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Plymouth Belvedere 1955, Руководство по обслуживанию

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Содержание Belvedere 1955

Страница 1: ......

Страница 2: ...MyMopar com...

Страница 3: ...PLYMOUTH SERVICE MANUAL 1956 P L Y 1955 O U T H P 26 P 27 56P128 MyMopar com...

Страница 4: ...tion There are over fifty four million automotive vehicles in op eration in the United States Every year as new vehicles are put into use new inexperienced drivers take the wheel increasing the proble...

Страница 5: ...On 187 and 200 horsepower Hy Fire V 8 engines the number is located on the left front face of the cylinder block BODY NUMBER LOCATION The body number is stamped on a plate which is attached to the lef...

Страница 6: ...ar this manual con tains over 200 diagnosis procedures In most instances it is advisable to make a road test to verify the condition described by the customer so that the corrections given in the diag...

Страница 7: ...PLYMOUTH SERVICE MANUAL NUT SUSHtNG AND SPACER WASHER BOLT BAR SEAL LOCK SEAL SCREW BUSHING BUSHING 5SP O58 Figure 1 Front Suspension Parts MyMopar com...

Страница 8: ...proper checking equipment Equipment that has been damaged by dropping or rough handling should be care fully checked and adjusted before it is used The floor must be level when using portable equipmen...

Страница 9: ...be 1712 to 19 degrees 5 to 6 degrees Upper 7960 to 7975 in Lower 7960 to 7975 in Upper Needle Bearing Lower 7960 to 7975 in 005 to 010 inch Nominal Length 12 in Nominal Length 33 in 20 in 20 in Tapere...

Страница 10: ...mount in degrees that the top of the king pin is inclined toward the front or rear of the car See Figure 5 TIRE CENTER LINE CAMBER ANGLE VERTICAL LINE K N6 PIN ANGLE KING P H CENTER LINE With positive...

Страница 11: ...following measurements taken at one lower control arm a From floor to center of grease fitting in the front bushing of the lower control arm bar b Fromfloorto center of lower control arm pin 2 Then f...

Страница 12: ...E IN Spin front wheels and scribe a thin line in the center of the tread of each tire Place wheels on turntables and set them in the straight ahead position Turn steering wheel full travel in both dir...

Страница 13: ...here is any evidence of looseness or binding in a tie rod end a new one should be installed ASSEMBLY When new tie rod ends are assembled to the rod the ends must be threaded in the rod an equal amount...

Страница 14: ...hing with the grease groove toward the welch plug as shown in Figure 14 Install lower bushing and line ream both bushings with reamer and pilot bushing tool C 691 See Figure 15 NOTE On 8 cylinder mode...

Страница 15: ...ould be required to turn the pivot bar NOTE Pivot bar may if necessary be rotated 1 turn in either direction to correct a slight centering error 7 UPPER CONTROL ARM PIN BUSHING AND DUST SEAL When repl...

Страница 16: ...up assembly resting on bench Reposition tool C 594 on pivot bar and thread remaining bushing into control arm using same torque Remove tool and assembly from vise and check pivot bar for free movemen...

Страница 17: ...for Dragging 5 STEERING TUBE AND WORM ASSEMBLY A bent steering tube and worm assembly will cause hard steering and may result in the car pulling to one side To test for this condition jack up the fro...

Страница 18: ...hreaded pin rides on the V shaped thread cut in the bushing With the weight of the car on the bushing the side of the pin thread bears against the side of the thread cut in the bushing New parts shoul...

Страница 19: ...t Capacity P 26 P 28 P 27 P 29 Semi Floating Hypoid 3 73 to 1 Optional Mountains and hilly country 4 1 to 1 4 1 to 1 3 73 to 1 3 54 to 1 Optional Mountains and hilly country 3 9 to 1 006 to 010 in 0 t...

Страница 20: ...the brake support plate and the axle housing flange Use special tool C 745 to pro tect oil seal when removing brake support plate If necessary to remove more than 020 inchin shims to decrease end pla...

Страница 21: ...her method is to slip a piece of tubing over the end of the broken shaft and guide it out If the axle shaft cannot be removed in either manner it will be necessary to remove the broken piece with the...

Страница 22: ...r C 748 when removing oil seal to avoid possible damage to the carrier housing Loosen adjusters to relieve bear ing preload before removing carrier bearing caps Lift the differential assembly out of t...

Страница 23: ...3 Pinion flange nut 14 Flange washer 15 Drive pinion flange 16 Oil seal 17 Bearing cone and rollers 18 Bearing cup 19 Bearing adjusting shims 20 Bearing spacer 21 Differential carrier 22 Pinion adjust...

Страница 24: ...l shaft should not fit loosely but should be a light drive fit in the case Inspect side gear thrust washers for roughness and differential bearings for roughness or wear ASSEMBLY AND ADJUSTMENT The co...

Страница 25: ...pounds Add or remove shims to obtain the specified turning torque To do this first loosen the tool assembly and then add or remove shims as needed 2 PINION ADJUSTMENT WITH SPECIAL TOOL C 758 Place the...

Страница 26: ...in the following thicknesses 084 086 088 090 092 094 096 and 098 5 ASSEMBLING DIFFERENTIAL Install the side gears and thrust washers Place the thrust block between the side gears so the axle shafts w...

Страница 27: ...090 092 094 096 and 098 Install washer with chamfered edge toward pinion RING GEAR AND PINION BACKLASH AND DIFFERENTIAL BEARING PRELOAD Obtained by tightening differential bearing adjusters Check rin...

Страница 28: ...rear face side until there is very little backlash Turn the ring gear a few times by hand to line up the bearing rollers Then find the point of least backlash on the ring gear by checking the gear at...

Страница 29: ...m pinion Install thinner washer be hind pinion if necessary to readjust backlash move ring gear toward pinion HEAVY TOE HEAVY HEEL 45x41 Move ring gear away from pinion If necessary to re adjust backl...

Страница 30: ...ng washer or to move the ring gear into or away from the pinion If the pinion setting is changed it may be neces sary to reset backlash If the ring gear is moved it may be necessary to reset the pinio...

Страница 31: ...MOVAL Be sure the area to be worked on is clean before the operation is started Disconnect the rear universal joint and remove the drive pinion flange unit and washer Remove the flange with special to...

Страница 32: ...ill fade when the engine speed is increased or decreased Loose tail pipe brackets or a bent tail pipe will cause rattling noise 4 CLUTCH Noise resulting from a faulty clutch disc unit may be heard whe...

Страница 33: ...in 11 in llin Sub 10 in urban only 006 in Molded asbestos Bonded 2 in in 030 in oversize 10 in 40 to 50 lbs 5 in 10 in 50 to 60 lbs 5 in 11 in 40 to 50 lbs 7 in 11 in 40 to 50 lbs 7 in l in l Sn 003...

Страница 34: ...t and turning the hex shoulder on the master cylinder push rod which will change the length of the push rod in either direction NOTE Free play is important to prevent brakes from locking up Too much f...

Страница 35: ...CREASE CLEARANCE OPPOSITE DIRECTION TO INCREASE CLEARANCE AT TOE OF FRONT SHOE TOE OF REAR SHOE HEEL OF FRONT SHOE 45x702 Figure 2 Adjusting Brake Shoes Front Wheel TOE OF REAR SHOE TURN CAM IN DIRECT...

Страница 36: ...correct clearance of 006 inch for both the heel and toe of the shoe Swing the brake shoe gauge around until the finger is over the toe of the brake shoe Turn the adjusting cam until the lining contac...

Страница 37: ...k off until wheel is free REAR BRAKE FRONT BRAKE REAR SHOE HEEL END 006 INCH CLEARANCE ANCHOR BOLT FOR REAR SHOE TOE END 006 INCH CLEARANCE v A FRONT x SHOE I f 1 I HEEL END 006 INCH m CLEARANCE ANCHO...

Страница 38: ...all shoes new or used See Figure 8 Figure 8 Sanding Brake Shoe Figure 9 Shoe and Lining on Bonder CAUTION Only pre cemented Cyclebond Brake Lining is recommended for Plymouth cars Lining which has bee...

Страница 39: ...stalling brake shoes exercise extreme care to prevent brake fluid oil or grease from con tacting the lining If the piston should accidentally be forced out of the wheel cylinder be sure to bleed the b...

Страница 40: ...ding the lining to make it square with the drum The shoe itself must be straightened or discarded To inspect the brake shoe for distortion support the anchor bolt end of the web on a surface plate hol...

Страница 41: ...system flush replace all rub ber parts such as cups hose etc refill with heavy duty Brake Fluid and bleed brakes AIR FREE SYSTEM Make sure there is no air in the system Proper bleeding will remove air...

Страница 42: ...BLEEDER TANK When bleeding the brake system with the compressed type bleeder tank first fill the tank half full with brake fluid and then bring the pressure up to 15 pounds If more pressure is used t...

Страница 43: ...EW WHEEL CYLINDER PISTON CUP BRAKE SHOE PUSH ROD RETURN SPRING PISTON CUP EXPANDER Front Wheel Cylinder PISTON CYLINDER BOOT BRAKE SHOE PUSH ROD PISTON CUP EXPANDER BLEEDER SCREW RETURN SPRING CYLINDE...

Страница 44: ...e cylinder bore is not increased more than 004 inch When a cylinder bore does not clean up within 004 inch install a new wheel cylinder Be extremely careful when cleaning cylinder walls Remove all dus...

Страница 45: ...decrease shoe to drum clearance until a slight drag is felt on the brake drum Back off adjusting nut at least one full notch to give approximately 010 clearance Prongs on adjust ing nut must be seated...

Страница 46: ...JUSTING NUT BRAKE ANCHOR WASHER BRAKE ANCHOR SHOt GUIDE BRAKE SHOE OPERATING LFVPR LINK BRAKE SUPPORT GREASE SHIELD SPRING BRAKE SHOE RETURN SPRING BRAKE SHOE ADJUSTING SCREW Install the transmission...

Страница 47: ...parts of the unit are shown The air vacuum housing is divided into two parts by the diaphragm which is assembled to the power piston in such a way that any movement of the diaphragm caused by vary in...

Страница 48: ...at its initial movement moves the air valve seat in against the control and reaction springs at the same time drawing the off stop seal away from the guide sleeve and admitting atmos phere as far as t...

Страница 49: ...metering hole sealed at all times until the unit once again returns to the fully unapplied position Thus as long as there is hydraulic reaction all communication through the power piston is effective...

Страница 50: ...brakes Of this hydraulic reaction an amount sufficient to provide the driver with the correct feel of the brake is transmitted back to him through the reaction rod which is free to move inside the hyd...

Страница 51: ...VE DIAPHRAGM RETAINER SPRING DIAPHRAGM AND STOP PISTON AND SLEEVE PISTON BOLT LOCKWASHER T NUT SPACER LOCKWASHER SCREW B O T GASKET RETAINER SEAL PLUG LOCKWASHER NUT GASKET VALVE SPRIN RETAINER LOCKWA...

Страница 52: ...held to gether in their proper relationship Figure 29 Removing Push Rod From Unit CAUTION Be sure to lift straight up while holding power piston guide sleeve down against re turn spring Valve side of...

Страница 53: ...e 34 Figure 32 Removal of Master Cylinder CHECK VALVE BODY FLOATING VALVE 54x552 SPRING Figure 33 Check Valve INSPECTION SCREW BODY VALVE SIDE GUIDE SEAL SEAL LUBRICATING WICK Figure 34 Guide Seal Ass...

Страница 54: ...remove cylinder plug assembly Disassemble cylinder plug assembly by hand by removing primary cup retainer and primary cup seal from cylinder plug Primary cup is easily removed by gripping the inner c...

Страница 55: ...ing new secondary cup with brake fluid insert it into cylinder Cup lips must be down be sure that cup lip is not turned back at any point as cup slides into cylinder Place secondary cup support washer...

Страница 56: ...ure 37 Install new air valve seat O ringseal in groove on outside diameter o new air valve seat assembly using care to preserve silicone grease on seal This seal is supplied pre greased in cellophane...

Страница 57: ...ubber seal is facing down against seat Then assemble spring and cap See Figure 33 6 ASSEMBLY OF MAJOR COMPONENTS Place new cylinder to body seal in groove around cylinder plug assembly being careful t...

