Chrysler Imperial 1960, Service Manual

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Page 2: ...MyMopar com ...

Page 3: ...PY 1 LE BARON 4 DOOR SOUTHAMPTON PC 3 N E W YORKER T O W N COUNTRY W A G O N MyMopar com ...

Page 4: ...Service literature such as Service Bulletins Service Manuals Owner Manuals Time Schedules W S C s or other Chrysler and Imperial Service literature should be addressed to Letters Telegrams Chrysler Corporation Chrysler and Imperial Division Chrysler and Imperial Division Attention Service Department Name of person to whom sent P O Box 1658 W U X Detroit 31 Michigan Detroit Michigan P h o n e V A l...

Page 5: ...Murphy Avenue S W Chrysler Motors Corporation P O Box 10786 Funston Chrysler Roads Atlanta 10 Georgia K a n s a s C i t y 1 5 K a n s a s Telephone Atlanta Telephone Kansas City Kansas Plaza 5 2531 Fairfax 1 3300 Parts Division Literature Request for Parts Division literature such as Parts Books Parts Price Lists Parts Bulletins etc should be forwarded direct to Chrysler Corporation Parts Division...

Page 6: ...rial Number 81 03100001 85 03100001 82 03100001 83 03100001 87 03100001 84 03100001 91 04100026 92 04100026 93 04 00026 Fig 2 Vehicle Number The vehicle number is stamped on a metal plate at tached to the left front door body hinge pillar as shown in Figure 2 For L A built cars the starting vehicle will be as follows Windsor Saratoga New Yorker L A Identification PC 1 81 05100001 PC 2 82 05100001 ...

Page 7: ...or Sedan 59 7 59 7 60 0 62 2 Rear Convertible Coupe 59 7 60 0 62 2 Two Door hard top 59 7 59 7 60 0 62 2 Town Country 59 7 60 0 Four Door hard top 59 7 59 7 60 0 62 2 Length with Four Door Sedan 215 4 219 4 219 6 226 3 Bumper Convertible Coupe 215 4 219 6 226 3 Two Door hard top 215 4 219 4 219 6 226 3 Town Country 216 0 220 0 Four Door hard top 215 4 219 4 220 0 226 3 Width with Four Door Sedan 7...

Page 8: ...ess Stick Lubricant WB Wheel Bearing Lubricant Medium UJ2 Universal Joint Lubricant CHRYSLER DE SOTO Generator 2 000 Miles Distributor Oil Cup 2 000 Miles Wick under Rotor 10 000 Miles Distributor Cam 10 000 Miles Clean Carburetor Air Cleaner 6 000 Miles Install New Carburetor Air Cleaner Element 15 000 Miles Manifold Heat Control Valve 2 000 Miles Automatic Transmission Check Fluid Level 2 000 Mi...

Page 9: ...heel Bearing Lubricant Medium IMPERIAL 6 0 x 1 3 7 0 Generator Oil Cup 2 000 Miles Distributor Oil Cup 2 000 Miles Wick under Rotor 10 000 Miles Distributor Cam 10 000 Miles Clean Carburetor Air Cleaner 6 000 Miles Install N e w Carburetor Air Cleaner Element 15 000 Miles Manifold Heat Control Valve 2 000 Miles Part No 1879318 MoPar Manifold Heat Control Valve Solvent Automatic Transmission Check ...

Page 10: ...5 Engine Oil 11 5 Engine Oil Filter 12 5 Foot Operated Parking Brake 5 4 Generator 13 6 Hydraulic System 4 4 Lubrication Recommendations 9 Manifold Heat Control Valve 14 6 Manual Transmission 19 8 Parking Brake Linkage 7 4 PowerFlite and TorqueFlite Transmission 18 7 Rear Axle 15 6 Service Brake 6 4 Steering 16 6 Power Manual 10 000 Mile Lubrication 17 6 Wheel Bearings 20 8 MyMopar com ...

Page 11: ... PC3 H PY1 L Imperial V 8 PY1 M PY1 H FireFlite Adventurer 23 2 22 8 00 x 14 8 50 x 14 Optional 22 Windsor 8 00 x 14 24 Town Country 22 8 50x14 24 Saratoga 8 50 x 14 22 New Yorker 16 23 N A N A 21 31 2 9 00 x 14 22 Town Country 22 9 00 x 14 22 Custom Crown 23 8 20 x 15 24 LeBaron 22 22 24 22 22 24 24 14 x 5 5K 14 x 5 5K 1 4 x 6 K 1 4 x 6 K 14 x 6 5K 1 4 x 6 5 K 1 5 x 6 L a b c Add 1 quart for heat...

Page 12: ...uld be cleaned i n kerosene and reoiled w i t h SAE 30 engine oil at each oil change period or oftener i n dusty areas as often as 500 miles i n extremely dusty areas daily The paper element carburetor air cleaner should be cleaned as often as conditions warrant but not to exceed 5 000 mile intervals and a new element should be installed at 15 000 mile intervals Fig 2 After removing the air cleane...

Page 13: ...cle is lubricated apply a t h i n film 60x820 i Fig 4 Chassis Lubrication 57x379 Fig 5 Gearshift Tube and lower Support Lubrication of Lubriplate to the apply release and pawl pivots the pawl springs the ratchet teeth and the cable connector Fig 3 6 SERVICE BRAKE Each time the car is lubricated apply a t h i n film of Lubriplate to the pivots and sliding contact sur faces i n the brake pedal suspe...

Page 14: ...d be used throughout the first 1 000 miles of operation The engine oil change period will vary widely depending upon the type of operation weather con ditions and other operating variables Short t r i p driving i n cold weather or driving on dusty roads can make oil changes advisable as frequently as every 500 miles while cross country driving day after day w i t h good oils may permit 5 000 miles...

Page 15: ...and to be sure the valve is free Fig 10 15 REAR AXLE Check the lubricant level at 2 000 mile or 2 month intervals each time the car is lubricated Replenish when level is below the filler hole Drain and refill every 20 000 miles or two years whichever occurs first Use Multi Purpose Gear Lubricant SAE 90 above 1 0 F SAE 80 below 1 0 F and SAE 75 below 3 0 F Sure grip differentials require replenishm...

Page 16: ...bits ADD l PINT 4 K t I LEFT FRONT I 1 I V RIGHT FRONT LEFT REAR RIGHT REAR a i FULL CHECK WHEN H O T IDLING IN NEUTRAL 60X819 Fig 12 Automatic Transmission Oil Level Indicator Uniform wear and m a x i m u m tire life care may be obtained by rotating the five tires at regular intervals of 3 000 miles and every 6 000 miles there after Fig 11 18 POWE1FL1TE AND TOIQUEFLITE TRANSMISSION a Fluid Level ...

Page 17: ...e linkage for proper shift pattern See Group 21 17 Test car performance C A U T I O N To prevent dirt from entering the transmission make certain that the dipstick cap is replaced prop erly onto the filler tube 18 PowerFlite Only I f starting is difficult when average temperatures consistently range below 10 F replace one 1 quart of fluid w i t h refined kerosene This service should be performed o...

Page 18: ...ey 10 000 MILE YEARLY INTERVALS EO Change Engine Oil C Brake Lining for Wear EO Engine Ventilation Inlet A i r Cleaner W B Front Wheel Bearings Remove Clean EO Engine Ventilation Outlet A i r Cleaner Repack A A Automatic Transmission Oil Level A A Automatic Transmission Maintenance EO Distributor Oil Cup M C L Speedometer Cable Remove Lubricate EO Generator Install S Manifold Heat Control Valve DC...

Page 19: ...4 On Off Switch and Volume Control 15 12 Push Button Adjustment 18 13 Radio Controls 12 6 Radio Removal and Installation 13 8 Service Diagnosis 1 3 HEATER Heater Blower 26 16 Removal Installation Heater Core 29 17 Removal Installation Heater Vacuum Actuator Replacement 27 17 Rear Window Defroster 30 18 Vent Deflector Replacement 28 17 Service Diagnosis 23 15 AUTOMATIC BEAM CHANGER A i m i n g the ...

Page 20: ...iagnosis 37 20 ELECTRIC CLOCK Electric Clock 45 23 Removal Installation Service Diagnosis 45 23 REMOTE CONTROL OUTSIDE MIRROR Operation 46 23 Removal Installation AUTO PILOT Auto Pilot 64 31 Removal Installation Control Cable Adjustment 65 32 Linkage Adjustment Procedure 66 32 Operation 63 29 Service Diagnosis 47 24 RECORD CHANGER Adjustments 80 36 Cleaning 81 38 Lubrication 82 38 Operation 79 35 ...

Page 21: ...om be neces sary to replace a power transistor Replacement and testing of transistors should be left to a competent radio service man After performing all of the pre ceding checks be sure to remove all parts marked for use i n testing 4 RADIO RECEPTION IS WEAK a When reception is limited to a few strong local stations adjust the antenna trimmer to align the radio to the antenna fully extended I f ...

Page 22: ...or power windows all ground connections to the radio antenna and lead in wire should be thoroughly checked b A poor ground connection at any point can pro duce the above trouble c A limited amount of noise from electrical appa ratus may be considered normal 10 RADIO RECEPTION IS DISTORTED OR GARBLED a Distorted or garbled sound may be caused by the voice coil rubbing on the center pole piece of th...

Page 23: ...re equipped w i t h hybrid type radio put Fig 3 a transistor driver stage a continu models 112 or 304 Figs 1 and 2 The radio re ously variable tone and rear speaker fader control ceiver features a two transistor push pull audio out and a socket for the record player Fig 1 Radio Installation Model 112 MyMopar com ...

Page 24: ...he right of the radio dial On search tuned radios models 402 and 403 tuning is controlled manually by five push buttons and the tuning knob search tuning is controlled by two additional push buttons and a foot switch Volume tone and on off switch are controlled by the dual knob to the left of the radio dial Rear speaker fader control i f so equipped and tuning knob are located to the right of the ...

