire harness and remove lead wires that con nect starting motor solenoid Disengage splash shield support bracket at radiator support and remove bracket Remove fender to cowl and rear splash shield attaching bolts lift rear of fender slightly and pull shield approximately 6 inches away from body Support fender in this position and pull splash shield out at rear pushing down and back ...

Страница 390: ...trip and headlining to lift the headlining off retaining barbs as shown in Figure 80 Pull headlining off retaining barbs at windshield header On all models retaining brackets hold the rear headlining bow in position at the center Fig 81 Pull the bow from brackets spring the bow and remove the end from holes in roof rail Two sets of holes are provided in roof rails Mark set of holes used as shown i...

Страница 391: ...eadlining bow support clip as shown Fig 84 Marking Headlining with Small V Shaped Cuts Fig 85 Cutting Holes in Listing for Support Clip in Figure 85 This will prevent headlining from wrinkling Bend the retainer clip around the rear bow Install the remaining bow stretching head lining evenly so that approximately the same amount of material hangs down at both sides Apply cement to windshield header...

Страница 392: ...ng into position after cement is tacky Make sure material is free from wrinkles To prevent headlining from pulling loose use cement to fasten material at seams 55P102A Fig 88 Tucking Headlining between Roof Rail and Retainer Fig 89 Cementing Material to Underside of Side Rails at Quarter Window to outside surface of rail as shown in Figure 90 To secure headlining at rear windows all models except ...

Страница 393: ...Soil Oil Grease Tar Trim Cement Fabric Fabric Candy Ice Cream Soda Catsup Mustard Dirt Vinyl and real leather Oil Grease Tar Trim Cement Vinyl and real leather Candy Ice Cream Soda Catsup Mustard Vinyl and real Dirt leather Cleaners Recommended MOPAR Fabric Cleaner Part 680183 0 5 solution of household detergent in water MOPAR Kar Kleen Part 1643100 and fairly stiff bristled brush MOPAR Fabric Cle...

Страница 394: ...hed condition rath er than a discoloration In view of the foregoing i t is advisable to wash cars frequently to prevent the possibility of such conditions occurring b Foreign Material in Paint In some instances where minute particles of foreign material have embedded themselves in the horizontal surface of paint they are quite likely abrasives such as metal particles that have been carried through...

Страница 395: ...ould be placed in the top cover bag and stored in luggage compartment Never store top cover In top well compartment b To Raise Top WARNING Never attempt to raise or lower the top while the car is in motion It is advisable to raise and lower the top at least once a month to keep the top mechanism in working condition Remove well compartment cover Move top control switch to right and hold it in this...

Страница 396: ...h hole in removable sun visor bracket 33 ADIUSTING THE TOP There are six adjustments on each side of roof rail to control alignment of top with the wind shield header doors roof rail and quarter windows Refer to Figures 91 and 92 and proceed as follows a Body Adjustment Before making any adjustments of top header panel roof side rails or power links tighten body bolts to 18 foot pounds torque Shim...

Страница 397: ...ELAY TOP LIFT SWITCH AND 25 AMPERE CIRCUIT BREAKER CONVERTIBLE ONLY Models C 75 C 76 57x730 HEATER AND DEFROSTER MOTOR TOP LIFT MOTOR CONVERTIBLE ONLY TO BATTERY ooo STARTER RELAY TOP LIFT SWITCH AND 25 AMPERE CIRCUIT BREAKER CONVERTIBLE ONLY 57x731 Fig 94 Windshield Wiper Heater Rear Window Defroster Top Lift Circuit Wiring Diagram Model Imperial MyMopar com ...

Страница 398: ...switch lever is moved to right or left the switch is at fault and should be replaced If top fails to operate during these tests follow procedure outlined in Paragraph 33 35 and 37 37 TESTING WIRES BETWEEN CONTROL SWITCH AND PUMP MOTOR This test can be made from the luggage com partment Check pump motor ground wire black wire between pump motor and ground to make certain i t has a good clean ground...

Страница 399: ... is in straight up position Remove the four screws and hinge at each end Fig 95 body half of hinge remove tail gate as an assembly b Installation Position tail gate straight up on body Install hinge attaching screws but do not tighten se curely Align and adjust position of tail gate in body opening Refer to Paragraph c be low After tail gate is adjusted to opening tighten hinge screws securely c A...

