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Dodge Charger 1967, Руководство по обслуживанию

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MyMopar.com

Содержание Charger 1967

Страница 1: ...MyMopar com...

Страница 2: ...MyMopar com...

Страница 3: ...Plant A 170 Cu In G 383 Cu In Std 1 Lynch Road 8 225 Cu In H 383 Cu In H P 2 Hamtrarnck C Spec 6cyl J 426 Cu In HemiLLos Angeles D 273 Cu In Std Kdd0 Cu In Std 7 St Louis E 273 Cu In H P L A 0 Cu In H...

Страница 4: ...0 INTRODUCTION AND GENERAL INFORMATION 3 f DODGE DART 2 DOOR SEDAN A DODGE DART 4 DOOR SEDAN DODGE DART 270 2 DOOR HARDTOP NP409 MyMopar com...

Страница 5: ...4 INTRODUCTION AND GENERAL INFORMATION 0 DODGE DART 270 4 DOOR SE DODGE CORONET FRONT VIEW DODGE CORONET REAR VIEW W NP410 MyMopar com...

Страница 6: ...0 INTRODUCTION AND GENERAL INFORMATION 5 DODGE CORONET 2 DOOR HARD TOP DODGE CORONET 440 STATION WAGON DODGECHARGER FRONT VIEW DODGE CHARGER REAR VIEW NP 558 MyMopar com...

Страница 7: ...erval basis Vehicles operated under conditions not classified as normal service for passenger cars such as in trailer Page HOOD LOCK RELEASE MECHANISM AND SAFETY CATCH 24 HYDRAULIC BRAKE SYSTEM 9 LUBR...

Страница 8: ...oor Mounted Manual Transmission Con trols If necessary use light engine oil Body Mechonisms See Body Maintenance Section See Crankcase Ventilation System Servicing TIRE PRESSURES Shown on decal on bod...

Страница 9: ...y 2 months Engine Oil Dipstick When refueling check engine oil level Fuel Filter Replace every 2 years or 24 000 miles whichever occurs first Carburetor Air Cleaner Paper Element Type Clean element ev...

Страница 10: ...0 4 LUBRICATION AND MAINTENANCE 0 Every 6 Months LUBRICATION AND MAINTENANCE SERVICES SERVICE SERVlCE INTERVAL Replace linings if necessary MyMopar com...

Страница 11: ...ONT WHEELS 4 REAR WHEELS NNl9lA Fig 34upport Locations for Frame Contact Hoisting Dart Models PAD POSITION WITHIN THESE LIMITS SATISFACTORY ALL MODELS 116 5 FRONT WHEELS REAR WHEELS N N l 9 2 A Fig 4...

Страница 12: ...cant at the factory Relubrication is required every 3 years or 36 000miles whichever occurs first The ball joints however should be inspected every six months or whenever vehicle is serviced for other...

Страница 13: ...stalled in the rear axle at time of assembly is a high quality product and regularly scheduled changes of the lubricant are not recom mended in vehicles where operation is classified as normal passeng...

Страница 14: ...brakes on all models equipped with drum brakes except for some police cars and high perform ance models are equipped with a self adjusting mech anism which makes it unnecessary to perform major brake...

Страница 15: ...time of major brake service The bushings located on the brake pedal pivot on all models and on the lower linkage pivots on Coronet models equipped with power brakes should be removed thoroughly clean...

Страница 16: ...se anti freeze products should not be used because of their low boiling points Refill cooling system with water and a suitable high quality permanent type anti freeze in sufficient quantity to provide...

Страница 17: ...Refer to Electrical Sys tem Group 8 for adjusting procedures WINDSHIELD WIPER BLADES Long exposure to heat and road splash tend to harden rubber wiper blades thus destroying their efficiency When bla...

Страница 18: ...l A prod uct suitable for this purpose is available under Part Number 1879406 Engine Oil Supplement FREQUENCY OF OIL CHANGES The engine oil should be changed every three 3 months or 4 000 miles whiche...

Страница 19: ...be followed The Standard Ventilation System Fig 21 consists of a ventilator valve mounted on the right hand cylinder head cover a carburetor with drilled pas sages in the throttle body a hose connecti...

Страница 20: ...specialvacuum control valve Servicing Procedures Periodic servicing of the crankcase ventilation sys tem is required to maintain good engine performance and prevent malfunction of the system because...

Страница 21: ...s Use a Chrysler Corporation filter element or equiva lent for replacement Remove carburetor Hand turn a 1 4 inch drill through the passages to dislodge solid particles Fig 27 Oil Filler Breather Cap...

Страница 22: ...y event replace filter element once every year Use a Chrysler Corporation filter element or equivalent for re placement If vehicle is used extensively for short trips with frequent idling these servic...

Страница 23: ...eader Heat Control Valve 426 Hem Engine 0 63x372 Fig 32 Carburefor Air Cleuner 64yl Engines 28 29 30 or 31 Apply solvent when manifold is COOL Allow solvent to soaka few minutes then work valve shaft...

Страница 24: ...e shelf discard old oil and thoroughly clean the air cleaner In any event the cleaner should be serviced at least once a year To clean remove cover and filter element Wash element thoroughly in kerose...

Страница 25: ...hose used on vehicles equipped with the 426 Hemi or 440 cubic inch engines disassemble joints as outlined under Propeller Shaft and Universal Joints Group 16 Clean and inspect all parts for service ab...

Страница 26: ...ricant level Lubricant should cover worm gear If lubricant is below prescribed level replenish I Fig 44 Manual Steering Gear Filler Plug with Multi Purpose Gear Oil SAE 90 as defined by MIGL2105B T h...

Страница 27: ...ce for passenger cars The fluid level however should be checked every six months and determined that it is at the bottom of the filler plug hole Fig 47 If lubricant is below specified level replenish...

Страница 28: ...t level should be at the FULL mark or slightly below but never above the FULL mark Fig 50 to avoid foaming of the fluid Fluid should be added or extracted depending upon the reading to restore level a...

Страница 29: ...The condition and quantity of the lubricant in r l Fig 5I Front Wheel BeorringLubricotion Fig 52 Front Wheel BearingAdjustment the front wheel bearings on cars equipped with either drum or disc type b...

Страница 30: ...T FRONT RIGHT FRONT NP158 Fig 54 Tire Rotation Diagram4 Tires Fig 55 HOOd Lock Lubrication Dart and Coronet except Charger Models housing at speedometer head Remove shaft and clean it thoroughly Apply...

Страница 31: ...1 A suitable lubricant is available under Part Number 1064768 Where Door Ease Lubricant is specified use a stainless wax type lubricant Such a lubricant is availableunder Part Number 1064769 Lock Cyl...

Страница 32: ...MyMopar com...

Страница 33: ...MyMopar com...

Страница 34: ...thin film of the prescribed lubricant on both ends of the accelerator shaft where it turns in the bracket and where it turns in the bracket mounted anti rattle spring Fig 69 Also apply a f i l mof the...

Страница 35: ...the prescribed lubricant to the accelerator cable anchor end and in the pocket in the accelerator shaft lever Fig 7 1 Be sure plug is in place in lever Coronet Models 273 3 18Cu In Engines On models...

Страница 36: ...erating characteristics and some because lubri cants will cause component failures In any event rubber bushings should not be lubricated not only because lubricants will cause rubber to fail but also...

Страница 37: ...0 LUBRICATION AND MAINTENANCE 0 31 NP403 Fig 72 Throttle Linkage krbricdon Coronet 273 3 18 Cu In Engines MyMopar com...

Страница 38: ...0 32 LUBRICATION AND MAINTENANCE 0 MyMopar com...

Страница 39: ...housing SERVICE PROCEDURES Removal Coronet Models Cluster Removal Group 8 crewin reset knob and remove knob of cluster housing and carefully remove clock plate Raise plate far enough to reach under a...

Страница 40: ...t the heater core The amount of blend is determined by the setting of the temper ature lever on the instrument panel Direction of the blended air is controlled by the Heat Defrost lever on the instrum...

Страница 41: ...ER MOTOR NOT OPERATING a Disengaged cable on temperature a Connect or replacecable b Thermostatstuck in closed position a Blownfuse b Faulty electrical connection c Faulty blower switch d Faulty motor...

Страница 42: ...g tool and test the heater operation To adjust the Temp control cable remove the cable clip at the temperature control door Place the temperature control lever to the extreme left position Rotate the...

Страница 43: ...switch wire connect and install gear selector light bulb c Install gear selector bezel by engaging front tabs under console housing lip and securing with the two metal screws at storage compartment e...

Страница 44: ...l 1 Remove heater as outlined in Heater Remov 2 Disconnect wiring from blower motor to the 3 Remove motor cooler tube 4 Remove heater backplate assembly from heater 5 Remove fan from motor shaft 6 Re...

Страница 45: ...und heater motor mount 3 Remove spring clips holding spacers and heater Fig 1 I Heater Hose Connections Dart 273 Cu In Engines 4 Remove fan from heater motor 5 Remove mounting support plate from heate...

Страница 46: ...radios offered as optional equipment are fully transistorized AM models The following are the radio model application used in each of the vehicles Radio Model Dart All Models 237 Coronet A II ModeIs...

Страница 47: ...horized radio service station for repair SERVICE PROCEDURES Antenna Trimming All radios are trimmed at the factory and should require no further trimmer adjustment However whenever a radio is being in...

Страница 48: ...a mast Tip lower adapter on mast 2 Feeding antenna lead through mounting hole in fender insert antenna assembly into mounting hole in fender from top of fender 3 Index tangs of spacer in lower adapter...

Страница 49: ...able 1 Holding radio under instrument panel connect 2 Rotate radio into position under panel till control shafts protrude through panel openings 3 Install mounting nuts and control knobs 4 From under...

Страница 50: ...nect antenna cable and radio feed wires 5 Lift radio out through instrument cluster open ing Installation 1 Insert radio through instrument cluster open ing and position radio mounting stud on support...

Страница 51: ...mounting studs through glove box opening The speaker terminals should face glove box 2 Hold speaker with one hand and install the four retaining nuts with the other 3 From under instrument panel posit...

Страница 52: ...t ball joints are equipped with a Knock Off type lubrication fitting After lubrica tion knock off that portion of the fitting over which the lubrication gun was installed A ball check is in stalled in...

Страница 53: ...r not adjusted properly Idler arm binding g Adjust steering gear h Free up idler arm Worn or loose front wheel bearings a Adjust or replace wheel bearings as Incorrectsteering gear adjustment b Adjust...

Страница 54: ...cannot be brought within the recommended specifi cations Fig 1 Do not attempt to modify any suspension or rteer ing componentsby heatingor bending All adjustments should be made in the following sequ...

Страница 55: ...t Caster Camber and Toe Grasp bumpers at center rear bumper first and jounce up and down several times Always release bumpers on the down cycle after jouncing both rear and front ends an equal number...

Страница 56: ...rsion bars are not interchangeable side for side The bars are marked either right or left by an R or an L stamped on one end of the bar Removal 1 Removeupper control arm rebound bumper 2 If vehicle is...

Страница 57: ...taching steering knuckle to brake support 7 Remove two lower bolts attaching steering arm to steering knuckle and remove steering knuckle Support the brake assembly during this operation to prevent da...

Страница 58: ...install washer and nut Tighten nut 45 foot pounds maxi mum and install cotter pin 2 Place center link over idler arm and steering gear arm studs and tighten nuts 40 foot pounds In Fig 7 Steering Link...

Страница 59: ...eparately pounds 3 insulator and sway bar Using a screwdriver or pinch bar between strut and sway bar if necessary apply pressure and install uppr rubber insulator retainer and nut tighten nuts 100inc...

Страница 60: ...an arbor press with torsion bar hex opening up and with a support under outer edge of control arm 5 Place a brass drift into hex opening and press shaft out of lower control arm The bushing inner she...

Страница 61: ...er ball joints are used on all models 1 Remove upper control arm rebound bumper 2 Raise vehicle so front suspension is in full re bound Remove all load from torsion bar by turning adjusting bolt count...

Страница 62: ...l Joint Stud Dart UPPER CONTROL ARM Figs 15 161 Removal and Disassembly 1 Place a jack under lower control a r m as close to wheel as possible and raise vehicle until wheel clears floor 2 Remove wheel...

Страница 63: ...e oil or grease to aid in instal lation 1 Position flange end of new bushing in Tool C 3710 support control arm squarely and press bush ings into control arm from outside until tapered portion of bush...

Страница 64: ...hose of the control arm square ly Balloon type seals should always be replaced once they havebeen removed 1 Screw ball joint squarely into control arm as far as possible by hand 2 Using Tool C 3560 To...

Страница 65: ...o n t Lower Upper Steering Gear Mounting Bolts Steering Knuckle Bolt Nuts Foot Inch Pounds 125 Min 100 100 55 130 150 85 200 40 45 50 25 50 REFERENCE Lower Coronet Dart Upper Front Rear Frame Bracket...

Страница 66: ...am age Clean out and refill axle to re quired capacity with proper lubricant See Lubrication section c Excessivespinningof onewheel c Replace scored gears Inspect all gears pinion bores and shaft for...

Страница 67: ...s d Check gears for excessive wear or scoring Replace as necessary e Insufficient ring gear to pinion clear e Readjust ring gear and pinion back ance lash and check gears for possible scoring REAR AXL...

Страница 68: ...t bearing journal and thereby weakens this area 6 Position axle shaft bearing retaining collar on a heavy vise or anvil and using a chisel cut deep grooves into retaining collar at 90 intervals Fig 3...

Страница 69: ...rosion 4 Install a foam gasket on studs of axle housing using tool c 3734 Fig 7 Fig CRernaving Axle Shaft Bearing 1 1 NK365 Fig 5 Tool C 3725 lnstcrlld on Axle Flange C 3725 Fig 6 lnrtalling R w r Axl...

Страница 70: ...housing and differential case and drive gear assembly 3 Measure for differential side play Position a screwdriver or pinch bar between left side of axle housing and differential case flange then usin...

Страница 71: ...nd preload shims must be kept with respective bearing cones Do not remove spreader tool 13 Remove drive pinion and rear bearing assem NY1034 Fig 12 Spreading Rear Axle Housing NK367 Fig 13 Loosening D...

Страница 72: ...remove any imperfections polish with 600 crocus cloth without reducing diameter of axle shaft oil seal surface 5 If axle shaft bearings collars and retainers are removed from shafts they are unfit fo...

Страница 73: ...n tool nut and 5 BORE ARBOR COMPRESSION CENTRALIZING REAR SPACER N f1028 Fig I7 Pinion Swing Ouuge Tool C 37I 5 SPACER SELECTIVE NY1027 Fig I8 Measuring Housing For Pinion Shim Thickness re tighten to...

Страница 74: ...vail able in one thousandths of an inch increments from 074 to lo6 inch TOOL NY1024 Fig 2 Installing CompanionFlange 5 When front pinion bearing preload is correct remove pinion nut washer and flange...

Страница 75: ...indicator stem slightly against opposite side of axle housing 10 Tighten spreader tool nut sufficientlyto obtain 012 to 015 movement of dial indicator to permit installation of differential case assem...

Страница 76: ...2 Install spring U bolts and tighten nuts to 45 foot pounds and install shock absorbers on spring plate studs 3 Connect hand brake cable 4 Install propeller shaft and tighten rear clamp 5 Connect bra...

Страница 77: ...IBILITY OF EARLY AXLE FAILURE RESULTING FROM CON TAMINATION OF THE LUBRICANT BY WATER DRAWN INTO THE VENT SERVICE PROCEDURES AXLE SHAFTS AND BEARINGS Removal 1 With wheels removed remove clips holding...

Страница 78: ...orch The use of a torch in the removal of the axle shaft collars or bearings is an unsafe practice because heat is fed NK57 Fig 5 Installing Axle Shaft Seal Fig 6 Notching Bearing Retainer Collar into...

Страница 79: ...he seal journal when pressing o f f the bearing cone as it was not designed for this purpose 6 To avoid scuffing seal journal when bearing cone is being removed it should be protected by single wrap o...

Страница 80: ...e gears 7 Repeat step 4 AXLE SHAFT END PLAY CAUTION When setting axle shaft end play both rear wheels must be off the ground otherwise a false W end play setting will occur 1 Using a dial indicator mo...

Страница 81: ...assembly 1 Mount carrier in Stand DD 1014and attach dial indicator Tool C 430 or Tool C 3339 to differential carrier flange in a position so pointer of indicator squarely contacts back face of ring ge...

Страница 82: ...sassembly recheck the case as follows Install differential case and respective bearing cups in carrier 4 Install bearing caps cap bolts and bearing ad justers Tighten bearing cap bolts down tightly an...

Страница 83: ...nd hammer remove dif ferential pinion shaft and axle drive shaft thrust block 11 Rotate differential side gears until each dif ferential pinion appears at large opening of case Remove each pinion and...

Страница 84: ...ble in matched sets only 12 Inspect companion flange for cracks worn splines pitted rough or corroded oil seal contacting surface Repair or replace companion flange as necessary 13 Inspect drive pinio...

Страница 85: ...OSSBORE TUBE GAUGE BLOCK SP 528 WRENCH 1 F r R F W KPl3A Fig 25 Seating BearingCups inCarrier Housing flange holding T o o l C 3281 and tighten nut Fig 25 allowing tool to rotate as nut is being tight...

Страница 86: ...eload Preload shims are available in two thousandths of an inch increments from 014 026 inch After correct pinion bearing preload is set DO NOT REMOVE THE TOOL Depth of Mesh 1 Reverse carrier in stand...

Страница 87: ...e tool and bearings out of carrier 7 Remove shims spacer tool sleeve and rear bearing cone from toolmain screw 8 With stem of pinion facing up install correct shim on pinion stem Shims are chamfered o...

Страница 88: ...and compression sleeve Lower tool down and out of carrier 11 Remove front pinion bearing cone from car rier 12 Add rear pinion bearing shim you selected on tool between spacer SP 2921and rear pinion...

Страница 89: ...f the bearings are being replaced place the new bearing cup in position in the carrier and drive the cups in place with a suitable drift After properly positioning the bearing cups in the carrier asse...

Страница 90: ...d attaching screw Tighten to 15 20foot pounds GEAR TOOTH CONTACT PATTERN The gear tooth contact pattern Fig 33 will disclose whether the correct rear pinion bearing mounting s h i m has been installed...

Страница 91: ...the axle housing Tighten the carrier to axle hous ing nuts to 45 foot pounds 3 Refer to Installation of Rear Axle Shaft when installing and setting axle shaft end play 4 Install rear universal joint o...

Страница 92: ...number ring gear teeth by the smaller number drive pin ion the axle ratio can be determined The drive pinion is supported by two preloaded taper roller bearings The rear pinion bearing cone is a tigh...

Страница 93: ...rear axle assembly for overhaul or repair proceed as follows 1 Raise rear of vehicle until rear wheel clear floor Support body at front of rear springs 2 Block brake pedal in the up position using a w...

Страница 94: ...for easy removal Fig 5 Pry up differential case and ring gear as straight up as possible using leverage against differential case and carrier to prevent damage Keep respective bearing cups with bearin...

Страница 95: ...the exception of bearing cones dry with compressed air To clean axle housing tubes insert a stiff wire into tube attach a clean cloth to wire at center section and withdraw from center outward 2 A l...

Страница 96: ...ential case without shims small end away from drive gear using Tool 2 4025 9 3 4 Axle or Tool C 4028 9 1 4 Axle Fig 9 An arbor press may be used in conjunction with installing Tool CAUTION Never exert...

Страница 97: ...the nominal distance between the front of the pinion and the center line of the carrier For example if a pinion marked 2 was originally installed with a shim pack 035 inch and the new pinion is marke...

Страница 98: ...n sions 3 125 which will be the corrected dimension of 3 127 The 9 1 4 axle 2 688 dimension will be cor rected to 2 690 11 If pinion setting is within 001 inch to 003 inch the pinion position can be a...

Страница 99: ...ngs in a similar manner Shims are available in 003 005 and 010 inch thickness NP414 Fig I7 Determinlng Shim Pack Thicknessfor Drive Pinion Depth of Mesh 11 Remove the tool arbor and tool from axle hou...

Страница 100: ...n the contact point against back face of ring gear Move the differ ential and ring gear assembly tight against the drive pinion set the dial indicator on 0 Move the differen tial and ring gear assembl...

Страница 101: ...d roll over or score resulting in excessive gear lash and noise This condition is corrected by install ing a thicker shim behind the rear pinion bearing DRIVE COAST q z 1 m CORRECT ADJUSTMENT Center C...

Страница 102: ...ure Grip Differentialand Sure Grip Differential 39 Carrier Assembly 42 Sure Grip Differential Identification 37 GENERAL INFORMATION The sure gri differential Figs 1 2 3 and 4 is similar to the convent...

Страница 103: ...ce construction has attaching bolts The con ventional type differential case one piece construe tion has a dome Eke shape with no case cap attach LE DRIVE PINION AXLE DRIVE GEAR XLE DRIVE PINION IFFER...

Страница 104: ...r level with new Sure Grip Lubricant Part Number 2585318 or equivalent Reinstall fill plug and tighten 7 Lower car on hoist and return to customer to drive and evaluate for approximately 100 miles to...

Страница 105: ...C l m hPlates Cap Side SIDE RETP GEAR LINE GEAR IAFl SPACER Fig 9 Removing Side Gear Cap Side PINION GEARS K R 723 AXLE THRUST SPACER Fig IO Removing or Installing Pinion Shafts and Gears EAR S I 1 RI...

Страница 106: ...l the differential case bolts and turn in a few threads IMPORTANT Insert the axle shafts from the vehicle to align the splines Make sure the axle shafts engage the side gear splines 7 With shafts inst...

Страница 107: ...cial multi purpose gear lubricant intended for use in limited slip differentials Such a lubricant is available under Part Number 2585318 Special Sure Grip Lubri cant AnticipatedTemperatureRange Viscos...