Page 25: ...R DC VOLTAGES MEASURED WITH A 20 000 OHMS VOLT METER 8 VOLTAGES SHOULD BE WITHIN 2 0 OF VALUES SHOWN C SENSITIVITIES ARE MEASURED AS FOLLOWS 1 USING A 40UUF SERIES AND 40 UUF SHUNT DUMMY ANTENNA FOR MEASURING ANTENNA SENSITIVITY FOR ALL OTHER MEASUREMENTS FEED THE SIGNAL GENERATOR OUTPUT THROUGH A O IUF CAPACITOR 2 WITH 400 CPS 30 MODULATION OF R F AND I F SIGNALS 3 FOR I WATT OUTPUT AT SPEAKER TE...

Page 26: ...INSTALLATION The radio is attached to the instrument panel w i t h Be sure that the battery is disconnected before re two mounting nuts and w i t h a support bracket at the moval of the radio rear of the set Figs 4 and 5 SCREW _ J Fig 4 Radio Installation Model 303 MyMopar com ...

Page 27: ...ioning Fig 2 1 Disconnect battery 2 Disconnect antenna leading A lead light lead front and rear speaker leads 3 Remove ash t r a y assembly to gain access to mounting bolts 4 Remove mounting bolts 5 Remove both radio to dash support brackets 6 W i t h d r a w the radio assembly from underside of instrument panel b Radio Removal Chrysler Vehicles Only With Air Conditioning Figs 4 and 5 On Chrysler ...

Page 28: ...2 OFF VOLUME CONTROL CIVIL DEFENSE SYMBOLS 640KC I240KC MANUAL TUNING 5 STATION 0 V 1 _ TONE CONTROL PUSH BUTTONS 6 0 x 1 2 5 4 DUMMY KNOB Fig 8 Radio Controls Model 112 c Removal Chrysler Vehicles Without Air Conditioning 1 Disconnect battery 2 Remove control knobs and shaft mounting bolts 3 Remove radio to dash support bracket 4 Disconnect A lead light lead front and rear speaker leads antenna l...

Page 29: ...uts 3 Connect the antenna lead i n light A and speaker leads to connect rear seat speaker leads remove jumper wire from rear speaker socket 4 Install the ash tray assembly 5 Connect the battery 14 ANTENNA COMPENSATOl ADJUSTMENT Figs 9 and 10 C A U T I O N The antenna compensator must be properly adjusted for the satisfactory operation of the radio The antenna compensator receives its original ad j...

Page 30: ...rd equip ARMATURE TERMINAL CONDENSER ANTING m m m Fig 12 Voltage Regulating Condenser GENERATOR GENERATOR NOISE SUPPRESSION CONDENSER MOUNT UNDER GROUND LEAD NUT CONNECT TO LARGE U 4 28 THD ARMATURE TERMINAL ONLY 60x1017 Fig 13 Generator Condenser ment The balance of the suppression equipment is installed as follows Install the voltage regulator condenser as shown in Figure 12 Connect the generato...

Page 31: ... Local push button will tune the receiver to only strong signal stations Distant push button will tune the receiver to most of the stations within range of the radio For weak stations manual con trol should be used for precise tuning 20 FOOT SWITCH FOR SEARCH TUNING The foot switch for search tuning on Models 402 and 403 is located on the left forward end of the floor panel B y depressing the foot...

Page 32: ...in cable to Y connector on rear mounted antenna and in radio set on front fender equipped models 5 Check radio for proper operation 22 CHRYSLER IMPERIAL AND DESOTO Motorized Antenna Figs 16 and 17 a Removal 1 On rear or right front fender equipped models unplug antenna switch to antenna motor wires at connector Fig 16 and 17 2 Unplug the antenna to radio set lead in wire at connector 3 Lower the a...

Page 33: ...side h Heater system airbound needs bleeding i Blower motor not operating fuse blown faulty wiring or loose connections 24 TOO MUCH HEAT a Temperature control valve stuck i n open posi tion b Disconnected or broken bowden cable wire c Engine thermostat controlling at two high a temperature d Thermostat stuck i n closed position e Temperature control valve not closing properly cable needs adjusting...

Page 34: ...Button Causes a major portion of the air to be forced onto the windshield through air outlets on top of instrument panel for defrosting or defogging HI Button Causes major portion of air to be di rected toward the car floor at high blower speed SERVICE P 26 HEATER BLOWER a Removal Fig 20 1 Disconnect the battery ground cable 2 Disconnect the heater ground wire at wind p u s h Barrens Fig 19 Temper...

Page 35: ...rs are installed between the heater housing and the dash panel when installing housing otherwise the housing could be damaged when tightening the screws 3 Reposition the heater water valve capillary coil i n the heater housing and install attaching clips 4 Connect the vacuum hoses at vacuum unit and install the attaching clips 5 Connect the heater wire at harness connectors and install the black g...

Page 36: ...unding of control units c Faulty tube d Poor electrical connections AUTOMATIC BEAM CHANGER The automatic beam changer is an automatic head light control unit which senses the headlight inten sity from other vehicles and automatically adj usts the headlights to a bright or dim setting A scanner and base assembly is mounted on top of the instrument panel Fig 21 The control unit is mounted on a conve...

Page 37: ...and other suspen sion parts to assume normal position I f gasoline tank is not full place an equivalent weight i n t r u n k of vehicle There should be no other load i n the vehicle other than the driver 36 AIMING THE SCANNER Mount scanner aimer leveling Tool C 3697 on the Fig 23 Scanner Leveling Hood scanner unit as shown i n Figure 23 Make sure that all conditions listed under pre aiming instruc...

Page 38: ...ible Causes a Low battery voltage b Faulty tube c Broken circuit 39 SENSITIVITY NOT WITHIN SPECIFIED LIMITS Possible Causes a Potentiometer out of adjustment b May occur when new tube is replaced MIRROR MATIC ELECTRONIC REAR VIEW MIRROR The electronically operated mirror matic rear view mirror as shown i n Figure 24 is a self dimming automatic device which provides m a x i m u m rearward vision at...

Page 39: ...n adjustment wheel Fig 24 protruding from the bottom of the mirror assembly is marked w i t h an off position and numbered through the turning range from one to ten w i t h number three six and t e n detented to facilitate adjustment by feel The adjustment wheel must be turned counter clockwise to reach the off position on the wheel When the mirror is set at the number three notch normal city driv...

Page 40: ...is pre set to specific dimen sions 2 I f sensitivity was incorrect adjust potentiom eter by t u r n i n g clockwise to increase counterclock wise to decrease Fig 28 CHASSIS STOP TAB eoxiooq CHASSIS Fig 29 Bending Chassis Tabs 3 I f flip angle was incorrect bend the chassis top tab Fig 29 rear the solenoid toward glass to reduce flip angle or away from glass to increase flip angle Do not bend the t...

Page 41: ... DeSoto 1 Install instrument bezel 2 Install 2 bezel attaching stud nuts 3 Install clock assembly and attaching nuts 4 Install transmission push button bezel 5 Connect clock feed wire 6 Connect battery e Installation Chrysler 1 Install the clock retainer screws 2 Connect the bowden cable clockwire and clock lamp wire 3 Install the bezel retainer screw 4 Install the glove box assembly and glove box...

Page 42: ...elerator pedal extension end and at the Auto Pilot rod end for possible loose nut and out of adjustment Fig 32 48 AUTOMATIC CONTROL DOES NOT ENGAGE AT SELECTED SPEED WHEN SELECTOR BUTTON IS PULLED OUT Possible Causes a Automatic control will not engage when driver s foot rides the brake pedal Resistance must be felt in the accelerator pedal before the Auto Pilot will engage b Check for brake pedal...

Page 43: ...TON IS PULLED OUT Possible Causes On Imperial models the Auto Pilot control assembly is mounted on the side of the instrument panel be tween the speedometer and instrument cluster Elec trical leads w i t h blade type terminals are connected to the control assembly AUTO PI LOT UNIT WIDE OPEN THROTTLE SWITCH A ENGAGING BUTTON t 19 1 HYDRAULIC SAFETY SWITCH MAGNET LATCHING REVERSIBLE MOTOR SWITCH MEC...

Page 44: ... CUT OUT SWITCH AUTO PILOT UNIT SIDE VIEW SPEEDOMETER CABLE BRAKE MECHANICAL CUT OUT SWITCH ACCELERATOR PEDAL AUTO PILOT JNIT FRONT END VIEW ACCELERATOR PEDAL EXTENSION 60x1119 Fig 32 Auto Pilot Schematic MyMopar com ...

Page 45: ...amp does not light it indicates that the mechanical brake switch is either faulty or out of adjustment c I f the test lamp remains lighted when the brake pedal is depressed to the point of brake application it may indicate faulty mechanical and hydraulic brake switches or a maladjusted brake mechanical switch 52 AUTO PILOT ENGAGES WHEN CONTROL BUTTON IS NOT PULLED OUT Possible Causes When the auto...

Page 46: ...ment at the Auto Pilot unit a Turn the control knob counterclockwise until the knob stop is reached b Loosen the cable sleeve nut at the Auto Pilot unit and push control cable all the way into the Auto Pilot unit until a click is heard c Tighten the sleeve nut on the cable end 60 SELECTOR I N O B HARD TO ROTATE Possible Causes a Knob binding the control body or binding on the speed control knob sh...

Page 47: ...knob located on the Fig 33 Auto Pilot Installed Fig 34 Auto Pilot Drive Cables instrument panel Figs 36 and 37 operates a rack and pinion assembly which applies or releases pres sure whenever the speed regulating knob is set to any given speed This pressure when activated by the speed regulating knob is applied to the flyweight governor located i n the Auto Pilot assembly Fig 35 Whenever the autom...

Page 48: ...d i n automatic operation the assembly will carry the pintle assembly w i t h i t to open the throttle When the Auto Pilot is not engaged the magnet assembly moves away from the pintle assembly allowing the application of the throttle opening to force the accel erator to force the acceleration opening without any emphasis of back pressure on the pedal Fig 35 Auto Pilot Cross Section View MyMopar c...