Страница 400: ...e upper and lower attaching screws located inside of tail gate and remove glass r u n chan nels Fig 97 Tail Gate Lock Striker Fig 98 Removing Pull Cord from Weatherstrip 43 INSTALLATION OF TAIL GATE LOWER GLASS RUN CHANNEL AND TAIL GATE GLASS Install lower glass run channels and tighten screws securely Install rear window glass I n stall upper stops Slip regulator control arms into glass channel s...

Страница 401: ...ove inner panel and replace wires To ad just length of latch pull wire loosen screw holding adjusting bracket located under inner lip of door inner panel and place wire in proper groove to apply tension Tighten screws f Removal Upper Glass Run Channel Remove attaching screws and pry out channel from retaining strip 45 REMOVAL AND INSTALLATION OF REAR QUARTER WINDOW Remove rear quarter window garni...

Страница 402: ...IL LIGHT 18 BLACK W I N D O W LIFT CIRCUIT BREAKER 2 0 AMPERE CIRCUIT BREAKER 1 5 AMPERE CIGAR LIGHTER SEAT ADJUSTMENT CIRCUIT BREAKER 2 0 AMPERE 57x598 Fig 100 Imperial Basic Body Wiring RIGHT REAR D O O R W I N D O W LIFT SWITCH RIGHT REAR D O O R AUTOMATIC SWITCH RIGHT FRONT D O O R W I N D O W LIFT MOTOR RIGHT FRONT D O O R W I N D O W LIFT SWITCH HEATER SWITCH FREEZE UP VALVE HEATER MOTOR RIG...

Страница 403: ... E L L O W 18 T A N LEFT PARKING AND TURN SIGNAL LIGHT LEFT FRONT DOOR AUTOMATIC SWITCH BACK UP LIGHT SWITCH PUSH BUTTON BOX LIGHT BLUE 18TAN 8 LIGHT G R E E N L A N D BRAKE INDICATOR LIGHT 18 WHITE RIGHT REAR DOOR ih A AUTOMATIC S W I T C H l RT ri n LT RIGHT TAIL STOP AND TURN SIGNAL LIGHT 18 B R O W N TURN SIGNAL MANUAL CANCELLING SWITCH DOME LIGHT 4 DOOR SEDAN 18 YELLOW Zfl ft cfl JD 18 BLACK ...

Страница 404: ...G N I T I O N D I S T R I B U T O R 16 BLACK IGNITION COIL C O I L R E S I S T O R N O 3 H O R N I M P E R I A L O N L Y ft 1 6 D A R K G R E E N W H I T E R A D I O C O N D E N S E R 12 R E D W H I T E B L A C K 18 DARK G R E E N GENERATOR REGULATOR 12 BLACK WHITE BATTERY 16 DARK GREEN WHITE 16 BROWN WHITE NEUTRAL SAFETY SWITCH 16 B R O W N STARTER WHITE RELAY aM B BLACK IGN 18 BROWN V A C U U M ...

Страница 405: ... NONE 12 BLACK U DK BLUE 14 NONE 14 NONE 14 NONE D 3 DK GREEN 14 NONE 12 WHITE 14 NONE D 2 RED 14 NONE 12 WHITE 14 NONE D l VIOLET 14 NONE 14 NONE 12 WHITE D BROWN 14 NONE 14 NONE 14 NONE B 3 WHITE 14 NONE 12 BLACK 14 NONE B 2 BLACK 14 NONE 12 NONE 14 NONE B 1 YELLOW 14 NONE 14 NONE 12 BLACK B TAN 12 WHITE 12 WHITE 12 WHITE 4 DOOR 4 DR SUB CLUB SED SP 4 DR SP CL CPE CONV CPE LEFT REAR DOOR OR QUAR...

Страница 406: ... A L A T T E N T I O N Recommended lubricants are based on average driv ing conditions A car driven in extreme dusty cold or high humidity climate will require more frequent lubrication and maintenance Replace oil filter cartridge after 5 thousand miles of operation T H E S E P O I N T S R E Q U I R E N O L U B R I C A T I O N Clutch release bearing C 75 when so equipped Starting motor Rear spring...