Страница 58: ...air cleaner cover sleeve are concentric If necessary tap cover sleeve lightly with rubber mallet to align Insert push rod into push rod boot then into air cleaner cover boot and insert assembly and sn...

Страница 59: ...e with brake applied 11 POWER BRAKES BELLOWS TYPE OPERATION The bellows type power brake unit is designed to reduce pedal effort by applying power directly to the pedal linkage The entire hydraulic br...

Страница 60: ...Figure 48 shows the unit unapplied The air valve is open so that air is freely admitted to the air vacuum bellows The vacuum valve is closed thus preventing any evacuation of air from the bellows The...

Страница 61: ...ING SPRING VACUUM VALVE VALVE HOUSING O RING BELLOWS RETURN SPRING INNER MOUNTING PLATE BELLOWS SUPPORTS OPERATING ROD BUTTON STOP SEAL WASHER OUTER MOUNTING COVER NUTS 4 O RING SET SCREW YOKE O RING...

Страница 62: ...ge in consistency on the working parts during high and low temperatures DISASSEMBLY 1 REMOVAL Place a wood wedge between the power brake lever and the forward edge of the triangular hole in the pedal...

Страница 63: ...ade to separate cover plate from the bellows flange Extreme care should be used to avoid marking or scratching inner face of plate where it clamps to bellows flange A scratch on this surface could cau...

Страница 64: ...e is scored or worn install new parts as required At assembly use new O rings and seal rings throughout Be sure all seal and O rings are suitably cov ered with silicone grease Rings and seals are pre...

Страница 65: ...y in the holding fixture lightly coat the outside surface of the air valve with sili cone grease do not use any other kind then insert air valve small end first into the bore of valve housing as shown...

Страница 66: ...ring bore The seal must nest snugly in bearing with the lips pointing outward Using silicone grease lubricate the inside of bearing and slide over guide while compressing bellows Install the bearing t...

Страница 67: ...it so that its axis inclines down toward front of car and that the vacuum inlet connection is toward the engine PEDAL LINKAGE ADJUSTMENTS If it becomes necessary to disassemble or replace the pedal li...

Страница 68: ...d power lever apart Check free play with linkage in this position by pushing lightly at the pad end of the brake pedal This will give a true free play measurement Pedal free play should TO ENGINE INTA...

Страница 69: ...the lines 3 BRAKE SHOE ANCHORS Check for loose brake shoe anchor bolts 4 BRAKE SHOE RETURN SPRINGS Check for broken return spring GRABBING BRAKES J ADJUSTMENT Check for improper adjust ment of brake s...

Страница 70: ...ront sus pension parts are loose J ADJUSTMENT Check brake shoe adjust ment The toe contact may be too heavy 2 BRAKE DRUM Inspect for an out of round or cracked brake drum 3 LININGS Inspect for oil gre...

Страница 71: ...n insert or under the reaction piston dome cup 2 Grease fluid or moisture on brake linings SPONGY PEDAL Air in brakes lines or in hydraulic cylinder of power unit CARS EQUIPPED WITH POWER BRAKE BELLOW...

Страница 72: ...he correct adjustment is to tighten the eye bolt sleeve nut on the clutch pedal overcenter spring bolt finger tight with the pedal in the depressed posi tion then tighten four complete turns 2 CLUTCH...

Страница 73: ...6 springs 9 Auburn 3 springs 10 B B 9 springs P 27 P 29 Borg and Beck 10 in std 11 in spec equip 10 B B 9 springs 11 B B 12 springs Single Plate Dry Ventilated TORQUE SPECIFICATIONS Clutch housing to...

Страница 74: ...R DRIVEN DISC PRESSURE PLATE PIVOT PIN DRIVE LUG OPENING 45x450 Figure 3 Borg Beck Clutch 10 inch Disassembled DISC ASSEMBLY ADJUSTING SCREW AND LOCK NUT RELEASE LEVER PIN RELEASE LEVER 55P1152 Figure...

Страница 75: ...balance With the assembly on fixture C 585 See Figure 6 install the three legged spider over the center screw so that it rests directly against the top of the clutch cover Install the plain thrust wa...

Страница 76: ...on washer Then lift off the cover To remove a pressure spring force each release lever downward by hand take out the block and release the finger slowly To remove the release levers from the cover gri...

Страница 77: ...e sure the springs rest on the bosses of the cover and are seated in the embossed seats of the levers Press down on the release lever and then insert steel blocks under the outer ends of the levers Pl...

Страница 78: ...tighten each bolt a few turns in progression until they are all tight Tighten bolts from 30 to 35 foot pounds When installing the transmission care must be taken not to dish or bend the clutch disc S...

Страница 79: ...hen release the clutch pedal and accelerate the engine slowly The engine should stall immediately if the clutch is not slipping 1 PEDAL FREE PLAY Inspect for insufficient pedal free play which may pre...

Страница 80: ...ch pedal down may indicate that the pilot bushing is tight worn or dry The noise is usually more evident in low or second gear than it is in high gear 4 CLUTCH DISC It a metallic grinding noise simila...

Страница 81: ...Models with Air Conditioning Cellular Standard Fin and Tube P 29 with Air Conditioning Centrifugal Oilite Bronze Bushings Note Late Model P 27 Ball Bearing 595 to 596 in 6704 to 6714 in 0005 to 005 in...

Страница 82: ...e cap after pressure has been released press down and continue to turn cap counter clockwise The coolant level should be 2 inches from the top of filler neck at normal engine operating temperature 2 C...

Страница 83: ...et hose from water pump and insert flushing gun in hose First make sure water will flow through radiator then apply normal water pressure When it is known water will flow through the core apply air pr...

Страница 84: ...em using a reputable cooling system cleaner An alcohol type anti freeze solution is subject to evaporation When used in the cooling system check the solution periodically If an alcohol base liquid is...

Страница 85: ...acket bolts and install the generator belt tool C 3379 and torque wrench C 3005 See Figure 4 Tighten belt to specified torque as shown in Belt Tightening Specifications Use the idler belt tool to obta...

Страница 86: ...Cooling System Data and Specifications on Page 80 The bellows actuated thermostat is fully open when approximately inch off its seat See Figure 8 The pellet actuated thermostat is fully open when the...

Страница 87: ...L RETAINING WASHER THRUST WASHER f SHAFT AND IMPELtES GASKFT 5 253 Figure 10 Hy F re V 8 Water Pump Disassembled Bushing Type 241 and 260 cu in engine WASHFR PUMP BODY GASKET SHAFT W BEARING THROWN HU...

Страница 88: ...Refer TOOL C 412 51x254 Figure 15 Removing Fan Pulley Hub to Figure 9 or Figure 10 On PowerFlow 6 engines remove the body cover plate and gasket Use puller C 412 to remove hub See Figure 15 Remove sha...

Страница 89: ...rom the inside surfaces HY FIRE V 8 Slide thrust bearing against nut on tool C 373 and then a 15 S inch flat washer Install front bushing on tool with bearing surface toward flat washer Install new pu...

Страница 90: ...ce of bushing as shown in Fig ure 18 Hy F re V8 Press rear bushing 130 inch to 155 inch beyond seat surface See Figure 20 Press front bushing far enough to seat shoulder Use suitable washer so as not...

Страница 91: ...ring assembly is prelubricated and sealed at both ends of the bear ing race by seal retainers No lubrication of this type pump is required The assembly is serviced as a unit See Figures 11 and 12 DISA...

Страница 92: ...to the body Do not press the bearing to the shoulder of the sleeve The bearing assembly should be pressed into the body 4 inch as measured from the end of the pump to the outer surface of the seal ret...

Страница 93: ...cylinder head always use a torque wrench Draw the cap screws down uni formly tight 70 ft lbs on PowerFlow 6 engines and 85 ft lbs on Hy Fire V 8 engines and in the proper sequence to avoid distortion...

Страница 94: ...bubbles do not appear in the water when the engine is accelerated with water pump inoperative air may be leaking into the system at the water pump It is possible for the connection to be tight enough...

Страница 95: ...nue to run the engine at a fast speed to increase water circulation and wash out sediment in thermostat Drain the cooling system immediately and refill with clean water If the engine does not warm up...

Страница 96: ...e level and disregard the curvature of liquid at the edges CELL CONNECTOR TERMINAL CASE ELEMENT REST SEDIMENT SPACE The reading of the hy drometer will vary with the temperature of the electrolyte An...

Страница 97: ...ttery See Figure 3 VOLTAGE TEST Connect a voltmeter from the positive post to the negative post of the battery Be sure the clips or prods make a solid connection with a clean por tion of the battery p...

Страница 98: ...y one inch be yond the leak or until the sealing compound is forming a tight seal Thoroughly dry the covers and all portions of the container where the sealing compound will make contact Since the sea...

Страница 99: ...rom the field terminal on the gener ator to ground When the jumper wire from the field terminal is grounded the armature should motor or rotate slowly If the armature does not motor disassemble the ge...

Страница 100: ...9x665 Figure 7 Undercutting Mica connections Resolder all loose connections and repair any frayed or chafed insulation provided the wire has not been damaged If the wire has been damaged the field coi...

Страница 101: ...aper will shorten life of the brushes and should be avoided Blow out all sand and carbon dust from the generator with compressed air and then tighten pigtail connections securely Brush spring tension...

Страница 102: ...mbly contains three units the circuit breaker the current regu lator and the voltage regulator Each unit performs a separate function The Circuit Breaker acts as an automatic switch between the genera...

Страница 103: ...roughly under stood and accurate meters are available Even a slight error in the setting of the unit may cause improper functioning resulting in a run down or an overcharged battery or damage to the g...

Страница 104: ...ther than at the battery terminal of the regulator This will avoid danger of the clip connector slipping off and simultaneously touching the battery and field terminal of the regulator 3 When flashing...

Страница 105: ...ced and cleaned readjust the armature air gaps to compensate for the metal removed from the points CAUTION Never use sandpaper or emery cloth or a file that has been used on other metal Particles of e...

Страница 106: ...on 6 ADJUSTING ARMATURE FOR PROPER OPENING AND CLOSING VOLTAGES Use bend ing tool from Kit C 828 With slot in end of tool placed over the lower spring hanger Figure 18 bend the hanger to decrease or i...

Страница 107: ...replaced AMMETER SHOWS HIGH CHARGE BATTERY FULLY CHARGED If the ammeter continues to indicate a high charge after the engine has run for a short time examine the following parts for possible loose co...

Страница 108: ...arm to the starter motor pinion gear Hook a spring scale of at least 15 pounds capacity to the end of the torque arm Before closing the switch be sure that the resistor is open to avoid excessive init...

Страница 109: ...ring Tension 42 to 53 ounces Maximum Voltage 5 5 10 Maximum Amperage Draw 50 to 65 5O 60 P 28 w P F Minimum Speed RPM 4700 to 4900 44OO 3200 P 28 w P F Voltage Maximum Amperage Draw 500 2IO 240 P 28 w...

Страница 110: ...remove the drive assembly from armature shaft loosen the set screw at the end of the drive spring and slide unit from shaft TEST PRODS IMPORTANT Do not immerse the drive assembly in any cleaning solu...

Страница 111: ...VE SERVICED ONLY AS AN ASSEMBLY SET SCREW CENTER PLATE 5 2 x 2 9 2 Figure 3 Starter Motor Disassembled 1955 BODY POLE PIECES BRUSHES BUSHING HOUSING THRUST WASHER HEAD ASSY THROUGH BOLTS BRUSHES B R U...

Страница 112: ...h or the fuel gauge and ammeter If the solenoid switch fails to click when energized with a jumper wire install a new solenoid Figure 6 Cleaning Starter Drive Assembly 3 STARTER MOTOR If test indicate...

Страница 113: ...ER SCREW t GROUND LEAD BREAKER POINT 7 SET WASHERS tOCKWASHER PRIMARY LEAD SPR NG AND BRACKET BEAR NG TERMINAL NSULAT ON 8USHfNG SPRING AND BRACKET SHER SCREW LOCK WASHER _ LOCK WASHER NUT CREW IOCKWA...

Страница 114: ...If movement is excessive remove the distributor and check amount of bushing wear with dial indicator as shown in Figure 9 Point gap can be adjusted by either using a feeler gauge or dwell meter Dwell...

Страница 115: ...pulley at the specified number of degrees advance Attach timing light Tool C 693 as shown in Figure 3 Start engine and allow to idle The timing light flash should occur at the instant the chalk mark...