Страница 108: ...ed slip differentials Such a lubricant is available under Part No 2585318 Special Sure Grip Lubricant 9 114 and 9 314 Axles 9 250 and 9 750 TYPE Sem Floatng Hypoid Type Taper Roller Pinion bearing dra...

Страница 109: ...le Housing Bolt Nuts Axle Shaft Retainer Nuts Propeller Shaft Bolts Rear Spring Clip U Bolt Nuts Wheel Stud Nuts Shock Absorber Stud Nuts Lower Differential Bearing Cap Bolts Differential Case Half Re...

Страница 110: ...hten all brake fittings or replace brake line f Leakingor worn mastercylinder f Recondition or replace master cyl inder and bleed hydrauIic system g Excessivelyworn brake lining a Air in hydraulic sys...

Страница 111: ...justment d Clean pack and adjust wheel bear brakes ings a Incorrect lining a Replace lining b Distorted or out of round brake b Grind or replacedrums c Overheated brake drums c Inspect for draggingbra...

Страница 112: ...r adjuster servicing BLEEDING THE BRAKE SYSTEM Clean all dirt and foreign material from the cover of the master cylinder to prevent any dirt from falling into the master cylinder reservoir when the co...

Страница 113: ...d and the tube nuts and connections should be properly made and tightened Double wall steel tubing should always be used to insure superior fatigue life Care should be taken when replacing brake tubin...

Страница 114: ...ng Recommendations 7 Brake Shoe Removal SERVICE PROCEDURES BRAKE DRUM REMOVAL Removing the Front Brake Drums To aid in the brake drum removal loosen the brake star adjusting wheel 1 With vehicle on a...

Страница 115: ...hydraulic sys tem during brake shoe removal I R NN294 Fig 3 Removing or lnstulling BrakeShoe Return Springs Left Front Removingthe FrontBrake Shoes With the vehicle elevated on a hoist jack or suit ab...

Страница 116: ...in cylinders CLEANING AND INSPECTION Wipe or brush clean dry the metal portions of the brake shoes Examine the lining contact pattern to determine if the shoes are bent The lining should show contact...

Страница 117: ...over guide and engage hook of cable into adjusting lever I Fig 9 lnstalling Brake Shoes Left Row lnsfalling Front Brake Drums drum and adjust wheel bearing to proper preload Procedures at front of th...

Страница 118: ...suitable stands remove rear plug from brake adjusting accesshole 2 Insert a thin screw driver into brake adjusting hole and push adjusting lever away from star adjust ing wheel Care should be taken n...

Страница 119: ...5 remove brake shoe return springs Fig 3 Note how secondary spring overlaps primary spring Fig 1 2 Remove brake shoe retainer spring and nails Fig 4 3 Slide eye of automatic adjuster cable off anchor...

Страница 120: ...toe Shoes showing contact only on one side should be replaced Shoes having sufficient lining but lack of contact at toe and heel should be measured for proper grind Clean the support using a suitable...

Страница 121: ...f support for nicks or burrs Apply a thin coat of lubricant to support platforms Shoecontact area 2 Attach parking brake lever to back side of secondary shoe Fig 9 3 Place secondary and a primary shoe...

Страница 122: ...power brakes with one exception the master cylinder for power brakes doesnot include the push rod The disc brake master cylinder is different than the standard drum brake master cylinder and is cov er...

Страница 123: ...New cups must be installed at reassembly if air pressureis used COVER RETAINING BOLT PRESSURE VALVE COVER CLAMP COVER GASKET Fig 3 Removing or lnstallhg ResidualPressure Valves 4 Remove front piston...

Страница 124: ...ing Fig 4 5 Install piston spring piston cup retainer piston and cups into bore of master cylinder Fig 5 Keep well lubricatedwith brake fluid Be sure the lip of cups enter bore evenly in order not to...

Страница 125: ...master cylinder compensates at both ports This can be done by applying the pedal lightly with the engine running power brakes and observing for a gyser of fluid squirting up in the reservoirs This ma...

Страница 126: ...be cleaned with crocus cloth using a circular motion However cylinders that have deep scratches or scoring may be honed using Tool C 3080 providing the diameter of the cyl inder bore is not increased...

Страница 127: ...nect brake tube to wheel cylinder and tighten to 95 inch pounds rear wheels or connect brake hose to wheel cylinder front wheels and tighten to 25 foot pounds before connecting brake hose to frame bra...

Страница 128: ...19 Installing the Rear Parking Brake Cable 20 GENERAL INFORMATION The rear wheel service brakes also act as parking brakes The brake shoes are mechanically operated by a lever and strut connected to...

Страница 129: ...p or on a suitable hoist remove rear wheels 2 Disconnect brake cable from equalizer 3 Remove retaining clip from brake cable brack 4 Remove brake drum from rear axle 5 Removebrake shoe return springs...

Страница 130: ...of cable equalizer bar Refer to Figs 1 or 2 housing and clip down out of pedal assembly bracket 7 Remove cable to floor pan clip and work cable and housing assembly up through floor pan INSTALLING TH...

Страница 131: ...eck valve and hy draulic tubes from the master cylinder to the wheel units SERVICE PROCEDURES REMOVING THE POWER BRAKE 1 With engine turned off apply brakes several times to balance the internal press...

Страница 132: ...mble brack ets from rear cover 7 Remove rubber boot from valve operating rod 8 Scribe a line across front cover clamp band and rear cover Fig 5 9 Remove clamp band screw and nut and disas semble clamp...

Страница 133: ...390 Fig 10 Removing Bellows from Control Hub RUBBER REACTION CONE SEGMENTS 1 PUSH ROD 1 VALVE OPERATING ROD I Fig 9 Removing Bellows Clamp PLASTIC PUSH ROD GUIDE NP391 Fig 11 Push Rod Assembly Fig 12...

Страница 134: ...essary to file burr from protruding end of plunger before it can be separated from control hub 2 Compress spring of plunger assembly toward rubber valve and remove spring retainer Fig 18 3 Separate sp...

Страница 135: ...the two round holes in valve indexes with two raised R U B B E R 0 RING 1 PLUNGER R U B B E R Fig 20 Control Housing and Plunger Assembly projections on hub Fig 20 3 Assemble washer into hub so that f...

Страница 136: ...tic DIAPHRAC CENTER PLATE z NP398 Fig 22 Installing Center Plate on Diaphragm LEVER ASSEMB USH ROD ASSEMBLY CONTROL HUB NP399 Fig 23 Lever Assembly and Push Rod Installed push rod guide on push rod In...

Страница 137: ...ake pedal link with brake pedal linkage Install nut and tighten to 30foot pounds 4 Connect vacuum hose to unit and connect hy draulic brake tubes Tighten securely 5 Refill master cylinder and bleed br...

Страница 138: ...washers 6 Remove power brake master cylinder and linkage from vehicle and place on a service bench for further disassembly TANDEM MASTER CYLINDER DRUM BRAKES POWER BRA KE ASSEMBLY I DISASSEMBLING THE...

Страница 139: ...des cone re tainer and reaction cone from push rod Fig 1 0 15 Using Tool C 3984 turn control hub clockwise while holding power piston Fig 1 1 Separate control hub tail stock and 0 ring from diaphragm...

Страница 140: ...ing dents or nicks small imperfections can be smoothed out using crocus cloth Replace all parts that are badly scored nicked or damaged At reassembly coat all rubber parts including the diaphragm with...

Страница 141: ...and seat Using Tool C 3984 turn control hub counterclockwise to lock in place Fig 16 8 Install lever assembly in control hub with rubber segments toward control hub 9 Slide reaction cone over push ro...

Страница 142: ...ter cover then snap cover and filter on metal hub with filter between Fig 3 18 Assemble cover filter and retainer assembly to unit with metal retainer against cover Filter in CONTROL HUB SPECIAL TOOL...

Страница 143: ...and cover together The basic elements of the vacuum unit are as fol lows A mechanically actuated control valve integral with the vacuum power diaphragms controls the de gree of power brake application...

Страница 144: ...cuum hose to check valve 5 Attach brake lines to master cylinder 5 Withdraw brake unit and master cylinder as 6 Fill and bleed master cylinder and bleed brakes 7 Inspect adjustment of stop light switc...

Страница 145: ...brake lines to master cylinder 5 Withdraw brake unit and master cylinder as 6 Fill and bleed master cylinder and bleed brakes 7 Inspect adjustment of stop light switch 6 Remove four master cylinder a...

Страница 146: ...om contacting the inboard side of the disc and lining surfaces Fig 4 The wheel itself provides protection for the outboard surface of the disc Braking action begins immediately upon applica tion of th...

Страница 147: ...eplacement of the shoe and lining assemblies are required Fig 3 The tabs located on the shoes create an audible metallic scraping noise from the brake by metal to metal contact on the braking disc Thi...

Страница 148: ...c Ordinarily the clearance should be 003 to 006 inch However if the vehicle was stopped by a brake application just prior to checking the clearance it is considered normal for the brakes to drag sligh...

Страница 149: ...f braking disc Excessive front bearing clearance Rear brake drums distorted by im proper tightening of nuts a Check disc for runout with dial indi b Loosen and retorque wheel nuts to c Check disc for...

Страница 150: ...unction a Air in hydraulic system or improper a Bleed system b Leak in system or caliper b Check for leak and repair as required c Pistons pushed back in cylinder bores c Reposition brake shoe and lin...

Страница 151: ...tained and shoe and lining have been properly seated 6 Install wheel and tire Tighten wheel stud nuts to 55 foot pounds Install wheel cover 7 Check and refill master cylinder reservoir with brake flui...

Страница 152: ...g 10 Re move remaining dust boots in same manner 6 Using Tool C 3999 remove each of pistons Fig 11 Care must be used so as not to scratch burr or otherwise damage piston on outside diameter To do so e...

Страница 153: ...ing Piston Bores proceed as follows 1 Clamp inner caliper half in a vise with protec tor jaws by mounting lugs 2 Dip new piston seals in clean brake fluid and install in caliper grooves The seal shoul...

Страница 154: ...ure and check for fluid tightness under maximum pedal pressures Recheck master cylinder reservoir level Check and be sure that lower shock absorber mounting bolt has been installed from rear and nut t...

Страница 155: ...uts in a star pattern to 30 foot pounds then to 55 foot pounds Install wheel cover Fig 16 Disc Splash Shield Mounting 6 Removejackstands or lower hoist BLEEDING THE DISC BRAKE The disc brake hydraulic...

Страница 156: ...The brake disc is made from high grade cast iron and has a series of air vent louvres to pro vide for cooling of the disc The splash shield that is bolted to the spindle is used to prevent road con ta...

Страница 157: ...ions The valve regulates the hydraulic pressure applied to the rear wheel cylinders thus limiting rear braking ac tion when high pressures are required at the front brakes In this manner premature rea...

Страница 158: ...0 BE NN998 MyMopar com...

Страница 159: ...tacts the brak ing disc at a point approximately one 1 inch from the outer edge Fig 18 Rotate the disc and check the indicator reading The maximum total indicator reading on the gauge should not excee...

Страница 160: ...e pressure Unbalanced c Inflate tires to recommended pres d Distorted brake shoes e Front end out of alignment f Restricted hose or line f Check hoses and lines and correct as g Unmatched linings tons...

Страница 161: ...inder bore Install new pis ment SERVICE PROCEDURES BRAKE SHOE REMOVAL sembly oneat a time through bottom opening Removing the Lining Fig l proceedas follows To remove disc brake shoe and lining assemb...

Страница 162: ...y foreign material on brakes and to seat linings The vehicle may pull to one side or other if this is not done REMOWNG THE CALIPER Should it become necessary to remove caliper for 1 Raise car on hoist...

Страница 163: ...ng or pitting Bores that show light scratches or corrosion can usually be cleaned with crocus cloth However bores that have deep scratches or scoring may be honed using CALIPER NP59 Fig 9 Removing Pis...

Страница 164: ...sealing lip over groove evenly Using Tool C 4030 press down on tool forc ing boot sealing lip into caliper groove Fig 1 5 Remove tool Install remaining pistons in same man SPECIAL TOOL CALIPER I PISTO...

Страница 165: ...proceed as follows 1 Removedamaged stud using an arbor press 2 Install new stud in position and press into place INSTALLING THE BRAKING DISC AND HUB Removing Wheel Stud from Hub 1 Slide brake hub and...

Страница 166: ...4007 and T in brake line between master cylinder and proportioning valve and remaining Gauge and T at output end of proportioning valve and brake line Fig 19 Be sure all joints are fluid tight 2 Have...

Страница 167: ...s that attach master cylinder to cowl panel and or power brake unit if so equipped 4 Slide master cylinder straight out from cowl panel and or power brake unit if so equipped DISASSEMBLING THE MASTER...

Страница 168: ...OVER 1 GASKET clean shop towel or paper Assembling seals dry can ruin them 1 Carefully work piston cup on front end of front piston with the lip away from piston Fig 4 2 Carefully work second piston c...

Страница 169: ...cure with bail on vehicle as follows 6 Remove master cylinder from vise and install INSTALLING MASTER CYLINDER ON VEHICLE 1 Install master cylinder on vehicle aligning push rod with cowl panel opening...

Страница 170: ...d with the ignition key turned ON The same light will also illuminate should one of the two service brake systems fail when the brake pedal is applied To test the system turn the ignition key ON and a...

Страница 171: ...Asbestos 8 112 1 1 8112 1 1 9 114 12 1 8 12 118 9 114 3116 114 1 11 8 15116 1 KELSEY HAYES DISC BRAKE SPECIFICATIONS Type of Brake Fixed Caliper Disc Location Front Wheels Only Master Cylinder Reservo...

Страница 172: ...ield portioning Valve and Disc Assembly Nuts Foot Pounds 4560 70 to 80 17 inch pounds 100 inch pounds 7 9 85 inch pounds 55 BENDIX DISC BRAKE SPECIFICATIONS DISC BRAKE Type Fixed Caliper Disc Location...

Страница 173: ...Center Diameter 14x 51 2JK Special Mounting Stud Circle 4 1 2 5bolt REAR BRAKES Size 10x 2 1 2 inch 40 micro inches 816 OOOY 605 625 Length 5 294 5 299 0 3 0 Thickness Lining at any point or a minimu...

Страница 174: ...engine is 9 1 4 inches The standard clutch size on Coronet models is SLEE TER Page GENERAL INFORMATION 1 SERVICE DIAGNOSIS 3 SPECIFICAT10NS 9 STEAM CLEANING PRECAUTIONS 9 TIGHTENING REFERENCE 10 TORQ...

Страница 175: ...hes and 10 inches for Coronet models with 273cubic inch engine The special equipment clutch on Coronet models with the 273 cubic inch engine is 10 1 2inches The standard clutch size on Coronet models...

Страница 176: ...eplace disc assembly Replace clutch assembly Replace disc assembly Adjust release fork rod Replace clutch assembly Adjust release fork rod Replace disc assembly Replace clutch assembly Remove disc ass...

Страница 177: ...from clutch housing CAUTION Handle clutch and disc carefully to avoid contaminatingthe friction surfaces Cleaning and lnspection 1 Use compressed air to clean dust out of clutch housing Inspect for o...

Страница 178: ...plate friction area should be flat within 005 inch and free from discoloration burned areas cracks grooves or ridges 9 Inner ends of release levers should have a uni form wear pattern _ A n g a surfa...

Страница 179: ...stallation lation Burnishing Tool 1 Soak new bushing in engine oil prior to instal 2 Remove nut and cup from C 3181 Installing and 3 Place new bushing on tool shaft and drive bush ing flush with end o...

Страница 180: ...s in clutch housing and install the transmission as detailed in Transmission Installation Group 21 3 Adjust clutch linkage as detailed under Ad justing Clutch Pedal Free Play page 3 TORQUE SHAFT AND B...

Страница 181: ...l while noting dial indicator needle deflection Out of round of bore must not exceed 008inch maxi mum total indicator reading or 004 inch one half total indicator reading 3 Excess bore runout can be c...

Страница 182: ...housing bolts to 50 foot pounds and 3 8 inch bolts to 30 foot pounds 3 Install clutch release bearing fork linkage and transmission Adjust clutch linkage STEAM CLEANING PRECAUTIONS Since the clutch h...

Страница 183: ...an CLUTCH COVER Pressure Springs nurnber 9 9 9 12 12 Spring Color White 6 Black 3White 6White 9 White Pedal Free Play at fork end 5 32 5 132 5 132 5 132 5 32 3 Lavender 6No Paint 6Tan 3 No Paint CLUTC...

Страница 184: ...to the water coolant for normal corrosion protection Air condi tioned cars require year round protection with permanent type anti freeze with a minimum of 15 F protection for summer operation and addi...

Страница 185: ...ump impeller as on shaft sembIy g Restricted radiator core water pas g Flush the radiator thoroughly or rod sages out if necessary h Restrictedengine water jacket h Flush the engine cooling system tho...

Страница 186: ...fan shroud remove upper half before proceeding as above 2 If equipped with one piece plastic fan shroud remove shroud attaching screws Separate shroud from radiator Position shroud rearward on engine...

Страница 187: ...ngdownward 4 Remove the bolts attaching the water pump body to the housing Remove the water pump and dis card gasket 1 1 NK480A Fig 2 Torque Control Fan Drive 9 0 NP54l Fig 3 Thermal Control Fan Drive...

Страница 188: ...PUMP BODY WITH SHAFT AND BEARING IMPELLER SEPARATOR PLATE SCREW AND CARTRIDGE SEAL N Y242C Fig 5 170 225 Cubic lnchEngine Water Pump 4 With pump housing supported at hub end apply pressure against ou...

Страница 189: ...sing Be careful not to bottom out end of shaft as this may damage the balls and bearing races 5 While supporting the pump on impeller end of shaft press fan hub onto shaft so shaft extends 11 32 inch...

Страница 190: ...face out so shaft extends 11 32inch through fan hub 6 Support pump on fan hub end of shaft and posi tion new impeller on pump shaft blade portion up Using a tool that will press against the impeller i...

Страница 191: ...using Transmission Fluid AQ ATFSuffix A solder Radiator REVERSE FLUSHING THE COOLING SYSTEM Reverse flushing of the cooling system is the forc ing of water through the cooling system using air pressur...

Страница 192: ...ches below filler neck with water and rust resistor or water and anti freeze GASKET VENT V A L V E 6 4 x 186 Fig 12 Radiator Pressure Cap RADIATOR HOSES The hoses are removed and installed using hose...

Страница 193: ...it indicates a leak on the bank still in operation If the needle ceases to fluctuate the leak is in the bank from which combustion has been released 5 If the needle on the dial does not fluctuate rac...

Страница 194: ...ensions to the belts being careful not to damage the accessory A 1 2 inch square drive hinge handle can be used if the acces sory has a square hole Tighten the mounting bolts and test the deflection S...

Страница 195: ...1 W CAP Speed Manual Automatic 1 W 3 Speed Manual 4 Speed Manual A C Automatic 1 Wt A C and CAP 3 Speed Manual Speed Manual Automatic 1 W Trailer Tow Automatic 1W 273 2 BBI None None i 6 4 i h 17 4 1...

Страница 196: ...383 4 BBI None C A P AIC AJC and C A P Trailer Tow Speed Manual 4BBI only CSpeed Manual Automatic None None Yes N A YeS NIA 18 1W NIA 18 NIA 18W 18 4 7 NIA 7 NIA F 95 Solid 1 24l 4 38 10 16 16 17 N A...

Страница 197: ...41 318 118 i a r 1 81 i a 114 11yr 3 8 Single Belt t Any belt that has operated for a minimum of a half hour is consideredto be used Dual Belt TORQUE METHOD TORQUE FT LBS TO BE APPLIED TO COMPONENTS...

Страница 198: ...rolatum after tightening 12 If electrolyte level is low fill to recommended level with mineral freewater SPECIFIC GRAVITY TEST A hydrometer Tool 40 Bis used to measure specfic gravity of electrolyte i...

Страница 199: ...fic gravity is less than 1 220 bat tery should be recharged Make a high rate discharge test for capacity If battery cells test O K recharge and adjust gravity of all cells uniformly Test voltage regul...

Страница 200: ...void a startingfailure D If ANY cell readings are in the RECHARGE AND RETEST section of the TOP SCALE and the balance of the readings are within the first four scale divisions the battery is too low t...

Страница 201: ...g is below 1 220the battery should be slow charged until fully charged in order to secure proper test results Test Procedure 1 Turn control knob of Battery Starter Tester to OFF position 2 Turn Voltme...

Страница 202: ...arging rate or remove battery from the circuit 2 As batteries approach full charge electrolyte in each cell will begin to gas or bubble Excessive gas sing must not be allowed 3 Do not fast charge long...

Страница 203: ...1 The starter utilizes a sole noid shift device the housing of the solenoid is in tegral with the starter drive end housing Condition Possible Cause Correction STARTER FAILS TO OPERATE STARTER FAILS...

Страница 204: ...holder sary plate or open hold in wiring tacts d Check for corrosion on solenoid con d Test and clean the contacts a Broken solenoid plunger spring or a Test and repair b Faulty ignition starter switc...

Страница 205: ...d z Y MyMopar com...

Страница 206: ...icgravity should be 1 220or above 2 Disconnect positive battery lead from battery terminal post Connect an 0 to 300 scale ammeter be tween disconnected lead and battery terminal post 3 Connect a test...

Страница 207: ...es field coils by means of a terminal screw Care fully pull frame and field assembly up just enough to expose terminal screw and solder connection of shunt field at brush terminal Place two wood block...

Страница 208: ...g 7 17 Release retainer that positions driven gear on pinion shaft Fig 8 CAUTION Retainer is under tension and a cloth should be placed over the retainer to prevent it from springingaway after removal...

Страница 209: ...nal relay stud 5 Clean all corrosion from solenoid assembly washers sleeve and retainer and inside of solenoid housing These metal parts are part of the solenoid hold in ground circuit and must be cle...

Страница 210: ...4 Test for ground using a 110 volt test lamp Touch one probe of test lamp to series field coil lead and other probe to field frame Lamp should not light Repeat the procedure for shunt field coil If la...