Page 49: ...d tighten attaching bolts 2 Connect the speedometer speed regulator con trol and Auto Pilot drive cables 3 Connect the electrical terminal leads f H I AU i O M A i K C O N l R O i l PULL BUTTON I H H 6 0 x 1 0 9 0 Fig 36 Auto Pilot Controls Chrysler iSStoW UTOMAJU CON1KOLJ 1 iJtl Blii if N Fig 37 Auto Pilot Controls Imperial TO C A R B U R E T O R FLOATING T H R O T T L E ARM LATCHING MAGNET L 3T ...

Page 50: ...rule of control cable i n dust shield and make certain ferrule rotates freely i n dust shield 6 Rotate the pointer on selector knob to 60 mph and then t u r n knob counterclockwise to the low speed position To properly position control cable i n dust shield 7 Push the cable up until a click is heard 8 Replace the clamp nut and tighten securely 66 LINKAGE ADJUSTMENT PROCEDURE WITH LINKAGE DISCONNEC...

Page 51: ...ecord hold switch and record hold electromagnet c Insufficient force of first record hold electro magnet due either to low voltage or to a bent stop ear Fig 47 70 RECORD STRIKES PICKUP A R M WHEN DROPPING a Pickup arm may be incorrectly positioned Fig 46 b Stop dog may be improperly adjusted Fig 45 71 PICKUP FAILS TO LAND PROPERLY a Landing adjustment may be improperly set Fig 46 b Return lever ma...

Page 52: ...W OR SPEED VARIATION a Inspect idler wheel and r i m or turntable for presence of grease or oil b Turntable bearing race may be worn c Idler spring may be weak d Idler link may be binding i n pivot 78 DISTORTED OR NO OUTPUT a Cartridge may have broken element b Stylus may be worn c Pickup leads may be shorted or open d Stylus holder may be off center and touch side of cartridge e Stylus holder may...

Page 53: ... automobile 79 OPERATION Figs 40 and 41 1 T u r n automobile radio on increase volume to approximate half way position 2 Slide record player OFF ON switch to the O N position N O T E Before loading pause long enough to permit the last cycle to be automatically cleared Stack rec ords w i t h the desired selections facing downward and with the last record to be played on top of the stack 3 L i f t t...

Page 54: ...d of play slide the START REJECT switch to START 80 ADJUSTMENTS Fig 42 Adjustment Locations a Tripping Adjustments Figs 43 and 44 T R I P P I N G A D J U S T M E N T S T U D C Y C L I N G CAM T R I P S P R I N G 60x1133 Fig 43 Automatic Tripping Adjustment N O T E The mechanism may be started into a change cycle either manually or automatically 1 Manual tripping occurs when the START REJECT switch...

Page 55: ...rd may not drop Make adjustments as follows a Place a stack of records on the spindle Fig 46 Pickup Arm Height Adjustment b Rotate the turntable by hand and adjust the position of eccentric stud so that the record drops when the pickup arm has moved to its maximum out ward travel e Pickup Landing Adjustment Under ordinary conditions the landing position may be adjusted by turning the large eccentr...

Page 56: ...ust be kept free from grease and oil Use chlorothene or equivalent cleaning solvent for cleaning these parts 82 LUBRICATION The mechanism is properly lubricated when i t leaves the factory to provide good performance under ex tremes of temperature additional lubrication should not be necessary for a long period of time A l l bearing surfaces should be lubricated w i t h Cosmo Lubric 270 On all sli...

Page 57: ...r Ball Joints 14 11 Removal Installation Lower Control A r m and Shaft 16 12 Removal Disassembly Assembly Installation Lower Control A r m Strut 12 9 Removal Installation Preparation and Inspection Front Suspension 7 4 Service Diagnosis 1 3 Steering Knuckles 18 15 Removal Installation Sway Bars _ 11 7 Removal Installation Torsion Bars 13 9 Removal Installation Upper Ball Joints 15 11 Removal Insta...

Page 58: ...nd Scriber Toe In C 3553 Remover and Installer Shock Absorber Lower Bushing A l l Models C 3556 Installer Lower Control A r m Bushing PC 1 PS 1 PS 3 C 3557 Installer Lower Control A r m Bushing PC 2 PC 3 and PY 1 C 3560 Wrench socket Ball Joint Assembly to Upper and Lower Control A r m PC 1 PS 1 PS 3 C 3561 Wrench socket Ball Joint Assembly to Upper and Lower Control A r m PC 2 PC 3 and PY 1 C 356...

Page 59: ...Steering Knuckle to Brake Support Bolt 55 Steering Knuckle to Steering Knuckle A r m N u t 50 Inch Pounds 200 200 110 SERVICE DIAGNOSIS 1 FRONT END NOISES a Ball joints or tie rod ends need lubricant b Worn or loose front wheel bearings c Worn tie rod ends d Loose control arm mounting brackets e Worn upper ball joint f Worn lower ball joint g Worn upper control arm pivot bushings h Worn lower cont...

Page 60: ... dragging c Incorrect front end alignment d Upper control arm bent e Lower control arm bent f Shock absorber inoperative g Uneven front car height h Broken or weak rear springs Group 2 FRONT SUSPENSION SERVICE PROCEDURES 7 PREPARATION AND INSPECTION 1 Inflate the tires to recommended pressure A l l tires should be the same size in good condition and have equal wear Note the type of wear to aid in ...

Page 61: ...car the same number of times and release the bumper at the same point i n the cycle each time 8 FRONT WHEEL BEARING ADJUSTMENT 1 Tighten the wheel bearing adjusting nut to Fig 1 Height and Level Gauge in Position on Right Side V i rm i r f nmiwiiiiMiiiiiiiii J jggg Fig 2 Height and Level Gauge Installed 180 inch pounds while rotating the wheel 2 Position the nut lock on the nut w i t h one pair of...

Page 62: ...t Ball Joint and Lower Control Arm b Without Using Tool C 3608 1 Jounce the car and measure from the ball joint to the floor Fig 4 and from the bottom of the lower control arm bushing housing to the floor 2 Subtract measurement B from measure ment A The difference should be 2 inches for all models and 2 y 2 inches inch for cars w i t h heavy duty springs Town and Country mod els 3 Measure the righ...

Page 63: ...ght wheel I f the reading is not to data and specifications inspect for a bent steering knuckle To check the angle of the left wheel attach the gauge and take readings as above but w i t h the wheels to the right first then to the left d Toe Out on Turns This test is used for determining that knuckle arms and steering gear arms have not been bent or the frame damaged 1 W i t h front wheels on turn...

Page 64: ...AND CAM SWIVEL BUSHING CAM NUT LOCK SEAL RETAINER UMPER KNUCKLE WASHER NUT C O T T E R PIN NUT WASHER s S P A C E R B O L T _ SEAL J A R M RIGHT ARM LEFT WASHER B A L L JOINT OILER STRUT 2 10 58 RETAINER 2 10 60 59P53 fig 5 Front Suspension Exploded View Typical MyMopar com ...

Page 65: ...ue 4 Tighten the nut on forward end of the strut to 50 foot pounds torque 5 Install the sway bar i f so equipped 13 TORSION BARS The torsion bars are not interchangeable side for side The bars will be indicated as either right or left by an R or an L right or left hand side stamped on the end of the bars a Removal W A R N I N G The torsion bar adjusting bolt should only be loos ened or tightened w...

Page 66: ...the front end of the bar in the hex opening of the lower control arm I f the anchor end is not in the position just described when installing the torsion bar i t will be impossible to adjust the front suspension to the correct height 8 Before installing the lock ring center the bar so that full contact is obtained at anchor and arm shaft Install the lock ring making sure i t is seated in its groov...

Page 67: ... the seal into position over the stud then BALL JOINT 7 STEERING KNUCKLE BALL JOINT 57x73 T O O L UPPER CONTROL ARM STEERING KNUCKLE M TOOL 57x72 Fig 10 Removing or Installing Ball Joint rt Fig 11 Removing Upper Ball Joint from Knuckle position stud in the steering knuckle Install the washer and nut Tighten to 135 foot pounds and install the cotter pin 4 Lubricate the ball joint using a good grade...

Page 68: ...he torsion bar Paragraph 13 3 Remove the wheel and tire assembly 4 Disconnect the shock absorber at the lower control arm bracket then push the shock absorber up into the frame out of the way 5 Remove the nuts lockwashers and bolts that attach the strut to the lower control arm 6 Remove the upper and lower ball joint stud nuts Slide Tool C 3564 over the upper stud until the tool rests on the steer...

Page 69: ...of 125 foot pounds torque until the ball joint is seated the ball joint will cut threads into the arm during tightening op eration d Installation Before installing the parts clean all rust scale mud and other foreign matter off of the mounting sur faces 1 Position the shaft and control arm i n the frame crossmember i n approximate operation posi tion Install the washer and nut Tighten inch nut to ...

Page 70: ...D B L O C K UPPER CONTROL ARM SSfe v I 57x76 A Fig 1 Removing Upper Control rm Bushing Typical Fig 18 Installing Upper Control Arm Bushing Typical PC 2 PC 3 and PY 1 Fig 10 2 Assemble Tool C 3710 over bushing and press the bushing out of the arm from inside out Fig 17 Be sure the control arm is firmly supported i f a hammer and drift is used in place of the tool N O T E Tool C 3669 w i t h adapter...

Page 71: ...t and away from the vehicle b Installation 1 Slide the upper and lower ball joint studs i n to the steering knuckle and install the lockwashers and nuts Tighten the upper ball joint stud nut to 100 foot pounds torque on Models PC 1 PS 1 PS 3 and 135 foot pounds torque on Models PC 2 PC 3 and PY 1 Tighten the lower ball joint stud nut to 135 foot pounds torque and install the cotter pin 2 Slide the...

Page 72: ...EL Caster Manual Steering 1 2 2 Power Steering 4 0 V i 0 ALL READINGS ARE IN DEGREES LEFT WHEEL INSTRUCTIONS A Adjust either the front or the rear cam bolt to obtain positive V degree camber Tighten the cam bolt locknut to hold this adjustment B Measure caster To correct caster and maintain camber within limits change camber Caster Manual Steering V2 dbV20 by adjusting first the front and then the...