Страница 116: ...ibutor automatically adjusts the spark advance to engine load conditions Upon sudden acceleration or wide open throttle operation manifold vacuum drops causing the spring in the chamber to retard the...

Страница 117: ...x ll l3 ll l3 1900 l7 l9 Max l7 l9 Max 12 5 I4 12 5 I4 2150 l4 l6 4 l6 Model Number IAT 4101B IAZ 4003C IAZ 4003E IAZ 4003G IAZ 4003H IBJ 4301A IBJ 4301B VACUUM ADVANCE Distributor Degrees and Inches...

Страница 118: ...ay have caused the points to oxidize Loose condenser connections or high resistance within the con 52x278 52x279 Figure 8 Releasing Distributor Breaker Plate Bearing 8 cylinder denser will also cause...

Страница 119: ...3 020 in 2 Bronze in Distributor 1 Bronze in Cylinder Block 2 1 8 34 2 27 l 018 in 17 to 20 oz 1 5 3 6 2 4 Crankshaft vibration damper 2 before T D C 1 8 4 3 6 5 7 2 Crankshaft pulley 4 before T D C 4...

Страница 120: ...upper bushing in both 6 and 8 cylinder distributors In addi tion the 6 cylinder distributor has a inch oil hole through the lower bushing After bushings are installed they should be burnished with bu...

Страница 121: ...Figure 16 Drive bushing in place with soft hammer As the burnisher is pulled through the bushing by turning the nut the tool swedges the bushing tight in the bore and burnishes it to correct size Do n...

Страница 122: ...ot in distributor drive shaft is pointing at the first intake manifold bolt on left side See Figure 17 Turn distributor rotor to number one spark plug insert Turn rotor counter clockwise until points...

Страница 123: ...or blistered dark brown deposits near the tip plus excessive burning of the electrodes If the insulator material is badly fused and blistered and the center and side electrodes are badly burned there...

Страница 124: ...etween the ground and the output side of a switch with the lamps burning the dif ference in readings will represent the voltage drop in the switch A switch showing a voltage drop of more than 1 10 vol...

Страница 125: ...ense Plate Lamp Back Up Lamp Headlamp Beam Indicator Dome Lamp Clock Lamp Radio Dial Lamp Glove Box Lamp Courtesy Lamp Ignition Lock Lamp Instrument Lamp Trunk Compartment Lamp Generator Indicator Lam...

Страница 126: ...d by checking each circuit individually Remove one wire at a time making certain that others are connected When the faulty circuit is located check that particular circuit for shorts or opens in the w...

Страница 127: ...minals 2 WIRING AND SWITCHES Test wiring and switches in lighting circuit for voltage drop DIM HEADLIGHTS ENGINE RUNNING ABOVE IDLE WITH BATTERY FULLY CHARGED 1 WIRING AND SWITCHES Test wiring and swi...

Страница 128: ...ant field coil is grounded internally and exerts a constant pull on the pointer toward the empty mark when the ignition is turned on The variable field coil is grounded through the tank unit and exert...

Страница 129: ...ollows Use a spare tank unit known to be in good con dition Disconnect the plug in terminal at the panel unit Connect the spare tank unit to the plug in terminal on the panel unit and ground the tank...

Страница 130: ...to be operating correctly Disconnect the wires at the terminals on the tank unit and connect them to corresponding terminals on the spare tank unit Connect a ground wire from the case of the unit to...

Страница 131: ...and move the left calibrat ing arm to the right If the pointer goes beyond the empty mark move the calibrating arm to the left Move the float arm to the full position Adjust the right calibrating arm...

Страница 132: ...e cable is kinked and should be replaced Inspect the housing for evidence of kinks If a cable sticks or binds as it is inserted in the housing the housing is damaged inside and should be re placed The...

Страница 133: ...s 2 HORNS The horns are operated by a relay feed through the ignition switch and can be operated only when the ignition is turned on They are located behind the radiator grille The high note horn is l...

Страница 134: ...s use the same wiper blades arm assembly and pivots Convertible and Sport Coupe blades arms and pivots differ from other models The variable speed motor has an off glass park ing feature which is acco...

Страница 135: ...head through bolts and carefully pull off end head Armature can then be removed VARIABLE SPEED MOTOR Remove end head through bolts and pull out end head using care so as not to break the lead wire to...

Страница 136: ...BRUSH SPRING PKG SWITCH Figure 12 Windshield Wiper Motor Disassembled Constant Speed ARMATURE CUTTING TOOL SPECIAL CHUCK UNDERCUTTING TOOL a CUTTING TOOL UNDERCUTTING TOOL COMMUTATOR Figure 13 Refac...

Страница 137: ...r the efficiency of the wiper Assemble the frame armature and head being careful to raise the brushes to allow entrance of the commutator Rap the motor frame several sharp blows with rubber hammer to...

Страница 138: ...uld park VARIABLE SPEED MOTOR Connect the yel low wire to the motor ground strap Connect the battery positive terminal to the motor ground strap Connect the red and black wires to the bat tery negativ...

Страница 139: ...jumper from the battery to the horn relay terminal marked Horn If horn does not blow inspect wire from horn relay to horn for an open circuit If horn blows connect a jumper from the horn relay GRD te...

Страница 140: ...on 2 SWITCH Make certain that lead wires are tight in switch and are installed in proper socket 3 CONTACT POINTS Clean contact points at switch plate variable speed znotor with fine sand paper Inspect...

Страница 141: ...2294S 2295S 120 215S 120 214S P 27 241 Cu In 260 Cu In P 29 270 Cu In 277 Cu In Downdraft Dual 2141S 2154S 2155S 120 21 IS 120 21OS 2259S 226OS 226IS 2422S 2423S 2424S 120 213S 120 212S 24O7S 24O8S 2...

Страница 142: ...EL PUMP The fuel pump is operated by an eccentric on the camshaft which actuates the rocker arm This action lifts the pull rod and diaphragm assembly upwards against the diaphragm spring creating a va...

Страница 143: ...ASKET VALVE HOUSING VALVE TO ROCKER ARM HOUSING SCREW 1 a V OUTLET PORT Figure 2 Hy F re V 8 Fuel Pump Disassembled INLET PORT 55P 091 LEVER SPRING PLUG STUD WASHER L BODY SERVICED IN ASSY PIN BODY SE...

Страница 144: ...e the rocker arm housing to the valve housing but do not tighten screws Hold diaphragm in fully compressed position and tighten screws This will prevent tearing the diaphragm DISASSEMBLY AND ASSEMBLY...

Страница 145: ...hoke valve is offset on the shaft so that as air enters the carburetor air horn it tends to position the choke valve depending on speed and load conditions The fast idle cam is connected to the choke...

Страница 146: ...ains heat it gradually winds and allows the choke to open At the same time the vacuum operated choke piston connected by a rod to the valve keeps a constant pull on the valve against the tension of th...

Страница 147: ...h throat of the dual carburetor supplies an air fuel mixture to four specific cylinders Thus it is essentially two carburetors in one Each throat contains its own idle air bleed high speed air bleed i...

Страница 148: ...main metering jet is controlled by the movement of the step up rod which in turn is moved by a spring and a vacuum controlled piston A vacuum passage to the intake manifold is provided for by a drille...

Страница 149: ...ETAINER SCREW STEP UP PISTON STEP UP MAIN METERING JET IDLE ORIFICE TUBE STEP UP PISTONS GASKET DASHPOT ASSEMBLY OWERFL TE TRANSMISSION ONLY DISCHARGE PASSAGE CHECK BALL SPRING FAST IDLE ADJUSTING SCR...

Страница 150: ...erFlow 6 carburetors Use care to prevent accidental damage to throttle body Disengage the accelerator pump plunger from the rocker arm by pushing up on bottom of plunger ACCELERATOR PUMP OPERATING ROD...

Страница 151: ...REW RETAINER D A M D A L I PISTON RETAINER P N 5PK NG PLUNGER __ _ CLUSTER GASKET NEEDLE GASKET ROD SCREW BODY NOT SERVICED GASKET VALVE ARM l WASHER OVERDRIVE BRACKET SCREW t K f SWITCH LEVER SPRING...

Страница 152: ...i assembly See Figure 26 Discard both gaskets Remove the discharge check ball Metering of fuel from the accelerator pump system is accomplished by two carefully drilled holes in the discharge cluster...

Страница 153: ...ALL SCREW PISTON SPRING RETAINER PIN NEEDLE GASKET SPRING SCREW GASKET INLET BALL STEP UP WIRE 2 JET RETAINER FLOAT BODY NOT SERVICED ROD LEVER SCREW SPRING FLANGE SCREW ARM SHAFT 56P186 Figure 25 Hy...

Страница 154: ...all parts in a good commercial cleaning solvent until deposit has softened Then scrub parts with a stiff bristled brush not a wire brush and dry with compressed air Do not use a lye bath or gasoline...

Страница 155: ...w from the pump inlet or discharge passage If gasoline is evident from either point clean the passages again and repeat tests If leakage is still evident replace the check ball Main Body PowerFlow 6 I...

Страница 156: ...plate Back out throt tle adjusting screw Open throttle valve partially and hold choke valve in fully closed position Then close throttle valve This procedure will allow fast idle cam to revolve to fas...

Страница 157: ...Open the throttle valve to wide open position and adjust the hex nuts on the switch to have 1 64 to 3 64 inch clear ance between the kickdown lever and switch stem guide See Figure 38 The kickdown sw...

Страница 158: ...VALVE SEAT NEEDLE VALVE FLOAT IDLE AIR BLEED IDLE TUBE FUEL INLET IDLE NEEDLE VALVE THROTTLE VALVE Closed IDLE DISCHARGE HOLES 56P195 Figure 40 Float System and First Stage of Idle IDLE AIR BLEED THR...

Страница 159: ...ower System in Main Body Thermostat Cover Number Idle Mixture both screws Idle Speed Fast Idle Speed Setting drill size Choke Positioning Spring Color Choke Positioning Spring Setting drill size Unloa...

Страница 160: ...ifold vacuum is maintained above the vacuum piston through a channel which connects the vacuum piston with the mounting flange of the carburetor During partial throttle operations the vacuum above the...

Страница 161: ...the fast idle cam to provide the correct throttle opening during the warm up period See Figure 45 As the engine continues to warm up the air flow through the carburetor forces the offset choke valve...

Страница 162: ...tubes as shown in Figure 49 Invert carburetor and remove accelerator pump inlet check ball Do not remove the two dome shaped high speed bleeders in the main discharge strut of the main body Remove th...

Страница 163: ...IN RETAINER FLOAT FULCRUM PIN DASHPOT POWERFLITE ONLY THROTTLE SHA AND LfcVh POWERFLm C CHOKE HOUSING GASKET REW 3 THERMOSTAT SHAFT AND LEVER FAST IDLE CAM MAIN DISCHARGE JETS TUBES 2 MAIN METERING JE...

Страница 164: ...Assemble throttle body to main body using a new gasket Place main discharge jets on Tool T 24967 and install into position See Figure 55 Make sure the opening in end of tube diagonal cut end is facing...

Страница 165: ...removed with the gauge at the center of float and the float lip held firmly against the fuel inlet needle To change the float setting bend the float lip toward the needle to lower and away from needle...

Страница 166: ...n obtained After adjusting make sure the tang is parallel to the throttle shaft Remove fast idle speed adjusting screw and reinstall with spring Fast Idle Cam To position the fast idle cam open the th...

Страница 167: ...unloader adjustment lightly hold the choke valve closed then open the throttle valves to wide open position The choke valve should open sufficiently to allow a number 19 drill to be inserted between...

Страница 168: ...ods ac celerator pump and integral automatic choke sys tem The secondary side contains the velocity valves which allow the secondary side to supply fuel only under certain operating conditions thus pr...

Страница 169: ...LOW SPEED SYSTEM Fuel for idle or part throttle operation is metered through the low speed system located in the pri mary side The low speed jets meter the required amount of fuel during engine idle...

Страница 170: ...harge check needle Remove main metering jets primary side as shown in Figure 76 Then remove the secondary side main metering jets Primary main metering jets are not inter changeable with secondary jet...

Страница 171: ...ne operation If wear in the throttle body is excessive it is ad visable to install a new throttle body assembly When a new shaft is installed mark the throttle valve position in the bore before removi...