Страница 211: ...assembly thrust washer retaining ring and thrust washer Fig 11 5 Complete installation of pinion shaft engaging shifting fork with clutch actuators Figure 19 shows correct relation of parts at assemb...

Страница 212: ...MyMopar com...

Страница 213: ...ush plate to prevent tearing the seal 14 Wrap solenoid lead wire tightly around brush terminal post as shown in Figure 22 and solder se curely with a high temperature resin core solder and resin flux...

Страница 214: ...armature shaft 22 Position starter end head assembly and install starter frame lockwashers and through bolts Tighten through bolts securely 23 Clean area at the joint between brush holder plate to fi...

Страница 215: ...CE PROCEDURES CHECK AMPERAGE DRAW TEST with BST 11 BST 10 or BST 5 Tester Check battery electrolyte gravity with a reliable hydrometer Gravity should be not less than 1 220 temperature corrected See t...

Страница 216: ...connection ovolt Replace faulty cables Clean and tighten all connec tions Starter Ground Circuit Test 1 Connect the voltmeter positive lead to starter housing and negative voltmeter lead to battery ne...

Страница 217: ...errunning clutch pinion gear toward commutator end of armature drive stop retainer to ward clutch pinion gear to expose snap ring and re 2 Remove thrust washers from armature shaft 3 Lift b n h holder...

Страница 218: ...be replaced Fig 5 Removing Shifter Fork Pivot Pin S T O P RETAINER SNAP RING S P A C E R W A S H E R N B23 Fig 6 Removing Shift Fork Brushes and springs can be replaced after removing commutator end...

Страница 219: ...of each commu tator bar with a pair of test lamp prods Fig 9 If lamp lights it indicates a grounded armature Replace grounded armature Testing Commutator Runout Refacing Place armature in a pair of V...

Страница 220: ...rmature support bushings for wear by placing them on shafts and checking for side play Replace commu tator end frame and bushing assembly if bushing is worn Replace drive end bushing if worn The bushi...

Страница 221: ...shaft to obtain 010 inch minimum end play 12 Install commutator end head 13 Install through bolts and tighten to 40 to 50 inch pounds ADJUSTING STARTER DRIVE G EAR PINION CLEARANCE 1 Place starter ass...

Страница 222: ...See Fig 2 SERVICE DIAGNOSIS Possible Cause Correction Condition ALTERNATOR FAILS TO a Blown fusible wire in voltage regula a Locate and correct cause of the fuse CHARGE No Output tor blowing Install n...

Страница 223: ...rotor fan damaged e Remove and disassemble alternator Install new rotor Open or shorted rectifier f Remove and disassemble alternator Test rectifiers Install new rectifiers as required Open or shorted...

Страница 224: ...ster to battery nega 5 Connect negative lead of voltmeter to field 6 Connect positive lead of voltmeter to battery HEAT SINK NDlOlA Fig 2 Ahernator Assembly SHIELD 1 PULLEY WASHER SCREW ND240B Battery...

Страница 225: ...y negative post VA ADAPTER d BATTERY POST 64x473A Fig Field Circuit Reridance and Field Current Draw Ted LIGHT SWITCH VEHICLE ALTERNATOR VA 64x474A Fig 5 Current Output Test 7 Reconnect slip on connec...

Страница 226: ...R BUILT GENERAL INFORMATION The only function of the regulator is to limit the output voltage The voltage regulator accomplishes this by controlling the flow of current in the rotor field coil and in...

Страница 227: ...gh the two parallel resistors through the FLD termi nal and through the rotor field to ground The two resistors in series with the field circuit reduce field current and rotor field strength with a co...

Страница 228: ...PM rotate Tester Control Knob clockwise until Ammeter reads exactly 15 amperes 9 Rotate Tester Field Control from DIRECT posi tion to OPEN position and then back to DIRECT posi tion to cycle the syste...

Страница 229: ...or Place soldering iron on rivet head and heat sufficiently to melt the solder Allow solder to cool sufficientlyfor fuse wire to make a good solder joint 4 Pull new fuse wire up enough to remove slack...

Страница 230: ...nator One terminal of the regulator is marked IGN and the other is marked FLD The IGN terminal of the regulator is connected to the coil side UPPER CONTACT 1STATIONARY ADJUSTMENT LOWER CONTAC FLEXIBLE...

Страница 231: ...lative Fig 16 Voltuge Regulutor Resistance Units ly high the regulator armature oscillates opening and closing the lower contacts This alternately puts in and takes out resistance in the field circuit...

Страница 232: ...s than 2 volt or more than 7 volt above previous operating voltage setting recorded in lower contact test A voltage read ing of less than 2 volt or more than 7 volt is an indication of a possible wron...

Страница 233: ...fixed contact bracket Fig 19 If the difference is below 2 volt increase air gap by bendingfixed contact bracket up a Connect a small dry cell test lamp in series with the IGN and FLD terminal of the v...

Страница 234: ...end shields the cause of the ground at the first ground test was a grounded insulated brush 4 Examine plastic insulator and screw Screw is a special size and must not be substituted 5 Install insulat...

Страница 235: ...or satisfactory rectifiers will be 1 3 4 amperes or more Reading should be approximately the same for three rectifiers TEST PROD POSITIVE CASE RECTIFIERS d I TEST PROD TO END HOUSING NK106 Fig 25 Tert...

Страница 236: ...ither direction rectifier is l open NK113 Fig 29 Testing Stator Windings for Continuity Possible cause of an open or blown rectifier is a faulty capacitor or a battery that has been installed in rever...

Страница 237: ...it on rotor shaft Remove pulley with Puller Tool C 3615 or C 3934 and BEARING RETAINER Fig 32 Disengaging Bearing Retainer from End Shield TOOL RETAINER ND112 Fig 33 Removing Bearingfrom Rotor Shaft s...

Страница 238: ...he new bearing is prelubricated and no additional lubricant should be added as an excessive amount of lubricant will contaminate the slip rings and cause premature brush and rotor failures 3IP RING A...

Страница 239: ...p lights slip rings are shorted to ground m Test slip ring for continuity by placing one test prod on the positive and the other test prod on the ground slip ring Light should go on showing the field...

Страница 240: ...against pos sible interference with the rotor fans Test each re RECTIFIER LEAD ND114 A Fig 43 Soldering Rectifier and Stator Leads Fig 44 Installing Rectifier EndShieldBearing placement rectifier to m...

Страница 241: ...t BAT and field FLD leads and connect ground wire 23 Connect battery ground cable 24 Start and operate engine and observe alter 25 Test current output and adjust regulator volt tion then tighten lock...

Страница 242: ...rmit water to enter the towers causing ignition malfunction To maintain proper sealing between the towers and nipples cable and nipple assemblies should not be removed from the distributor or coil tow...

Страница 243: ...2 Leave Selector Switch in CALIBRATE position connect Tach Dwellred lead to distributor terminal of coil and black lead to a good ground 3 Turn ignition switch ON Observe dwell meter reading Meter poi...

Страница 244: ...e as follows 1 Disconnect vacuum hose at distributor 2 Connect secondary lead of Power Timing Light to No 1 spark plug red primary lead to positive terminal of battery and black primary lead to nega t...

Страница 245: ...s and condenser as an assembly Distributor cap clamp springs are held in place by peened metal around the openingsand should not be removed 5 Remove oil felt wick from distributor cam Fig 5 Remove wir...

Страница 246: ...G 0 wASHER GEAR WASHER N Y1128A J SCREW Fig 5 Removing or lnstalling Distributor Cam felt Fig 6 Distributor Cam lnstalled Invert housing and install lower bushing flush with face of distributorbase Fi...

Страница 247: ...DISTRIBUTOR Refer to Fig 4 weight springs for distortion 1 Test operation of governor weights and inspect 2 Lubricate governor weights 3 Inspect all bearing surfaces and pivot pins for 4 Install cam...

Страница 248: ...een two of the gear teeth is in line with centerline of rotor electrode Fig 14 drill a 124 129 inch hole and in stall the roll pin CAUTION Support hub of gear when installing roll pin so that gear tee...

Страница 249: ...deposit on the contact surfaces will cause them to burn rapidly This is easy to detect since the oil produces a smudgy line under the con tacts Clogged engine breather pipes permit crankcase pressure...

Страница 250: ...crease spring tension and retard the spark The light tension spring con trols lower end of advance curve the heavier spring controlsthe upper end of advance curve Vacuum Diaphragm Leak Test With distr...

Страница 251: ...and adjust contacts ing installation g Replace ignition switch h Recondition distributor IGNITION COIL FA1LURE a Coil damaged by excessive heat from a Replace coil Inspect condition of the b Coil towe...

Страница 252: ...ximately the initial position CAUTION DO NOT reverse rotation of crankshaft if you have passed the timing mark as this would affect valve timing and distributor timing IGNITION COIL The ignition coil...

Страница 253: ...istance type cable for open circuits loose terminals or high resistance as follows a Remove cable from spark plug and install the proper adapter between cable and spark plug b Lift distributor cap fro...

Страница 254: ...inst its stop 6 Note engine RPM on 1000 RPM scale and adjust carburetor idle speed to specifications See Fuel Sus tem specifications DISTRIBUTOR CONTACT DWELL The degrees of distributor dwell are the...

Страница 255: ...m hoseto distributor DISTRIBUTOR REMOVAL 1 Disconnect vacuum hose at distributor 2 Disconnectprimary lead wire at coil 3 Unfasten distributor cap retaining clips and lift off distributor cap 4 Scribe...

Страница 256: ...until top of bushing is 1 613 inches from top machined face of distributor housing Place a straight edge on machined surface of housing and measure from bottom face of straight edge to the top of the...

Страница 257: ...KER PLATE d C LEAD FELT SNAP RING CAM SPRING SET ___c WEIGHT 4 SHAFT CLAMP LOCKWASHER BEARING I HOUSING CLAMP WASHER SCREW OILER NBlWC Fig 5 Distributor fDEsarsembJed View Chrysler Built PIN WASHER GA...

Страница 258: ...TESTING CONTACT ARM SPRING TENSION 1 Hook a spring scale Tool MTU 36 on the breaker arm and pull in a straight line at a right angle to the contact surfaces Fig 12 Take a reading as the contacts star...

Страница 259: ...ill occur between the contacts result ing in low secondary voltage and enginemiss High series resistance in the condenser circuit will prevent normal condenser action so the contacts will burn rapidly...

Страница 260: ...tension The governor spring tabs can be reached through the access hole at breaker plate Rotate shaft until proper spring and tab line up with access holes Insert a screwdriver blade through ac cess...

Страница 261: ...The ignition coil is designed to operate with an external ballast resistor When testing the toil for output include resistor in tests Inspect coil for external leaks and arcing Always make two tests w...

Страница 262: ...y be suddenly loosened when normal combustion temperatures are restored upon installation of new plugs During a high speed run these materials shedding off the combus Fig Wet Fouling Fig 4 Splashed Fo...

Страница 263: ...detect reversed polarity While these examples may not be conclusive in all instances they may indicate possible corrective pro cedures and further diagnosismay be necessary Cleaningand Regapping Caref...

Страница 264: ...ature warns the driver that one or both of the headlights are not fully opened and therefore not lighting the road properly Turning the headlight switch off rotates the hous ings 180 degrees with the...

Страница 265: ...e of the features of this system is the ability to open the headlight housing should the electrical system fail or suffer external damage To perform this operation use a screw driver and loosen the tw...

Страница 266: ...tion of b Replace limit switch c Replace switch d Replace relay e Replace relay system side cowl PRE AIMING INSTRUCTIONS On Charger models turn the headlight switch ON and place the override switch in...

Страница 267: ...or LevelCompensators Fig 5 Chocking Aimer Calibration screwuntil bubble is centered in spirit level 6 The horizontal aim is correct if targets on oppo site aimers are aligned in viewing ports If targe...

Страница 268: ...ehicle side of center Use care to VERTICAL ADJUSTMENT SCREWS HORIZONTAL ADjkTMENT SCREWS ND388B Fig 7 Headlight Adjustment Points avoid disturbing installed position of aimers Then turn screw clockwis...

Страница 269: ...of the black wire fastened to the radiator yoke Do not touch the screw head I f the light fails to light remove the screw and clean the paint from the metal surrounding the contact area and repeat th...

Страница 270: ...ion Position override switch to ON and then turn headlight switch OFF This keeps headlightsopen 1 Disconnectbattery ground cable 2 Remove four screws in air shield below bumper bar and remove shield 3...

Страница 271: ...king light assembly STOP AND LIMIT SWITCHES Fig 12 Housing to Motor Mounting LIMIT SWITCH Fig 13 Motor Mounting 3 Remove the three terminals from connector insulator with a thin screw driver and caref...

Страница 272: ...e lobe FENDER INDICATOR LEFT PARK i r AND TURN I RIGHT PARK TURN AND PANEL INDICATORS 9 FENDER INDICATOR TIT BATTERY BULKHEAD CONNECTOR I Page Service Diagnosis 75 Switch 76 with the canceling cam ret...

Страница 273: ...ion 1 Attach string or wire that was left in steering column jacket tube during removal to turn signal switch wiring and carefully pull string or wire down through column jacket tube until turn signal...

Страница 274: ...light fails to illuminate inspect for corroded battery terminals dead battery or an open circuit in the wire from the starter relay to the B terminal of the horn relay Should the test light illuminat...

Страница 275: ...al Information 78 Heater or Air Conditioning Controls 88 Instruments 86 Instrument Clusters 84 Light Bulb Replacement 82 Page Printed Circuit Boards 86 Service Diagnosis 80 Specifications 95 Speedomet...

Страница 276: ...uel gauge It is important to note this dif ference if gauges are to be tested on the bench Fvel Level Indicating System Figs 3 and 4 A hinged float arm on the fuel tank raises or lowers dependent on t...

Страница 277: ...el a Faulty voltage limiter a Test voltage limiter U O N W GAUGE POINTERS DO a Faulty voltage limiter or an open a Test voltage limiter Test wiring re NOT MOVE WHEN circuit on battery side input of pa...

Страница 278: ...on L panel gauge should read Empty plus or minus 3 32 If the panel gauge does not perform as described continuity of the circuit from the tank sending unit to the panel unit should be tested with spec...

Страница 279: ...dvance to the H position of the dial Should the gauge respond to the above tests but H E A T E R O R A C CONTROL MOUNTING E W S not operate when the wire is attached to the sending unit it should be r...

Страница 280: ...st the system turn the ignition key ON and apply the parking brake If the light fails to light inspect for a burned out bulb discon nected socket a broken or disconnected wire at the switch To test th...

Страница 281: ...uster from the housing Using a 12 volt test battery and four jumper wires connect one jumper from the white wire terminal of the cluster to the white wire terminal of the test power pack Connect anoth...

Страница 282: ...l knobs and tighten set screws 6 From under panel connect speedometer cable and printed circuit board multiple connector index ing key facing upward 7 Remove tape from steering column and close glove...

Страница 283: ...ace down on a padded work bench remove all light bulb sockets and voltage limiter 2 Remove eight screws retaining cluster bezel to cluster housing and carefully separate 3 Remove fuel and temperature...

Страница 284: ...e instrument panel lower reinforcement by a self tapping screw In the fuse block are mounted radio cigar lighter air conditioner or heater tail stopdome light and ac cessory fuses The fuse capacity is...

Страница 285: ...embly below instrument panel and disconnect blower switch wires control cables or vac uum connectorif air conditioning equipped The blower switch is attached to the control a t sembly with one metal s...

Страница 286: ...iming a See Wiper Arm Adjustment 2 speed only other drive parts angle to glass ish on glass c Iosed position straighten bent or twisted arm 2 speed only Replace motor assembly Variable speed only a Mo...

Страница 287: ...th Auto motive Multi Purpose Lubricant NLGI 2 only if serivce of parts is necessary The motor and gear box assembly is lubricated at the factory and are not to be serviced Fig 2 End Play Adjustment PA...

Страница 288: ...or shaft Install the motor and be sure the ground strap is installed on the left mounting stud Install the motor mounting nuts 2 From under the instrument panel index the flats of the crank arm with f...

Страница 289: ...terminal The wiper motor should run continuously in wipe direction 2 Connect a jumper wire between wiper motor blue wire and battery positive terminal Connectgreen to brown wire Connect another jumpe...

Страница 290: ...D C T A IklCD RETAINING N DRIVE LINK FELT WASHERS 4 Fig 4 Pivot Arm and Link Assemblies All Models taining nuts from pivot mounting studs and lower pivot far enough to remove connecting link and drive...

Страница 291: ...ing the windshield glass is not centered on the center of the stream The stream center i s toward the bottom of the oval pattern Motor and Pump Assembly Removal 1 Disconnect motor feed wire connector...

Страница 292: ...Engine Standard Equipment Capacity Ampere Hours Voltage Number of Plates Per Cell Ground Terminal Model Identification Number Capacity Ampere Hours VoItage Number of Plates Per Cell Ground Terminal M...

Страница 293: ...ltage 4 Amperage Draw 400to 450 Pull In Coil 14 4 16 0Amps 6 0Volts Hold In Coil 11 5126 Amps 6 0 Volts Locked Resistance Test Solenoid Engine should be at operatingtemperature STARTER Direct Drive Ta...

Страница 294: ...lts 2 38 to 2 75 Maximumamperes Current Output Standardwith 170or 225 Cu In Engine 26 plus or minus 3 amperes Standard All Others 34 5 plus or minus3 amperes Special Equipment Heavy Duty and or Air Co...

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Страница 296: ...8 d N ass O O O N o o m r l Id 0 Ei 0 b l l u x 2 E a Q r I h E 5 E x M c m L Q i 7 J U u 0 L s E v MyMopar com...

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Страница 307: ...up 24 Body AlI Except Station Wagon 1 1 3 Body Station Wagon 1 1 6 Console 110 Engine Compartrnent All Except Hemi Engine 1 1 1 Engine Compartment Hemi Engine 112 Instrument Panel 114 Power Windows Se...

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Страница 310: ...MyMopar com...

Страница 311: ...OTOR RESISTOR TO MOTORFC6A 16 LGNJ II r i Q2 12 BK D 1 1 8 B K Q 2 A 1 4 1 1 D32 18 R LASHER I31 18 BK I DlO iE LGN BACK UP LAMP SWITCH AUTOMATIC B2 11 v I 1 DIMMER SWITCH 4 iKI x12 5 J L 4 2 4 2 J2 R...

Страница 312: ...0 WIRING DIAGRAMS ELECTRICAL 8 115 M2F 18 Y RIGHT DOOR SWITCH MyMopar com...

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Страница 316: ...MP I SWITCH I r I v 4 1 E2A RIGHT TURN SIGNAL INDICATOR INDICATOR INSTRUMENT LAMPS LEFT TURN SIGNAL SWITCH LAMP G4 f I EXTERNAL LIMITER E l I M I TO LEFT FRONT DOOR AUTOMATIC SWITCH M 1 l 1 6 R6A 1121...

Страница 317: ...I I 1 MyMopar com...

Страница 318: ...MyMopar com...

Страница 319: ...8 122 ELECTRICAL WI RING DIAGRAMS 0 MyMopar com...

Страница 320: ...0 WIRING DIAGRAMS ELECTR ICAL 8 123 IGNITION IGN T13 126 SWITCH J2 123 15 D9 CONTROL SWITCH WINDSHIELD WIPFR SWITCH 1 3 I Pig 2 lnstrunnnt Punel Charger MyMopar com...

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Страница 322: ...MyMopar com...

Страница 323: ...ne and allows space in the engine com partment for the long intake manifold branches The engine has in line overhead valves and wedge shaped combustion chambers and a nominal compression fuel ratio of...

Страница 324: ...f a rotor type oil pump and a full flow oil filter On 273 and 318 cubic inch engines the pump is mounted internally on 383 426 and 440 cubic inch engines the pump is mounted externally Oil is forced b...

Страница 325: ...ng j Dirt or water in fuel line or car j Clean linesand carburetor k Carburetor flooded k Adjust float level check seats I Incorrect carburetor float setting I Adjust float level check seats m Faulty...

Страница 326: ...veplay in distributor shaft d Removeand repair distributor e Worn distributor shaft or cam e Removeand repair distributor f Dirty or incorrectly gapped spark f Clean plugsand set gap at 005 8 Dirt o r...

Страница 327: ...ndvalve seats and valves j Incorrect tappet lash j Adjust to specifications 035 ENGINE MISSES AT HIGH SPEED utor contacts 035 or filter filter a Check for correct oil level b Change oil c Check engine...

Страница 328: ...st cranking voltage See Starting Motor 3 Tighten intake manifold bolts to 15 foot pounds 4 Perform cylinder compression test Compres sion should not vary more than 20pounds 5 Clean or replace spark pl...

Страница 329: ...emove transmission 16 Lower vehicle 17 Install engine lifting fixture Tool C 3804to cyl inder head and attach a chain hoist to fixture eyebolt 18 Remove engine support fixture move oil cooler lines fi...

Страница 330: ...ll speedometer Instal1 torque shaft brake and gear shiftrods and extended bushing of rocker arm Install lines and transmission Be sure to install long retainer in center position only 3 Install rocker...

Страница 331: ...ifold and car buretor as an assembly cover 10 Remove closed vent system and cylinder head 11 Remove rocker arms and shaft assembly 12 Remove push rods and place them in their respective slots in holde...

Страница 332: ...e and spark plug cables distributor flange 19 Install closed vent system VALVES AND SPRINGS Valves are arranged in line in the cylinder head and operate in guides that are integral with the cylin der...

Страница 333: ...valve seat using dial indicator No 13725 Total runout should not exceed 002inch totalindicator reading 5 Inspect valve seat with Prussian blue to deter mine where valve contacts the seat To do this c...

Страница 334: ...ol C 3422A in VALVE SPRING KR145A EXHAU VALVE RETAINER SPRING 1 ST OIL Fig 19 Valve Assembly stall locks and release the tool If valves and or seat are reground measure the installed height of springs...