Page 73: ...th Contact Pattern 18 19 Heavy Face Contact 19 19 Heavy Flank Contact 20 19 Heavy Toe Contact 21 19 Heavy Heel Contact 22 19 Pinion W i t h Bearing Spacer Installation Using Tool C 758 D3 13 13 Bearing Pre load Depth of Mesh Pinion Without Bearing Spacer Installation Using Tool C 758 D3 14 14 Depth of Mesh Pinion Bearing Pre load Pinion Depth of Mesh and Bearing Pre load W i t h o u t Using Tool C...

Page 74: ...ent Shim Pack Differential Bearings Tapered Roller 2 Differential Bearing Adjustment Threaded Adjuster Drive Gear and Pinion Serviced in Matched Sets Only Drive Gear Runout 005 inch Maximum Drive Gear and Pinion Adjustment Select Washer Drive Gear and Pinion Backlash 006 to 008 inch Differential Side Gear Clearance Models PC 1 PC 2 PC 3 PY 1 001 to 012 inch Models PS 1 PS 3 004 to 012 inch Differe...

Page 75: ...t Puller C 637 Axle Shaft and Inner Oil Seal Puller C 685 Torque Wrench Inch Pounds C 745 Rear Axle Shaft Oil Seal Installing Sleeve C 748 Pinion Oil Seal Puller C 758 D3 Pinion Setting Gauge Set C 839 Rear Axle Shaft Inner Oil Seal Driver C 845 Universal Wheel and Hub Puller C 3281 Companion Flange Holding Wrench C 3339 Dial Indicator C 3565 Axle Shaft Outer Seal Driver C 3571 Adapter K i t C 365...

Page 76: ...nd loose or no gear lash 4 CLICKING NOISE IN DRIVE LINE a Noise i n drive line when vehicle is backed up or moved forward Clean axle shaft taper keys and drums Apply a heavy coating of chalk around entire circumference and length of the tapered sec tion of rear axle shaft Install drums and tighten axle shaft nuts 145 foot pounds torque minimum Check universal joints and flange splines Tighten comp...

Page 77: ...E A R A N D P I N I O N BOLT Mlf W C U P j i j SIDE GEAR I I THRUST W A S H E R x THRUST BLOCK P I N O N THRUST WASHER SIDE G E A R THRUST WASHER 1 f 4 h i i CUP I BOLT J BEARING CONE ADJUSTING WASHER P L U G CAP ADJUSTER L O C K BOLT A N D LOCKWASHER W A S H E R G U A R D 57 x 1 Fig 1 Rear Axle Disassembled View Pinion Without Spacer Fig 2 tear Axle Disassembled View Pinion with Spacer MyMopar co...

Page 78: ... from each end of the axle housing Identify each shim pack as to location to aid i n reassembly REAR AXLE SHAFT 46x140 Fig 3 Removing Axle Drive Shaft and Bearing JHll mm mm 6X57 Fig 4 Removing Bearing from Axle Drive Shaft 1 Axle Drive Shaft 2 Tool 3 Bearing 5 Remove the axle shafts and bearing assembly using Tool C 499 Fig 3 I f necessary the bearings may be removed from the axle shafts using be...

Page 79: ...he flange studs t o o l V 56x23 Fig 6 Installing Axle Shaft Inner Oil Seal TOOL 56x235A Fig 7 Installing Axle Drive Shaft Bearing Cup 3 Working from the same side of the axle housing lubricate the axle shaft bearing w i t h multi purpose gear lube and install the axle shaft 4 Install the bearing cup w i t h the installing Tool C 413 Fig 7 Make certain the bearing cup is driven into the axle housin...

Page 80: ...ar axle carrier assembly from under vehicle a Differential and Drive Pinion 1 Mount differential in stand Tool DD 1014 and attach the dial indicator Tool C 3339 to the differential carrier flange so the pointer of i n dicator squarely contacts the back face of ring gear Fig 8 Make certain there is no end play i n the differential side bearings I f end play is evident remove the adjuster lock and s...

Page 81: ... The bearing cups can be removed from the carrier w i t h a blunt brass drift and a hammer b Differential Case Disassembly 1 Grip the r i n g gear In an upright position using brass jaws In a vise Remove the 12 r i n g gear to differential attaching cap screws N O T E The ring gear attaching screws have left hand threads t u r n clockwise to loosen 2 Remove the assembly from the vise and w i t h a...

Page 82: ...aft thrust block 12 Rotate one differential side gear until each pinion appears at the large opening of the case Remove each pinion and thrust washer at that time 49xJ22 Fig 14 Checking Differential Gear Clearance PLATES TOOL A 57x8 Fig 15 Removing Differential Bearings 13 Remove the two differential side gears and thrust washers c Cleaning and Inspection 1 Clean all parts i n mineral spirits or a...

Page 83: ...anion flange as necessary 12 Inspect pinion bearing shim pack for damaged or distorted shims Replace shims w i t h correct ones during establishment of pinion bearing pre load d Differential Case Assembly 1 Install the thrust washer on each of the differ ential side gears and position the gears i n case 2 Through the large side opening of the case insert each of the two pinion and thrust wash ers ...

Page 84: ...l e Pinion Bearing Cup Installation 1 Place the bearing cups squarely in position Assemble Tool C 758 D3 Fig 17 by placing the spacer SP 2919 followed by the rear pinion bearing cone over the main screw of the tool and inserting i t into the carrier from the gear side Fig 18 2 Place the front pinion bearing over the main screw followed by the compression sleeve SP 535 centralizing washer SP 534 an...

Page 85: ...ng Pre Load Torque Inch Pounds Fig 22 Installing Gauge Block directions to align the bearing rollers Recheck torque to 240 foot pounds torque may have diminished as bearing rollers were aligned by rotating 7 Correct bearing pre load readings can only be obtained w i t h the nose of the carrier up Use inch pound torque wrench C 685 W i t h the handle of the wrench floating read torque when the wren...

Page 86: ...a pinion marked 2 install a washer 084 inch thick 086 002 084 or when a washer 086 inch thick is too loose and 088 inch too tight use 088 and the pinion marking 5 Remove tool arbor from the carrier 6 Remove the tool and bearings out of the carrier 7 Remove the shims spacer tool sleeve and rear bearing cone from the tool main screw 8 W i t h the shaft end of the pinion facing up install the correct...

Page 87: ...suitable for the carrier can be determined by using Tool C 758 D3 1 Install the pinion locating spacer SP 2921 on the main body of Tool C 758 Place large end of rear bearing over shoulder of spacer and insert tool in the carrier 2 Place front bearing small end down com pression sleeve SP 535 centralizing washer SP 534 and compression nut SP 533 on the main body 3 W i t h the nose of the carrier up...

Page 88: ...ssembly sever al turns in both directions to align the bearings rollers Recheck torque to 240 foot pounds torque may have diminished as bearing rollers were aligned by rotating 4 Correct bearing pre load readings can only be obtained with the nose of the carrier up Use inch pound torque wrench C 685 W i t h the handle of the wrench floating read the torque when the wrench is moving through at leas...

Page 89: ...ote the identification marks on the differential bearing adjusters and reinstall each in its re spective side 4 Screw i n adjuster by hand Each bearing adjuster can be screwed into the carrier sup port w i t h little or no effort due to the fact that the support cap bolts are only hand tight No attempt should be made at this time to apply any excessive pressure To square the bearing cups w i t h t...

Page 90: ... A L L B A C K L A S H M E A S U R E M E N T S S H O U L D B E MADE AT T H E POINT OF MINIMUM B A C K L A S H 59S164 Fig 31 Gear Tooth Contact Turn drive gear a few times by hand to seat bearings W i t h a dial indicator find point of least backlash on drive gear at 90 degree intervals A t least point of backlash screw i n adjuster at back face of drive gear until 001 inch appears on indicator Scr...

Page 91: ...d by moving the ring gear toward the pinion This would result in decreasing the backlash making i t again necessary to insert a thinner washer behind the pinion rear bearing 23 WELDING BEAR AXLE HOUSING The axle housing should be completely disassembled if i t is to be welded w i t h arc welding equipment I t is also possible to weld the assembled housing w i t h gas welding equipment i f precauti...

Page 92: ...is additional clearance in the case to permit a slight peripheral movement of the ends of the pinion shafts within the case 27 SURE GRIP DIFFERENTIAL IDENTIFICATON N O T E Identification of the Sure Grip type differ ential assembly can be made by the letter S stamped on the identification pad on the right side of the carrier housing or by a metal tag reading Use Sure Grip Lube attached by means of...

Page 93: ...pe differential case one piece construction has a dome like shape w i t h no case cap attaching bolts 28 LUBRICATION Use special differential gear lubricant Part No 1879414 or a gear lubricant designated GL 4 in axles equipped w i t h the Sure Grip differential The lubri cant should be changed every 20 000 miles 29 REMOVAL AND INSTALLATION SURE GRIP DIFFERENTIAL W A R N I N G Before raising a rear...

Page 94: ...e marks on each half to aid in aligning case when reassembling F i g 36 2 Remove case cap attaching bolts and remove case cap Fig 37 Remove the clutch plates Fig 38 3 Remove the side gear retainer Fig 39 and side gear Fig 40 4 Remove pinion shafts w i t h pinion gears Fig 41 PINION _ SHAFTS 58x722 Fig 40 Removing or Installing Side Gear Cap Side 4 RSI IB AXLE SHAFT THRUST SPACER PINION GEARS 58x72...

Page 95: ...ace worn or distorted clutch plates I f the case is worn i t will be necessary to replace both halves c Assembly 1 Install a thin plate i n each half of the case then a disc plate disc and plate 2 Place the side gears i n their retainers Insert splines of the retainers through splines of clutch discs Fig 45 Installing Axle Shaft Thrust Spacers FEELER GAUGES Fig 46 Checking Clearance Between Pinion...

Page 96: ...ch discs When both the side gears turn freely tighten bolts to 55 foot pounds for left hand thread 7 W i t h differential resting on one hub insert two feeler blades one over each end of the pinion shaft having ramps above i t Fig 46 Clearance should not exceed 020 inch at each end of shaft 8 Invert differential to rest on opposite hub Check opposite pinion shaft in like manner to same specificati...