Страница 407: ...apparent that oils for service MS will most nearly suit the average driver s requirements a Service MS 1 Continuous high speed highway driving where the oil becomes unusually hot such as summer vacation trips 2 Heavy load operation such as towing a house trailer in hilly country 3 Driving in areas where temperatures be low zero degrees F are encountered for extended periods 4 Driving in moderately...

Страница 408: ...ENT SILENCER BODY j WING SCREW SHROUD 57 x 205 N U T L O C K W A S H E R S T U D Fig 3 Air Cleaner DRAIN SLOT BRACKET Fig 2 Typical Engine Oil Level Indicator Full and Add Oil I f the oil level is be tween the F u l l and A d d O i l marks i t is not necessary to add oil I f the oil level drops to the Add O i l mark or slightly below it add not more than one quart of oil 7 CARBURETOR AIR CLEANER T...

Страница 409: ...l of filler plug hole Do not overfill d 3 Speed Transmission Car So Equipped Use SAE 10 W Engine Oil at all temperatures Remove filler plug and check lubricant level Replenish to level of filler plug hole e TorqueFlite Transmission Checking Fluid Level Apply parking brakes Run engine at idle speed and operate the drive selector lever through all ranges and return to Neutral N Check level at transm...

Страница 410: ...s Interval 14 EVERY 20 000 MILES Refer to Lubrication Chart as shown i n Fig ure 1 20 000 Miles and also to the informa tion that follows a 3 Speed Transmission Use S A E 80 Fluid Gear Lubricant Drain and refill Keep level at bottom of filler plug hole I n w a r m area where SAE 80 Fluid Gear L u bricant is not available SAE 90 may be used To refill remove transmission drain plug hole and allow un...

Страница 411: ...ngs They are de signed to grip the contracting metal parts firmly and operate as a flexible medium between these parts The use of any lubricant will destroy the necessary friction and cause premature failure of these rubber parts b Oillte Bearings The bearings are self lubricating and are used in locations where lubrication is difficult to maintain When Oilite Bearings are subjected to heat or pre...

Страница 412: ...tuning and automatic search tuning The Music Master Model 847 Fig 3 has five tubes and one transistor I t includes a variable tone control with manual tuning and push button tuning CIVIL DEFENSE SYMBOLS 640 KC 1240 KC ON OFF VOLUME CONTROL MANUAL TUNING TONE CONTROL SPEAKER CONTROL LOCAL SEARCH TUNING DISTANCE SEARCH TUNING 57x431 Fig 1 Operating Controls 920HR CIVIL DEFENSE SYMBOLS 640 KC 1240 KC...

Страница 413: ...HRYSLER SERVICE MANUAL RADIO HI FI AND HEATER 411 NOT SUPPLIED IN KIT PART OF VEHICLE Fig 4 Radio Model 920HR Typical of Model 847 NOT SUPPLIED IN KIT PART OP VEHICLE Fig 5 Radio Model 921 HR MyMopar com ...

Страница 414: ...in Figure 8 Adjust antenna compensator CAUTION Antenna compensator must be properly ad justed for satisfactory operation of radio 3 REMOVAL MODELS IM 1 2 and 4 Fig 5 Disconnect antenna pilot lamp lead from or Fig 6 Generator Condensor TO BALLAST RESISTOR MOUNTING K BOLT r CONDENSER 57x439 Fig 7 Coil Condensor ange wire on harness two wire lead from speaker A lead from accessory terminal on tempera...

Страница 415: ...formance from search tuning antenna should be ex tended 9 FOOT SWITCH SEARCH TUNER The foot switch search tuner on Models 920 HR and 921 HR is located on the left forward end of the floor boards By depressing with the foot i t will select a station on the radio HIGHWAY HI FI RECORD PLAYER 10 OPERATION Turn on radio Put control knob in Phono position of Hi Fi record player Place record on turntable...

Страница 416: ...414 RADIO HI FI AND HEATER CHRYSLER SERVICE MANUAL Fig 10 Hi Fi Record Player Disassembled View MyMopar com ...

Страница 417: ...VER SHIELD BLACK AVC WHITE POT RED 12V BLACK SCREENS PILOT LAMP CARTRIDGE K 7 1 6 J C C P H O N O O SW l SCW RADIO BLACK Ll RF CHOKE MOTOR 56x183 Fig 11 Hi Fi Record Player Electrical Circuit Wiring Diagram MyMopar com ...