Страница 335: ...lock bolt and apply torque in the direc tion of crankshaft rotation to take up slack 30 foot pounds cylinder head installed or 15 foot pounds cylinder head removed With torque applied to the camshaft...

Страница 336: ...late through the seal opening inside of chain case cover facing up 7 Place the seal in cover opening with neoprene down Place seal installing plate into the new seal with the protective recess toward...

Страница 337: ...e timing sprockets distributor and oil 3 Remove fuel pump 4 Install a long bolt into the front of camshaft to facilitate removal of the camshaft remove camshaft being careful not to damage cam bearing...

Страница 338: ...his operation 2 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in the cylinder bore 3 Remove connectingrod cap 4 Insta...

Страница 339: ...ETER A THAN ACROSS ETER B MEASUREMENT IS MADE 1s IN BELOW LOWER RING GROOVE NY221B DIAMETERS AT C AND D CAN BE EQUAL OR DIAMETER AT D CAN BE 0015 IN GREATER THAN C THE THRUST FACES AT DIAM Fig 34 Pist...

Страница 340: ...G ROD KR195 B GUIDE LARGE TOOL Fig 36 Tool Arrangement for Removing Piston Pin PRESS MAIN SCREW TOOL PILOT TOOL Fig 37 Removing Piston Pin a sliding fit in piston at 70 degrees F Piston pins are suppl...

Страница 341: ...Maltese Cross stamped on the engine numbering pad on right side of block on top boss directly behind coil indicates that engine is equipped with a crankshaft which had one or more connecting rods and...

Страница 342: ...l Fig 42 5 Side play should be from 006to 012 inch Fig 42 Removing and lnstalling Connecting Rod Be careful not to nick connecting rod journals 7 Tap piston down in cylinder bore using handle of a ham...

Страница 343: ...ated the bearing is too small and should be replaced with the correct size It is permissible to use one 001 inch undersize bearing shell with one standard bearing shell or one 002 inch undersize beari...

Страница 344: ...t Remove o i l pan attaching bolts rotate engine crankshaft to clear counterweight and remove oil pan 225 Cubic lnch Engine I 16 5 Wheelbase 1 Remove oil dipstick raise vehicle on a hoist Drain oil pa...

Страница 345: ...shield 3 Lower vehicle install oil dipstick and fillcrank case to recommended level with proper grade of motor oil Connect negative ground cable at battery OIL PUMP Removal 1 Drain radiator disconnect...

Страница 346: ...e inner rotor 5 Slide outer rotor and inner rotor into pump body and place a straightedge across face between bolt holes Fig 53 6 If a feeler gauge of more than 004 inch can be inserted between the ro...

Страница 347: ...t Bearings 37 Crankshaft Identification 41 Crankshaft Main Bearings 42 Crankshaft Main Journals 42 Crankcase Ventilation System 87 Cylinder Block 39 Cylinder Heads 28 Distributor Drive Shaft Bushing 3...

Страница 348: ...v alent Service unit more frequently when driving under severe conditions such as in dusty areas 13 Inspect crankcase ventilation system as out lined on page 87 14 Inspect and adjust accessory belt dr...

Страница 349: ...crossmember and remove transmission from vehicle 10 Lower vehicle and attach a crane or other suitable liftingtool to fixture eyebolt 11 Remove engine front mounts Raise engine with lifting tool and...

Страница 350: ...shaft bolts and retainers 5 Remove rocker arms and shaft assembly Removal 3I 8 CubicInch Engine CANADIAN BUILT It will be necessary to remove the cylinder heads for cleaning inspection or installatio...

Страница 351: ...r in the V notches of side seals after installation 10 a On U S BUILT position intake manifold on engine and install the twelve attaching cap screws Fig 7 Cylinder Heud Tightening Sequence Finger Tigh...

Страница 352: ...the valve at the correct height for checking with a dial indicator b Attach dial indicator Tool C 3339 to cylinder head and set it at right angle of valve stem being measured Fig 11 c Move valve to an...

Страница 353: ...ig 14 1 Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested As an example the compression length of the spring to be tested is 1 5 16 inches...

Страница 354: ...g rods to dip into the o i l while engine is running and create foam Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily...

Страница 355: ...spective holes in ToolC 3068 head and seat tool firmlyin the head of tappet Disassembly Fig 18 body above plunger cap plunger flat check valve retainer and 1 4 Separate plt check valve spring place i...

Страница 356: ...on damper on crankshaft 3 Install Tool C 3688and pull vibration damper from end of crankshaft Fig 20 4 Remove fuel lines and fuel pump 5 Loosen oil pan bolts and remove the front bolt at each side 6 R...

Страница 357: ...se a straight edge to check alignment of timing marks Fig 23 1 Install the fuel pump eccentric cup washer I NK16 Fig 23 Alignment of Timing Marks and camshaft bolt Tighten bolt to 35 foot pounds m Che...

Страница 358: ...installed when neoprene is tight against face of cover Try to insert a 0015 feeler gauge between neoprene and cover Fig 28 If the seal is installed properly the feeler gauge cannot be inserted Cover l...

Страница 359: ...2 inches of its final position in cylinderblock 2 Install Tool C 3509with tongue back of distrib utor drive gear Fig 22 3 Hold tool in position with distributor lock plate screw This tool will restric...

Страница 360: ...ition using a soft hammer 3 As the burnisher is pulled through the bushing by tightening the puller nut the bushing is expanded tight in block and burnished to correct size Fig 3 5 DO NOT REAMTHIS BUS...

Страница 361: ...is job In addition to deglazing it will reduce taper and out of round as well as removing light scuf fing scoring or scratches Usually a few strokes will clean up a bore and maintain the required limi...

Страница 362: ...es sary if there is excessive clearance between the pin and the piston Ream piston and connecting rod to next oversize New pistons are supplied with properly fitted pins 2 Assemble pistons and rods fo...

Страница 363: ...ain that the V groove in the shell is in line with the V groove in the cap This provides lubrication of the cylinder wall in the opposite bank The bearing shells must be installed so that the tangs ar...

Страница 364: ...and scoring Limits of taper or out of round on any crankshaft journals should be held to 001 inch Journal grinding should not exceed 012 inch under the standard journal diameter Do NOT grind thrust fa...

Страница 365: ...85 foot pounds 5 If a slight drag is felt as crankshaft is turned moved no more than 1 4 turn in either direction THRUST BEARING Fig 44 Main Bearing Identification Fig 45 Removing or Installing Upper...

Страница 366: ...l screw into cap Clamp screw into a vise and while supporting oil pump remove cap by tapping pump body using a soft hammer Discard cap and remove spring and re lief valve Fig 49 2 Remove oil pump cove...

Страница 367: ...B 0 l L I Y U B 4 Z OL m al t P t YI I Cg P 6 I MyMopar com...

Страница 368: ...mp body is being used 8 Check clearance between inner rotor and outer rotor Fig 56 If measurement is more than 006 FEELER G A U G E DIAMETER 63x933 Fig 52 Measuring Outer Rotor Thickness L 63x934 Fig...

Страница 369: ...uld test 16 2 to 17 2 lbs when compressed to 1 11 32inch Discard spring that do not meet specifications 6 Install the relief valve spring and a new re tainer cap Spring seats inside retainer cap Press...

Страница 370: ...ump for pressure and vacuum Refer to Fuel System Group 14 Specifications 11 Inspect the manifold heat control valve in the right exhaust manifold forproper operation and apply Manifold Heat Control Va...

Страница 371: ...CROSS MEMBER ASSEMBLY Q NN526 w Fig 4 Engine Rear Support I 16 5 Wheelbase with 4 Speed Transmission 11 Lower vehicle and attach chain hoist to fixture eyebolt 12 Remove engine front mounting bolts Ra...

Страница 372: ...and remove rocker arms and shaft assembly 3 If rocker arm assemblies have been disassem bled for cleaning inspection or replacement refer to Figure 5 for proper reassembly Installation 1 Install rocke...

Страница 373: ...n the number two and four positions Tighten bolts to 25 foot pounds 8 Place new cylinder head gasket in position and Fig 7 Cylinder Head Tightening Sequence CYLINDER HEAD INTAKE PUSH RODS INSTALLING R...

Страница 374: ...at a right angle to the valve stem being measured Fig 1 1 6 Move valve to and from the indicator Total dial indicator reading should not exceed 017inch If the dial indicator reading is excessive or i...

Страница 375: ...sion from valve spring seat r in the head to the valve tip should be measured with gauge Tool C 3648 Fig 13 8 The end of the cylindrical gauge and the bottom of slotted area represent the maximum and...

Страница 376: ...hile engine is running and create foam Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily Oil Level TooLow Low oil level...

Страница 377: ...tappet bodies are 008 inch oversize CYLINDER HEAD ASSEMBLY HYDRAULIC TAPPET CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve must always be fitted to the original bo...

Страница 378: ...rankshaft clockwise normal running direction until intake valve has lifted 034 inch with 256 260 camshaft and 033 inch with 268 284 cam shaft See specifications for engine application The timing on th...

Страница 379: ...t sprocket and crankshaft sprock et on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft sprocket bores h Place timing chain around both sprockets i Turn...

Страница 380: ...d lip of seal retainer Fig 27 The lip of the neoprene seal must be toward source of oil 8 Install flat washer and nut on remover screw hold screw and tighten nut Fig 28 9 The seal is properly installe...

Страница 381: ...3 Install Tool 2 3509 in place of distributor drive gear and shaft as shown in Figure 23 4 Hold tool in position with distributor lock plate screw This tool will restrict camshaft from being C H A I...

Страница 382: ...hread down until a tight fitis obtained Fig 33 ing is removed 1 Insert Tool C 3052 into the old bushing and 2 Hold remover screw and tighten nut until bush nstallcrtion 1 Slide a new bushing over burn...

Страница 383: ...stall and tighten hold quired limits 2 Deglazing of the cylinder walls using a cylinder surfacing hone equipped with 280 grit stones C 350 strokes depending on the bore condil cient to provide a satis...

Страница 384: ...ees to piston pin axis Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line Pistons and cylinder bores should be measured at normal room...

Страница 385: ...in hole Assemble rods to pistons of the right cylinder bank 2 4 6 and 8 with indent on piston head opposite to the larger chamfer on the large bore end of connect ing rod Assemble rods to pistons of t...

Страница 386: ...REW TOOL KR168 B Fig 44 Testing Fit of Piston Pin in Connecting Rod Fig 45 Showing location of ExternalEngine Numbering Pad alternate from one bank to another because when rods are assembled to the pi...

Страница 387: ...time guide connecting rod c 7 Fig 47 Installing Connecting Rod Using Tool C 3221 into position on crankpin journal 7 The notch or groove on top of piston must be pointing toward front of engine and l...

Страница 388: ...s 5 If a slight drag is felt as crankshaft is turned moved no more than 1 4 turn in either direction clearance is 001inch or less and is considered satis factory If however no drag is felt the bearing...

Страница 389: ...tallation Perform the following operations as rapidly as pos sible These side seals are made from a material that expands quickly when oiled 1 Apply mineral spirits or diesel fuel to the side seals 2...

Страница 390: ...il pump attaching bolts and remove pump Disassembly pump rotor liftout the spring and relief valve plunger Fig 53 lnspeciion and Assembly 1 Clean all parts thoroughly The mating face of filter base oi...

Страница 391: ...inch and should test 14 85 to 15 85 lbs when compressed to 1 19 32 inch Discard spring that fails to meet specifications If the oil pressure is low inspect for worn bearings O U T E R ROTOR Fig 58 Mea...

Страница 392: ...primary secondary resistance Test Condenser 8 Reset the ignition timing with the vacuum ad vance line disconnected The ignition timing should be set to compensate for altitudes and or gasoline grades...

Страница 393: ...ve been installed add one quart of MoPar Engine Supplement Part Number 1879406 or equivalent to engine oil to aid break in The oil mixture should be left in engine for a minimum of 500 miles and drain...

Страница 394: ...pper bellcrank Drain coolingsystem 2 Disconnectfuel line at tee fitting 3 Disconnect intake manifold heat tubes located at rear of manifold Remove air tube between auto matic choke and exhaust manifol...

Страница 395: ...ing dowels marked A in Figure 6 Tighten screws marked B to 72 inch pounds and screws marked C to 48 inch pounds Repeat the tightening procedure in the sequence shown until all screws maintain their sp...

Страница 396: ...Ream a Fig 9 Measuring Valve Guide Wear reading is excessive or if the valve stems are scuffed or scored d Service valves with oversize stems are avail able in 005 015 and 030 inch oversize e Slowly...

Страница 397: ...to 1 41 64 inches valve closed and 86 to 96 pounds at 1 11 64inches Fig I I Testing Valve Spring valveopen The outer valve spring with surge damp er removed should test 102 to 108 pounds when compres...

Страница 398: ...adjuster screw in one complete turn to remove lash Zero the indicator 3 Rotate crankshaft clockwise normal running 5 and 6 1and 2 Fig 14 Installing Intake Valve Stem Sed direction until valve has lift...

Страница 399: ...f chain is not satisfactory remove camshaft sprocket attaching bolts and remove timing chain TORQUE WRENCH e Fig 17 Camshdt Holding Tool C 3509 with crankshaft and camshaft sprockets When installing t...

Страница 400: ...up 6 Insert remover screw with the plate through seal opening insideof chain case cover facing up 7 Place seal in cover opening with neoprene down Place seal installing plate into the new seal with pr...

Страница 401: ...d rotate arm 180 degrees 3 Install Tool C 3509 in place of distributor drive gear and shaft as shown in Figure 17 4 Hold tool in position with distributor lock plate screw This tool will restrict cams...

Страница 402: ...ead down until tight fit is obtained Fig 26 ing is removed 1 Insert Tool C 3052 into the old bushing and 2 Hold remover screw and tighten nut until bush Fig 27 Installing Distributor Drive Shaft Bushi...

Страница 403: ...oval install the corresponding bear ing cap on the rod Cleaningand Inspection 1 Clean cylinder block thoroughly and inspect all core hole plugs for evidence of leaking 2 If new core hole plugs are ins...

Страница 404: ...pins and are available in standard and the following oversizes 005 020 and 040inch FWing Rings 1 Measure piston ring gap about two inches from bottom of cylinder bore in which it is to be fitted An in...

Страница 405: ...ssion ring gaps are staggered so that neither are in line with oil ring rail gaps 2 The oil ring expander ends should be positioned toward the outside of the V of the engine The oil ring rail gaps sho...

Страница 406: ...ankshaft Fig 33 ing the bearing into position Remove Tool 2 3059 MeasuringMain Bearing Clearance 1 Smooth edges of a 1 2 x 3 4 inch piece of brass shim stock 001inch thickness 2 Install bearing in cen...

Страница 407: ...side seals 2 Install seals immediately in the seal retainer grooves 3 Install seal retainer and tighten screws to 30 foot pounds Failure to presil the seals will result in an oil leak ENGINE OILING S...

Страница 408: ...ldbe installed 5 Slide outer rotor and inner rotor into pump body and place a straightedge across the face be tween the bolt holes Fig 40 6 If a feeler gauge of more than 004 inch can be inserted betw...

Страница 409: ...engine using a new gasket on engine and tighten attaching bolts to 35 foot O U T E R R O T O R INNER ROTOR Fig 42 Measuring Clearance Between Rotors Fig 43 Removing Oil Filter NN359 pounds Install oi...

Страница 410: ...dle loosely hold a piece of stiff paper or a parts tag over the oil fill pipe Within a few seconds it should be sucked against the oil fill pipe with a holding force If this occurs a final test should...

Страница 411: ...at idle remove the venti lator valve and cap assembly from the rocker cover If valve is not plugged a hissing noise will usually be heard as air passes through the valve and a strong vacuum should be...

Страница 412: ...ed more frequently if vehicle is used extensively for short trips with fre quent idling REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads can be repaired by the use of Heli Coils Essentially t...

Страница 413: ...4 Number of Links Pitch CAMSHAFT BEARINGS Diameter after reaming TIMING CHAIN Width TAPPETS Type Clearance in Block Body Diameter Clearance Between Valve Stem and Rocker Arm Pad Engine Hot PISTONS Ty...

Страница 414: ...Exhaust Valve Duration Material Head Diameter Length to gauge dim Line Stem Diameter Stem to Guide Clearance Maximum Allowable Before Reconditioning Valve Face Angle Adjustment Lift Material Head Dia...

Страница 415: ...NGINE LUBR1CAT1ON OIL FILTER Rocker Arm Screw 395 12 1 92 49 57 Ibs 1 11 16 137 150 Ibs 1 5 16 1 010 to 1 030 1 5 8 1 11 16 Wedge Type 0 0 P 45 070 to 090 450 040to O6oN 022 3 4000 005 010 001 040 905...

Страница 416: ...for taper and out of round Maximum Allowable Oversize cylinder bore Tappet Bore Diameter Distributor Lower Drive Shaft Bushings press fit in block Ream to Shaft to Bushing Clearance PISTONS Type Mater...

Страница 417: ...N BEARING JOURNALS Maximum Allowable Out of Round and or Taper 189 205 184 194 Std 005 020 040 Oversize Std 005 020 040 Oversize Full Floating 9 8 4 1 9843 2 810 2 820 oooo 0005 0 0 4 026 oooO 0005 St...

Страница 418: ...NTAKEI Head Diameter Length to center of valve face Stem Diameter Standard Stem to Guide Clearance Maximum Allowable Face Angle VALVE GUIDES 2 124 2125 OOlff Chain Steel Backed Babbitt 5 001 003 005 T...

Страница 419: ...0 Oversize stem biam 405 425 16 1 92 2 W 49 57 Ibs 1 11 16 78 88 Ibs 1 11 16 137 150 Ibs 1 5 16 17 1184 Ibs 1 5 16 1 010 1 030 1 5 8 1 11 16 1 16 Rotary Full Pressure 4 U S or 3 1 4 ImperiaI Camshaft...

Страница 420: ...ithout C A P with C A P Manual Automatic Left Bank Right Bank Cylinder Bore Standard Cylinder Bore Out of Round Max aIlowable before reconditioning Cylinder Bore Taper Max aIIowable before recondition...

Страница 421: ...Oil Seal Surface Diameter Maximum Allowable Out of Round and or Taper MAIN BEARING JOURNALS 770 gms 3 84 220 22U 208 Std 005 020 040 Oversize Press Fit in Rod 1 0935 1 0937 0007 0012 Standard Only 3 2...

Страница 422: ...de Bore Diameter Head Diameter Length to center of valve face Stem Diameter Standard Stem to Guide Clearance Maximum Allowable Face Angle Valve for Service Lift Zero Lash VALVES EXHAUST Head Diameter...

Страница 423: ...Ibs 7 9 Ibs FuII Flow 4 87 3W 372 002 004 017 4 5 O Std 005 015 N O Oversize Stem Diam 458 16 2 23 100 110 1 55 64 236 256 1 23 64 1 070 1 090 1I16 Spiral Type 153 64 1 57 64 Rotary Full Pressure 4 U...

Страница 424: ...r Max allowable befare reconditioning Reconditioning Working Limits for taper and out of round Maximum Allowable Oversize cylinder bore Tappet Bore Diameter Distributor Lower Drive Shaft Bushings pres...

Страница 425: ...al Surface Diameter Maximum Allowable Out of Round Maximum Allowable Taper Bearings for Service Available in Standard and the following undersizes CONNECTING RODS CONNECTING ROD BUSHING CONNECTING ROD...

Страница 426: ...e Diameter Head Diameter Length to center of valve face Stem Diameter Standard Stem to Guide Clearance Maximum Allowable Face Angle Valve for Service Lift Zero Lash Head Diameter Length to center of v...

Страница 427: ...ons ROCKER SHAFT ASSEMBLY ENGINE LUBRICATION Rocker Shaft Clearance in Rocker Arm Rocker Shaft Clearance in Bracket Pump Type Capacity qts Pump Drive Minimum Pump Pressure 500 rpm Operating Pressure a...

Страница 428: ...n lbs Distributor Clamp Bolt 200 in lbs Engine Front Mounting to Frame Nut 85 Engine Front Mounting to Block Nut 45 Engine Rear Mount Bolts 35 Exhaust Manifold Nut Exhaust Pipe Flange Nut Exhaust Pipe...

Страница 429: ...n Damper Bolt 200 in lbs Engine Rear Mounting 383 440 CUBIC INCH ENGINES Connecting Rod Nut Plain Cylinder Head Bolt Main Bearing Cap Bolt Spark Plug Carnshaft Lockbolt Carburetor to Manifold Nut Chai...

Страница 430: ...Distributor Clamp Bolt Exhaust Manifold Bolt Fan Attaching Bolt 4 Flywheel Cap Screw Clutch Cover to Flywheel Flywheel Pan Screws Flywheel Housing to Block Bolts Ft Lbr 30 15 30 40 7 15 18 1518 75 13...

Страница 431: ...em used on Coronet models equipped with the 426 Hemi engine uses an H type exhaust pipe arrangement Fig 7 The dual pipes are connected near the center by a short crossover Page INTAKE MANIFOLD 426 Hem...

Страница 432: ...LD a Thermostat broken a Replace thermostat a Heat control valve frozen in the open a Free up manifold heat control valve using a suitable manifold heat con b Weak broken or missing anti rattle b Repl...

Страница 433: ...XHAUST SYSTEM 11 3 Fig I Exhaust System Dart 170 225 Cu In Engines AND TAIL PIPE LOCKWASHER 4 BBL CARBURETOR N CIRCLE A WASH Fig 2 Exhaust System Dart 273 Cu In Engine 2 and 4 BBL Carburetors MyMopar...

Страница 434: ...tighten exhaust pipe to manifold ball joint connec tion bolt nutsat this time 2 Adjust tail pipe and muffler supports to pro vide proper clearance with underbody and adjacent parts Do not fully tight...

Страница 435: ...stributor Disconnect fuel line crankcase venti lator valve hose automatic choke rod and throttle linkage at carburetor and remove carburetor 3 Disconnectexhaust pipe at exhaust manifold 4 Remove nuts...