Page 97: ...xpanding L O C A T I O N Propeller Shaft at Rear of Transmission D R U M D I A M E T E R 7 inches L I N I N G T Y P E _ Internal Moulded Asbestos W I D T H 2 inches THICKNESS 5 32 inches C L E A R A N C E 015 to 020 inches SPECIAL TOOLS Tool Number Tool Name C 452 Puller Parking Brake D r u m C 3015 Installer Parking Brake Cable C 3281 Wrench Brake D r u m Holding C 3723 Wrench Brake Adjusting N u...

Page 98: ...chor pin 3 BRAKE GRABBING a Improper brake or cable adjustment b Oil on lining c Loose brake drum d Broken anchor pin e Warped or bent brake drum f Scored or cracked brake drum 4 BRAKE CHATTERING a Improper brake or cable adjustment b Worn lining c Scored or cracked drum d Loose anchor pin G r o u p 4 PARKING BRAKE A l l De Soto cars equipped w i t h PowerFlite or Torque Flite Transmissions and al...

Page 99: ...WASHER BRAKE SUPPORT GREASE SHIELD BRAKE SHOE OPERATING LEVER LINK BRAKE SHOE LINING ASSY SHAFT FLANGE BRAKE DRUM ASSY J SHAFT FLANGE WASHER SHAFT FLANGE NUT BRAKE SUPPORT GREASE SHIELD SPRING BRAKE SHOE RETURN SPRING BRAKE SHOE ANCHOR PIN BRAKE SHOE ANCHOR BRAKE SUPPORT J BRAKE SUPPORT m SPACER BRAKE SUPPORT SPACER SLEEVE f BRAKE ADJUSTING I 1 SCREW COVER I BRAKE ADJUSTING SCREW COVER SCREW BRAKE...

Page 100: ... left hand brake shoes under the guide spring and up on top of the inner anchor guide 3 Spread the shoes and insert the operating lever strut w i t h the wide slot toward the operating lever and stamped top facing up 4 Work the shoe return spring under the grease shield spring and secure ends in proper holes i n webs of shoes as shown in Figure 3 5 Spread the bottom of both shoes apart and i n sta...

Page 101: ... taut between any of the fastening points To provide free cable operation care must be used to prevent kinking of the housing also all bends must have a radius of 6 inches or more 3 Route cable from transmission up the front of dash panel 4 Install the plastic sealer washer on the cable Fig 4 and insert the cable through dash panel opening 5 Install the housing retainer 6 Insert the threaded end o...

Page 102: ...linders 15 12 Installation Front Support Plates and Wheel Cylinders Installation Rear Support Plates and Wheel Cylinders Removing the Brake Shoes 10 7 Removing the Front Brake Shoes Removing the Rear Brake Shoes Removing the Front and Rear Support Plates and Wheel Cylinders 14 11 Removal Front Support Plates and Wheel Cylinders Removal Rear Support Plates and Wheel Cylinders Cleaning and Inspectio...

Page 103: ...bly Service Diagnosis 22 17 Testing the Brake System 34 25 POWER BRAKES Oval Metal Type Master Cylinder 50 36 Operation 43 26 Pedal Linkage Adjustment 49 36 Removal Installation Pedal Trigger Adjustment Power Brake Adjustment 48 36 Pedal Free Play Adjustment Alternate Method of Measuring Pedal Free Play Power Brake Installation 47 34 Power Brake Removal 45 29 Disassembly Cleaning and Inspection As...

Page 104: ... 2 Rear 2 i 2 Thickness 170 Brake Shoe Return Spring Tension Pounds Front 45 to 55 Pounds Rear 45 to 55 Per Cent of Braking Torque Rear Wheels 40 Diameter of Wheel Cylinder Bore 1V6 Diameter of Master Cylinder Bore l V s Piston Cylinder Clearance A l l Bores 003 to 0065 Brake Pedal Free Play Power Brakes y i e to SPECIAL TOOLS Tool Name Tool Number Hose Bleeder C 650 Protector Seal C 745 Filler Wh...

Page 105: ...there is evidence of the master cylinder by passing fluid internally Recon dition the master cylinder 2 SPONGY PEDAL a A i r in system bleed brakes b Brake fluid contamination Paragraph 17 re place w i t h Super Brake Fluid c Brake drums replace excessively refaced or broken drums 3 BRAKES PULLING TO ONE SIDE a Tires inflate to proper pressure b Brake adjustment for proper clearance c Drums out of...

Page 106: ... AND LINING SHOE RETAINER SHOE RETURN SPRING A D J U S T I N G C A M CONNECTING TUBE LOWER CYLINDER ASSEMBLY Fig 1 Total Contact Brakes Front Assembled View CYLINDER ASSEMBLY ADJUSTING CAMS SHOE RETURN SPRINGS DUST SHIELD SUPPORT SHOE RETAINERS SHOE A N D LINING ANCHORS 59x139 Fig 2 Total Contact Brakes Rear Assembled View MyMopar com ...

Page 107: ... lining correct leak and replace lining d Wheel cylinders repair or replace as necessary e Oil seal leaks replace i f necessary f Master cylinder push rod adjust compensating port plugged 8 BRAKE PEDAL FAILS TO RETURN a Pedal return spring adjust or replace as neces sary b Master cylinder tighten loose mounting bolts c Brake pedal mounting bracket adjust bracket and tighten bolts Group 5 SERVICE B...

Page 108: ...l ing point MoPar Super Brake Fluid 10 REMOVING THE BRAKE SHOES Figs 3 and 4 a Removing the Front Brake Shoes 1 Block the brake pedal to prevent any down ward movement of the pedal 2 Remove the front wheel and drum as an as sembly after backing off the adjusting cams 3 Use a suitable tool to remove the shoe return springs as shown i n Figure 7 The end of the tool should be inserted between the spr...

Page 109: ...es as shown i n Figure 9 b Removing the Rear Brake Shoes 1 W i t h the brake pedal blocked to prevent any BRAKE SHOE RETURN S P R I N G S 6 0 X 2 1 5 Fig 7 Removing and installing Brake Shoe Return Spring Front downward movement back off the adjusting cams The shoes and support plates may become bent i f the cams are not backed off 2 Remove the rear wheel Use puller Tool C 845 to remove the rear w...

Page 110: ...r height and flatness Nicks and burrs should be removed 12 GRINDING RECOMMENDATIONS 60X217 Fig 9 Removing or Installing Brake Shoe Front 60X218 Fig 10 Removing or Installing Brake Shoe Rear a Brake Shoe lining New lining I f not pre ground should be checked and ground 010 to 024 Inch under the drum diameter on a machine having a cylindrical grinding wheel be Drum Refacing Measure the drum runout w...

Page 111: ...ld read 45 to 55 foot pounds at the instant the toe of the brake shoe moves A dial indicator may be used to indicate shoe movement 5 Install guide rod and retainers Fig 8 Be sure the positioning lip of the guide rod is posi tioned properly i n the spring retainer 6 Install the drum wheel and tire assembly after backing off the adjusting cams Adjust the front wheel bearings as described i n the Fro...

Page 112: ...29 6 0 x 328 Fig 14 Removing or Installing Support Plate Front Fig 15 Removing or Installing Support Plate Rear 7 Remove the connecting tube between the wheel cylinders N O T E Do not distort the tube 8 Remove each wheel cylinder mounting bolt after removing the sealer Remove the support plate assembly from the dust shield as shown i n Figure 15 9 Remove the wheel cylinders I f i t is necessary to...

Page 113: ...per Brake Fluid Refer to Figures 16 and 17 then assemble the brake cylinders I f the boots are deteriorated or do not fit tightly on the brake shoe push rod or on the wheel SCREW BODY EXPANDER SPRING PISTON CUP BOOT 57x357 BOOT PISTON EXPANDER i l l SCREW CUP CUP BODY BOOT SPRING V EXPANDER PISTON 57x358 A Fig U W h e e i Cylinder Rear Fig 16 Wheel Cylinder Front cylinder casting new boots should ...

Page 114: ... Tool C 3496 are con venient to use for the following operations use w i t h adaptor Tool C 349A 2 Back off the adjusting cams to the fully re leased position This allows the pistons i n the wheel cylinders to move back trapping all the air near the bleeder screw hole 3 Starting w i t h the right rear wheel cylinder wipe the dirt off the bleeder valve and attach bleeder hose Tool C 650 to the valv...

Page 115: ...ses the brake shoes to center themselves to assist in the adjust ment a Front Brake Adjustment 1 Perform the following operations on one cam at a time on both front wheels T u r n the adjusting cam i n the direction of wheel forward rotation until the shoe lining is solidly against the drum as shown in Figure 6 and the wheel is locked 2 T u r n the adjusting cam slowly i n the oppo site direction ...

Page 116: ...o harm Use extreme care in cleaning master cylinder after reconditioning Remove all dust or grit by flushing the cylinder w i t h alcohol wipe dry w i t h a clean lintless cloth and clean the second time w i t h alcohol D r y the master cylinder w i t h air pressure then flush w i t h clean heavy duty brake fluid Be sure the compensating port i n the master cylinder is open c Assembly Before assem...

Page 117: ...16 SERVICE BRAKES Fig 21 Bellows Type Power Brake Disassembled View MyMopar com ...

Page 118: ...faulty check valve b Blocked air passage in power piston guide sleeve assembly or in air cleaner element 25 LOSS OF PEDAL Possible Causes a Foreign material lodged between the reaction piston and the reaction piston insert under the reac tion piston dome cup resulting i n excessive friction between the ports Grease fluid or moisture on brake linings Brakes improperly adjusted 28 SPONGY PEDAL Possi...

Page 119: ...d i through the hole i n the dash panel the trigger arm may be damaged 2 Disconnect the vacuum hose at the power vent 3 Remove the master cylinder power unit and the bracket assembly hex nuts and lockwashers 4 Carefully withdraw the unit from the dash 57x475 panel Fig 22 Fig 22 Removing or Installing the Power Brake Unit Bellows Type N O T E Use care to prevent loss of the nylon bush Fig 23 Power ...