Страница 172: ...the vacuumeter piston spring in the piston cylinder Air Horn Assemble choke housing to air horn using a new gasket Tighten screws securely As semble the choke piston to the choke link Slide choke shaf...

Страница 173: ...4 in b 1 64 in 012 in 016 in Bend the tang on fast idle cam to permit velocity valves to open slightly before choke valves are fully open Two adjusting screws to l turns open Adjusting Screw 450 to 50...

Страница 174: ...and pump plunger and install in air horn and engage the pump connector link Secure with hairpin clip See Figure 87 Carefully lower air horn assembly into main body Be sure pump plunger enters the pump...

Страница 175: ...URE NEEDLE SPRIN THROTTLE BOD DUST COVER DUST COVER GASKET CHOKE VALVE HAIRPIN CLIP ACCELERATOR PUMP ARM PUMP CONNECTOR LINK METERING ROD SPRING VACUUMETER PISTON LINK METERING ROD SPRING BRACKET AIR...

Страница 176: ...dge of straight edge Metering Rod Adjustment Loosen metering rod arm just enough to provide a slight drag on the shaft Lift lever slightly With the primary throttle valves seated in the bores depress...

Страница 177: ...ader Adjustment Hold the primary throttle valves in the wide open position and insert a 3 16 inch unloader gauge Tool T 109 28 or a 3 16 inch drill between the upper edge of choke valve and inner divi...

Страница 178: ...ed adjusting screw Then proceed to adjust the idle mixture screws to obtain a smooth idling engine Changing the idle mixture may change the idle speed 8 MANIFOLD HEAT CONTROL The purpose of the manifo...

Страница 179: ...engine mo mentarily to wide open throttle The counterweight should respond by moving clockwise inch and return to its normal position If there is no move ment the shaft is frozen or the spring is wea...

Страница 180: ...anifolds Layers of carbon act as a heat insulator and retard the heating action of the exhaust gases in the heat chamber of the intake manifold Thus fuel will not vaporize as much as it could causing...

Страница 181: ...welded to gether forming a complete assembly To replace the muffler the exhaust pipe should be cut off as close to the front of the muffler as possible Then loosen the tail pipe clamps and slide the t...

Страница 182: ...of the cylinder head and cylinder block Clean the ma chined surfaces and inspect for nicks or scratches Inspect all cored passages Check surfaces for parallelism with a quality straight edge A new ga...

Страница 183: ...t 1600 RPM 120 to 150 P S I 10 P S I 1 2 3 4 5 6 1 5 3 6 2 4 P 27 24Ocu n 260 cu in P 29 270 cu in 277 cu in 8 37 9 241 3 7 16 in 40 6 260 3 9 16 in 42 2 270 3 5 8 in 3 1 4 in 7 6 to 1 157 at 4400 RPM...

Страница 184: ...ot pounds Repeat the tightening procedure and tighten the bolts in sequence to the specified torque Run the engine until normal operating temperature is reached Then recheck all cylinder head bolts an...

Страница 185: ...4 in x 3 4 in 1 7 16 in x 7 8 in 1 9 16 in x 15 16 in Adjustment None Number of Links 48 68 Width 1 in Stem Diameter 340 in to 341 in 372 in x 373 in Std Head Diameter 1 17 32 in 1 23 32 in 1 27 32 in...

Страница 186: ...ffing cylinder bores can be satisfactorily honed Honing limits should not exceed 005 inch removal of metal If only one or two cylinder bores have light scratches or scores hone the cylinders up to 005...

Страница 187: ...7 A B D C Valve Clearance for Checking Valve Timing 014 Cold Running Clearance Intake Exhaust 010 in Hot 010 in Hot 010 in Hot 018 in Hot Type U Slot Cam Ground Slotted Cam Ground with Steel Belt Mate...

Страница 188: ...in two sizes 1 for cylinder bores from standard to 023 inch oversize and 2 for cylinder bores from 025 inch to 060 inch oversize Only the skirt and lands of a semi finished piston require finishing Do...

Страница 189: ...piston in the cylinder bore with the piston pin installed The pin may distort the piston and a false fit may be indicated Figure 15 Measuring Piston Ring Gap PowerFlow 6 Typical of Hy Fire V 8 6 PIST...

Страница 190: ...or allowable clearances Install piston rings on piston with a suitable piston ring applier It is important that piston rings be installed correctly as shown in Figure 17 8 CRANKSHAFT When removing the...

Страница 191: ...ow Bolt Water Pump Body Bolt Water Pump Housing Bolt Flywheel Nuts Carburetor to Intake Manifold Stud Nut Intake Manifold Stud Nut P 26 P 28 15 ft lbs P 27 125 ft lbs P 29 35 ft lbs 15 ft lbs 15 ft lb...

Страница 192: ...g in bearing failure After regrinding use hand grinder to remove rough edges from all crankshaft oil holes Clean out all oil passages Do not grind thrust face of rear bearing journal The width of this...

Страница 193: ...aft journal Excessive clearance will result in bearing noise while insufficient clearance results in lack of lubri cation and may cause a wiping action resulting in damage to the bearing insert or cra...

Страница 194: ...idual to accurately read the graduated scale Check one bearing at a time leaving other caps tightened to their specified torques Remove the bearing cap and wipe the crank shaft journal and bearing cap...

Страница 195: ...cept when installing a replacement cap On replacement caps stud holes are 1 64 inch larger than production caps and bearing cap length is 1 16 inch shorter This per mits fitting of the replacement bea...

Страница 196: ...re 29 CHECKING FOR TWIST Use tool C 481 for checking for twist as shown in B of Figure 28 Tilt the piston and if more than 002 inch feeler stock can be inserted between piston and tool dis assemble ro...

Страница 197: ...al and bearing shell Make sure shim edges are smooth Remove any burrs or rough edges to pre vent damage to the bearing Apply light coat of oil to shim Install the cap and tighten nuts alternately to t...

Страница 198: ...ct ing rod bores are chamfered more on one side than the other The larger chamfer must be installed toward the crankshaft journal fillet It should be noted that each bearing cap has a small v groove a...

Страница 199: ...in Figure 35 If varnish build up is exces sive use puller part of tool C 3158 and work tappet out of bore as shown in Figure 36 Remove the four camshaft thrust bolts Camshaft can now be removed Insert...

Страница 200: ...welch plug with suitable sealer and install in cylinder block at rear cam bearing with tool C 897 Slide new bearing on adaptor and insert in position as shown in Figure 43 Install horseshoe lock and d...

Страница 201: ...gure 43 Installing Camshaft Bearings Hy Fire V 8 12 CHAIN CASE COVER OIL SEAL HY FIRE V 8 Drain coolant and remove ra diator 1955 Support engine with a suitable chain hoist fastened to intake manifold...

Страница 202: ...al make sure seal is driven into place evenly to insure a tight fit Use a new gasket and position cover in place Install screws but do not tighten Install the pulley and hub on crankshaft far enough s...

Страница 203: ...t plug POWERFLOW 6 Rotate crankshaft until zero mark is in line with center of camshaft Match the sprocket mounting holes with camshaft hub mount ing holes Rotate camshaft so that zero mark is in line...

Страница 204: ...clearance should not exceed 008 inch on intake valves and 014 inch on exhaust valves If these clearances are exceeded replace valves and ream guides NOTE If an or an is stamped on the cylinder head at...

Страница 205: ...n the valve face If this contact surface is not properly central ized the seat should be relocated by using a 20 stone at the top or a 60 stone at the bottom whichever is necessary Refer to Figure 53...

Страница 206: ...sassembled for cleaning inspection or the in stallation of new parts they should be assembled in the following manner Hold the rocker arm shaft and end bracket in a horizontal position with the oil gr...

Страница 207: ...IC TAPPETS When removing hydraulic tappets use tool C 3158 shown in Figure 35 If varnish build up is excessive use puller part of tool C 3158 and work tappet out of bore as shown in Figure 36 Before d...

Страница 208: ...t is important that each tappet serviced be reinstalled in its original bore in the engine block TAPPET BORE If the tappet bore shows evidence of scuffing scores or sticking ream the bore to the next...

Страница 209: ...ve head Valves and seats may be lightly lapped together to assure a tight seal with a suitable compound Valve heads may be rotated by means of a rod fitted with a vacuum cap which can be operated by h...

Страница 210: ...Exhaust 344 to 345 inch Use reamer C 249 for this operation See Figure 67 VALVE SPRINGS When valves are removed for reconditioning or replacement test springs for proper tension Exhaust and intake val...

Страница 211: ...ousing pan the clutch assembly and the oil pan Remove the flywheel nuts and the two lower bolts so that the flywheel can be turned to make the upper bolts accessible Before installing the flywheel che...

Страница 212: ...the clutch housing alignment Always check the torque of the cylinder head bolts before starting the engine Crank the engine with the starter until oil pressure is registered on the oil gauge before r...

Страница 213: ...ure 72 End Sectional View of Hy F re V 8 Engine 241 260 and 270 cu in Engines DISTRIBUTOR INTAKE MANIFOLD THERMOSTAT CAMSHAFT OIL PUMP DRIVE GEAR REAR MAIN BEARING OIL SEAL CRANKSHAFT REAR MAIN BEARIN...

Страница 214: ...bly out of the pump body Wash all parts in cleaning solvent and dry with compressed air Inspect all parts for damage or excessive wear RELIEF VALVE PLUG OIL STRAINER ASSEMBLY RELIEF VALVE SPRING RELIE...

Страница 215: ...FLOWS TO ONLY ONE BRACKET ON EACH HEAD BRACKET IS SECOND FROM REAR ON RIGHT HEAD BRACKET IS SECOND FROM FRONT ON LEFT HEAD OIL GALLERIES FLOATING OIL INTAKE E OIL FILTER TO CONNECTING ROD BEARINGS FE...

Страница 216: ...flow from filter to crankcase LUBRICATION FOR THRUST FACE OF CAMSHAFT TUBE LUBRICATING TIMING CHAIN AND SPROCKETS Oil G OOVt ANNUIU5 CARRISS CONTINUOUS HOW Of OIL FROM MA N BEARING OIL PASSAGE TO CRAN...

Страница 217: ...216 PLYMOUTH SERVICE MANUAL CO CN Q_ es MyMopar com...

Страница 218: ...lim its listed below replace both inner and outer rotor Hy Fire V 8 Allowable minimum limit 998 in PowerFlow 6 Allowable minimum limit 74 in ROTOR DEPTH Slide rotors in pump body Place a straight edge...

Страница 219: ...Clearance Over Pump Rotors 51x70 Figure 83 Measuring Clearance Between Pump Rotors Hy Fire V 8 Typical of PowerFlow 6 51x69 Figure 85 Measuring Clearance Between Outer Motor and Pump Body Hy Fire V 8...

Страница 220: ...tributor cap It should be ready to fire the No 1 spark plug rotor in seven o clock position If the position of the No 1 piston was accidental ly changed while the oil pump was removed take out the spa...

Страница 221: ...erent colored springs are used in the oil pressure relief valve The same colored spring should be installed See spring chart above OIL FILTER REPLACEMENT HY F RE V 8 The shunt type oil filter shown in...

Страница 222: ...locked the passage If oil fails to flow from a main bearing the oil passage in the cylinder block is probably blocked and the main bearing supplied by this main bear ing oil passage take out the main...

Страница 223: ...the carburetor or ignition timing Check vacuum gauge readings with compression gauge readings to determine the exact cause of an internal engine condition See Figure 92 A steady reading of 18 to 21 i...

Страница 224: ...hen the accelerator linkage is moved there may be a re striction in the fuel line from the tank to the carbu retor or the fuel pump may be faulty Disconnect the fuel line at the carburetor and crank t...

Страница 225: ...arburetor Fuel pump pressure should be checked Check the carburetor float level 2 IGNITION SYSTEM Inspect the spark plugs for fouling improper gap or cracked porce lains Check the ignition timing and...

Страница 226: ...alled and are not damaged b Drain Plug Inspect the oil pan drain plug for tightness c Rear Main Bearing Oil Seal Inspect the underside of the clutch housing for traces of oil Oil at this point usually...

Страница 227: ...in the crankcase A heavy oil will not flow as rapidly as a light oil and high oil pressure may result 3 OIL PRESSURE GAUGE Inspect the oil gauge for accuracy ENGINE NOISES The noises described here ar...