Страница 436: ...ews securing intake manifold to exhaust manifold to 15 foot pounds starting with inner screw 5 Attach exhaust pipe to manifold flange using a new gasket and tighten bolt nuts to 35 foot pounds 6 Insta...

Страница 437: ...ig Exhaust Sydem Dual Coronet483 Cu in Engine 4 CIRCLE A PLAIN WASHER MUFFLER RIGHT 4 TAIL PIPE RIGHT PIPE LEFT U BOLT LOCKWASHER EXHAUST PIPE RIGHT BALL JOINT CONNECTION Fig 7 Exhaust Sydem Dual Coro...

Страница 438: ...ct mating surfaces of manifold for paral lelism with a straightedge Gasket surfaces must be flat within 008inch 3 On right hand manifold test manifold heat con trol valve for free operation If necessa...

Страница 439: ...sconnect spark plug cables 2 Remove alternator 3 Disconnect exhaust pipe at exhaust manifolds 4 Remove stud nuts attaching exhaust manifolds to cylinder heads Slide manifolds o f f studs and away from...

Страница 440: ...her Tighten screws to 200 inch pounds 4 Install clamp bolt washer and nut and tighten nut to 100inch pounds EXHAUST HEADERS 426 Hemi Engine Removal buretor choke heat tube 1 On right hand exhaust head...

Страница 441: ...y loosening clampbolt Fig 15 from valve shaft slot 1 Remove counterweight and lock from end of 2 Unhook thermostat from stop pin and remove Cleaning and Inspection Move valve shaft back and forth and...

Страница 442: ...ig 19 from valveshaft slot 1 Remove counterweight lock and bumper from 2 Unhook thermostat from stop pin and remove Cleaningand inspection Move valve shaft back and forth and test operation If shaft i...

Страница 443: ...rth until it turns freely The counterweight and the thermostat being lo cated on opposite ends of the valve shaft can be serv iced individually without the necessity for complete disassembly i i Fig 2...

Страница 444: ...shaft retainer is in place on outer end 2 Install counterweight and bumper on outer end Fig 25 Thermostat Instulld 383 440 Cu In Engines CLAMP B O L T NN209 Fig 26 Installing Counterweight 383 440 Cu...

Страница 445: ...n shaft Fig 29 with outer end of thermostat in lower left hand posi tion Press inner end of thermostat into shaft and seat firmly 3 Wrap outer end of thermostat counterclockwise RETAINER VALVt HAPI RE...

Страница 446: ...assembly Servicing Test manifold heat control valve for proper opera tion during engine tune up and apply a suitable mani fold heat control valve solventto dissolvethe deposits as outlined on page 13...

Страница 447: ...ble is not located elsewhere before disassembling the carburetor When overhauling the carburetor several items of importanceshould be observed to assure a good job 1 The carburetor must be completely...

Страница 448: ...osition in park position 5 On air conditioned cars tuFn air conditioning 6 Connectignitiontachometer 7 Insert probe of exhaust gas analyzer in the t a i l pipe as far as possible 2 ft minimum distance...

Страница 449: ...increase time the distributor vacuum remains above 6 inches of mercury after throttle is released One turn of ad justing screw will change valve setting by approxi mately 1 2 inch of mercury If valve...

Страница 450: ...st as necessary to obtain correct loat leveI lisassemble carburetor Replaceworn 3ccelerator pump and throttle linkage ind measure for correct position Free up manifold heat control valve ising recomme...

Страница 451: ...Only CAP Carburetors require special pro cedures See Owners Manual CHOKE VALVE FAILS TO CLOSE than specified a Choke thermostat adjustment leaner a Adjust b Choke thermostat corroded such that b Repl...

Страница 452: ...nsshowing the various disassembly procedures will not always show any one specific carburetor The spring staged choke Fig 1 is a device in corporated in the choke mechanism which limits the choke blad...

Страница 453: ...e to be cleaned as a special item A liquid cleaner may damage diaphragm mate rial 6 Remove air horn retaining screws Remove dash pot if so equipped 7 Tilt air horn toward throttle lever far enough to...

Страница 454: ...nd the component parts of each disassembled as far as necessary for cleaningand inspection It is usually not advisable to remove the throttle shaft or valve from the throttle body unless wear or damag...

Страница 455: ...system fuel inlet and dischargecheck balls proceed asfollows 2 Pour clean gasoline into carburetor bowl ap proximately 1 2 inch deep Remove pump plunger from jar of gasoline and slide down into pump c...

Страница 456: ...not attempt to change the netting without moving the float as the synthetic rubber tip can be compressed sufnciently to cause a falw APPLY P R E S S U R E TO RETAINER e TO gCH FLOATS AT CROWN T O SEAT...

Страница 457: ...vent and air horn Fig 13 If an adjustment is necessary bend the pump oper ating rod using Tool T109 213 at the lower angle until correct bowl vent opening has been obtained This is an important adjus...

Страница 458: ...i n k to obtain correct choke opening Length changes should be made carefully by bending open or closing the bend provided in diaphragm link CAUTION DO NOT APPLY TWIST ING OR BENDING FORCE TO DIAPHRA...

Страница 459: ...and the distributor control valve are correctly adjusted as outlined under Idle Speed Adjustment Curb Idle CAP Carburetors SpringStaged ChokeAd usiment ating clearance Fig 18 then proceed asfollows 1...

Страница 460: ...flat so that lip bears firmly against needle Addi tional fuel may be admitted by slightly depressing float If the fuel pressure in line is insufficient to force additional fuel into the bowl add the n...

Страница 461: ...The dash pot used only on manual transmission A power valve mounted in the metering body actu equipped vehicles is mounted on the carburetor ated by manifold vacuum delivers the additional fuel thrott...

Страница 462: ...t of carbu retor Fig 4 7 Remove fuel bowl attaching screws then re move fuel bowl baffle and gasket Fig 5 Slide V I _ 1 1 1 VALVE R n W l VFNT VENT ROD SPRING ECONOMIZER ENT DIAPHRAGM TUBE 2 Fig 3 Rem...

Страница 463: ...haft and valve from the throttle flange unless wear or damage necessitatesthe installation of new parts INSPECTI0N AND REASSEMBLY ThrottleShaft and Valve 1 Check throttle shaft for excessive wear in b...

Страница 464: ...Tighten seat securely Install float bumper spring Check float setting as follows C 3748 Fig 8 CheckingFloatSwing With the carburetor inverted slide the float gauge C 3903 into position and check the...

Страница 465: ...k Adjustment Thts test can be made ON or O F F the vehicle The choke diaphragm adjustment controls the fuel delivery while the engine is running It positions the choke valve within the air horn by act...

Страница 466: ...se just far enough to recover speed that was lost This procedure will assure that the idle has been set to the leanest mixture possible for smooth idle This setting is very important Since correct spe...

Страница 467: ...ting the BOWL VENT DRILL OR GAUGE NN746 Fig Irl Checking BowlVent Opening NN747A CKET Fig 15 Adjusting Dash Pot stem of the dashpot but not depressing it The ta chrometer should read 2500 rpm if the s...

Страница 468: ...d then dis connect the rod 4 Remove vacuum hose between carburetor air horn and vacuum diaphragm 5 Remove E clip from choke operating link at choke lever and disengage link from vacuum dia phragm stem...

Страница 469: ...from flying out L i f t out float and fulcrum pin 16 Remove power by pass jet and gasket Fig 6 17 Remove screws and lockwashers that hold throttle body to main body Lift off throttle body 18 With mai...

Страница 470: ...1 Fig 8 Porls in Relation to throttle Varfvos speed adjusting screw The idle speed adjusting serow must be backed out when seating the valves in tho followingoperation The dash stamped on the valves m...

Страница 471: ...age valve upper cutting off the supply of fuel through the upper hole No changes in service procedures are required ex cept to be sure the Power By PassJet is clean 6 Install accelerator pump inlet ch...

Страница 472: ...n order to secure the best performance and fuel economy To correctly set the float height when the carbu retor is being overhauled proceed as follows 1 Install float with fulcrum pin and retaining spr...

Страница 473: ...Release the diaphragm stem If the stem moves more than 1 16 inch in 10 seconds the leakage is excessive and the assembly must be re placed Install the diaphragm assembly on the air horn as follows 1...

Страница 474: ...kick adjust ment 4 An adjustment will be necessary if a slight drag is not obtained as drill is being removed Shorten 6r lengthen diaphragm l i n k to obtain correct choke opening Length changes shou...

Страница 475: ...the short or long stroke position a corresponding change must be made in the location of the bowl vent clip and the amount of the lift of the bowl vent rechecked and adjusted The accelerator pump trav...

Страница 476: ...e to close The fast idle speed screw should rest on the slowest speedstep of fast idle cam Fig 22 3 ON C A P CARBURETORS close choke valve until fast idle screw can be positioned on second highest spe...

Страница 477: ...DJUSTING SCREW 2 DO NOT REMOVE SCREWS FROM THROTTLE BODY O R DAMAGE WILL RESULT ACCELERATOR PUMP ROD IN OUTER HOLE OF ROCKER ARM VALVE ACCELERATOR PUMP ROCKER ARM FAST IDLE CONNECTOR ROD CHOKE VACUUM...

Страница 478: ...d remove bowl vent valve spring seat and spring If the old plunger can be used again or if a new plunger is to be installed place plunger in a jar of clean gasoline or kerosene to prevent leather from...

Страница 479: ...Installing Main Metering Jets shaft or valves from the throttle body unless wear or damage necessitates the installation of new parts INSPECTION AND REASSEMBLY Throffle 6ody 1 Check throttle shaft for...

Страница 480: ...ur clean gasoline into carburetor bowl ap proximately 1 2 inch deep Remove pump plunger ACCELERATOR PUMP INTAKE CHECK B OF CYLINDF Fig 8 lnstalling Arcelerrrtor Pump Discharge Check Ball BRASS ROD Fig...

Страница 481: ...rect level of fuel in the bowl After being compressed the tip is very slow to recover its original shape It is very important that the float lip be perpendicu lar to the needle or slanted not more tha...

Страница 482: ...ss in low speed fuel economy Remember that if the pump operating rod is moved to either the short or long stroke position a corres ponding change must be made in the location of the bowl vent clip and...

Страница 483: ...ment if necessary to provide proper link operation TO VACUUM OPERATING LINK FOR ADJUSTMENT II I f DIAPHRAGM STEM JJ RETRACTED BY VACUUM NN701 STANDARD AND CAP CARBURETORS Fig 15 Checking Choke Vacuum...

Страница 484: ...speed and mixture then proceed as follows 1 With engine off and transmission in PARK or NEUTRALposition open throttle slightly 2 ON STANDARD CARBURETORS close choke valve about 20 degrees then allow...

Страница 485: ...hree Tool T 109 287s and one Tool T 109 2888 elevating legs through carburetor throttle body stud holes These tools are used to protect throttle valves from damage and to provide a suitable base for w...

Страница 486: ...d gasket The carburetor now has been disassembled into three subassemblies the air horn main body and throttle body and the components o f each disassem bled asfaras necessary for cleaningand inspecti...

Страница 487: ...bores Tighten screws lightly Hold up to a strong light to check for a proper position in bore They may have to be rotated slightly as the valves areeliptical When properly positioned tighten screws se...

Страница 488: ...etainer in main body 2 Install rubber tipped needle seat and gasket in body and tighten securely 3 Invert main body so that weight of float only is forcing needle against seat Hold finger against reta...

Страница 489: ...of air horn and end of plunger shaft Fig 9 This measurement should be 29 32 or 1 64 inch 1inch for C A P Carburetors 3 To adjust pump travel bend pump connector rod using Tool T 109 213 at lower angle...

Страница 490: ...O DIAPHRAGM 5 Reinstall vacuum hose on correct carburetor fitting Return fast idle linkage to its original condi tion if disturbed as suggestedin Step No 1 6 Make following check With no vacuum applie...

Страница 491: ...to obtain highest rpm While making adjustment carefully watch tachometer and notice that speed can be de creased by turning screws in either direction from setting that gave highest rpm reading 3 Rea...

Страница 492: ...hoke valve about 20 degrees then allow throttle to close The fast idle speed screw should rest on the slowest speed step of fast idle cam Fig 1 4 3 ON C A P CARBURETORS close choke valve until fast id...

Страница 493: ...5 Remove vacuum hose between carburetor air horn and vacuum diaphragm 6 Remove clip from choke operating link and dis engage link from diaphragm plunger stem and choke lever Fig 1 7 Remove remaining...

Страница 494: ...rd gasket 8 Unscrew and remove two idle mixture adjusting screwsand spring from throttle body The carburetor now has been disassembled into three units namely air horn main body and throttle body and...

Страница 495: ...hey are eliptical When valves are properly seated tighten attaching screwssecurely and stake with pliers 8 Install two idle mixture adjusting screws and springs in throttle body The tapered portion mu...

Страница 496: ...torcasting 5 Install venturi cluster gasket then slide venturi cluster down into position Install attaching screws and tighten securely Fig 6 Again depress accelerator plunger A clear straight stream...

Страница 497: ...Fig 2 The choke valve must be held par tially closedwhile installing the air horn 8 Remove two short screws holding main body and throttle body together Fig 3 and install air horn Reinstall two long s...

Страница 498: ...deflect a wire spring before it reaches end of travel within lever slot The link must travel to end SPECIAL GAUGE O R D R I L L AT WIDEST CHOKE OPENING CLOSING T O CHOK Y i 1 Fig 1I Checking Vacuum K...

Страница 499: ...fast idle cam engine o f f fast idle 2 Turn each idle mixture screw in or out until smooth idle has been obtained 3 Readjust to 550 rpm with the idle speed screw 4 Repeat idle mixture screw adjustmen...

Страница 500: ...y slow to recover its original shape It is very important that the float lip be perpendicu lar to the needle or slanted not more than 10 degrees away from the needle when the float is set correctly 7...

Страница 501: ...pump system and one automatic choke control system SERVICE PROCEDURES DISASSEMBLING THE CARBURETOR To disassemble the carburetor for cleaning or over haul Fig l proceed asfollows 1 Place carburetor as...

Страница 502: ...Main Body Disassembly 1 Remove screws that attach acceleratorpump jet housing to main body Lift out jet housing and gasket Fig 3 Discard gasket Now invert main body and drop out discharge check needl...

Страница 503: ...dis assembled as far as necessary for cleaning and in spection It is usually not advisable to remove the throttle shafts or valves unless wear or damage necessitates the installation of new parts Duri...

Страница 504: ...turi 5 Place new primary venturi gaskets in position then install the primary venturi pump and choke side by lowering straight down on gaskets Fig 5 Install attaching screws and tighten securely 6 Ins...

Страница 505: ...ition 5 Slide right and left floats into position in air horn then install float fulcrum pins Be sure marked float is installed on pump side of the air horn See disassemblyprocedures 6 After floats ha...

Страница 506: ...air horn The valve should be evenly spaced on all sides Loosen screws and reposition if necessary 7 Engage throttle connector rod with primary throttle shaft lever then install hairpin clip Install cl...

Страница 507: ...Hg LIGHT AGAIF FAST I ADJUS IEST STEP NK592A 1 ANU KIC OF HIGk c DRILL OR GAUGE Fig 134ad Idle Cam Position Adjustment DRILL OR GAUGE Fig 14 Checking Choke Vacuum Kick Setting 3 Insert specified drill...

Страница 508: ...the lower edge of the primary valve and the bore opposite idle port Fig 17 At this measure ment the secondary valves should just start to open If an adjustment is necessary bend the secondary throttl...

Страница 509: ...rclockwise richer just enough to regain lost r p m The procedure will assure that the idle has been set to the leanest possiblemixture for smooth idle This setting is very important Since the correct...

Страница 510: ...tween piston and cylinder slotswith linkage hanging free 6 Adjust the link connecting the choke shaft to the choke piston lever by bending the link at an angle to give 1 8 d r i l lopening between cho...

Страница 511: ...inlet valve and fuel is drawn into the valve housing chamber On the return stroke the main spring forces the dia phragm to the down position which closes the inlet valve and expels the fuel i n the v...

Страница 512: ...rate reading 3 Vent pump for a few seconds t h i srelieves a i r trapped in fuel chamber If this is not done pump will not operate at full capacity and low pressure Fig 4 64x414A reading will result 4...

Страница 513: ...ct a vacuum gauge on FUEL TANK INDEX Page Page General Information 67 Removing Fuel Tank 68 Installing Fuel Tank 68 Removing Fuel Tank Station Wagon 69 Installing Fuel Tank Station Wagon 70 GENERAL IN...

Страница 514: ...ctor 3 Remove 3 screws that hold filler tube and gas ket to rear quarter panel 4 move 5 screws and washers that attach filler tube seal to floor pan then remove end of vent tube from seal 5 Grasp fill...

Страница 515: ...ing in quarter panel Install a new gasket over end of tube then slowly withdraw tube from tank and into position against quarter panel A l i g n attaching screw holes install screws and tight en secur...

Страница 516: ...tube seal on outer filler tube outer filling vent tube and atmosphericvent tube 2 Position Corbin clamp on outer filler tube and new Keystone clamp on outer filling vent tube slide rubber elbows on t...

Страница 517: ...ing sure it returns to full forward position 9 Loosen cable clamp nut 4 adjust position of cable housing ferrule 5 in the clamp so that all slack is removed from cable with carburetor at curb idle To...

Страница 518: ...gth of carburetor rod 12 by pushing rearward on rod with a slight effort and turning the threaded carburetor lever pin without exerting any forward force on pin when slotted adjuster link 1 is in its...

Страница 519: ...le cam then return carbure 7 tor to curbidle 3 Hold or wire transmission lever 11 firmly forward against its stop while performing adjust ments in the next four steps It is important that the lever re...

Страница 520: ...se on accelerator shaft 1 where it turns in bracket anti rattle spring 2 where it contacts shaft bellcrank pivot pin 8 ball end and pocket 11 at rear end of throttle cable 2 Disconnect choke 4 at carb...

Страница 521: ...ng fix ture Automatic Transmission Fig 5 Coronet with 225 Cu In Eng 1 Apply a thin film of multi purpose grease on accelerator shaft 3 where it turns in bracket bell crank pivot pin 7 ball end and sup...

Страница 522: ...o remove slack from cable move ferrule 5 in the clamp in direction away from carburetor lever NN974A 4 Back o f f ferrule 5 1 4 This provides 1 4 cable slack at idle Tighten cable clamp nut 4 to 45 in...

Страница 523: ...ock nut 18 13 Remove choke valve blocking fixture Manual Transmission Fig 6 WithHem Engine 1 Apply a thin film of multi purpose grease on accelerator shaft 19 where it turns in bracket and roller ball...

Страница 524: ...75 1594 75 1626 75 1591 Diameter 024 029 024 032 ADJUSTMENTS 114 114 114 114 3116 Float Setting Choke Unloader 3116 3116 3116 Fast Idle Cam Position 48 48 48 48 Vacuum Kick drill size 20 41 28 35 Bow...

Страница 525: ...alve Idle Mixture Screw turns open Approx Fast Idle Speed Engine Hot and Screw on Lowest Step of Main Metering Jet ADJUSTMENTS Idle Speed Curb Idle rpm Cam rpm Manual Trans Automatic Trans Control Typ...

Страница 526: ...051 051 1Size Lean 388539 050 O W 049 049 2 Sizes Lean 388539 048 048 047 047 Main Metering Jet Power Jet 2 Stage 031 x 367 031x 067 O Bx 067 028x 067 ADJUSTMENTS Idle Mixture Screws turns open 1 1 4...

Страница 527: ...pe Downdraft Downdraft Downdraft Downdraft ModeI BBD 4296S BBD 4297S BBD 4306S BBD 4307S Engine Displacement cu in 383 Bore 1 9116 Venturi 1 118 Main Metering Jet Standard 120 314s Two Steps Lean 120...

Страница 528: ...rd Type Model Engine Displacement Cu In Primarv THROTTLE BORE Secondary MAIN VENTURI Primary Secondary Primary Secondary Primary Standard 1Size Lean 2 Sizes Lean Accelerator Pump top of plunger to air...

Страница 529: ...e Lockout Adj Float Setting Float Drop Idle Mixture both screws open Control Type Setting When viewed from drivers seat Engine Displacement Cu In THROTTLE BORE MAIN VENTURI MAIN JET LOW SPEED JET STEP...

Страница 530: ...ing Coil Spring On Index On Index CHOKE Control Type Setting Well Coil Spring On Index After Approx 500Miles If Necessary 7116 50 7 32 118 5 32 rt 1 64 1600 650 650 21164 CAP Cleaner Air Package Type...

Страница 531: ...er Piston Index Bowl Vent Valve Setting Fast Idle Speed r p m 1 Idle Speed r p m With air conditioning ON Secondary Throttle Lever Adj Secondary Throttle Lockout Adj Float Setting Float Drop Idle Mixt...

Страница 532: ...1Notch Rich FUEL PUMP SPECIFICATIONS v 8 6 v 8 383 CU In 170 Cu In 273 Cu In 426 Cu In Fuel Pump 225 Cu In 318 CU In 440 Cu In Make Carter Carter Carter Model MS 3674s MS 3962 MS 3672s Type Diaphragm...

Страница 533: ...xcept where noted The propeller shaft used with the 426 Hemi engine is a special selected pro peller shaft having a minimum of runout and very close balance Fig 3 Some Coronet and Dart models due to e...

Страница 534: ...quipped with six cylinder engines use right side of the engine The gauge must be held vertical as shown with arrow on gauge SP 5060 point ing toward the front of car 3 Adjust position of bubble in spi...

Страница 535: ...e from differential and carrier housing and pusition gauge SP 5060on the machined pads with locating pin in rear bolt hole Fig 9 The arrow on gauge should point toward the front of car On models equip...

Страница 536: ...d is installed Presently there are a number of makes of wedge type shims available commercially Always make sure ADAPTER IMPERIAL SP 5053 NN120 shims you use are made of steel and are the same width a...