Page 120: ... that attach the mounting plate to the unit 2 Slide the plate off and away from the unit Figs 23 and 24 3 Remove and discard the mounting plate 0 ring 4 Using an Allen wrench back out two set screws sufficiently to allow the removal of the yoke Fig 25 Y O K E SET SCREWS STOP SEAL WASHER ALIGNMENT ARROWS GUIDE VALVE OPERATING ROD I Fig 25 Removing or Installing the Yoke N O T C H VALVE COVER PLATE ...

Page 121: ...el back the outer lip of the bellows com 56x535 Fig 29 Removing the Air Valve pletely around the inner mounting plate Keep one hand on the inner mounting plate to prevent i t from snapping up 13 Remove the plate and lift out the return spring and the return spring retainer 14 Place the unit on its side and remove the bolts and lockwashers that attach the valve cover to the valve L i f t off the co...

Page 122: ...h as necessary for cleaning and inspection 1 Clean all parts except the bellows bearing and air filter i n solvent and blow dry w i t h com pressed air VALVE SEAL VACUUM VALVE SPRING GUIDE SEAL B O L T c VALVE HOUSING 56x537 VACUUM VALVE VACUUM VALVE RETAINER VALVE HOUSING 56x538 Fig 32 Removing the Vacuum and Retainer 2 Place cleaned parts on clean paper for re assembly 3 I f necessary the bellow...

Page 123: ...I O N Be sure the countersunk holes at the end of the guide line up w i t h the long centerline of the valve housing SEAL UPS TOWARD BORE H T M GUIDE 56x542 FOLD LIP O V E R l V A L V E B O D Y H O L D I N G FIXTURE 56x543 Fig 36 Installing the Bellows 11 I f new bellows are being installed position the supports in the bellows The supports must be centered i n three center accordion folds and alig...

Page 124: ...stamped on the plate is i n line w i t h the arrow on the edge of the bellows 23 Compress the return spring and fold the bel lows lip over the edge of the plate Be sure the bellows fit evenly all around the plate 24 Install the new guide bearing seal i n the groove inside the bearing bore 25 The seal mr v ct jxiugly i n the bearing 26 Using silicone grease lubricate the inside of the bearing and s...

Page 125: ...er chatter t u r n the adjusting screw i n a counter clockwise direction A more likely cause of chatter is an empty master cylinder or an improperly bled brake system Refill or bleed N O T E Rotation of the adjustment screw should be limited to plus or minus 90 degrees about the original setting a Assembly of the Pedal Linkage in the Pedal Bracket C A U T I O N Use extreme care during assembly or ...

Page 126: ...foot pressure and less pres sure will be required to hold the pedal in the applied position 4 I f there is NO noticeable difference in the pedal effort w i t h or without the engine running the vacuum system is not functioning 5 Check for restriction i n the vacuum supply line restriction on the air cleaner faulty pedal ad justments or faulty power unit operation Stop the engine and again exhaust ...

Page 127: ... h a master cylinder and pedal linkage of the reactionary type A tube extending from the air cleaner at the rear is connected to the intake manifold through a hose a vacuum reservoir and a check valve see Figure 43 The power brake consists of three basic com ponents namely an eliptical shaped powe r cylinder a vacuum piston and rod assembly and an internal poppet type control valve as shown in Fig...

Page 128: ...oppet The mechanical contact between the power unit and the brake linkage exists only when the power unit is assisting i n a brake application I n the event there is a loss of engine vacuum the brake pedal is free to function independent of the power unit to apply the brakes i n the conventional manner 44 TESTING THE POWER BHA1E O n the Vehicle 1 Remove the screw plug from the mounting ring and co...

Page 129: ... depleted 7 I f there is no noticeable difference i n the pedal effort w i t h or without the engine running check for a restriction i n the vacuum supply hose B air cleaner incorrect pedal adjustment or faulty power unit operation WOOD BLOCK 5 7 x 4 8 4 Fig 45 Removal of Power Brake Unit 8 Disconnect the vacuum hose from the power unit and place a finger over end of hose A high vac uum indicates ...

Page 130: ... Remove the stop light switch wires and mas ter cylinder brake tube from the master cylinder END PLATE HOUSING BALANCING PIN PISTON O RING GASKET VACUUM HOSE 57x184 Fig 49 Removing or Installing the Balancing Pin 6 Remove the master cylinder 7 Remove the bolts that attach the power unit mounting bracket to the fire wall Slide the unit and the bracket straight out from the fire wall and out of the ...

Page 131: ...peel the dia phragm from the valve 6 Using a thin blade screwdriver and a 1 inch square block pry the nylon button from the end of the valve shaft as shown i n Figure 52 Slide the valve rod seal from the end of the rod 7 Using pliers Tool C 3229 remove the snap ring that retains the valve rod i n the piston as shown i n Figure 53 8 Slide the valve rod washer and spring off end of rod as shown i n ...

Page 132: ...nd the piston plate remove the expander spring wick END PLA E SEAL PISTON ROD 5 7 x 1 9 2 Fig 57 Removing the Piston Rod from the End Plate END PLATE _ 57x193 Fig 58 Removing the Mounting Ring packing plate and leather packing as shown i n Figure 59 b Cleaning and Inspection 1 Clean all metal parts in a suitable solvent then blow dry w i t h compressed air including re cesses and internal passages...

Page 133: ...r plate 57x209 Fig 62 Installing the Wicking and align the holes i n the plate w i t h the threaded holes i n the piston plate Install screw and tighten securely N O T E Do not remove the tool from the piston until ready to install in the vacuum cylinder 6 Insert the vacuum inspection port screw and gasket into the mounting ring Insert the ring re taining bolts through the holes i n the end plate ...

Page 134: ...n Figure 53 13 Install the valve rod seal over the end of Z S T I N G RING VACUUM PORT HOLE SCREW 57x212 Fig 65 Installing the Mounting Ring YOKE AND PISTON ROD END PLATE Fig 66 Installing the Piston Rod through the Seal the valve rod and piston rod N O T E To aid i n the seal assembly t u r n the seal partially inside out and slide the small diameter end of the seal over the valve rod first then ...

Page 135: ...ing the operation tests the power cylin der piston should move throughout its full stroke without hesitation bo Leakage Test To make a leakage test a vacuum source vacuum gauge and a shut off valve are necessary The gauge should be close to the power unit and the shut off valve so arranged that the volume of the test line should not exceed 6 cubic inches i n volume 1 Press i n on the valve operati...

Page 136: ... until contact is made w i t h the master cylinder piston 2 T r y to insert the push rod end pin through the power lever and push rod end hole I f the push rod must be pulled back to allow passage of the push rod pin free play is present 3 I f the push rod must be pushed further into the master cylinder to allow passage of the push rod end pin no free play is present and an adjustment must be made...

Page 137: ...e curvature of the trigger arm does not fall within the scribed lines and the concentricity of the 640 inch and the 730 inch circles i t can usually be brought within the desired radius by carefully bending the trigger arm until conformation has been obtained I f the trigger however is out an excessive amount install a new pedal and trigger adjust as described to conform to the gauge I t will be n...

Page 138: ...ing Radiator 7 Service Diagnosis 1 3 Silent Flite Fan Drive 4 4 Engine Overheating 4 Excessive Fan Noise 4 Testing Radiator Cap 12 8 Thermostat 10 8 Transmission Oil Cooler 7 6 Testing Oil Cooler for Leaks 6 Repairing Oil Cooler 6 Radiator Installation 7 Water Pump 5 4 Removal from Vehicle 4 Disassembly 4 Assembly 5 Installation oil Vehicle 6 DATA AND SPECIFICATIONS MODELS PS 1 PS 3 PC 1 PC 2 PC 3...

Page 139: ...acer Thickness Standard iy2 inch Tube and Spacer W i t h A i r Conditioning 2 inch Tube and Spacer PS 3 PC 1 w i t h A i r Conditioning have a box type shroud seven blade fan w i t h 2 l 4 inch Tube and Spacer radiator and Fan Drive Black color hub PC 2 PC 3 PY 1 with A i r Conditioning have a box type fan shroud seven blade fan w i t h 2 inch tube and spacer radiator and fan drive Silver color hu...

Page 140: ...f block by hand d Failed thermostat e Incorrect valve timing f Incorrect ignition timing g Excessive engine idling 3 OVERCOOLMG Possible Causes a Test temperature gauge units and replace as necessary b Test operation of thermostat may be sticking in the open position Group 7 COOLING SYSTEM The cooling system incorporates a tube and spacer type full flow radiator and a centrifugal water pump w i t ...

Page 141: ...at 2000 engine rpm on Models PC 1 PC 2 PC 3 PY 1 and 1665 r p m on Model PS 3 or at a higher engine speed the drive is satisfactory I f however the engine speed at which this occurs is less than 1665 r p m on Model PS 3 and less than 2000 r p m on Models PC 1 PC 2 PC 3 P Y 1 the drive is operated below mini mum speed and must be replaced w i t h a new unit DO N O T A T T E M P T TO S E R V I C E T...

Page 142: ...ughly Inspect condition of seal seat and recondition using refacing Tool C 551 c Assembly Fig 3 1 Support pump body as close to center bore as possible i n an arbor press DO NOT SUPPORT BODY ON A T T A C H I N G FACE OR ON S E A L SEAT 2 Press shaft and bearing assembly into body using Tool C 3468 as shown i n Figure 5 SHAFT AND BEARING Fig 4 Removing Plastic impeller PIPE 57x137 Fig 5 Installing ...

Page 143: ... 4 Remove the radiator b Cleaning 1 Drain cooling system and refill w i t h clean SOFT water and add the contents of one can No 1 top compartment of MoPar Cooling System Cleaner 2 Run engine at a fast idle for l 2 to hour 3 Drain cooling system and refill with clean water 4 Pour conditioner No 2 bottom compartment into radiator and run engine for ten minutes 5 Flush entire cooling system until wat...

Page 144: ...shing gun to the inlet hose 4 Connect water hose of gun to a pressure water source and the air hose of gun to a pressure air source 5 T u r n on water and when cylinder block is filled t u r n on the air i n short blasts 6 Allow cylinder block to fill between the blasts of air 7 Continue this procedure until water runs clean Check thermostat and i f satisfactory reinstall otherwise replace VARIABL...