Страница 228: ...up pis ton is operating properly Check for high float level and for dirt in the air cleaner which might restrict the passage of air Test for excessive fuel pump pressure 4 CHOKE If the choke is not wi...

Страница 229: ...ole Circle diam Bolt Size Type Size Ply Tread TIRE PRESSURE Pounds Cold 6 70 x 15 and 7 10 x 15 P 26 P 27 P 28 P 29 Steel Disc Drop Center Safety Wheel 15 in x 4 in 5 4 in in 2 0 Super Cushion Tubeles...

Страница 230: ...ut against the flange even though rapid de flation occurs REMOVING TIRE FROM SAFETY RIM WITH CAR JACK With wheel and tire removed from car deflate tire completely by removing valve core After loosenin...

Страница 231: ...depending on the size of the rope Using a tire iron twist the rope and at the same time pound the tread using a rubber mallet at various places to evenly distribute the tension When the beads have mov...

Страница 232: ...placement of the rubber gasket A snap in type rubber valve stem that leaks must be replaced See Figure 9 OUTSIDE REPAIR METHOD Ordinary punctures are easy to repair with a tubeless tire repair kit usi...

Страница 233: ...od is recommended first because it is the easiest This condition when found will require the use of the inside method for repair PREPARATION Remove the tire from the wheel Install spreaders as shown...

Страница 234: ...high speed driving tires hot 29 lbs Cars with Hy FireV 8 Engine 26 lbs 29 lbs 31 lbs Always use an accurate gauge when testing tire pressure An inaccurate gauge can be in error as much as 2 or 3 poun...

Страница 235: ...he wheel and tire assembly around its axis of rotation An as sembly can be in static balance yet not balanced dynamically A wheel and tire assembly correctly balanced should run smoothly at all speeds...

Страница 236: ...be completely removed by thorough wash ing and cleaning of bearings in clean solvent NEVER ADD GREASE TO WHEEL BEARINGS After cleaning inspect the bearing and races for cracking flaking brinelling or...

Страница 237: ...ontrolling spotty wear is to keep the tires inflated to the recommended pressure and rotate them every 3 000 miles 2 UNDER INFLATION WEAR This type of wear can be recognized by excessive wear on the t...

Страница 238: ...camber will cause noticeable wear on the outer ribs of the tire See Figure 25 Excessive negative camber will 45x4O5 Figure 25 Camber Wear develop wear on the inner ribs of the tire Camber wear may al...

Страница 239: ...ANUAL BUTTON CLAMP BALL AND ROLLER ASSY P N WASHER BALL AND ROLLER SPRING BUTTON NUT LOCKWASHER BOLT 45x432 Figur 1 Universal Joint Disassembled BODY BALL HEAD DUST COVER 45 X 128 Figure 2 Installing...

Страница 240: ...ew pin INSTALLATION Install trunnion pin with special tool C 552 The trunnion pin should be a tight press fit Each end of the pin should protrude the same distance from the universal joint ball head A...

Страница 241: ...drive Diameter PowerFlite Transmission Length Center to center of pins on shaft Three Speed Transmission Three Speed and Overdrive PowerFlite Transmission Make Type Number Used Bearing Lubrication Bod...

Страница 242: ...k the inside of the housing with about l ounces of Universal Joint Grease Install the gasket and grease cover Be sure the tabs on the cover are bent over tightly Tighten the flange bolts to 35 foot po...

Страница 243: ...SHER OIL SEAL INSULATOR NOT SERVICED WASHER LOCKWASHER NUT WASHER LOCKWASHER NUT NUT OIL SEAL BUSHING HOUSING BOLT CUP CAGE AND ROLLERS TUBE AND WORM INSULATOR SPACER FERRULES AND PLATE USED ON 6 CYL...

Страница 244: ...ection feeling carefully for free play Tighten the cross shaft adjusting screw clockwise until no free play can be felt in the steering wheel See Figure 2 When properly adjusted there should be no fre...

Страница 245: ...seal at the housing cover If it is necessary to remove all the shims to obtain proper bearing adjustment it will be necessary to install new bearings cups or a worm and tube assembly 2 STEERING WHEEL...

Страница 246: ...orm bearing adjustment is correct 4 TUBE AND WORM ASSEMBLY If it is necessary to replace the tube and worm assembly the gear housing worm and tube must be removed from the car The column jacket and ge...

Страница 247: ...246 PLYMOUTH SERVICE MANUAL u I i OQ LU CO CO ION f u L Li u 3 Ct a X o o z 1 I I I L o tu z o CO L u 3 Q a X K O CL MyMopar com...

Страница 248: ...t NOTE The plate rubber pad spacers and ferrules used with direct tie rod linkage on 6 cyl models between the steering gear and frame are not used on 8 cyl cars with the idler arm type steering linkag...

Страница 249: ...hydraulic system If the steering wheel is not turned the valve remains in a neutral position and the oil is free to flow through the unit maintaining equal low pressures on both sides of the piston Th...

Страница 250: ...e the coaxial steering gear provides full time steering it is necessary to incorporate some meth od to enable the power to maintain the feel of the road This is done through the use of a reaction valv...

Страница 251: ...ton back to the neutral position in direct opposition to the force of deflection hence the front wheels will not vary from their fixed direction and the driver maintains control over rough roads with...

Страница 252: ...h travel from one extreme to the other with torque wrench Tool C 3005 and 1 7 16 inch socket observing torque reading The torque should be the same in both directions See Figure 10 Where torque is hig...

Страница 253: ...SNAP RING PISTON ROD OIL SEAL WASHER NUT HEAD K5 OIL SEAL WASHER NUT LOCK CUP INNER J BEARING CUP OUTER COUPLING SNAP RING BEARING GEAR SHAFT THRUST WASHER ADJUSTING SCREW O RING WASH R O BOLT WASHER...

Страница 254: ...through pressure and return connections by turning steer ing tube coupling from one extreme of travel to the other Using a 3 16 inch Allen wrench remove worm housing filler plug and drain worm upper...

Страница 255: ...Unlock worm connector nut lock and slide lock back sufficiently to loosen worm connector nut See Figure 16 DISASSEMBLY OF PISTON AND RODS Remove valve rod adjusting disc from valve rod See Figure 17 S...

Страница 256: ...cer Remove the worm connector nut from upper piston rod and slide housing head off of upper piston rod removing housing head O ring See Figure 20 Using a suitable drift remove the upper piston rod sea...

Страница 257: ...wer VALVE ROD O RING 53x823 Figure 26 Removing Valve Rod O Ring 53x824 Figure 27 Upper Piston Rod O Ring piston rod Inspect piston for nicks and burrs Make sure all oil passages are open and free of d...

Страница 258: ...ll housing shaft needle bearing assemblies into gear housing until bear ings bottom in bores if removed Always drive on letter side of bearing otherwise damage to bearing may result Install piston rod...

Страница 259: ...stall one on each upper and lower piston rod See Fig ure 27 Make sure they seat properly in the ring grooves Install lower piston rod with rack into end of piston assembly opposite piston pin hole and...

Страница 260: ...ays select a spacer to match The length of the valve control spacer selected must be identical to the distance between the seat of the valve control spacer seal retainer and seated upper piston rod nu...

Страница 261: ...GS TX P 26 P27 ONLY J wL TYPE RINGS 5 P 8O Figure 41 Installing Piston Rings Insert assembly into holes until it seats on worm connector Place ball guide clamp into position on ball guide and install...

Страница 262: ...orm housing Make sure cup seats properly in housing Lubricate worm housing inner bearing race and slide wide section of cone first over threaded end of worm until it seats 55P1304 Figure 43 Adjusting...

Страница 263: ...and Bushing End Clearance Between Rotors and Face of Body 008 inch 006 inch 001 to 002 inch h I Free Length Working Length Pressure at Working Length 2 13 inch 1 20 inch 14 l lbs I Free Length Workin...

Страница 264: ...nsert adjusting screw thrust washer into gear end of steering gear shaft Insert adjusting screw assembly into gear shaft and lock in position by installing internal snap ring Use C 3229 pliers and mak...

Страница 265: ...o 30 25 to 30 10 to 12 25 to 30 35 to 40 INSTALLATION OF GEAR SHAFT OIL SEAL Before attempting to install a new seal thor oughly clean the sealing surfaces on the gear shaft and counterbore of steerin...

Страница 266: ...ver Start engine and operate at idle Fill reservoir to level mark and allow system to warm up Oil level must be maintained above filter while hydraulically centering valve Insert manual control valve...

Страница 267: ...man arm backlash should become evi dent equal distances in both directions when turn ing from center It may be necessary to reposition the coupling to obtain equal travel in both direc tions in which...

Страница 268: ...parts PUMP REMOVAL Disconnect the pressure and return hoses from pump assembly Loss of oil will be noted when hoses are removed keep both hose ends up to prevent further loss of oil Ends of hose shoul...

Страница 269: ...COVER VALVE OIL SEAL FLANGE WASHER i V3 BOLT AND LOCKWASHER SCREW AND WASHER FLANGE COUPLING SPRING ADAPTER 56P 77 Figure 54 Coaxial Power Steering Pump Disassembled MyMopar com...

Страница 270: ...inch to 002 inch In spect the pressure relief valve and the flow divider plunger for scoring replace if necessary PUMP COVER BUSHING Place pump cover in a vise equipped with pro tective jaws install T...

Страница 271: ...stalling Pump Shaft Oil Seal with Tool C 3230 install snap ring Install shaft protector thimble C 3228 in pump body until it bottoms Figure 61 Using care not to damage the babbitt bushings when instal...

Страница 272: ...s level and one is at an angle a binding action may occur on extreme turns 4 CROSS SHAFT Turn the steering wheel from right to left through the center position If binding is evident at the center posi...

Страница 273: ...he piston rings or an internal seal or O ring leak within the unit 7 STEERING COLUMN A bind in either the steering gear or column will cause hard steering HARD STEERING IN ONE DIRECTION 1 TIRE PRESSUR...

Страница 274: ...ckets are bent these measurements may be taken from corresponding points on the frame side rails and cross members Any two diagonals compared must represent exactly corresponding points on each side o...

Страница 275: ...E 34 i _i _ NOT ON SPECIAL 4 DOOR I SPECIAL 4 DR i O CP AKI 56P24l Figure 2 Frame Dimensions All Models P 26 P 27 P 28 Except Convertible Coupe A rti H 55P1042 Figure 3 Frame Dimensions P 27 Convertib...

Страница 276: ...bs 70 ft lbs 50 ft lbs 55 ft lbs 55 ft lbs be taken without removing the body by using a plumb bob and chalk line To take diagonal measurements with the body on the car place the car on a level floor...

Страница 277: ...r and sup port the frame side rails just ahead of the rear spring front mountings Support the weight of the rear axle Disconnect the shock absorbers Remove the spring clips U bolts and shackle bolt nu...

Страница 278: ...e interliner makes contact Use sandpaper wrapped around a flat file and sand the surface until all traces of dirt and rust are removed leaving a smooth metal surface Wipe off the loose particles with...

Страница 279: ...ttach the mounting brackets to the underside of the frame horns Always install clamping screw with the nut toward the rear of the car to prevent damage to the tires 6 DIAGNOSIS PROCEDURES UNSATISFACTO...

Страница 280: ...reverse the nut is too loose Tighten it until there is no play in the rod Then back it off 1 2 turn and tighten the lock nut Make sure the adjusting nut is not too tight or it will not shift into sec...

Страница 281: ...SCREW GEARSHIFT FORK SECOND GEARSHIFT RAIL INTERLOCK UNIVERSAL JOINT ATTACHING BOLT GEARSHIFT RAIL INTERLOCK PLUG GEARSHIFT LEVER SHAFT tt GEARSHIFT LEVER PIN f LOCK SPRING 1 COUNTERSHAFT THRUST WASH...

Страница 282: ...s proper position Seal must protrude 7 32 inch from end of extension case Seal and rear main shaft bearing may become damaged if seal is driven in too far See Figure 4 Figure 4 Removing and Installing...

Страница 283: ...Run Out Gear Ratio First Second Third Reverse Lubricant Capacity P 26 P 27 P 28 P 29 Helical 14 Steel Rollers 22 Steel Rollers each end 22 Steel Rollers 003 to 008 inch 003 inch preferred 003 to 008...