Страница 537: ...spirit level is within the acceptable range Fig IO Adjusting Gauge on Differential Rear Joint Angle Reference Models with 7 114 Axle Q Fig I I Measuring Rear Universal Joint Angle 9 Reinstall rebound...

Страница 538: ...rear universal joint roller and bushing assembly clamps from rear axle drive pinion flange Figs 3 and 4 Do not disturb the retaining strap used to hold bushing assemblies on universal joint cross if s...

Страница 539: ...ies with Automotive Multi Purpose Grease NLGI EP Grade 2 or Multi Mileage Lubricant part number 2525035 or equivalent Also fill reservoirs in the ends of the cross 2 Place cross in propeller shaft yok...

Страница 540: ...n 8 3 4 Axle 56 17 275 R 273 Cu In Engine aII models 8 3 4 Axle 56 17 2 75 R 3 0 0 2 318 Cu In Engineall models 8 3 4 Axle 5203 275 1 275 R 383 Cu In Engine all models 8 3 4 Axle 52 03 275 1 426 440 C...

Страница 541: ...of the vehicle It is not usually necessary to replace shock absorbers in pairs Their action does NOT change with use Replace a shock absorber only if it is broken or leaking badly not just damp or ha...

Страница 542: ...elling Air 1 With shock absorber removed extend fully in 2 Inspect for evidence of fluid running from up per end of reservoir Actual leakage will be a stream of fluid running down side and dripping of...

Страница 543: ...ble work ing position 2 Using floor stands under axle assembly raise axle to releave load on shock absorber 3 Loosen and remove nut and washer attaching shock absorbers to spring plate mounting stud a...

Страница 544: ...BUSHING NK546A Flg 6 Rear Spring Darf i NP333 Fig 7 Rear Spring Coronet Charger placement procedure 1 Assemble shackle and bushings in rear of spring and rear spring hanger Do not lubricate r u b ber...

Страница 545: ...l weight of vehicle on the wheels tighten pivot bolts and or nuts 60 foot pounds on 170 cubic inch 6 cylinder Dart Fig 9 Zinc lnterleaf and 125 foot pounds on all other models Tighten shackle nuts 35...

Страница 546: ...ckle Rubber Bushing Double Acting Rubber Bushing Zinc lnterleaf used betweenall leaves Models equipped with 426 Hemi or 440 C 1 engine use 6 full spring leaves on left side and 5 leaves PIUS two 112 l...

Страница 547: ...x tends through the housing cover SERVlCE DIAGNOSIS Condition Possible Cause Correction HARD STEERING a Low or uneven tire pressure a Inflate tires to recommended pres sures b Insufficient lubricant i...

Страница 548: ...rms loose at steering f Tighten accordingto specifications knuckles Worn ball joints sary cording to instructions Wheel Alignment necessary g Replace the ball joints as necessary See Front Suspension...

Страница 549: ...sh load Readjust cross shaft adjustment screw if necessary to obtain proper torque reading 4 After adjustments have been completed place front wheels in a straight ahead position and with steering gea...

Страница 550: ...CAUTION The adjuster must be handled carefully to avoid damageto aluminum threads Becareful that ball nut does not run down to either end of wormshaft The ball guide ends can be dam aged if ball nut i...

Страница 551: ...shaft for wear and check fit of shaft in housing bearings Inspect fit of shaft pilot in cover bearing Make sure wormshaft has not been bent or otherwise damaged 18 The cross shaft and wormshaft oil se...

Страница 552: ...ins between 1 1 8and 4 1 2inch pounds 32 Before installing cross shaft pack wormshaft cavities in housing above and below ball nut with steering gear lubricant Use steering gear lubricant whenever pos...

Страница 553: ...ter spline on wormshaft with master spline in coupling and slide steering column assembly down far enough to engage coupling with wormshaft 4 Install coupling pin 5 With jacket clamp bolts loose posit...

Страница 554: ...ects the flow of fluid in the system Fluid is supplied to the steering gear by an engine driven constant displacement type pump through a pressure hose Oil is returned to the pump reservoir from the s...

Страница 555: ...d Tires b See Front Suspension Front Wheel Alignment Group 2 c If vehicle leads to the left move the steering valve housing down on the steering housing If vehicle leads to the right move the steering...

Страница 556: ...rust bearing ad c Repair as necessary d Coupling loose on the worm shaft d Inspectwormshaft splines for wear justment a Oil leaking past worm shaft oil seal a Recondititon steering gear b Broken or wo...

Страница 557: ...m pressed air Lubricate pistons and bores with power R CROSS SHAFT S E C T O R G E A R _ NY1248 P W E R PISTON 2 steering fluid 8 Install steering spool valve in valve body so valve lever hole is alig...

Страница 558: ...f grease retainer Place the two half rings SP 1932 and Tool retainer ring over both portions of the Tool Fig 5 Turn the tool nut counter clockwise to withdraw grease retainer from housing 4 Remove oil...

Страница 559: ...383 and 440 Cu In Engines Remove steering gear from under vehicle Coronet and Charger Models 426 Cu In Engine Remove battery and battery tray From topside of engine compartment remove left engine mou...

Страница 560: ...ce power train vertically in a vise equipped with soft jaws to avoid damaging piston assembly See Fig 13for parts identification The 33 worm bearing needle rollers will fall out when housing head is r...

Страница 561: ...MyMopar com...

Страница 562: ...16from the piston flange should not exceed 008inch when the end of bearing race thick spring HOUSING HEAD NY1245A Fig 15 Removing Reaction Seal From Worm Shaft Support 0 RINGS HEAD KR46 Fig 16 Removin...

Страница 563: ...NG NUT 19 17 d KR65A PUNCH Fig 20 Checking Center Bearing Preload wormshaft in this position with splined nut Tool C 3637 and socket wrench and hold in this position thru items 35 and 36 then tighten...

Страница 564: ...side of seal out Fig 22 Install 0 ring in groove on housing head 44 Slide housing head and arbor Tool C 3929 over the wormshaft carefully engaging cylinder head ferrule and 0 ring and making sure rea...

Страница 565: ...both direc tions and observe the action of the lever It must be in the center of the hole and snap back to its center positionwhen the worm torque is relieved 58 Install valve body on housing making...

Страница 566: ...rter lower engine into posi tion and install left front engine mount stud washer and nut Coronet and Charger Models 273 318 383 and 440 Cu In Engines Install steering gear on mounting bracket from und...

Страница 567: ...et side of the pump to the flow control valve In the 1 2 pump orifices in the metering insert permit a flow of approximately two gallons per minute to the steering gear before the valve moves to the l...

Страница 568: ...els against the stops the pressure built up in the steering gear also exerts pressure on the spring end of the flow control valve This action forces the pressure relief ball from its seat and allows o...

Страница 569: ...ounds or replace as necessary g Rear bolt holes stripped or casting g Repair if possible or replace pump cracked See CoolingSystem Group 7 9 4Pump Only SERVICE PROCEDURES CheckingFluid Level 9 I 2 Mod...

Страница 570: ...cking bolt 2 Install drive belt and adjust See Cooling System Group 7 Tighten pump bracket bolts to 30 foot pounds 3 Connect pressure and return hoses routing the hoses in same position they were in b...

Страница 571: ...dels 1 Remove pump from engine Fig 9 Removing Ferrule f 96 Pump Shown 2 Clamp pump in vise upside down to prevent chips from falling into pump 3 Use a No 4 screw extractor E Z out and turn into ferrul...

Страница 572: ...agnet If valve is stuck in bore it may be necessary to push in on valve against spring pressure Release pressure exerted against valve abruptly and allow valve to spring out of bore 3 Clamp land end o...

Страница 573: ...ft Use caution in handling rotor to prevent damage to sharp corners which are necessary for good pump performance 8 Install springs by turning clockwise into pockets in rotor using a pencil with point...

Страница 574: ...bind 16 Replace shaft seal See Oil Seal Replace ment and 0 ring seal on front insert Lubricate and position insert in pump body so punch marks align with punch marks on pump flange Fig 12 17 Support p...

Страница 575: ...pringunder cover should push cover up 9 Remove pump body from vise place in inverted position on flat surface and tap end of drive shaft with plastic hammer to loosen pressure plate rotor and thrust p...

Страница 576: ...face of cam ring for heavy scuff or chatter marks Replace if necessary Light score or scuff marks can be removed by polishing with a small flat oil stone 6 Inspect end cover for nicks or burrs on sur...

Страница 577: ...n pump cavity by pressing down on pressure plate with both thumbs 11 Place spring in groove in pressure plate and position end cover lip edge UP over spring 12 Press end cover down below retaining rin...

Страница 578: ...tart engine and inspect for leaks COLUMN INDEX Page Steering Column Automatic Transmission 33 GENERAL INFORMATION The new 1967 steering column under head on col lision conditions is designed to telesc...

Страница 579: ...es that allows the mounting bracket to slip off the at taching points permitting the steering column to compress or yield in a forward direction under a severe impact from the driver side SERVICE PROC...

Страница 580: ...pry lower coupling from steering gear wormshaft then remove column assembly out through passenger compartment being careful not to damage paint or trim Disassembly 1 Remove four bolts attaching brack...

Страница 581: ...refully pull wiring through gearshift housing 9 If shift lever gate requires replacement Fig 8 TURN SIGNAL SWITCH NP7 Fig 7 Removing or fnsfafling Bearing Housing BEA RING HOUSING c A SHIFT LE RETAINI...

Страница 582: ...all snap ring in lower groove on upper end of steering shaft Slide shaft assembly into column and through upper bearing by hand Install Tool C 3879 washer and steering wheel nut Fig lo pull shaft thro...

Страница 583: ...down the jacket and into recess in floor plate position re taining plate over 0 ring and secure with the two bolts Do not pry to align plates and attaching bolts or column misalignmentwill occur 6 Pla...

Страница 584: ...careful not to damage paint or trim Disassembly 1 Remove four bolts attaching bracket assembly to column jacket Fig 1 Set bracket aside to pro tect breakawaycapsules 2 Remove two screws and lift off w...

Страница 585: ...any signs of roughness or wear it should be replaced Replacement bearings are pre lubricated Assembly Apply a thin coating of Multi Purpose grease to all friction surfaces 1 Coat spring washer with g...

Страница 586: ...steering wheel nut Fig 9 pull shaft through bearing then install upper snap ring 13 Position turn signal switch in bearing housing install switch retainer plate and secure with the three screws 14 Be...

Страница 587: ...r 9 Place steering wheel on steering shaft with master splines aligned Install retaining nut and wash er tighten nut to 24 foot pounds Do not drive wheel on shaft draw wheel down with retaining nut 10...

Страница 588: ...TEERING Foot Foot Pounds Pounds 55 Cross Shaft Adjusting Screw Lock Nut 35 Steering Arm Nut 120 Cross Shaft Cover Bolt 25 Steering Wheel Nut 24 Gear Assembly to Frame Bolt POWER STEERING GEAR Foot Inc...

Страница 589: ...e synchromesh type with helical cut gears to provide silent operation The countershaft gear is in constant mesh and is supported by roller bearings at each end The mainshaft front end is piloted in ro...

Страница 590: ...rs in neutral The neutral de tent balls must be engaged to make this adjustment correctly To check this start engine with clutch disengaged then release clutch slowly 2 Inspect fore and aft movement o...

Страница 591: ...6 Make sure clutch pedal free play is adjusted to specifica tions 2ND AND 3RD CONTROL ROD Fig 4 A 903 A 745bearshift Controls Dart Models Fig 5 A 903 A 745 GearshiftControls Coronet Models 8 Loosen c...

Страница 592: ...Fig 7 6 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into extension housing and tighten retainer bolt to 100 inch pounds EXTENSION HOUSING AND BUSHING...

Страница 593: ...haft to rear axle pinion shaft yoke SERVICE OUT OF VEHICLE TRANSMISSION REMOVAL Removal 1 Drain lubricant from the transmission 2 Disconnect propeller shaft at rear universal joint Carefully pull shaf...

Страница 594: ...ghtly then slide synchronizer front inner stop ring from the short splines on pinion as assembly is being removed from the case Fig 15 3 Remove snap ring Fig 16 which locks bear ing on pinion shaft Re...

Страница 595: ...countershaft bearing arbor Tool C 578 for A 903transmission or 2 3834 for A 745transmis sion drive countershaft toward rear of case until small key can be removed from countershaft 3 Drive countersha...

Страница 596: ...e Remove bearing rollers from gear CLUTCH GEAR SYNCHRONIZER SLEEVE S T O P INNER RING O U T E R RING ASSY S NB120A Fig 18 A 745 Synchronizer Unit C L U T C H G E A R SNAP RING SPE NY854B Fig 19 Removi...

Страница 597: ...hem off with a fine mill file If threads are stripped install Helicoil inserts Ball Bearings Wash ball bearings using a clean solvent and blow dry with compressed air CAUTION Do not spin bearings with...

Страница 598: ...RANSMISSION CountershaftGear To reassemble transmission refer to Fig 12 or 13 then proceed as follows 1 Slide countershaft gear bearing roller spacer over arbor Tool C 578 for A 903 transmission or C...

Страница 599: ...ring is bottomed all way around in groove Fig 19 Fig 25 Installing Detent Balls 2ND SPEED GEAR SPREADER AGAINST THIS FACE INSERT SHIM 64x498 Fig 26 Synchronizer Float Shim location 5 A 903 Install 2n...

Страница 600: ...lts to 15foot pounds 7 Install speedometer pinion and adapter assem bly 8 Install drain plug and back up light switch and tighten securely 9 Refill transmission with Automatic Transmis sion Fluid AQ A...

Страница 601: ...s of roller bearings and one at each Page Service Out of Vehicle 17 Assembling Transmission 23 Disassembling Transmission 17 Transmission Installation 25 Transmission RemovaI 17 Specifications 93 Tigh...

Страница 602: ...and work it rearward to disengage from front of console Disconnect any wiring connected to finish plate work rubber boot over lever T handle and remove plate and boot assembly 4 Remove four screws sec...

Страница 603: ...Speedometer Pinion Chart for pinion usage 1 Remove bolt and retainer securing speedometer SPEEDOMETER PINION CHART A 833 4 SPEED OUTPUT SHAFT DRIVE GEAR 13 TEETH lire Axle Ratios Size Number of Pinion...

Страница 604: ...osition Fig 4 6 Install retainer and bolt with retainer tangs in adapter positioning slots Tap adapter firmly into ex tensiort housing and tighten retainer bolt to 100 AD9PTER OIL SEAL B O L T AND WAS...

Страница 605: ...drive pin ion shaft clears clutch disc before lowering trans mission 10 Lower transmission and remove from under vehicle Thoroughly clean exterior of unit preferably by steam Mount transmission in rep...

Страница 606: ...21 18 TRANSMISSIONS4 SPEED 3 0 Fig IO A 833 transmission 64X740C MyMopar com...

Страница 607: ...ating Lever Housing Bearing 70 Flatwasher 51 Countershaft Gear Cluster 52 Needle Bearing Rollers 73 Gearshift Control Housing 74 1st and 2nd Operating Lever 3 Carefully push gearshift lever shafts out...

Страница 608: ...IN SLEEVE G E A R 2ND SPEED GEAR 1ST AND 2ND SYNCHRONIZ CLUTCH GEAR EXTENSION HOUSING v PLIERS 64x744 Fig I5 Removing or Installing Rear Bearing Snap Ring Front 64x745 EXTENSION HOUSING Fig I6 Removin...

Страница 609: ...3638 Power Steering Worm Shaft Seal Remover or 3 3642 Pump Shaft SealRemover Fig 23 Place tool in case with socket against end of shaft and other end of tool against the case Turn screw counterclockw...

Страница 610: ...sed air CAUTION Do not spin bearings with air pressure turn slowly by hand Spinning unlubricated bearings may cause damage to racesand balls Be sure ball bearings are clean then lubricate them with li...

Страница 611: ...Allow gear assembly to rest on bottom of case Besure thrustwashers stay in position 5 Press main drive pinion bearing on pinion shaft Be sure outer snap ring groove is toward front Fig 27 Seat bearing...

Страница 612: ...d all around its slot 8 Slide third speed gear over mainshaft with synchronizer cone toward front followed by third gear stop ring Fig 14 9 Install third and fourth speed synchronizer clutch gear asse...

Страница 613: ...le 2 Raise transmission until drive pinion is centered in clutch housing bore 3 Roll transmission slowly forward until pinion shaft enters clutch disc Turn pinion shaft until splines are aligned then...

Страница 614: ...lator Piston and Spring 71 Extension Housing Bushing and Oil Seal 71 Front Clutch A 904 G and A 904 LA 76 Front Clutch A 727 A and B 78 Governor and Support 72 Kickdown Servo and Band 88 Low Reverse S...

Страница 615: ...MyMopar com...

Страница 616: ...w c Z z 2 E m w v v 6 Y V 41 w t 5 n 4 m P 0 P 3 3 E L f r C 8 Q 5 0 c P P 0 Q Y 0 3 0 c e 4 f P I t P 2 ij E v i Y Z V Z w MyMopar com...

Страница 617: ...the various valves with color coded passages to indicate those under hydraulic pressure for all operations of the transmission The hydraulic control system makes the transmis sion fully automatic and...

Страница 618: ...21 30 TRANSMISSlON S T ORQUEFLlTE 0 Park Hydraulic Circuits CONTROL SYSTEM IN PARK ENGINE RUNNING NN34A CONTROL SYSTEM IN NEUTRAL ENGINE RUNNING Neutral Hydraulic Circuits NN35A MyMopar com...

Страница 619: ...0 TORQUEFLITE TR ANSMISSI0NS 21 31 TORQUE CONVERTER TO LUB PUMP I I HALF THROTTLE NN36A Drive Breakaway Hydraulic Circuits MyMopar com...

Страница 620: ...21 32 TRANSMISSIONS TORQUEFLITE 0 ruw SUCTION COWVEllEl 30 15 p CONTROL SYSTEM IN DRIVE SECOND HALF THROTTLE NN37A TO LUB PUMP 7l Drhro Soeond Hydraulic Circuits MyMopar com...

Страница 621: ...ONVERTER MANUAL VA PUMP 1 1 1 OIL FILTER 1 1 1 r r r r 1 OIL PRESSURES LINE SI 90psi PUMP SUCTION THROTTLE 0 90 psi GOVERNOR 6 90 psi CONVERTEl 30 75 psi LUBRICAIION 140 psi CONTROL SYSTEM IN DRIVE DI...

Страница 622: ...PUMP B TORQUE CONVERTER TO LUB 011 PRESSURES I LlWt H P ruw SUCTION IHROrnt w r i GOVtlNOI 60 65 ri CONVtIlfR 30 15 psi LUbIICAIIOW 5 30 pi CONTROL SYSTEM IN DRIVE KICKDOWN AT 50 M P H NN39A Drive Kic...

Страница 623: ...NVERTER TO LUB PUMP OIL FILTER I 0 1 1 PRESSURES LlNf 15 psi PUMP SUCTION GOVfllWOR 6 55 psi COllVfRlfR 30 15 psi LUBRICATION 5 30 psi i CONTROL SYSTEM IN MANUAL SECOND CLOSED THROTTLE NN40A Selector...

Страница 624: ...c Soiedor Lever Low Hydrouiic Cinuilr 011 PRESSURES LIWE SIpl ruw su iow 6OVttWOI O J O p l tOllVERlEI XIS pl a LUIIICITIOW CONTROL SYSTEM IN MANUAL LOW CLOSED THROTTLE NN41A MyMopar com...

Страница 625: ...SSIONS 21 37 TORQUE C0NVERTER TC LUB PUMP 1 W OIL PRESSURES LINE PUMP SU TI0N ONVERIER LUBRKATION 230 260 psi I E 30 15 psi 5 CONTROL SYSTEM IN REVERSE OIL FILTER l l l l l l l Reverse Hydraulic Circu...

Страница 626: ...ft at approximately the speeds shown in the Shift Pattern Summary Chart All shift speeds given in the Chart may vary somewhat due to pro duction tolerances and rear axle ratios This is not too importa...

Страница 627: ...tow a disabled vehicle with a rear end pickup or remove the propeller shaft SERVICE DIAGNOSIS The transmission should not be removed nor disassembled until a careful diagnosis is made the definite ca...

Страница 628: ...g linkage or faulty band lining Repair as required j Worn or faulty front clutch j Disassemble and inspect clutch Re pair as required k Worn or broken input shaft and or k Inspect and replace seal rin...

Страница 629: ...t Hydraulic pressures too high or low e Perform hydraulic pressure tests and adjust to specifications Governor sticking f Remove and clean governor Replace parts if necessary Oil filter clogged g Repl...

Страница 630: ...c Valve body malfunctionor leakage c Perform pressure tests to determine cause and correct as required d Faulty oil pump d Perform hydraulic pressure tests ad just or repair as required e Clutches or...

Страница 631: ...r sticking broken seal band linkage malfunction rings binding linkage or faulty band lining Repair as required d Front and or rear clutch faulty d Disassemble and inspect clutch Re pair or replace as...

Страница 632: ...epair without removing the transmission from the vehicle The removal reconditioning and installa tion procedures for these components are covered here except the valve body reconditioning which is des...

Страница 633: ...r tap the pan to break it loose allowing fluid to drain then remove the oil pan 3 Remove access plate from in front of converter remove drain plug allowing fluid to drain Fig 3 Install and tighten con...

Страница 634: ...rench Fig 7 Unscrew button spring and knob as sembly from cable end and remove from the lever 3 Coronet and Charger Models Remove two Fig 6 External Controls and Adjustments C A B L E END SHIFT L E V...

Страница 635: ...in NEUTRAL thread but ton spring and knob assembly on the cable end until serrated surface on button is approximately 1 32 inch above top of knob Secure knob with set screw 4 Connect battery ground ca...