Страница 418: ...als Remove both screws which retain motor frame to bracket Remove motor assemby and coupling will drop out Install coupling on motor install motor and resolder wires Do not burn separators when soldering wires to terminals 15 REMOVAL AND INSTALLATION OF COUPLING CHASSIS REMOVED FROM CASE Two types of couplings are used pin type with brass coupling shaft and star type with nylon coupling shaft The ...

Страница 419: ...pling to see that it is properly seated on both shafts I f coupling is properly seated tightness may be caused by shift in position of self aligning bearing used for motor shaft Place screw driver on center of flywheel With handle of another screw driver gently tap handles together Care must be exercised to avoid hitting flywheel too hard or damage to motor may result When properly done this shoul...

Страница 420: ...ippery rubber drive ring under turnta ble due to oil or grease on r i n g c Bump or poor cementing of rubber drive ring d Worn knurl on idler wheel This wheel drives rubber ring under turntable e Tight or rough center spindle f Poorly cemented rubber top on turntable edge too high or loose g Warped turntable or record 28 STYLUS SKIPS OR JUMPS GROOVES WHEN CAR IS IN MOTION a Insufficient stylus pre...

Страница 421: ...CHRYSLER SERVICE MANUAL RADIO HI FI AND HEATER 419 Fig 12 Heater Installation Engine Side 57x522 Fig 13 Heater Installation Driver s Side MyMopar com ...

Страница 422: ...lower Is turned on can be caused by either blower not working or duct door not open Disconnect three electrical lead wires to blower motor Remove mounting screws Disengage rubber boot from heater housing Remove blower motor mounting plate from blower housing and remove motor assembly When installing fan adjust to y inch clear ance between fan wheel and mounting plate 31 REAR WINDOW DEFROSTER The r...

Страница 423: ...rovided by a lever on the instrument panel which opens the duct door on the right side of the car to admit air to the distribution duct As the lever is moved towards warmer the control cable moves the thermostat to demand more heat Defrosting is provided by heated air flowing from distribution duct to defroster outlet on top of instrument panel The damper in the distributor duct divides the heated...

Страница 424: ...o reduce noise in the blower 33 HEATER ASSEMBLY Figs 14 and 16 The heater assembly consists of heater housing heat exchanger burner assembly and the shield which surrounds the heat exchanger The hous ing of the Model 801 heater is constructed in two plastic sections one of which is perma nently mounted on the engine side of the dash panel There will seldom be any reason to re move this part of the...

Страница 425: ...sing an Allen wrench 4 in across flats and remove valve seat and valve seat gasket e Inspection of Burner Inspect the valve seat for scoring around the sealing surface and inspect the end of plunger The plunger contains a rubber insert which must be flat and slightly recessed into the metal retainer I f the insert is uneven replace the plunger assembly Do not attempt to clean or repair the nozzle ...

Страница 426: ...rwise repair the heat exchanger Clean as much of the deposits from inside the exchanger as possible and blow it out with compressed air Replace entire unit if i t appears unserviceable after cleaning Inspect overheat switch in heat exchanger shield for broken porcelain burned or broken wiring loose or broken contact points or other visible damage Replace switch i f such condi tions exist 35 THERMO...

Страница 427: ...at has been traced to ignition unit it will be necessary to determine which component is responsible This is most easily done by first substituting a vibrator that is known to be good If the trouble is eliminated the old vibrator was at fault If substitution of the vibrator fails to correct the difficulty the ignition coil is probably at fault Capacitor failure will usually lead to failure of the ...

Страница 428: ...e lead to touch ground while making these tests g I f the solenoid valve is operating proper ly i t will be necessary to check the ignition unit T U R N I G N I T I O N SWITCH OFF Separ ate two sections of ignition cable at the con nector Insert a dual electrode automotive type plug i n end of ignition unit section of ignition cable and ground plug to engine block This plug should be adjusted to a...

Страница 429: ... air blower and short coupling duct between blower and heater also distribution duct door where air enters duct on right side of passenger compartment b Another cause of intermittent operation is air lock in heater fuel pump caused by small air bubbles in fuel To correct this condition inspect the heater fuel take off tee in engine fuel pump I f heater fuel line comes off at top remove fittings fr...