Page 145: ... i t h a 14 psi cap as standard equipment and 16 psi w i t h air conditioning as shown in Figure 9 Always check identification number on cap when replacing Fig 10 Checking Pressure Cap W A E N 1 N G When removing pressure cap t u r n counter clockwise to the stop permitting built up pressure to escape through overflow tube This will prevent hot water from spraying out of radiator filler opening 12...

Page 146: ...d gasket 4 Remove wires from spark plugs on one bank and operate engine on the opposite bank I f the needle continues to fluctuate i t indicates a leak on the bank still in operation I f needle ceases to fluctuate the leak is in the bank combustion has been released from 5 I f needle on dial does not fluctuate race engine a few times and i f an abnormal amount of water emits from the exhaust syste...

Page 147: ...MyMopar com ...

Page 148: ...s A L L MODELS Accessory Belt I n Use N e w B e l t Power Steering Bracket 55 90 Generator Without A C 20 30 W i t h A C 35 65 Fan Idler Bracket 35 50 A C A i r Conditioning Belt Deflection Method Deflection Inches to be Applied at Midpoint of Belt Segment Under a 5 Lb Load See Figure 1 A L L MODELS Accessory Belt I n Use N e w Belt Power Steering 3 16 Fan Belt Idler Vo 1 16 Generator Without A C ...

Page 149: ...eering assist loss in air conditioning capacity reduced generator charging rates and greatly reduced belt life To avoid any such ad verse effects the following service procedure should be followed 1 Adjust all belts to the specified used belt tension at new car preparation 2 Readjust all belts as part of the during war ranty inspection 3 Check all belt tensions by the deflection method at servicin...

Page 150: ...an be used to establish the five pound load See Figure 1 for correct location at which to measure deflection This method should be used only when i t is not possible to use the torque method To tension the belts by the deflection method loosen all mounting bolts and use a bar to apply tension to the belts being careful not to damage the accessory A y2 inch square drive hinge handle can be used i f...

Page 151: ...STARTING MOTOR Armature Testing 22 17 Brushes and Springs Replace 21 17 Bushing Servicing 25 18 Drive Unit Servicing 26 18 Field Coil Replace 24 18 Field Coil Testing 23 18 Service Diagnosis 9 14 Starting Motor Bench Test 18 16 Starting Motor Cleaning 20 17 Starting Motor Disassembly 19 17 Starting Motor Removal 17 16 Starter Assembling 27 18 Starter Drive Gear Adjusting 28 19 Starter Installing 2...

Page 152: ... Removal Installation Generator Testing Components 52 28 Insulated and Ground Circuit Resistance Test 43 21 Preparation for Tests 40 20 Service Diagnosis 30 19 Voltage Regulator Test 44 23 IGNITION SYSTEM Aligning Contact Points 72 38 Breaker A r m Testing 71 38 Checking Secondary Circuit 62 34 Distributor Advance Checking 74 39 Distributor Assembly 70 37 Distributor Disassembly 69 36 Distributor ...

Page 153: ...t 98 48 Refacing Commutator 95 47 Service Diagnosis 84 44 Undercutting Bakelite 96 47 Windshield Wiper Removal 91 44 Windshield Wiper Switch 97 47 Windshield Wiper Motor Installation 103 49 Wiper Blade Adjustment 90 44 Wiper Inspection 94 46 Wiper L i n k Assembly 101 48 Wiper Pivot Replacing 102 49 HORNS Horn Adjustment 107 50 Horn Testing 106 49 Service Diagnosis 104 49 THERMAL TYPE GAUGES Opera...

Page 154: ...val and Installation 130 60 ELECTRIC LOCKING DOOR LOCKS Solenoid 131 61 Removal Installation PANELESCENT LIGHTING Dome and Instrument Cluster Removal PC 1 2 3 135 63 Steering Wheel Removal Instrument Cluster and Speedometer Removal Instrument Cluster and Speedometer Installation Steering Wheel Installation Instrument Cluster or Speedometer PY 1 136 65 Removal Installation Operation 132 61 Service ...

Page 155: ...ed Solenoid Switch Pull in Coil 28 6 to 32 9 Amps at 6 Volts Hold in Coil 10 2 to 11 8 Amps at 6 Volts GENERATORS ALL MODELS Generator Model Standard Low Cut in Single A i r Conditioning Dual A i r Conditioning A i r Conditioning Heavy Duty W O A i r Conditioning Heavy Duty Auto Lite No GJM 8201A GHM 8001B GJM 8202A GHM 8002A GGA 6003F GGA 6003 Generator Model Voltage Rated Out Put Ground Polarity...

Page 156: ...und Polarity Resistors Marked 60 Marked 38 34 5 to 45 ohms Marked 30 Voltage Regulator Voltage Winding Resistance Armature A i r Gap Auto Lite VBO 4202CC Chrysler No 2095341 For 30 Amp Gen 12 Negative Auto Lite VBO 4202AC Chrysler No 2095200 For 40 Amp Gen 12 Negative 55 0 to 70 0 ohms 34 5 to 42 0 ohms 28 0 to 34 5 ohms 44 0 to 49 0 ohms 048 to 052 inch Contacts closed w i t h high limit gauge in...

Page 157: ... near to hinge as possible Point Gap Minimum 015 inch Closing Voltage 12 6 to 13 6 Volts Discharge Amperes Must be below 6 amperes DISTRIBUTOR Auto Lite Model 1BP 4005C 1BP 4005D 1BP 4006C Chrysler No _ _ 1889562 2095054 1889564 Centrifugal Advance 0 250 to 450 0 275 to 425 0 310 to 490 Degrees and rpm 0 to 2 450 3 5 to 5 5 800 7 to 9 2200 0 to 4 3 425 3 3 to 5 3 540 10 to 12 2150 0 to 2 490 3 5 t...

Page 158: ...34 to 40 25 to 285 mfd 17 to 21 5 oz Counter clockwise 5 BTC CIRCUIT BREAKERS Circuit Type Lighting System _ Circuit Breaker Windshield WT iper Constant Speed Circuit Breaker Variable Speed Circuit Breaker Window Lifts Circuit Breaker Six Way Seat Circuit Breaker Rated Capacity 22 A M P 6 A M P 5 A M P 20 A M P 30 A M P Spl 4 Dr 40 A M P Location Integral with Headlight Switch Back of Wiper Switch...

Page 159: ...ts 32 1073 Dome Light 15 1004 Luggage Compartment L i g h t When So Equipped 15 1003 Rear License Plate L i g h t 4 67 Headlight High Beam Indicator L i g h t 2 57 Clock When So Equipped 2 85 1816 Radio When So Equipped 2 44 Trans Selector Control Lights 2 85 1816 Parking Brake Warning L i g h t When So Equipped 6 90 Instrument Lights 2 57 T u r n Signal Indicator Lights 2 57 Ash Tray L i g h t fr...

Page 160: ...eam Indicator L i g h t 2 57 Trans Selector Control Lights 2 85 1816 Parking Brake Warning Light 6 90 Turn Signal Indicator Lights 2 57 Speedometer L i g h t 2 57 Auto Pilot L i g h t 2 85 1816 BATTERY SERVICE DIAGNOSIS 1 BATTERY IS RUN DOWN a Low voltage regulator setting b Circuit breaker points stuck c Short i n the charging circuit d Battery terminals corroded e Faulty stop light switch 2 BATT...

Page 161: ...rd corrosion Tighten the battery hold down screw nuts to 3 foot pounds torque d Examine the battery for cracks in the case or raised cells 5 SPECIFIC GRAVITY TEST A hydrometer is used to measure the specific gravity of the electrolyte i n a battery cell The liquid level of the battery cell should be at normal height bottom of vent plug hole and the electrolyte should be thoroughly mixed w i t h an...

Page 162: ... terminals red to positive black to negative using caution not to connect across more than one cell The point of prod will have to be pushed through sealing compound to make contact w i t h the buried link for each cell reading The individual cell readings should not vary more than 0 15 volt between any two cells A battery vary ing more than 0 15 volt between any two cells should be recharged and ...

Page 163: ... cell voltage variation of more than 1 volt 6 I f cell voltages are even within 1 volt use 16 volt scale of battery starter tester and measure the total voltage of the battery posts while the battery is being fast charged I f the total voltage under charge exceeds 15 5 volts the battery is sulphated and should be cycled and slow charged until the specific gravity reaches 1 260 See Slow Charging Pa...

Page 164: ...AGNOSIS 9 STARTER FAILS TO OPERATE a Weak battery or dead cell in battery b Ignition switch defective c Loose or corroded battery cable terminals d Open circuit wire between ignition starter switch and ignition terminal on starter relay e Faulty drive unit f Faulty solenoid or solenoid switch relay g Faulty starting motor h Armature shaft sheared 10 STARTER FAILS AND LIGHTS DIM a Weak battery or d...

Page 165: ...MyMopar com ...

Page 166: ...nnect a 0 to 300 scale ammeter between the disconnected lead and the battery terminal post 3 Connect a test voltmeter w i t h 10 volt scale divisions between the battery positive post and the starter switch terminal at the starter 4 Crank the engine and observe the readings on the voltmeter and the ammeter The voltage should not exceed 12 volt per 100 amperes of current The current should not exce...

Page 167: ...Fig 7 Testing Armature for Short Fig 8 Testing Armature for Ground 9 I f necessary to replace the field coils discon nect the field coil to the brush leads Remove the terminal post nut and washers Remove the pole shoe screws w i t h a special pole shoe impact screw driver Tool C 3475 20 CLEANING THE STARTER PARTS Do not immerse parts i n cleaning solvent Immersing the field frame and coil assembly...

Page 168: ...surfaces and bushings for wear by placing core in vise equipped w i t h soft jaws Do not squeeze tightly T r y the commutator end frame the drive end frame and the armature support bushings for wear by placing them on shafts and checking them for side play Replace the commutator end frame and bushing assembly i f the bushing is worn Also replace the drive end bushing i f i t is worn The bushing sh...

Page 169: ...ywheel mounting surfaces are free Fig 9 Adjusting Starter Drive Pinion Clearance of dirt and oil These surfaces must be clean to make a good electrical contact 2 Install the starter from beneath the engine 3 Tighten the attaching bolts securely 4 Attach wires to the solenoid switch or the starter terminal 5 Install the battery cable and test the opera tion of the starter for proper engine cranking...