Страница 636: ...ew in this position and tighten lock nut to 29foot pounds Low and Reverse Band move the oil pan 1 Raise vehicle drain transmission fluid and re 2 Loosen adjusting screw lock nut and back off nut appro...

Страница 637: ...n spring 13 in place 8 Remove wire securing transmission lever then check transmission linkage freedom of operation move slotted adjuster link 1 to full rearward posi tion then allow it to return slow...

Страница 638: ...the ball end with a slight downward effort on rod 5 Assemble ball socket 2 to ball end and remove 3 16 rod 9 from upper bellcrank and lever 6 Disconnect return spring 13 then adjust length of carbure...

Страница 639: ...4 pivot points of both upper 6 and lower 7 linkage bell cranks ball end and pocket 15 at rear end of throttle cable 2 Disconnect choke 8 at carburetor or block choke valve in full open position Open...

Страница 640: ...move ferrule 14 in the clamp in direction away from carburetor lever 4 Back off ferrule 14 1 4 inch to provide 1 4 inch cable slack at idle Tighten cable clamp nut to 45 inch pounds 5 Connect choke r...

Страница 641: ...just position of cable housing ferrule 6 in the clamp so that all slack is removed from cable with carburetor at curb idle To remove slack from cable move ferrule 6 in the clamp in direction away from...

Страница 642: ...ar end of throttle cable 2 Disconnect choke 8 at carburetor or block NN974A choke valve in full open position Open throttle slightly to release fast idle cam then return carbu retor to curb idle 3 Loo...

Страница 643: ...tor is also at wide open throttle To lengthen this rod 4 turn adjusting stud 17 clockwise as viewed from front of engine Tighten the lock nut 18 13 Remove choke valve blocking fixture Manual Transmiss...

Страница 644: ...essure 1 Connect a 0 300psi pressure gauge Tool 2 3293 to apply pressure take off point at rear servo Fig 21 2 With transmission control in R reverse posi tion and engine speed set at 1600 rpm reverse...

Страница 645: ...he adjusting screw may be turned with an Allen wrench One complete turn of adjusting screw changes closed throttle line pressure approximately 1 2 3 psi Turning adjusting screw counter clockwise incre...

Страница 646: ...tion of servo is indicated by a tightening of front band Spring tension on servo piston should release the band L L I 1 FROM TORQUE CONVFRTFR 0 TORQUE I Fig 25 Air Pressure Tests If clutches and servo...

Страница 647: ...RING I TOOL S E A L NP2 Fig 28 Installing Speedometer Pinion Seal TOOL NN361 Fig 29 Removing ExtensionHousingYoke Seal range numbers aligned with 6 o clock position Fig 26 6 Install retainer and bolt...

Страница 648: ...NAP GROOVE RING Fig 32 Output Shaft Bearing lnstallafion 1 Place a new extension housing gasket on the transmission case Position output shaft bearing re taining snap ring in extension housing Slide e...

Страница 649: ...secure with snap ring inside of large governor weight Place weight assembly in governor body and install snap ring 4 Place governor valve on the valve shaft insert assembly into the body and through...

Страница 650: ...on the valve body 4 Place valve body manual lever in LOW position Lift valve body into its approximate position connect Fig 36 Parking Lock ControlRod Retaining Clip Fig 37 Installing Valve Body Manua...

Страница 651: ...the transmission 12 Disconnect oil cooler lines at transmission and remove oil filler tube Disconnect the speedometer cable 13 Disconnect propeller shaft at rear universal joint Carefully pull shaft...

Страница 652: ...alternately on opposite sides of converter to minimize distortion 3 The following suggestions are offered as an aid in making the weld a Do not gas weld b Use a D C welder that is set at straight pola...

Страница 653: ...d by compressed air Do not wipe parts with shop towels All mating surfaces in the transmission are accurately machined therefore careful handling of parts must be exercised to avoid nicks or burrs Dri...

Страница 654: ...lve body manual lever Fig 36 3 While lifting valve body upward out of trans mission case disconnect parking lock rod from the lever Accumulator Piston and Spring piston from the case 1 Lift spring off...

Страница 655: ...aft and driving shell carefully slide assembly forward and out through the case TRANSMISSION VENT CAUTION Be very careful not to damage ground sur faces on output shaft during removal Rear Band and Lo...

Страница 656: ...SEMBLY CAUTION Never clamp any portion of valve body or transfer plate in a vise Any slight distortion of the alumin m body or transfer plate will result in stick ing valves excessive leakage or both...

Страница 657: ...aft Remove the detent ball and spring 9 Remove manual valve carefully slide it out of valve body with a rotating motion 10 Remove throttle lever and shaft from the valve body 11 Remove shuttle valve c...

Страница 658: ...perating levers and shafts for being bent worn or loose If a lever is loose on its shaft it may be silver soldered only or lever and shaft assembly should be replaced Do not attempt to straighten bent...

Страница 659: ...that it engages manual valve and detent ball Install seal retaining washer and E clip on throttle shaft 10 Position valve body assembly on the repair stand 11 Place six steel balls in valve body cham...

Страница 660: ...bolts and separate support from governor body 1 Remove large snap ring from weight end of 2 Remove snap ring from inside governor weight 3 If lugs on support gear are damaged remove Cleaning and lnsp...

Страница 661: ...SP 3633 and hex nut Tool SP 1191 Fig 61 CAUTION Do not clamp any part of reaction shaft or support in a vise 2 With cup held firmly against reaction shaft thread remover into bushing as far as possibl...

Страница 662: ...3283 into threaded holes of reaction shaft support flange 2 Assemble and place rotors in center of the sup port Fig 62 3 Lower pump body over the pilot studs insert Tool C 3756through pump body and e...

Страница 663: ...sing a blunt punch or similar tool Fig 65 A gentle tap at each stake slot location will suffick 8 Using a narrow bladed knife or similar tool re move high points or burrs around staked area Fig TOOL H...

Страница 664: ...pump housing Fig 74 2 Install reaction shaft support and position vent baffle over vent opening Install retaining bolts and tighten to 150inch pounds 3 Place a new oil seal in opening of pump housing...

Страница 665: ...lide a new bushing on installing head Tool SP 3626 and start them in clutch retainer bore Fig 69 4 Install handle Tool SP 3549 in installing head Drive bushing into clutch retainer until tool bottoms...

Страница 666: ...are the same as those used in rear clutch and are available in 060 062 068 070 and 076 078 inch thickness FRONT CLUTCH A 727 A AND B Disassembly Figure 71 shows a disassembled view of the front clutch...

Страница 667: ...ling head Tool SP 3628 and start them in clutch retainer bore 4 Install handle Tool SP 3549in the installer Fig 73 Drive bushing into clutch retainer until tool bottoms 5 Thoroughly clean clutch retai...

Страница 668: ...and are available in 060 062 074 076 and 088 090 inch thickness REAR CLUTCH A 904 G AND A 904 LA Disassembly Figure 78 shows a disassembled view of the rear clutch assembly 1 Remove large selective sn...

Страница 669: ...wear Washer thickness should be 043 to 045inch replace if necessary Assembly 1 If removed press input shaft into piston re tainer and install snap ring 2 Lubricate and install inner and outer seal rin...

Страница 670: ...es pressure plate in clutch retainer Lift pressure plate clutch plates and inner pressure plate out of the re tainer 2 Carefully pry one end of wave spring out of its groove in clutch retainer then re...

Страница 671: ...removed press input shaft into clutch piston retainer and install snap ring 2 Lubricate and install inner and outer seal rings on clutch piston Make sure lip of seals face toward head of clutch retai...

Страница 672: ...emove thrust washer from forward side of rear planetary assembly and remove planetary gear set from rear annulus gear If necessary remove snap ring from rear of annulus gear to separate support from a...

Страница 673: ...40 044 048 052 and 059 065 inch thickness n TORQUEFLITE TRANSMISSIONS 21 85 PLANETARY GEAR TRAIN A 727 A AND B Measure end play of planetary gear assemblies sun gear and driving shell before removing...

Страница 674: ...lace thrust washer in side the front driving shell 5 Place thrust washer on rear hub of front plane tary gear set then slide assembly into front annulus gear 6 Carefully work front planetary and annul...

Страница 675: ...emove four bolts securing output shaft support to rear of transmission case Insert a punch through bolt holes and drive cam from the case Fig 90 Alternate punch from one bolt hole to another so cam wi...

Страница 676: ...seal rings unless conditions war rant Inspect piston for nicks burrs scores and wear Inspect piston bore in the case for scores or other damage Inspect fit of guide on piston rod Inspect A ADAPTER Fi...

Страница 677: ...xactly as shown in Figure SPRl Fig 96 Overrunning Clutch Low and Reverse Band Link 96 Low Reverse Servo and Band 1 Carefully work servo piston assembly into the case with a twisting motion Place sprin...

Страница 678: ...clutch plate splines are fully engaged on rear clutch splines 5 Align rear clutch plate inner splines grasp in put shaft and lower the two clutch assemblies into the transmission case 6 Carefully work...

Страница 679: ...cumulator piston 3 Insert parking lock rod through opening in rear of case with the knob positioned against the reaction plug and sprag Move front end of rod toward center of transmission while exerti...

Страница 680: ...onverter bolts Tighten bolts to 270 inch pounds 11 Install crossmember and tighten attaching bolts securely Lower transmission so extension hous ing is aligned and rests on rear mount Install bolts an...

Страница 681: ...chronizer Float 050 to 090 Trans Models A 833 Lubricant Gear Ratio 4 Forward Speeds Capacity Approx 8 1 2 Pts Imp Meas 7 Pts First 2 66 Type Warm Climate Second 1 91 Multi Purpose Gear Third 1 39 Oil...

Страница 682: ...273 Cu In Eng 4 383 440 Cu In Eng 5 426 Hemi 3 3 273 Cu In Eng 4 4 273 Cu In Eng 2 170 225 Cu In Eng 3 170 225 Cu In Eng GEAR RATIOS 022 to 091 056 to 104 4 Disc SNAP RINGS THRUST WASHERS Output Shaf...

Страница 683: ...nd Adjusting Screw Lock Nut Kickdown Lever Shaft Plug Converter Bolt 270 Case Bolt 24 Mounting Bolt 35 Frame Bolt 75 A 727 A and B 29 100 A 904 G A 904 LA 25 150 Foot Pounds 50 15 Foot Pounds Shift Le...

Страница 684: ...ill have longer life than tires used for high speed driving in hot climates with heavy loads Abrasive road surfaces will accelerate tire wear Driving habits have more effect on tire life than any othe...

Страница 685: ...ght They assist in retaining air and also keep foreign LEfT FRONT RIOHT FRONT LEFT REAR s x RlQHT l IREAR Fig 1 tire Rotation material out of the valve Tire Rotation Under normal operating conditions...

Страница 686: ...erns An inspection of the tires together with informa tion as to locality of vehicle operation will usually in dicate whether abnormal wear is due to operating UNDER INFLATION conditions or to mechani...

Страница 687: ...statically out of balance and can produce a bouncing motion A wheel and tire to be in dynamic balance must first be in static balance and also be in balance from inside to outside A wheel not in dynam...

Страница 688: ...4 Remove bolts that attach disc brake caliper assembly to steering knuckle 5 Slowly slide caliper assembly up and away from brake disc and support caliper assembly on steering knuckle arm CAUTION Do n...

Страница 689: ...eel Bearing Adjustment 7 Slowly slide caliper assembly down on brake disc assembly and position correctly 8 Install caliper assembly over disc and align mounting holes Install mounting bolts and tight...

Страница 690: ...Dart 55 Coronet Charger 65 Wheel Stud Nut Equipment Qualifications The factory installed tires on your car are selected to provide adequate load carrying capacity for all vehicle loads up to the full...

Страница 691: ...0 1150 I 1200 1 Cold inflation pressures must not exceed 32 psi for 4 ply rating and 40psi for ply rating tires Pressure build up during driving is normal Do not reduce pressure of warm tires 2 In cas...

Страница 692: ...tructure and the body assem bly An integral fore structure assembly extending for ward of the front passenger compartment is bolted to the Unibody with ten body bolts eight of these lie in a fore and...

Страница 693: ...od of testing is to rub the back of a fingernail over the surface of the material Synthetic materials appear to whistle when this is done Spots and Stains When using water to remove a spot be sure t o...

Страница 694: ...or sponge Avoid over soaking the material do one section at a time only Frequently stains will be evident when material is damp but will disappear when dry Use care not to damage fabric by attempt ing...

Страница 695: ...dallions name plates or any other ex terior ornamentation Bright Metals When cleaning anodized aluminum use care not to rub through the anodized coating Bumpers grilles exterior mouldings wheel covers...

Страница 696: ...4 18 25 18 26 25 26 25 25 26 25 26 18 18 20 19 21 18 23 23 24 24 24 23 14 16 13 12 14 13 12 Page CoronetCharger Dart Trim Panels 14 Weatherstrips 16 Windcords 16 FENDERS 8 GRILLE 10 HOOD 6 Alignment 6...

Страница 697: ...until spacing appears equal 3 Tighten bolts lower hood and inspect fit When spacing is correct on one side only loosen hood to hinge bolts on side to be adjusted If hood needs to be moved out insert a...

Страница 698: ...d with hinge and 3 Close hood and inspect alignment GROMMET NP590 Flg 5 Hood Lack and Striker Coronet 4 Adjust alignment and tighten bolts 180 inch 5 Remove protective coverings pounds LOCK To adjust...

Страница 699: ...can be shifted slight ly forward 1 Loosen fender to cowl side panel screws and move fender forward 2 When spacing between door and fender is cor rect and hood is even with front end of fender tighten...

Страница 700: ...nder fenders remove splash shield to 4 Remove support to frame screws and support wiring from core support core support screws lnstallation screws finger tight core support screws finger tight only pr...

Страница 701: ...dures for internal door com ponents do not include obvious operations such as re moving door or quarter panel trim panels testing GRILLE ALIGNMENT AND REPLACEMENT Refer to Figs 17 18 and 19 for grilIe...

Страница 702: ...a line around upper and lower hinge straps 2 Place a wooden block on lifting plate of a floor jack and position it under door Support door near center of balance when hinge bolts are loosened 3 Loose...

Страница 703: ...ar bolts 5 Loosen lower hinge to pillar bolts 6 Raise or lower jack until lower part of door is in desired position lowering jack moves lower end into door opening 7 Tighten attaching bolts 8 Close do...

Страница 704: ...nstallation 1 With door inner hardware installed place door in position in door opening supported by a padded jack 2 Position hinge plates on door and install screws finger tight only 3 Adjust jack to...

Страница 705: ...the retaining clips Snap clips out of door panel and remove trim panel 4 Before installing trim panel make certain the watershield is properly cemented in place 5 With escutcheon spring placed on regu...

Страница 706: ...control rod from lock 4 Remove lock assembly to door screws 5 Rotate lock and disconnect remote control link 6 Lubricate all moving points of lock assembly when removing lock lnstaIlation mote control...

Страница 707: ...s Connectlock link to lock OUTS1DE HANDLE Front Door Removal 1 With door glass in up position remove nuts from mounting studs Figs 34 and 35 and link from handle to lock 2 Lift handle up and out of do...

Страница 708: ...into holes 3 Position pillar seal at belt line Make sure weatherstrip dove tails into groove of seal and install screws Fig 36 Door Weatherstrips Dart Sedan Fig 37 Door Weatherstrips Coronet Sedan Cor...

Страница 709: ...g type retainers Fig 42 Windcords method of attachment for the windcords GLASS S EDAN MODELS Coronet Front Door Glass and Vent Wing Adjustments even or slightly below belt line edge of glass and tight...

Страница 710: ...support boor Glass Replacement Removal 1 Loosen front run channel lower mounting screw OUTER WEATHERSTRIP SECTION A A WEATHERSTRIP NP609 Fig 42 Belt Weathersfrips Dart Figs 44 and 45 channels 2 Move c...

Страница 711: ...Assemblies magnet type Direction of rotation is determined by polarity of the leads to the motor The door switches control the polarity and thus the direction of rotation All motors are grounded thro...

Страница 712: ...each switch in the same manner Motor Bench Test Connect a jumper from the positive terminal of a test battery to one of the motor leads Connect an other jumper from the test battery negative terminal...

Страница 713: ...nt Adjust rear run channel lower end in or out Adjust down stopso glass top edge is flush with edge of open ing in door Vent Wing Replacement Removal 1 Remove nut and washer from lower vent frame stud...

Страница 714: ...ft bracket 1 Loosen division channel lower screw Fig 53 2 Move glass to the rear and remove regulator 3 Remove glass from door 4 Push plug out of lift bracket rivet Fig 52 pinch ends of rivet together...

Страница 715: ...ss If additional channel movement is required lower the glass and loosen the attachment screw at lower end of channel If additional in or out movement is re quired to obtain proper glass alignment adj...

Страница 716: ...ew NP618 Fig 58 Rear Door Stationary Glass Dart INNER 4 I IFORE AND AFT IN AND OUT CHANNEL S U P P O R T i BRACKET REGULATOR S T O P NN492 Fig 59 Front Door Glass Adjustments Coronet Charger 9 Tighten...

Страница 717: ...lacement Manual and Electric The regulators are attached to the door inner panels with screw and washer assemblies Fig 46 Electric Regulator Motor Whenever it is necessary to remove the motor from the...

Страница 718: ...oor and disengage regulator arm from glass lift bracket and remove from door 7 Invert vent wing and door glass assembly and remove adjusting stud rod and retainer from vent wing Fig 66 8 Slide door gl...

Страница 719: ...W Fig 69 Regulator Assembly over tighten the mounting screws or the moulding will become damaged at the screw hole area Figs 70 and 71 TRIM PANELS The rear seat cushion and back must be removed to ga...

Страница 720: ...and remove stud 1 Remove clip attaching regulator front arm stud A A MANUAL LIFT CONVERT BLE NN794 2 Move glass rearward and disengage regulator rear arm roller from pivot bracket channel 3 Removequa...

Страница 721: ...KET U P AND DOWN REGULATOR S O P NN496 Fig 75 Querrlsr Window Adjustments Sedcm bPIVOT BRACKET NN798 CLIP Fig 76 Qucrrter Window Repkrcement Sdun HARDTOP MODELS CORONET CHARGER Adjustments 1 With door...

Страница 722: ...nd tighten regulator stop against regulator sector stop 12 Position and tighten down stop against bumper INDEX POINT NOTCH Fig 794lasr Run Sedan REGULATOR STOP NN495 Fig 80 Quarter Window Adjustments...

Страница 723: ...t track brace Fig 84 to inner panel and front track and remove brace PIVOT BRACKET Fig 83 Quurter Window Regulators Hurdtop Fig 84 Quarter Window Front Truck Hardtop 2 Remove nut and washer attaching...

Страница 724: ...er from glass frame center slot 4 Raise glass and disengage from rear stabilizer 5 Remove glass and frame from panel 6 Inspect slide areas and roller assemblies 1 Lubricate slide areas of glass lower...

Страница 725: ...arter window stabilizer Fig 87 is attached to the inner panel at the upper end and to the side sill outer panel and reinforcement at the lower end The adjusting stud at the upper end allows in and out...

Страница 726: ...SECTION X X NP634 VIEW A A NP641 Fig 94 Quarter Glass Assembly Sedan GlassRun the front channeland window opening frame HARDTOP MODELS Adjustments 1 Raise quarter window 2 inches above belt line 2 Adj...

Страница 727: ...rom glass frame rear track and roller assemblies from tracks in front sec tion Fig 100 lnstallcrtion 1 Position roller assemblies and slide to front and rear tracks of glass lower frame 2 Insert glass...

Страница 728: ...ront track upper attachments so glass touches lightly on outer belt weatherstrip Fig 104 3 Raise window until top of glass touches lightly on the roof rail center and rear weatherstrips 4 Push regulat...

Страница 729: ...9 Fig 107 Quarter Window Assembly Convertible track and rear stabilizer regulator studs into rollers and install spring nuts 4 Install upstops and adjust quarter window Regulcrtor Assembly The regulat...

Страница 730: ...6 Remove hinge plate attaching bolts from pillar 7 Slide hinge plate and torsion bar in through 8 Lower tail gate down and out of body opening 111 pillar post for future assembly post Fig 111 guide t...

Страница 731: ...handle which is inoperative and the vehicle is fully loaded prohibiting access to the tail gate inner panel it will be necessary to remove the three mounting studs from the handle by drilling through...

Страница 732: ...ASS AND FRAME NK943 Fig I I4 Tail Gate Glass Replacement SECTION BB WEATHERSTRIP LOWER FRAME NN825 Fig I IS Tail Gate Glass Attachment glass lower frame and weatherstrip to glass Fig 115 and remove th...

Страница 733: ...the UP position The bulb should light Repeat test with the yellow wire but position switch in the DOWN position If bulb fails to light either time and all wire terminals are tight replace the circuit...

Страница 734: ...rsion bar from hinge screws Fig 111 and remove clamp screws installation areas tail gate screws 30 foot pounds 1 Lubricate torsion bar at right hinge and bearing 2 Install hinge on torsion bar and ins...

Страница 735: ...r tail gate glass run retainer on seal and install screws Upper Run and Pillar Run Removal Fig 123 lower opening weatherstrip screw and remove run and retainer Installation 1 Position pillar glass run...

Страница 736: ...nd of torsion spring to one of the three slots in the hinge face Replacement The deck lid is attached by two screws on each side An assistant s aid is recommended when replacing to prevent it sliding...

Страница 737: ...s and test 4 Adjust bars progressively until lid stays in open lock Replacement The lock assembly Figs 127 128 and 129 are attached by two screws Scribelocation of lock mount ing flangesto aid in inst...

Страница 738: ...eluxe 60 Convertible 61 Hardtop 60 4 4 0 4 Door 60 Station Wagon 2nd and 3rd 65 Dart Sedan 61 SERVICE PROCEDURE GARNISH MOULDINGS When removing a garnish moulding positioned under the end of the adjoi...