Страница 430: ...Replace switch c Repair as necessary ignition unit d Replace plug and adjust gap e Replace solenoid coil f Replace nozzle g Replace pump h Repair or replace hose i Replace coupling 45 HEATER IGNITES BUT GOES OUT LATER a Replace or repair blower b Open vent c Remove obstruction d Replace duct 46 HEATER BURNS INTERMITTENTLY HEAT OUTPUT IS TOO LOW a Replace thermostat b Bleed fuel line and check all ...

Страница 431: ...arging the System 443 Testing Thermal Switch 444 Testing for Proper Super Heat 445 Pressure Relation Chart 446 Testing Electrical Switches and Control Circuits 447 Removal and Installation of Air Conditioning Unit 448 Removal and Installation of Expansion Valve 450 Removal and Installation of Compressor 451 Service Diagnosis 455 DATA AND SPECIFICATIONS COMPRESSOR Airtemp Location Right Cylinder Ty...

Страница 432: ...et cases Calibrated from 0 to 220 F C 3444 TORCH Leak Detector Includes extra tank of liquid petroleum fluid C 3358 WRENCH Flare Nut Open End Box Type W and iys two per set C 3361 WRENCH Ratchet Special Refrigeration Type M sq Drive with sq and Y2 Hex in Handle C 3372 PUMP Refrigeration Vacuum Pump charged with 75 Vis Ref Oil C 3128 PLIERS Drive Pulley Seal Retainer Snap Ring C 3420 ADAPTOR Freon ...

Страница 433: ...ted by the heater core to a temperature that is selected by the driver The amount of reheat added to the air as i t passes through the heater core is con trolled by metering hot water through the heater core The flow of hot water is regulated by a modulating valve A reheat type tempera ture control gives dehumidification even when minimum cooling is desired During the heating cycle outside air is ...

Страница 434: ...e 8 illustrates the dampers used in con trolling the system and control components that are mounted on the instrument panel COOLING HEATING RECIRCULATING DOOR OPEN DAMPER 57x591 Fig 6 Recirculating and Fresh Air Door TWO WAY S O L E N O I V A L V E CHECK V A L V E X A TO P R E V E N T L O S S OF OIL P R E S S U R E DURING ENGINE I D L E A U X I L I A R Y DRAIN T U B E FOR AIR AND O I L L E A K A G...

Страница 435: ...ECEIVER STRAINER DRIER LINE VALVE Fig 9 Heater Air Conditioning Schematic of Components 57x593 1 Compressor clutch and water valve heating element will be energized Figs 9 and 10 2 Hot water shut off to heater core 3 Fresh air door closed and recirculating door open resulting in 80 recircula tion air 20 fresh air 4 Maximum cooling will be obtained h Moving the main control lever to the right from ...

Страница 436: ...OSED CLUTCH CIRCUIT OPEN FOOLER CIRCUIT OPEN FRESH AIR DOOR CLOSED RECIRCULATING DOOR OPEN NO 1 SWITCH OPEN NO 2 SWITCH CLOSED COMPRSSOR CLUTCH r 18 BLUE THERMAL SWITCH FOOLER ELEMENT WATER VALVE RHEOSTAT RESISTANCE DECREASES AS l A WATER VALVE IS OPENED r MGV C Z 3 1 8 W H I T E 18 RED 18 WHITE SWITCH NO 2 NORMALLY CLOSED SWITCH NO 1 NORMALLY OPEN FRESH AIR AND RECIRCULATING DOOR SOLENOID ENERGIZ...

Страница 437: ...P LOWFR DISTRIBUTION DUCT WATER FLOW VAlVEi 57x623 ALIGNMENT ARROW5 57x624 Fig 13 Discharge Grille Conditioned air is forced into the car by the blower that is mounted to dash The air enters a distribution duct and can either be discharged toward the floor of car through slots in the distribution duct or it can be forced up to two discharge grilles in the top of instrument panel by means of a damp...

Страница 438: ... which is wound around the secondary capillary tube Heating the secondary tube in effect tricks the pri mary capillary tube Fig 15 located in the distribution duct by making it appear warmer than the discharge air flowing over it The valve will then tend to close thus reheating the air less and shifting the temperature to the desired cooler level 5 INSPECTION AND TESTING OF COMPLETE AIR CONDITIONI...