Страница 284: ...essary GEARS Inspect backlash between the synchronizer sleeve and clutch gear If splines or teeth on clutch gear are worn replace both parts Gear and sleeve are supplied in matched sets so backlash be...

Страница 285: ...be stoned off Remove rollers from each end of gear and spacer Check rollers for chips and nicks If damaged replace all rollers Inspect countershaft for wear DRIVE PINION Remove the drive pinion and i...

Страница 286: ...pipe or tubing to install it on the pinion shaft Coat pocket in pinion shaft lightly with grease and install roller bearings Slide last bearing in from the end Install mainshaft pilot bearing snap rin...

Страница 287: ...2 under cap screws SHIFTER RAILS AND FORKS Place synchronizer clutch sleeve in the neutral position Insert fingers of second and high shifter fork into the groove in sleeve with hole for the guide rai...

Страница 288: ...ace should not exceed 003 inch total indicator reading To correct excessive run out place proper thickness of shim stock between the clutch housing and engine or between trans mission and clutch housi...

Страница 289: ...ugh a rail lockout switch on cars so equipped then to the governor which grounds the circuit whenever the car speed is above approxi mately 25 miles per hour This grounding completes the circuit permi...

Страница 290: ...breaking the circuit through the kick down switch and normal engine operation is re established and the transmission is in third gear When the pedal is momentarily released the over drive unit is auto...

Страница 291: ...ATIONS Mainshaft Flange Nut Overdrive Housing To Transmission Screw 140 150 Ft Lbs 30 35 Ft Lbs RAIL LOCKOUT SWITCH On cars so equipped When servicing the rail lockout switch care must be exercised to...

Страница 292: ...hold it in position Remove the two recessed screws and lock washers located in the front face of the adapter plate See Figure 23 Tap the end of the overdrive mainshaft a few times with a soft hammer t...

Страница 293: ...OCKWASH R LOCKWASHER GOVERNOR COVER ASSEMBLY DRIVEN GEAR SLEEVE LOCKWASHER BRAKE SUPPORT HOUSING SCREW LONG SNAP RING LOCKWASHER CAM RETAINING CL P PINION CAGE PINION CAGE RETAINING CLIP HOUSING BEARI...

Страница 294: ...t outer race and ring gear for wear or damage If it is necessary to replace one or the other pry off the snap ring and remove the ring gear from the outer race Always use a new snap ring when assembli...

Страница 295: ...that the balk ring is installed correctly on the control plate Place the embossed face forward against the control plate Check the assembly by installing it in the adapter plate The Figure 31 Testing...

Страница 296: ...ion cage and secure the assembly with the pinion cage retaining clip Slide the assembly on the splines of the transmission mainshaft and in SHIFT RAIL stall the clutch cam retaining clip Make sure tha...

Страница 297: ...car in low range and then automatically shifts the transmis sion into direct drive at the proper time depending upon the degree of acceleration desired by the driver The shift is fully automatic allo...

Страница 298: ...Direct Clutch Piston Retainer Thrust Washer 3 sizes 078 to 080 in thin f 095 to 097 in medium 112 to 114 in thick Kickdown Planet Pinion Carrier Thrust Washer 124 to 126 inches Reverse Planet Pinion C...

Страница 299: ...KE ASSEMBLY KICKDOWN PLANETARY GEAR SET IMPELLER INPUT SHAFT REVERSE PLANETARY GEAR SET GOVERNOR L f DIRECT CLUTCH FRONT OIL PUMP OUTPUT SHAFT REAR OIL PUMP REVERSE BAND OIL STRAINER KICKDOWN BAND I m...

Страница 300: ...nes When this action takes place the stator is carried along by the force of oil on the backs of the stator vanes because the stator is mounted on an overunning clutch permitting it to rotate in the d...

Страница 301: ...put shaft to the annulus gear of the kickdown front planetary set and to the sun gear of the reverse rear planetary gearset When the kickdown sun gear is held stationary and the annulus gear is the dr...

Страница 302: ...ts revolving may be audible HYDRAULIC OPERATION NEUTRAL When the engine is started panel control placed in Neutral the manual valve which is connected to the panel control by mechanical linkage is pos...

Страница 303: ...ion output shaft and incorporates a valve in the gov ernor body As output shaft speed car speed increases a greater oil pressure is applied to the governor pressure area of the shift valve If accelera...

Страница 304: ...GOVERNOR CONTROL SYSTEM IN NEUTRAL WITH ENGINE RUNNING 55P1278 1956 MODELS LEGEND W E LINC O M l DOTTED LUC PUMP SUCTION YELLOW CONVERTER O O OOTTCO YELLOW LU I CONTROL SYSTEM IN NEUTRAL ENGINE RUNNIN...

Страница 305: ...ENO LUC LIMt tO M l DOTTED LUE PUMP UCTIO I YELLOW CONVERTER DOTTED YELLOW LUIC KEEN THROTTLE ROWN 0VERN0R 0 0MI CONTROL SYSTEM IN DRIVE BREAKAWAY NOTE A 8 C 0 E ARE METERING HOLES 56P216 OIL STRAINER...

Страница 306: ...1280 LEGEND LUC LIW O M l OOTT O LUE PUMP SUCTION YILLOW COHVINTIM O O M OOTTIO VILLOW LU I RUN TMMOTTLI l tOMI MOWN OVfRNOft O tOMI CONTROL SYSTEM IN DRIVE DIRECT MOTE A CD E ARE METERING HOLES 56P21...

Страница 307: ...P UCTION YELLOW CONVERTER O O Ptl DOTTED YELLOW LU E REEN THftOTTLE IS tOPSI MOWN 0VERN0R O O PSI DOTTED REE K O LIMIT T6 PH SERVO RESTRICTOR VALVE CONVERTER CONTROL VALVE CONTROL SYSTEM IN DRIVE KICK...

Страница 308: ...trictions thus preventing kickdown at too great a car speed RESTRICTION D This restriction prevents line pressure 90 p s i from entering the throttle pressure lines when the transmission is in Low L A...

Страница 309: ...W ILUM IO 10 Ml C4LSTRAI R OOCRNON LEVER IN LOW 55P1282 LEGEND LUI UNE O M l 0OTTI0 LUC PUMP SUCTION YELLOW CONVERTER SO O M l DOTTED YELLOW L U I MEN TMHOTTLE l tOMI MOWN OVENNOR O O M l CONTROL SY9T...

Страница 310: ...NVEftTCR O Ptl OOTTtD Y LLOW LU C K OMI OIL TRANER GOVERNOR LEVER IN REVERSE 55P1283 LIOENO RED RCVIRSE H O M l OOTTtO LWt PUMP WCTIOM VtLLO CONVIRTIR O O P l OOTTIO VILLOW L U I I CONTROL SYSTEM IN R...

Страница 311: ...point Operate engine at speeds shown on throttle pressure chart If pressures do not correspond refer to Diagnosis Procedures CAUTION To prevent overheating of transmission and torque converter do not...

Страница 312: ...s obtained through the use of a single push pull cable One end of the wire cable is secured to the cable actuator in the speed range selector unit on the instrument panel The other end enters the tran...

Страница 313: ...le slightly CABLE TO SELECTOR UNIT BRACKET AND ATTACHING SCREWS HOUSING CABLE ACTUATOR CABLE CABLE LOCKING CLIP Figure 54 Speed Range Selector 56P 88 SCREWDRIVER CONTROL CABLE C A B L E LOCK ADAPTER S...

Страница 314: ...ent at transmission See Figure 58 Figure 58 Adjusting PowerFlite Gearshift Selector Lever THROTTLE LINKAGE AND PRESSURE ADJUSTMENTS Adjustments are made in the engine compart ment however the linkage...

Страница 315: ...ar of the car to take up all slack Then tighten the clamp nut Be sure carburetor is off the fast idle cam IMPORTANT One of the most important adjustments is the connection between the two parts of the...

Страница 316: ...odels 2 With panel control in N start the engine 3 Move the panel control to R noting the speed and smoothness of the shift Back car up 4 Attach an electric tachometer to the engine Move panel control...

Страница 317: ...over the manual valve lever shaft and slide into position Install manual control lever on shaft with arm side Figure 64 Removing or Installing Transfer Plate Assembly Figure 65 Install Tool C 3277 to...

Страница 318: ...talled behind the rear edge of planet pinion carrier and is attached to the trans mission case with a pan screw See Figure 68 Remove the seven transmission extension to case screws and lockwashers Ins...

Страница 319: ...SEMBLY REVERSE BAND STRUT EXTENSION BREATHER GOVERNOR BODY SCREW GOVERNOR BODY SCREW LOCKWASHER GOVERNOR PRIMARY WEIGHT GOVERNOR WEIGHT SPRINC GOVERNOR SECONDARY WEIGHT GOVERNOR SECONDARY WEIGHT SNAP...

Страница 320: ...slightly See Figure 70 Remove the crossmember to frame bolts and remove the crossmember Lower the engine two or three inches Place transmission jack in position and adjust jack to just support the we...

Страница 321: ...FRONT OIL PUMP GEAR FRONT OIL PUMP PINION FRONT OIL PUMP HOUSING SEAL FRONT OIL PUMP HOUSING TRANSMISSION FRONT OIL PUMP HOUSING DUST SEAL FRONT OIL PUMP DRIVE SLEEVE FRONT OIL PUMP DRIVE SLEEVE SEAL...

Страница 322: ...er assembly is a welded unit and cannot be serviced except as an assembly RING GEAR REMOVAL To replace the ring gear it will first be necessary to remove the torque converter from the crank shaft Care...

Страница 323: ...clutch assembly and move the clutch assembly to its forward position Measure the distance between the planet pinion carrier housing and clutch assembly Then insert screwdriver between transmission ca...

Страница 324: ...GOVERNOR LOCATING SCREW GOVERNOR VALVE SHAFT GOVERNOR VALVE Figure 80 Removal or Installation of Governor Valve and Shaft GOVERNOR BODY GOVERNOR WEIGHT ASSEMBLY 45x2103 Figure 79 Removal or Installati...

Страница 325: ...l ball Use care when removing Inspect keyway in pinion and ball pocket in shaft for wear Check clearance between pump housing face and face of gears with tool C 3335 and feeler gauge Clear ance limits...

Страница 326: ...during disassembly Remove snap ring with screwdriver and identify it to aid during assembly See Figure 88 Remove the input shaft kickdown planet pinion carrier assembly and kickdown annulus gear from...

Страница 327: ...Remove burrs or score marks with crocus cloth DIRECT CLUTCH PISTON RETAINER DISASSEMBLY Remove the kickdown sun gear snap ring selec tive fit as shown in Figure 95 Lift out sun gear as sembly See Fig...

Страница 328: ...4S 2 2C Figure 95 Removal or Installation of Kickdown Sun Gear Snap Ring Figure 98 Removal of Clutch Discs and Clutch Plates KICKDOWN SUN GEAR ASSY DIRECT CLUTCH HUB Figure 96 Removal or Installation...

Страница 329: ...ews Torque Converter Housing to Adapter Plate Screws Output Shaft Support to Case Screw Governor Body Screws Oil Strainer Support Screws Oil Pan Screws Front Oil Pump Housing Screws Rear Oil Pump Hous...

Страница 330: ...vent damage to the neoprene seal Install the di rect clutch spring in the retainer and position the spring retainer and snap ring on spring Using tool C 3302 and compress the direct clutch spring suf...

Страница 331: ...nd Remove band as shown in Figure 104 Both the kickdown band and reverse band have bonded lining and no attempt should be made to reline them If grooves in lining are no longer visible replace the ban...

Страница 332: ...hen both the valves and body are dry Crocus cloth may be used to polish valves pro viding care is exercised not to round the sharp edge portion of the valves The sharp edge portion is vitally importan...

Страница 333: ...ide and remove the snap ring Loosen compressing portion of tool and re move tool from transmission case Remove piston rod guide piston spring kickdown piston rod assembly and kickdown piston cushion s...

Страница 334: ...Figure 114 Installing Manual Control Lever Oil Seal Screw adjusting screw with locking nut at tached into transmission case until there is approx imately one inch of screw left on outside of case Do...

Страница 335: ...ing a piece of brass rod flattened on one end work seal ring into position gradually compressing spring until seal ring enters case and snap ring can be installed Install the kickdown piston rod guide...