Страница 739: ...uarter inner panels and support brackets with screws When replacement of a scuff plate i s required a continuous 1 4 inch bead NPV6 W Fig 2 Instrument Panel Trim Pad Dartl of sealer should be applied...

Страница 740: ...ing on station wagons is held in position with three retainers Fig 8 SHIFT LEVER N N 4 O b Fig 5 Console Adaptation Dart HEADLlNlNG Rernoval F abric Type CoronetModels 1 Remove rear seat cushion dome...

Страница 741: ...listing wires from side rail retainers and support wire from rear listing wire Fig 1 2 8 Remove all foreign material and cement from windshield header area and rear window opening areas 9 Remove list...

Страница 742: ...bracket screw holes cut holes in fabric slightly larger than screws and install mirror 12 When installing headlining at side rail re tainers work only a small section at one time to make certain the...

Страница 743: ...ws Starting at either outer end remove the Fig 15 Headlining lrim Moulding end cap and pry the moulding off the retainer When installing moulding make certain it is fully seated and evenly spaced from...

Страница 744: ...e box Fig 20 Hinges for glove box doors are posi tioned through openings in instrument panel and are attached to the doors with screws Figs 21 and 22 Removcrl Coronet 1 Remove glove box door from hing...

Страница 745: ...e panel at front and remove retainers from 5 Slide panel forward and up to remove 6 Remove retainers from t r i m panel The silencer pad Fig 24 is retained on the shelf panel with cement Raise front e...

Страница 746: ...een the adjuster base and floorpan To move seat fore or aft reposition the adjuster mounting bolts in the adjuster base Three holes are provided at each mounting bolt area SHELF PANEL NP567 Fig 26 Seu...

Страница 747: ...are attached to brackets welded on the floor pan Rear Seat Cushion Charger brackets on the rear floor pan with screws Fig 28 Back Assembly Charger 1 Remove seat cushion and bolt and washers at taching...

Страница 748: ...de bushing on link rod and tap into hinge bracket and seat panel 6 Install spring type pin in link rod 7 Position handle on rod and install retaining screw 8 Install jam nut on inner hinge pin The nut...

Страница 749: ...BACK USH HI ON SEAT CUSHIONI NK853 Fig 33 Third Seat Buck and Cushion 2 Install hinges on quarter panel and tighten 3 Inspect seat fit and alignment test operation of securely seat Seat Build Up The i...

Страница 750: ...g 5 Front Attach to each slot in bottom frame 6 Sides Attach to each slot in bottom frame 7 7 Rear Attach to each spring 10 hog rings 8 Rear facing ends 2 door models attach to slots in bottom frame 2...

Страница 751: ...ar Attach to retainer slots 2 hog rings fnsulator ring each side 6 Front Attach to 8th bar of 1stelement 1 hog ELEMENT ING PAD NN421 Fig 39 Rear Seat Cushion Coronet Deluxe 7 Rear Attach to 13thbar of...

Страница 752: ...d 1 Front Attach to spring frame slots 5 hog ringseach side 2 Sides Attach to spring frame slots 1 hog ring each side and to semi bottom rim 1 hog ring each side Pad Support Sides 4 hog rings each sid...

Страница 753: ...g rings 1 Front Attach to top rim 6 hog rings equally 2 SidecAttach to top rim 3 hog rings each 3 Rear Attach to 9th bar of each intermediate Cover 4 FronGAttach to spring retainer holes 11 hog rings...

Страница 754: ...s seat cushion 5 hog rings each side 4 Kick pad Attach to slots in retainer 5 hog 5 Lower front facing Attach to kick pad listing 6 Lower side and inner facing Attach to front 2 Door Dart 270 Fig 48 S...

Страница 755: ...to spring retainer slots 5 hog Cover Listing each side Coronet 7 Vertical Attach to listing wires 3 hog rings COVER LISTING COVER CORONET P P O R T P A D SECTION B B VIEW I N CIRCLE A NN4W 8 Vertical...

Страница 756: ...ig 52 Rear Seat Back Coronet Convertible NN458 Fig 53 Second Seat Back Coronet Station Wagon 2nd and 3rd Seats Coronet Figs 53 and 54 Spring Pad 1 Top Attach 2nd seat trim rim 10 hog rings or 3rd seat...

Страница 757: ...nt IFront OF BELTS NN572 Fig 58 Swr Belt Attachment Corona Reur Cover rings each side and side facing 14 hog rings 4 Top Attach to each slot in retainer 12 hog 5 Sides Attach to retainer brace 7 hog r...

Страница 758: ...ht twist to wedge unlock by moving wedge around weatherstrip 4 Carefully loosen weatherstrip from glass inner and outer sides 5 With an assistant supporting one end of wind shield exert pressure from...

Страница 759: ...hield wiper arms and blades 4 Starting at bottom center of windshield pry out end of mylar strip and remove strip from weather strip Fig 6 5 Insert tapered end of a fibre stick between weatherstrip an...

Страница 760: ...s and screws attaching header trim cap to header 7 Pry header moulding up slightly to clear mould ing from weatherstrip disengage from header and remove 8 Remove windshield in same method as other mod...

Страница 761: ...rip to fence areas on outside 10 Water test rear window area 11 Install window mouldings clear glass and r e make certain it is fully seated only Remove all excesssealer move protective covering Dart...

Страница 762: ...her strip Fig 15 6 With an assistant position window in opening VIEW IN CIRCLE I NN260 Fig 13 Rearr Window Seals Dart Fig I4 Rear Window Seals Charger and with the assistant supporting glass in positi...

Страница 763: ...els GUIDE DOWELS LEAKAGE AT WINDSHIELD HEADER Improper power link adjustment Adjust header fore or aft to align with Header latch not properlyadjusted Adjust by turning hook in or out SERVICE PROCEDUR...

Страница 764: ...p adjustments doors vent wings and door and quarter glass must be properly aligned Misalignment in any of these areas make it impos sible to obtain satisfactory results from top adjust ments alone Gla...

Страница 765: ...ail structure mounting support assemblies Figs 6 and 7 the main control prop link and the front hinge set screw Fig Power Cylinder and link Dart LINK u NP528 Fig 5 Power Cylinder and link Coronet Fron...

Страница 766: ...n assumes its normal position from leak back in the hydraulic system Cam Adjustment The cam assembly Fig 8 is used to change the top header position in relation to the windshield header The cam turns...

Страница 767: ...hould be replaced If the top fails to oper ate during these tests inspect wires between switch and motor Motor Should the test bulb light on one wire but not the other inspect wire harness for a broke...

Страница 768: ...and Welts The entrance of water and air between the top and windshield headers is eliminated by a tube type weatherstrip Fig 13 secured to the underside of the top header The forward edge of weatherst...

Страница 769: ...ing from top header The moulding attaching screws are located under the weatherstrip 8 Raise top to the 1 2 open position and remove rear roof rail weatherstrip Fig 1 2 Mark location of retainer screw...

Страница 770: ...s and making sure all wrinkles are removed secure with 34tacks or staples 10 Trim excess material from curtain at bow tack ing strip 11 Position cover on folding structure align centerline marks at re...

Страница 771: ...85 Dart 86 APPLICATION GENERAL INFORMATION Page Station Wagon 83 Quarter Panel and Roof Extension 86 Roof Extension 86 Side Sills Connet 86 Dart 82 Spare Tire Compartment Station Wagon 83 Tail Gate A...

Страница 772: ...h erstrip will transfer to the A post when the door is closed if a good contact exists SEALERS AND COMPOUNDS Super Rubber Cement May be used where a strong bonding of rubber parts to painted or un CON...

Страница 773: ...VER DRAIN LOUVER TO cc I I cn BE FREE OF SEALER DRAIN LOUVER TO BE FREE OF SEALER SE4LER SEALER I VIEW IN CIRCLE A VIEW 4BBp SEALER W I 4 NN330 VIEW ARROW Z REAR FLOOR PAN Fig f f l o o r Pan and Side...

Страница 774: ...be painted with a touch upbrush Heavy Sealing Putty For Interior SealingLA heavy fibrous putty like compound which can be formed or rolledinto pelletsor long stringshapes N ARROW B VIEW DIRECTION ARRO...

Страница 775: ...23 84 BODY AND FRAME 0 SEALER V l t W IN L I K L L t X VIEW IN CIRCLE A VIEW IN CIRCLE Z VIEW IN CIRCLE Y SEALER Y SECTION A A NN323 Fig 11 Windshield Area MyMopar com...

Страница 776: ...0 BODY AND FRAME 23 85 Fig 12 Quurter Inner Puneland Fence Area fConver ibfe ATION WAGON VIEW DIRECTION ARROW 0 VIEW CIRCLE E DART Fig 13 Druin Trough Area MyMopar com...

Страница 777: ...6 BODY AND FRAME 0 Fig 1 4 4 d Extensionand Quarter Panel SEALER VIEW IN CIRCLES A NN331 Fig I5 Floor Pan and Side Sills fCoronet Charger O F ARROW A NN324 Fig 1 W n n e r Quarter Panels Dart MyMopar...

Страница 778: ...ve all sealer from drain trough wind shield and rear window reveals TOP MASKING PAPER NK5W lnstallation The entire roof panel surface must be clean and smooth 90 the new cover will fit properly 1 Mask...

Страница 779: ...6 16 Grasp outboard edge of cover and while Fig 5 Trimming and Sealing Cover at Windows pulling material outward and down use upper edge of drain trough flange as a breakover for draping material on...

Страница 780: ...erence Infra red heat lamps provide a suitable source of heat 6 Remove heat source and allow cover to cool A method of rapid cooling will be beneficial 7 Using a DRY No 19 hypodermic needle punc ture...

Страница 781: ...23 90 BODY AND FRAME 0 I I I I BODY 0 L I N E I I 4 b 2 7 2 1 g 3 7 8 6 7 WAGON 56 87 58 33 63X842C Fig I Body Alignment Dimensions Coronet 63x835C Fig 2 Body Alignment Dimensions Dart MyMopar com...

Страница 782: ...t made from iron or do not present an iron steel sur face such as aluminum aluminum alloys brass cop per and magnesium Flash enough of the solvent has passed off for recoating This is the term applied...

Страница 783: ...ld be used when working on these minor conditioners 1 O i l sand by hand the affected area using 600 paper which has been soaked in mineral spirits Cau tion should be used not to rub too hard over any...

Страница 784: ...closed pattern is best matched by reducing the DDL color 150 with DTL 135 Acrylic Thinner or equivalent adjusting the air pressure at the gun to 35 lbs and applying medium wet coats An open pattern i...

Страница 785: ...lW1 8362 TABlX9 9Ooo Academy Blue Metallic BAB2B9 13040 Copper Dust Metallic CAB2K4 22710 Desert Tan Metallic CAB2T4 22712 Sparkle Silver Metallic TAB2S1 31603 Station Wagon Bow Clips Coronet440 500an...

Страница 786: ...demy Blue Metallic Copper Brown Metallic Medium Red Metallic Color Name TAB3X9 9028 AAB5W3 8389 TAB5X9 9028 BAB6B9 13060 CAB6K4 22729 CAB6Y4 22732 CAB6K8 22735 BAB6R7 71495 TAB5X9 9028 BAB6B9 13060 CA...

Страница 787: ...ceiver Face Plate Glove Box Door face Back and Hinge Glove Box Door Back 270 and GT Black only Satin Black VAC38X9 9324 Ensign Blue Metallic BAC39B8 13157 Indian Turquoise Metallic CAC39Q8 13279 Chest...

Страница 788: ...33 Gauge Set Manifold and Installation 15 Handling Tubing and Fittings 24 Coronet Charger 1 Coronet Charger 2 Heater Core Inspection and Test Procedures Coronet Charger 39 Dart 4 4 Coronet Charger 1...

Страница 789: ...UTTON POSITION When testing or adjusting the doors in the distri bution system it is necessary to know the correct position of each door for each push button position It is also necessary to know whic...

Страница 790: ...0 AIR CONDITIONING 24 3 FRESH AIR THRU COWL VENT n n n n n EVAPORATOR HEATER HEATE CORE Fig 2 Air Flow Maximum Cooling FRESH AIR THRU COWL VENT NK1425A Fig Air Flow A C Fresh Air Cooling MyMopar com...

Страница 791: ...L VENT 7 t I I I I I A Fig Air Flow Heating FRESH AIR THRU COWL n y In ntnf z 1 r EVAPORATOR HEATER CORE DEFROSTER ATING LET ED HEATER DOOR POSITIONS 2 REAR VIEW OF SWITCH NK1426A LFRESH AIR DOOR NK14...

Страница 792: ...own If the car has been parked in the hot sun open the windows and drive the car for several minutes to ex pel the warm air and at the same time 1 Slide the temperature control lever to the Off positi...

Страница 793: ...ontained in one unit secured to the lower edge of the instrument panel Each outlet can be adjusted independently to direct air up down or to either side Two fixed outlets in the heater unit installed...

Страница 794: ...0 AIR CONDITIONING 24 7 Fig 7 Air Conditioning Controls OFF NK1432A N K 1433A Fig 8 Air Flow Max A C Position MyMopar com...

Страница 795: ...24 8 AIR CONDITIONING 0 FRESH AIR THRU COWL Fig 9 Air Flow A C Position FRESH AIR THRU COWL RECIRCULATING EVAPORATOR Fig IO Air Flow HEAT Position NK1434A NK1435A MyMopar com...

Страница 796: ...0 AIR CONDITIONING 24 9 FRESH AIR THRU COWL NK1436A Fig I I Air Flow Heaf Posttton Blend Door Half Open FRESH AIR THRU COWL RECIRCULATING NK1437A Fig 12 Air Flow DEFROST Position MyMopar com...

Страница 797: ...DOW 1 Make sure the summer doors located under each end of the instrument panel are closed and latched If the vehicle has been parked in the hot sun open the windows 2 Slide temperature control lever...

Страница 798: ...he combined air conditioning and heating system is dependent upon proper operation and adjustment of all operating controls as well as proper functioning of all refrig eration system units The inspect...

Страница 799: ...t Figs 15 and 16 The temperature control water valve is mounted from the engine compartment side of the dash panel The sensing unit is located at the lower right hand corner of the air conditioning ho...

Страница 800: ...pressure and horsepower load on the engine The use of a bug screen is not recommended as it too will decrease the free flow of air Inspect the condenser for bent or damaged fins The bent fins on the...

Страница 801: ...rt summarizes the incomplete inspect for mechanical misalignment binding or improper linkage adjustment connection at engine manifold electrical and vacuum controls actions that should take place when...

Страница 802: ...al A continuous flow of water in dicates that the valve is not closing properly or the vacuum hoses are not properly connected I f the temperature control valve does not close CABLE Radiator Cap The 1...

Страница 803: ...is used to damp out gauge needle oscillations so that accurate readings can be obtained Compressor Inlet Gauge is mounted at the right side of the manifold set This mounting is for conven ience only...

Страница 804: ...eration system Refrigerant 12 evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts For this reason ex treme care must be taken to prevent...

Страница 805: ...ake sure that the needle valve located below the discharge pressure gauge is open Purge air from the gauge hoses Figs 20 and 21 as follows 1 Open suction gauge valve momentarily then close it 2 Open d...

Страница 806: ...line liquid from the con denser must be attached to the connection marked IN The word IN is stamped on the top face of the inlet connection Fig 22 If the receiver strainer drier is reversed and the li...

Страница 807: ...e free end of this test hose into an exhaust system outlet Open the right hand gauge set manifold valve a frac tion of a turn to let the sweep test charge escape slowly Allow the system to discharge u...

Страница 808: ...ge does not exceed 50 psi Keep refrigerant container upright N K 1439A 10 Add refrigerant gas until there is no foam visible at the slight glass As soon as all foam clears note the weight registered o...

Страница 809: ...to standard This test also provides valuable clues to the possible cause of trouble The preliminary inspections in TESTS 1 thru 4 outlined previously should be made before the Over All Performance Te...

Страница 810: ...on Performance Chart perform the Evaporator Pressure Regulator and Ex pansion Valve Test Test 6 until proper performance is obtained 42 43 44 45 46 47 48 49 50 50 50 51 51 52 52 53 53 53 54 54 55 56...

Страница 811: ...assemblies Make sure that all of the old gasket material is removed from the valve plates cylinder head and crankcase before rebuilding the compressor QUALIZER TUBE NK1411A Fig 26 ExpanslonValve Detai...

Страница 812: ...e diameter of the hose Sharper bends will reduce the flow of re frigerant The flexible hose lines should be routed so that they are at least 3 inches from the exhaust mani fold It is good practice to...

Страница 813: ...capped until it is ready for use and then tightly capped after use to prevent entrance of dirt and moisture Refrigerant oil will quickly absorb any moisture with which it comes in contact ACCESSORY BE...

Страница 814: ...hed and refilled Install a gallon of permanent type antifreeze in the system and add enough water to fill the system Do not re use the old antifreeze The permanent type antifreeze does not lose its an...

Страница 815: ...finger blocking the prod on end of test hose Fig 32 It is absolutely essential that the bleed valve be adjusted so the vacuum gauge pointer will return to exactly 8 inches when the prod is covered by...

Страница 816: ...hether actuator or hose is at fault use the test hose on the actuator involved Fig 35 A leak in a hose may be detected with leak tester by running the fingers along the hose and watching vacuum gauge...

Страница 817: ...8 inches when the prod is covered by a finger Otherwise a false reading will be obtained when the control circuit is tested CAUTION Alternately release and reblock the hose prod several times Make sur...

Страница 818: ...um Source 7 A C Inlet Door Open 1 Fresh Air Door Closed 2 Defroster Door Open 3 Fresh Air Door Open 4 Defroster Door Closed each of the 6 holes the hoses and actuators are not leaking The control swit...

Страница 819: ...ey in the crankshaft 3 Insert clutch assembly on crankshaft 4 Install washer and a new self lacking bolt Hold clutch from turning with a spanner wrench inserted in the holes of front bumper plate Tigh...

Страница 820: ...formed with the compressor re moved from the vehicle On some models however the valve plate and crankshaft gas seal assemblies can be repaired with compressor installed on vehicle CAUTION The system m...

Страница 821: ...tem Refer to Discharging the System 2 Measure and record the refrigerant oil level so that the oil level of a replacement or repaired com pressor can be adjusted to the exact level in the compressor r...

Страница 822: ...e the height on the dipstick and determine the amount of oil in the unit by refer ring to the followingchart Dipstick reading should be at least six ounces and not more than eight ounces Dipstick Read...

Страница 823: ...ore removingthe pistons rods or rod caps mark all parts to insure reassembly in the original position 6 Remove rod caps remove piston and rod as sembly from cylinder Inspection Inspect piston and ring...

Страница 824: ...g action The carbon seal must be assembled as shown in Figure 55 2 Hold seal firmly on the outside edge to prevent it from rotating out of the index slots Do not touch sealing face of carbon seal 3 Lu...

Страница 825: ...o check freeness Shaft should turn without binding 7 Install oil sump valve plates and cylinder heads using new gaskets Fig 56 Measuring Crankshaft Axial Movement Oil Pump Removal refrigerant oil from...

Страница 826: ...ting air inlet hose 4 Disconnect floor air actuator rod from linkage 5 Disconnect actuator vacuum hoses and remove fresh air recirculating door housing assembly Fig 61 6 Remove defroster hoses disconn...

Страница 827: ...r on the 0 rings will facilitate installation 10 Install temperature control valve capillary tube in heater core cover 11 With the air conditioning door open approxi mately one inch install the distri...

Страница 828: ...the six evaporator attaching screws and carefully remove the evaporator and drain pan from case Fig 68 lnstallation Coronet and Charger 1 Install the evaporator and drain pan being careful not to dama...

Страница 829: ...ct and distribution housing 15 Install all flexible hoses to instrument panel 16 Install glove box assembly 17 Fill cooling system For summer operation as well as winter operation be sure the system i...

Страница 830: ...The system must be completely discharged before opening any of the refrigerant lines 1 Remove equalizer tube from evaporator suction line fitting Fig 71 2 Disconnect expansion valve from elbow assem b...

Страница 831: ...al wires from resistor block vacuum hoses from the fresh air recirculating actu ator the temperature control cable evaporator tem lnstullcrtion 1 Place a small bead of sealer in heater housing flange...

Страница 832: ...tuator hoses 4 Remove maunting stud nuts and remove evapo rator assembly with blower motor as a single unit Fig 77 5 Remove defroster actuator evaporator tempera ture control switch and carefully with...

Страница 833: ...assembly Heater Installation 10 After the evaporator and heater assemblies are installed in the vehicle it will be necessary to sweep the system test for leaks and charge the system with All service t...

Страница 834: ...able in bulk tanks or in sealed 15 ounce cans The use of canned refrig erant is preferred by most technicians because it pro vides a very quick and simple means of adding re frigerant or charging the...

Страница 835: ...M U F F L E R A S S E M B L Y DISCHARGE M U F F L E R AND T U B E A S S E M B L Y W A T E R VALVE CONDENSER A S S E M B L Y AND THEN P NP673 Fig 76 Air Conditioning and Heater Plumbing DaH 225 Cu In...

Страница 836: ...owly CAUTION Do not allow the system to discharge rapidly since this would sweep some of the refriger ant oil out of the compressor 7 Allow the system to discharge until the dis charge pressure gauge...

Страница 837: ...ndow of the burner shield not through the top of the shield 1 Open the torch valve until you hear a faint hiss of escaping gas Light the test torch and adjust the valve until the flame is very small A...

Страница 838: ...and swept with a test charge before replacing the receiver drier strainer To remove the receiver drier simply unscrew it at the fittings When installing a new receiver drier use new 0 rings Tighten t...

Страница 839: ...f vacuum indi cates a leak in the refrigeration system or a defective vacuum pump Locate and correct the trouble before recharging the system CHARGING THE SYSTEM Figs 82 and 83 An accurate scale must...

Страница 840: ...oes not exceed 50 psi Maintain the tem wise to open them perature of the water in the pan by adding warm 5 Momentarily loosen the charging hose at the water as necessary gauge set manifold to allow th...

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