Страница 439: ...e valve clockwise until valve is completely front seated Front seating the valves will cause suction pressure to drop to zero and from a zero reading to a vacuum reading pumping down all of the refrigerant out of compressor With compound gauge read ing 20 to 25 inches of vacuum rotate valve stem of discharge service valve clockwise until valve is completely front seated Open right hand shut off va...

Страница 440: ...ont seat the valve This will allow small amount of gas accumulated i n suction line to flow into compressor and crankcase mixing with and to be absorbed by the oil NOTE This operation will also cause the gas to flow through the compressor s cylinder and out through the manifold gauge center connec tion Probe the gauge center connection w i t h tip of finger I f probing with finger at connection in...

Страница 441: ...ani fold center outlet from test hoses To admit pressure gauges rotate valve stems of both suction and discharge service valves one turn clock wise 8 TESTING FOR LEAKS WITH DETECTOR When system is found to be low in refrigerant or following repairs on system that necessitated opening of connection it is necessary to test for leaks and tighten connections or to make repairs as required before syste...

Страница 442: ...stall service valve stem and service port protective caps 11 DISCHARGING THE SYSTEM Install gauge set manifold Tool C 3354 Using Tool C 3361 be sure both discharge and suction service valves are fully backseated counter clockwise Connect eight foot test hose to gauge set manifold center fitting Insert free end of eight foot hose into exhaust suction sys tem and turn exhaust blower on NOTE Expellin...

Страница 443: ...his can be illustrated by say ing that one drop of water in one million drops of water is one part per million I t can also be further illustrated by stating that one drop of water raises the moisture content of 25 pounds of Refrigerant 12 about 5 PPM or 1 pound of R 12 about 125 PPM In order to be certain the moisture content of a Refrigerant 12 Air Conditioning is kept out of the freeze up range...

Страница 444: ...embly as shown i n Figure 20 remove valve stem caps from suction and discharge service valves back seat and fully open counter clockwise both valves Remove caps from valve service ports and attach tubing and flare fitting as sembly to the valve service ports as shown in Figure 20 S U C T I O N S E R V I C E VALVE ON COMPRESSOR D I S C H A R G E S E R V I C E VALVE A T C O N D E N S E R r o w M O I...

Страница 445: ...E ON COMPRESSOR MOISTURE D E T E C T I N G E Y E WITH DRIER C A R T R I D G E Y DISCHARGE S E R V I C E VALVE AT CONDENSER Fig 21 Moisture Detecting Eye and Drier Cartridge Installation Schematic Drawing if the drier cartridge is allowed to remain in system long enough it will also partially re activate or dry out the system s saturated drier To remove the drier cartridge dry eye and tubing from c...

Страница 446: ...service valves one turn clockwise i f not previously done If discharge gauge hand fluctuates when en gine is running close discharge valve slowly counter clockwise until gauge hand steadies Use Charge through Drier Refer to Figure 21 and install drier as indicated Open valve tank one turn and loosen eight foot test hose at gauge manifold Leave con nection loose for about a second to purge air from...

Страница 447: ... fully charged with Refrigerant 12 and is dry Use a moisture detecting eye to check system for being dry Make a compressor ca pacity check and check all the other components for proper working condition Install thermometer in evaporator as out lined in Testing Thermal Switch Test Par agraph 17 Start engine and adjust engine speed to 1200 r p m Turn toggle switch to cool ing position Place control ...

Страница 448: ...14 6 48 44 6 81 85 5 114 144 2 12 15 8 49 45 6 82 87 0 115 146 3 14 17 1 50 46 6 83 88 5 116 148 4 16 18 3 51 47 8 84 90 1 117 151 2 18 19 7 52 48 7 85 91 7 118 152 7 20 21 0 53 49 8 86 93 2 119 154 9 21 21 7 54 50 9 87 94 8 120 157 1 22 22 4 55 52 0 88 96 4 121 159 3 23 23 1 56 53 1 89 98 0 122 161 5 24 23 8 57 55 4 90 99 6 123 163 8 25 24 6 58 56 6 91 101 3 124 166 1 26 25 3 59 57 1 92 103 0 125...