Страница 336: ...mission front oil pump gear and pinion driv ing lugs of pinion facing up in oil pump housing See Figure 119 CAUTION Unless oil pump pinion is installed correctly considerable damage will result when t...

Страница 337: ...rse annulus gear snap ring Selectively fit the snap ring with one of the following three sizes 078 to 080 inches thin 082 to 084 inches medium and 086 to 088 inches thick CAUTION Reverse annulus gear...

Страница 338: ...fit Make sure it is positioned and seated properly See Figure 88 Lubricate gear and splines Using a feeler gauge check the clearance between the kickdown planet pinion carrier housing snap ring and th...

Страница 339: ...the two governor support piston rings with lubriplate and install on the governor support Stagger rings and make sure they are free to rotate in lands Position governor body on sup port and install th...

Страница 340: ...ure the brake support spacer neoprene is in position on back of brake support and spacer sleeve is in center of support Slide brake support assembly over rear of extension housing and anchor pin Make...

Страница 341: ...it turns freely 45x2154 Figure 127 Removal or Installation of Speedometer Drive Pinion Coat nylon gear and threads on speedometer drive pinion with Lubriplate and install in trans mission extension To...

Страница 342: ...throttle valve spring and slide the throttle valve cam assembly from the manual valve lever assembly See Figure 132 IMPORTANT Remove any burrs from the throttle valve camshaft and manual valve lever s...

Страница 343: ...N VALVE BALL KICKDOWN ROD J I PUMP CHECK VALVE PLUG SERVO BLEED VALVE THROTTLE PRESSURE CHECK BALL THROTTLE VALVE SPRING SHUTTLE VALVE PACKAGE VALVE BODY PLATE MANUAL VALVE LEVER T H R O m E V A L V E...

Страница 344: ...a screwdriver compress the detent ball and slide out manual valve lever until it is dis engaged from detent ball CLEANING AND INSPECTION OF VALVE BODY AND TRANSFER PLATE ASSEMBLY Place all parts in c...

Страница 345: ...lve lever until it snaps over the detent ball See Figure 141 Place the kickdown rod with the large end to ward the end cover into the valve body and install the snap ring Install the direct clutch shi...

Страница 346: ...sult to the valves valve body plate or transfer plate when the screws are tightened Keep sufficient pressure on the transfer plate and valve body plate to hold them together Place the assembly over th...

Страница 347: ...to 25 ft lbs INSTALLATION OF TORQUE CONVERTER AND HOUSING Inspect mating surfaces on torque converter and crankshaft flange for burrs and dirt Install torque converter on crankshaft Install the eight...

Страница 348: ...ed while the car is driven in second gear When the transmission is in high low or reverse gear the noise caused will be indistinct 3 LOW AND REVERSE SLIDING GEAR A worn or damaged low and reverse slid...

Страница 349: ...ng the clutch is generally due to gear butting which is caused by the leading edges or bevels of the gears being flattened by continual unnecessary gear clashing on the part of the driver d Idler Gear...

Страница 350: ...the horn relay to the governor 4 ROAD TEST Check the governor operation by road test Leave the jumper wire connected to the terminal on top of the governor and run the other end of the wire inside th...

Страница 351: ...lamp may come on before the accelerator pedal is depressed if the distributor points are closed depending upon which B terminal is connected If test lamp lights move the connection to the other B ter...

Страница 352: ...emove the plug Cover the oil filler tube with a cloth or plug and hold firmly in place to prevent the air from forcing the trans mission oil out through the filler tube Screw a piece of pipe into the...

Страница 353: ...ction shaft oil seal rings for wear or broken ends Inspect condition of clutch plates and condition of friction material on seal ring Check clutch check valve ball 5 EXCESSIVE ENGINE SPEED INCREASE ON...

Страница 354: ...OVERNOR PRESSURE High governor pressure at low engine speeds is due to the governor valve stuck in the open posi tion usually caused by a particle of dirt Use air pressure as outlined in 1 No Governor...

Страница 355: ...e which would cause dragging Inspect clutch ball check 2 CAR MOVES FORWARD IN NEUTRAL AT HIGH ENGINE SPEED Clutch check valve ball bleed hole may be plugged causing centrifugal oil pressure to partial...

Страница 356: ...ND HARDWARE INSIDE DOOR AND WINDOW REGULATOR HANDLES The door and window regulator handles are attached with a spring type clip and can be re moved with a special tool Figure 1 gives the dimensions of...

Страница 357: ...ive free travel be tween the door handle and the lock slide Part No 1655469 is used on the front doors and 1655470 on the rear doors These spacers snap on to the lock slide See Figure 5 DOOR TRIM PANE...

Страница 358: ...igure 9 PUSH TOWARD FRONT OF CAR TO LOCK PULL TOWARD REAR OF CAR TO RELEASE Figure 9 Sliding Latch Plate to Remove or Install Lock Cylinder To remove the lock cylinder insert the screw driver through...

Страница 359: ...a block of hardwood and a mallet When installing the channel on a new glass make certain it is correctly positioned on the glass before driving the channel in place After installation of the glass is...

Страница 360: ...per channel attaching screws and lift the channel out of the door Disengage the glass from the regulator and remove the glass Remove the regulator attaching screws and re move the regulator through th...

Страница 361: ...upper garnish moulding Figure 18 Removing Side Moulding Attaching Screws at A Post Insert tool C 34I2 or a wedge shaped piece of hardwood or fiber in locking seam in weatherstrip and twist slightly to...

Страница 362: ...ont lip of the weatherstrip and glass Start at either bottom corner and work to the center Work the glass into the weatherstrip groove See Figure 23 Do not attempt to push glass in too far at this tim...

Страница 363: ...g lip as shown in Figure 26 Releasing the locking lip will allow the rear window glass to be removed without disturbing the weatherstrip Remove the glass by pushing on the glass from the inside Use of...

Страница 364: ...e rear seat cushion from the car Then remove the garnish moulding regu lator handle and trim panel Lower the window and remove the window pivot set screw Carefully raise the regulator and glass to app...

Страница 365: ...ss and carefully push the weather strip and glass assembly from the body opening Work the weatherstrip off the glass and remove old sealer from the weatherstrip groove INSTALLATION Apply a suitable se...

Страница 366: ...misalignment Figure 35 Body Adjusting Tools NOTE The following tools will be very useful when making fender adjustments Turnbuckle Tool Fronf Fender To make this tool use two pieces of steel rod 17 l...

Страница 367: ...gure 38 Raise the jack until the bottom edge of the fender is in line with the bottom edge of the sill panel Retighten the fender attaching bolts and remove jack REAR EDGE OF FENDER EXTENDS TOO FAR ST...

Страница 368: ...as shown in Figure 45 Then bend the hood strainer bar down at the center This will lower the contour of the hood at the center The contour of the hood should match the contour of the cowl FRONT OF HO...

Страница 369: ...nge support bracket so that the hinge movement can be checked Loosen all the hinge to bracket stud nuts and pull the hinge forward until proper spacing between the hood and cowl is obtained See Figure...

Страница 370: ...Hood too High to Line Up With Front Fender Moulding Figure 50 Rear Corner of Hood Binds on Fender Figure 53 Adjusting Hood Striker 55PHO5 Figure 51 Repositioning Hood to Obtain Clearance at Fender Fi...

Страница 371: ...edge of the fender and cowl After the front door is correctly positioned align the rear door with the rear edge of the center pillar post Before loosening the door hinge screws scribe a line around t...

Страница 372: ...tion it will be neces sary to readjust the striker plate After the adjust ment is made test the weatherstrip compression by closing the door on a shipping tag The weather strip should offer a reasonab...

Страница 373: ...SE TO BODY Figure 68 Loosen the lower hinge screws at the door Place Figure 65 Moving Upper Half of Door Away from Body Figure 66 Rear Door Too Low in Opening a floor jack under the bottom rear corner...

Страница 374: ...is limited by a stop on the bracket which contacts the hinge arms The torsion bar ends are lubricated at the fac tory and should not require lubrication however if the torsion bar is replaced or shoul...

Страница 375: ...d the upper flange of the deck lid Spacing should be close and uniform at this line The contour of the deck lid should conform with the contour of the deck lid opening upper panel Following are some c...

Страница 376: ...d rear seat cushion assem bly as well as the sun visors and upper windshield garnish moulding SPORT COUPE MODELS Remove the quarter glass garnish moulding front pillar and roof side rail weatherstrip...

Страница 377: ...illar and roof side rail weatherstrip and the drive nails at the ends of the headlining seams Use a dull putty knife to separate the headlining from the roof rail and carefully remove the mate rial fr...

Страница 378: ...ain ing screws and pivot Install visors before tucking in the corners of the headlining at the top of the windshield posts to prevent tearing ihe headlining when tightening the screws Install garnish...

Страница 379: ...re 89 The procedure for installing the headlining at the rear window is basically the same on all models except the Suburban Apply a light coat of cement to the surface of the opening Use cement spari...

Страница 380: ...they are positioned away from each other This precaution will avoid incorrect operation of windows WINDOW LIFT MOTOR REMOVAL Remove the door handle arm rest and trim panel Disconnect the wires from mo...

Страница 381: ...T DOOR DOWN 7 LEFT REAR QUARTER DOWN 8 RIGHT REAR QUARTER D O W N 9 SWITCH FEED 10 SWITCH GROUND NOTE Terminals 3 4 7 and 8 have colored sleeves on wires at master switch D GREEN To left relay UP E OR...

Страница 382: ...ecking out any electrical system with a test lamp or voltmeter and ammeter 14 POWER OPERATED FRONT SEAT The power operated seat is driven by an electric motor which is located under the front seat on...

Страница 383: ...UP 3 LEFT REAR DOOR OR QUARTER UP 4 RIGHT REAR DOOR OR QUARTER UP 5 LEFT FRONT DOOR DOWN 6 RIGHT FRONT DOOR DOWN 7 LEFT REAR DOOR OR QUARTER DOWN 8 RIGHT REAR DOOR OR QUARTER DOWN 9 LEFT DOOR SWITCH...

Страница 384: ...RIGHT FRONT DOOR UP 3 LEFT REAR DOOR OR QUARTER UP 4 RIGHT REAR DOOR OR QUARTER UP 5 LEFT FRONT DOOR DOWN 6 RIGHT FRONT DOOR DOWN 7 LEFT REAR DOOR OR QUARTER DOWN 8 RIGHT REAR DOOR OR QUARTER DOWN 9...

Страница 385: ...d ing the cause is probably due to improper linkage alignment and adjustment See Figure 99 CARE OF TOP WATER PROOFING THE TOP Worn fabric top material can be waterproofed with the use of wind shield R...

Страница 386: ...re 100 To decrease clearance between the quarter glass and roof rail weatherstrip move the bracket for ward The adjustment should be approximately the same on both sides ROOF SIDE RAIL ALIGNMENT PROP...

Страница 387: ...Stop screw provides adjust ment of side rails to fit quarter window VERTICAL PROP L VERTICAL PROP LINK Can be adjusted up or down to obtain proper leveling and centering of the top POWER LINK Can be a...

Страница 388: ...ing screws to obtain proper alignment of door glass and channels Figure 101 Convertible Coupe Window Adjustment 4 QUARTER WINDOW ATTACH ING SCREWS Adjust attaching screws to tilt quarter window in or...

Страница 389: ...run channel position is changed See Figure 101 REAR QUARTER WINDOW ADJUSTMENT Re move the rear seat cushion remove the garnish moulding regulator handle and trim panel Rear window can be adjusted in...

Страница 390: ...DRAIN TROUGH A water leak at the trough will show up on the headlining around the body pillar on the floor or possibly in the luggage compartment The drain trough is sealed on the top of the roof pan...

Страница 391: ...the seal See Figure 107 If the cowl ventilator weatherstrip is loose seal it with Rubber Cement COWL AREA All welded seams should be sealed with a heavy caulking compound In addition all pad fastening...

Страница 392: ...st 20 minues before applying he weatherstrip to the door After pressing weather strip into place leave the door open for at least two hours before closing Closing the door too soon after applying the...

Страница 393: ...EL HOUSE FLOOR PAN TO REAR BODY PANEL AND FUEL TANK FILLER NECK COVER TO BODY PANEL 9 FUEL TANK SUPPORT BRACKETS C O FLOOR PAN TO FLOOR PAN EXTENSION 7 1 BODY SILL JOINT BOTH SIDES to m COACH JOINTS U...