Страница 449: ...uit and the other lead to ground With toggle switch in Cold position and control lever in Off position test lamp should be off Move control lever to Cold position test lamp light dimly Move control lever to Warmer position test lamp should increase from dim to bright as resistance is decreased in rheostat Feel the water valve el ement Valve should go from warm to hot as control lever is moved to t...

Страница 450: ...he gas pressure from the compressor When the pressure in compressor is completely purged loosen do not remove the oil filler plug on side of com pressor just enough to allow gas pressure i f any in crankcase to escape When pressure has been released remove filler plug and use a clean dry plunger type dip stick i 8 inch round or similar rod to measure oil level The correct oil level is from 2 to 21...

Страница 451: ...eaks the fan belt for proper tension and make certain radiator contains sufficient coolant 23 REMOVAL OF HEATER CORE Remove heater core to evaporator housing at taching screws Carefully slide core assembly to left and remove core CAUTION Use care when removing core to avoid damag ing equalizer lines 24 REPLACEMENT OF RECEIVER STRAINER DRIER Fig 26 Wherever the receiver strainer drier unit is plugg...

Страница 452: ...e Never replace a damaged fusible plug with a pipe plug Evacuate system as outlined in Paragraph 12 Charge system with three pounds of re frigerant as outlined i n Paragraph 16 26 REMOVAL AND INSTALLATION OF EXPANSION VALVE a Removal Disconnect the inch and y inch line flare fittings NOTE t Use two flare wrenches to loosen or tighten fittings Remove the valve control bulb CAUTION Cap or plug open ...

Страница 453: ...han 53 psi If expansion valve successfully passes these tests it may be considered to have the proper super heat setting a proper pressure limit valve the rated capacity and that it has not lost its thermal charge The valve should there fore give satisfactory performance I f expan sion valve fails to pass either test No 4 or No 5 it should be rejected d Installation Reinstall expansion valve contr...

Страница 454: ... gauge hand valve VALVE PLATE AMD HEAD REMOVING LIP CYLINDER HEAD CYLINDER HEAD PILOT STUDS fQOD VALVE PLATE ASSEMBLY k f VALVE PLATE ASSEM mm mm rY DER AD G A ET VALVE PLATE GASKET 57x683 Fig 30 Replacing Head Gasket 57x682 Remove compressor cylinder head bolts and tap the head off with a brass drift or plastic hammer NOTE Use tab Fig 29 located at side of cylinder head to tap off head I f when l...

Страница 455: ...roken the coil cannot be re at tached DRIVE PLATE AND FACING ASSEMBLY Fig 31 Magnetic Clutch Disassembled View AIR GAP AJK V3Ar 025 TO 035 INCH 54x605 Fig 32 Air G a p Adjustment a Testing Electro Magnet Current Draw To test the coil for a short or open circuit con nect an ammeter 0 10 Ampere Scale in se ries with a fully charged 12 volt battery and the insulated brush lead The current draw at 12 ...

Страница 456: ...OMETER CLIPS C 3421 FLARE NUT WRENCHES 53x240S CAPACITY TEST CAP TOOL SP 2922 FLARE REFACING TOOL C 3367 FREON CYLINDER ADAPTER C 3420 THERMOMETER SET TOOL C 3356 FREON WEIGHING SCALE C 3429 Fig 33 Special Heater Air Conditioning Tools MyMopar com ...

Страница 457: ...replace c Test switch with voltmeter or jump wire Replace faulty switch d Test circuit with voltmeter for voltage drop Clean and tighten all loose connections 31 BLOWERS AND COMPRESSOR OPERATING NO COOLING a Check for low refrigerant Recheck sys tem after testing and repairing all leaks b Test for moisture with dry eye c Test compressor capacity d Test for restriction in strainer drier as outlined...

Страница 458: ...w i t h refrigerant as outlined i n Paragraph 16 c Wash out condenser w i t h w a r m water and apply compressed air from side next to engine 35 LOW SUCTION PRESSURE HEAD PRESSURE O 1 a Test for moisture b Test for restricted receiver strainer c Test super heat 38 TESTING FOR LEAKS WITH LEAK DETECTOR For Diagnosis Where a system has been found to be low on refrigerant or following repairs on the s...

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