Страница 394: ...by sealing washers Tighten the nuts as necessary FLOOR PAN AREA Road splash can enter the body through any openings in the floor pan seams Figure 109 shows all sealing points on the body floor pan Fo...

Страница 395: ...DAL 11412 DAL 41763 DAL 11357 DAL 41841 DAL 41842 DAL 21209 DAL 31320 DAL 31146 DAL 70598 DAL 70621 DAL 8038 DAL 80787 INTERIOR Ditzler Co or Name Code No Jet Black 9000 Aster Blue Light 11372 Alamo B...

Страница 396: ...2 7741 22 7742 22 7743 22 7744 22 7745 22 7746 22 7747 22 7748 22 7749 1724 7736 7737 7738 7739 7740 7741 7742 7743 7744 7745 7746 7747 7748 7749 DQE 9000 DQE 11233 DQE 11234 DQE 11236 DQE 11235 DQE 4...

Страница 397: ...speaker INSTRUMENT PANEL SPEAKER MTG STUDS 3 SPEAKER CONTROL RADIO ASSEMBLY RADIO MTG SCREW L AND WASHER ASSY RADIO MTG BRACKET RADIO MTG BRACKET LOCKNUTS INSTRUMENT PANEL REINFORCEMENT HOLE IN TOP OF...

Страница 398: ...D ANTENNA Detailed instructions for installation are fur nished wth each radio and antenna package For best radio reception be sure the antenna rod is clean When installing the antenna route the lead...

Страница 399: ...isconnect the battery lead wire at the fuse holder disconnect dial light lead disconnect speaker wires from radio Remove two lower grille attaching screws located inside of glove box Remove the four u...

Страница 400: ...istributor duct of the right side and forces air through slots in the windshield fence Defrosting is continuous along the entire length of the windshield fence Due to the design of the duct greater ef...

Страница 401: ...neously with bulbs in tail and parking lights until turn is completed On 1955 models the directional signals operate only when the ignition key is turned to the left On 1956 models the directional sig...

Страница 402: ...and plug it into another antenna If the interference disappears the dis turbance is being picked up by the antenna If the antenna is picking up engine interference make sure the antenna lead is proper...

Страница 403: ...ich might be caused by the fuel gauge points Make sure that the filter is properly con nected as shown in Figure 11 VOLTAGE REGULATOR A condenser which filters out noise from the Voltage Regulator com...

Страница 404: ...the heater heat output will be affected This means that air has entered the sys tem and may have become trapped limiting the circulation of the hot water To correct condition by forcing out the trapp...

Страница 405: ...URN SIGNAL TAIL LAMP I 16 BROWN 16 BLACK t f c RIGHT BACK UP LAMP 16 BLACK CJO YELLOW J_ I PO X l LEFT BACK UP LAMP 16 BLACK f 16 GREEN LEFT PARKING TURN SIG LAMP LEFT TURN SIGNAL TAIL LAMP 55P1010 Wi...

Страница 406: ...ION DISTRIBUTOR GENERATOR REGULATOR I 1 4 V3V I R E D 16 STARTER MOTOR NEUTRAL SAFETY SWITCH POWER FLITE ONLY 16 BLACK YELLOW STARTER IGNITION SWITCH STARTER SOLENOID STANDARD TRANSMISSION ONLY O o i...

Страница 407: ...IGNITION DISTRIBUTOR RADIO CONDENSER GENERATOR REGULATOR RADIO CONDENSER NEUTRAL SAFETY SWITCH 6 P F ONLY BLACK STARTER MOTOR 18 BLACK YELLOW 4 BLK WITHOUT P F i STARTER SOLENOID 12 BLACK HORN BUTTON...

Страница 408: ...GE TEMP GAUGE 184RED BLK i 18 RED BLK ANTENNA SWITCH O L LGEN V LAMP OIL PRESSURE WARNING LAMP HEADLAMP SWITCH AND 15 AMP CIRCUIT BREAKER FUEL GAUGE TANK UNIT 18 RED RADIO 9 AMP FUSE 16 BLACK GN TARTE...

Страница 409: ...TO BATTERY POSITIVE POST 16 RED 16 BLACK GLOVE BOX LAMP AND SWITCH _t jTEMP GAUGE AND 5r FUEL GAUGE LAMP h 18 YELLOW 18 WHITE 18 BROWN 18 GREEN 18 BLACK 18 GREEN RIGHT TAIL STOP AND TURN SIGNAL LAMP...

Страница 410: ...rator coil carries it to the con denser and there discharges it to the outside air Starting with the compressor inlet as shown in Figure 1 the vapor entering the compressor is at a relatively low temp...

Страница 411: ...reaks the circuit to the solenoid and the valve opens This allows hot vapors to flow from the compressor to the evaporator and moderates the cooling effect of the system A drop in the tem perature of...

Страница 412: ...tecting cap This cap is used to protect valve and safety plug from damage Always replace cap after using charge drum The drum should never be exposed to radi ant heat or an open flame as the resultant...

Страница 413: ...drop exceeds specifications TESTING COMPRESSOR VALVES Start engine and operate at 1200 r p m Turn blower switch to high and the temperature switch to Cold Operate for five to 10 minutes to warm compr...

Страница 414: ...is defective partially plugged and must be replaced TESTING THERMAL SWITCH AND SOLENOID BY PASS VALVE Disconnect the Wade connector at solenoid valve and insert special adaptor Figure 5 in series with...

Страница 415: ...ermal switch is functioning Figure 7 Thermometer Installed in Suction Line TESTING EXPANSION VALVE OPERATION FOR PROPER SUPER HEAT The proper super heat should be 8 degrees to 15 degrees F Before atte...

Страница 416: ...he thermometer reading and corrected chart reading The following is an exam ple Insert values obtained in test If super heat is outside specifications of 8 degrees to 15 degrees F replace the expansio...

Страница 417: ...suction of 28 inches of vacuum for a period of 30 minutes after sweeping with one pound of Freon 12 Sweeping the system means to charge the sys tem with one pound of Freon 12 or charge until a pressu...

Страница 418: ...t weighing the Freon as is normally required Follow the preliminary steps in charging the system but eliminate those steps involving the scales Start the engine and operate at 1200 r p m Turn the blow...

Страница 419: ...age to tubing and fittings Silver solder flux should be put on the joint When the joint is silver soldered or brazed clean the newly made joint vigorously with a stiff wire brush to make sure the join...

Страница 420: ...e the compressor crankcase to become comparatively free of liquid refrigerant An oil sight glass is provided in the compressor crankcase so that the oil splash may be observed while the compressor is...

Страница 421: ...the system Connect a hose or tube to the discharge side Insert hose or tube in a pail to receive flush ing Reverse flush the system with carbon tetra chloride At least one gallon of the solution shoul...

Страница 422: ...tension adjusting strap Adjust belts to a inch deflection with a 9 to 12 pound pull applied with a scale at the center of the longest span between pulleys Install manifold gauge set Tool C 3354 Crack...

Страница 423: ...oroughly Be sure to remove all shreds left from old gaskets Install the cylinder head bolts in the head Place a piece of cardboard over the bolt heads and turn assem bly upside down Lay on the bench w...

Страница 424: ...plate screws Tighten screws evenly to 15 to 20 foot pounds torque Coat carbon seal with refrigerant oil and place over shaft positioning tangs on carbon in the recesses in the bearing end plate Lubric...

Страница 425: ...he protective cap from the valve spring and remove the valve assembly from the valve body Wash valve parts with carbon tetrachloride blow dry with dry compressed air and reassemble valve CAUTION Prote...

Страница 426: ...e system raise car on hoist Disconnect flared connections at both ends of receiver Re move attaching bolt nuts and remove receiver Cap ends of receiver immediately if unit is to be used again Leave ca...

Страница 427: ...d sleeve Raise car uncap and connect hoses to refrigerant tubes Install washers and attaching nuts on drain tubes Install drain and tube dust seals Lowei car and test operation of blower motors Charge...

Страница 428: ...NG J CIRCUIT BREAKER Test circuit breaker with jumper wire Check for loose wires shorts or a faulty switch or motor 2 OPEN CIRCUIT Test electrical circuit with point to point voltage test Repair or re...

Страница 429: ...LONG TOOL C 33 TEST HOSES SHORT 2 TOOL C 33 5 TUBE BENDERS TOOL C 33 2 LEAK DETECTOR TORCH C 3444 COMPRESSOR SEAL PULLER C 3473 RATCHET WRENCH TUBE FLAR NG TOOL C 8 4 TUBE CUTTER TOOL C 3478 FREON WE...

Страница 430: ...9 60 0 61 3 62 5 63 7 64 9 66 2 67 5 68 8 70 1 71 4 72 8 74 2 75 5 76 9 TEMP F 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 FOR FREON PR...

Страница 431: ...operation if faulty replace 3 CONDENSER PLUGGED Clean with warm water and compressed air applied from side next to engine Remove bug screens 4 EXPANSION VALVE SUPER HEAT SETTING INCORRECT Install man...

Страница 432: ...oil level in the crankcase whenever the car is refueled and while the engine is warm When checking the oil level make sure the car is level If the oil level is checked immediately after the car has b...

Страница 433: ...s where temperatures are not lower than 10 degrees above zero SAE 10 W engine oil is recommended as a gen eral winter oil for temperatures as low as 10 de grees below zero NOTE When seasonal temperatu...

Страница 434: ...ile cruising in high Watch the temperature and oil pressure gauges or lights closely Speeds up to 50 miles an hour in high gear will give the engine and the other units a chance to run in for smooth e...

Страница 435: ...inkage automatic choke LUBRICANT REQUIRED Chassis Lubricant Water Pump Grease Dripless Penetrating Oil Door Ease SAE10W Engine Oil SAE 10W Engine Oil SAE 90 Fluid Gear Lubricant Automatic Transmission...

Страница 436: ...degrees below zero use SAE 90 For sub zero temperatures that remain lower than 10 degrees below zero use SAE 80 Maintain lubricant level at bottom of filler plug hole Add recommended lubricant as nece...

Страница 437: ...stment Engine Tune up Minor Engine Tune up Major Replace Oil Filter Repack Front Wheel Bearings Lubricate Speedometer and Cable Check Fan Belt Adjustment Check Wheel Alignment Check Headlight Aiming C...

Страница 438: ...ange bolts securely to prevent grease leaking across face of gasket Inspect dust covers periodically and replace if damaged See page 239 for d st cover installation procedure It is not necessary to re...

Страница 439: ...n order to let any remaining air out of the system Check the fluid level in the reservoir and add fluid if needed to cover filter The total capacity is 3 1 2 pints 4 SEASONAL CARE AND PREPARATION In t...

Страница 440: ...the speed of the engine without causing it to stall This opera tion should take about one minute Provide adequate ventilation while pouring the Rust Preventive Oil into the carburetor air intake becau...

Страница 441: ...and soapy water WOOL CARPETING Brush often with a whisk broom or use a vacuum cleaner The carpet will shed some when new Use any reputable carpet cleaning material to remove stains REMOVAL OF STAINS...

Страница 442: ...lubricant every 20 000 miles Use only automatic transmis sion fluid type A Drain and add five S quarts fluid through transmission filler tube Start engine and add four 4 more quarts Allow engine to i...

Страница 443: ...rn 77 Clutch Release Lever Adjustment Borg and Beck 76 Clutch Shaft Pilot Bushing 77 Clutch Torque Specifications 72 Coil and Condenser 121 Coil Data and Specifications 118 Coil Test 121 Compressor Ai...

Страница 444: ...d Gauges 127 Instruments and Gauges Data and Specifications 130 King Pin Inclination 11 Leak Detector Air Conditioning 415 Lighting Circuit Test 125 Lighting System Data and Specifications 124 Lightin...

Страница 445: ...and Stationary Glass Suburban 364 Spark Plug Inspection 122 Spark Plugs Data and Specifications 118 Speedometer 131 Starter Assembly 109 Starter Cleaning and Lubrication 109 Starter Data and Specifica...

Страница 446: ...sfactory Ride 224 225 226 224 227 224 226 226 226 225 278 278 Front Suspension System Car Leads to One Side 16 Front End Noises 16 Wander 16 Fuel and Exhaust Systems See Diagnosis Procedures Under Eng...

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