Page 170: ...ter selector switch to the 16 volt position 2 Press the voltmeter check button and adjust the zero correction until the meter reads on volt meter checkline 3 Release the button the meter should return to the black bar at the left of the scale N O T E The voltmeter check push button is used to connect a constant voltage cell across the voltmeter for the purpose of checking voltmeter accurately 4 Ch...

Page 171: ...d as shown in Figure 10 N O T E When the control knob is turned to the No 2 position the ammeter circuit remains direct but the switch i n the field jumper circuit automatically opens so that the generator output is controled by the regulator 2 Decrease engine speed until the voltmeter reading is below battery voltage indicating that the output relay points are open 3 Very slowly increase the engi...

Page 172: ...loss should not exceed 1 volt I f the voltage loss exceeds 1 volt check for loose or cor roded connections at armature terminal generator armature terminal of regulator back of ammeter or battery terminal of the starter solenoid Also check for faulty w i r i n g from generator to the regulator armature terminals battery terminal of regulator to 12 VOLT 60X877 BATTERY GENERATOR Fig 12 Ground Circui...

Page 173: ...ratic i t should be removed from the vehicle for further tests service and adjustment 1 Disconnect the battery wire from the battery terminal of the regulator and connect the negative lead of the test ammeter to the battery wire that was disconnected from the regulator B terminal and the ammeter positive lead to the regulator B ter minal Fig 14 2 Connect the positive voltmeter lead to regula tor B...

Page 174: ...t possible reading on the test ammeter The peak ammeter reading is the setting of the current regu lator N O T E When t i e control knob is rotated through the No 4 position a variable carbon pile resistance is inserted i n series w i t h t i e ammeter circuit When connected from the battery terminal o f the regulator to ground w i t h the battery wire disconnected the resistance of t i e carbon p...

Page 175: ... held down so that the stop rivet rests on the magnet core the point gap should be a minimum of 012 inch 47 CHECKING CUTOUT RELAY AIR GAP To check the cutout relay air gap use the flat tool gauge 031 inch from K i t Tool C 828 Insert the gauge between the armature and the magnet core Fig 19 Be sure that the gauge is placed as near to the hinge as possible W i t h the relay armature against the upp...

Page 176: ...Disconnect the battery negative terminal Disconnect the wires at the generator 2 Loosen the generator adjusting strap bolts and the generator mounting bolts 3 Push the generator towards engine to relieve belt tension and remove the generator attaching bolts and the generator b Disassembly Fig 22 1 On generators so equipped remove the com mutator cover band disconnect the armature ter minal field l...

Page 177: ...SNAP RING Fig 22 Generator Disassembled View MyMopar com ...

Page 178: ...loth When clean ing the ball bearings do not spin them w i t h com pressed air Inspect the field coils for burned or dam aged insulation Inspect the commutator for wear and check condition of soldered coil leads A n arma ture that has been overheated will show signs of throwing solder and will require resoldering or re placement Inspect the commutator for trueness Inspect the bearings for wear or ...

Page 179: ...e connecting lead between the two ELECTRICAL AND INSTRUMENTS 29 coils away from the field frame I f light still burns ground is i n field coils 5 Touch one of the 110 volt test lamp probes to the A R M terminal post and the field frame I f the lamp lights i t indicates that either the terminal post or the brush holder is grounded 8 Remove terminal post and retest brush hold er I f the lamp still l...

Page 180: ...ive use of sandpaper will shorten the brush life and should be avoided Blow out all sand and carbon dust from the generator N O T E Generators that have the brush holders riv eted to the commutator end head should have the brush spring tension checked w i t h the commutator end head and brushes installed on the armature Hook a spring scale under the brush spring and pull upward Take the scale read...

Page 181: ...he positive post of battery and the generator armature terminal post Connect a jumper lead from the field terminal post to a ground Con nect a jumper lead to the battery negative post and the generator frame This will cause the armature to rotate as a motor Adjust the battery voltage to 10 volts The reading on the test ammeter should be w i t h i n specifications with the armature turning smoothly...

Page 182: ... G O V E R N O R W E I G H T SPRING SET G O V E R N O R W E I G H T S 58x271 A A WASHER S C R E W SPRING CLIP km A N D BRACKET BASE ASSEMBLY BUSHING SHAFT THRUST WASHERS BUSHING SPRING CLIP A N D BRACKET S C R E W A N D WASHER S C R E W A N D WASHER V A C U U M CHAMBER S P R I N G WASHER COLLAR PIN S C R E W A N D WASHER PRIMARY LEAD WASHERS G A S K E T PLUG Fig 26 Ignition Distributor Exploded Vi...

Page 183: ... C K W A S H E R BREAKER PLATE PRIMARY LEAD S P R I N G CLIP A N D BRACKET THRUST W A S H E R S B U S H I N G TERMINAL I N S U L A T I O N BUSHING S P R I N G CLIP A N D BRACKET W A S H E R L O C K W A S H E R S C R E W L O C K W A S H E R N U T S C R E W L O C K W A S H E R CAM S R I N G 3 C f OILER B S E W I C K SPACER G O V E R N O R W E I G H T g i f S P R N G SET V A C U U M CHAMBER ASSEMBLY ...

Page 184: ...dicates the resistance of the ignition pri mary circuit from the distributor side of the coil through the points and the distributor ground Ex cessive resistance in this portion of the ignition sys tem will prevent the coil from producing sufficient output for good over all ignition To perform test proceed as follows I Connect a jumper wire from the armature ter minal to a good ground N O T E Grou...

Page 185: ...torted breaker arm is indicated ELECTRICAL AND INSTRUMENTS 35 66 DWELL VARIATION This test indicates the mechanical condition of the distributor Excessive wear in distributor mechani cal parts cause dwell variations which will effect igni tion timing 1 W i t h engine at idle speed and distributor vacuum line disconnected and with the test leads connected as in the point dwell test turn the ta chom...

Page 186: ... 57P296 Fig 28 Distributor Cam Installed 5 2 x 2 8 0 Fig 29 Checking Distributor Shaft Side Play Typical vance arm Remove the two screws and lockwashers attaching the vacuum control unit to the distributor housing and remove the control unit 4 On single breaker distributors remove pri mary lead wire and rubber grommet as an assembly On a double breaker distributor remove the primary lead terminal ...

Page 187: ...g Fig 32 flush w i t h the face of the distributor base Fig 32 Installing Lower Bushing Typical h Insert a 3 32 inch rod through the housing oiler hole to see i f the slot i n the bushing indexes w i t h the oiler hole i n the housing I f the rod cannot be inserted through the housing and the bushing drill a 1 8 hole through the upper bushing by drill ing through the oil wick hole Remove burrs cau...

Page 188: ... cap w i t h 3 to 5 drops of light engine oil and install the rotor GOVERNOR WEIGHT G O V E R N O R W E I G H T S L U B R I C A N T C H A M B E R L U B R I C A N T CAM AND YOKE w UPPER THRUST WASHER if Fig 35 Distributor Shaft Assembly 71 TESTING BREAKER ARM SPRING TENSION 1 Hook a spring scale Tool MTU 36 on the breaker arm and pull i n a straight line at right angles to the point surfaces Pig 36...

Page 189: ...r being tested Refer to Distributor Advance Specifications in this manual 3 T u r n the battery switch O N 4 Adjust the tester speed control to operate the distributor at 200 distributor r p m 5 Hold the distributor breaker plate i n the full retard position and aline the 0 distributor tester degree ring w i t h any one of the arrow flashes 6 Adjust the tester speed control to operate the distribu...

Page 190: ... battery terminal 5 Start the engine Idle the engine at a slow idle Rotate the distributor housing so that the speci fied timing mark and the pointer are i n alignment Moving the distributor housing against the shaft rotation advances the timing and w i t h shaft rotation retards the timing 6 Tighten the distributor clamp screw after the timing has been set and recheck the timing adjust ment with ...

Page 191: ...s 1 Check dimmer switch for faulty operation 2 Check high beam indicator indicates that high beam is i n operation when lighted 3 Check for badly rusted or defective headlamp assemblies These must be corrected before a satis factory adjustment can be made 4 Place vehicle on a level floor 5 Check front suspension height Adjust to specifications as necessary M O U L D E D INTO G L A S S I N B O A R ...

Page 192: ...contact w i t h the aimer mounting flange and that the aimer target is facing inboard 2 Push the release lever forward to expel air from suction cup and while holding the aimer firmly against the headlight aiming pads slowly pull the release lever back until the spring lock engages in the slot 3 Mount the second aimer on the other outboard headlamp i n the same manner 4 On each aimer set pointer t...

Page 193: ...Proceed to adjust the Inboard units by following the Instructions as outlined for the outboard head lamps Install headlamp t r i m panels 82 CHECKING AIMER FOR CALIBRATION Fig 43 1 Using a carpenter or stone mason level of known accuracy locate a true vertical plate glass window or smooth surface 2 Set DOWN UP pointer on D O W N 2 3 Set R I G H T L E F T pointer and floor level com pensator at 0 4...

Page 194: ...he wiper switch and from the wiper switch B terminal to the ACC accessory terminal of the ignition starter switch so that the wiper motor is actuated only when the ignition switch key is turned to the right or left position The variable speed wiper motor Fig 44 and Fig 45 is connected from the motor to the switch and from a circuit breaker to the ignition switch Refer to the W i r i n g Dia grams ...

Page 195: ...ust not be dis assembled when the cranks are i n the parked position or damage to the motor switch and contact follower will occur when the cover is removed N O T E When the switch plate on variable speed mo tors is removed position the crank arm 180 degrees from the park position This Is done to disengage the spring follower from the tang on the switch plate 1 Remove the clip holding the left han...

Page 196: ...ush holder 2 Remove the switch plate and the cover screws 3 Rotate the armature in reverse so that the tang in the switch plate will disengage the gear fol lower to permit removal of the plate assembly 4 Remove the crank arm nut washers crank arm gear and armature in that order 94 INSPECTION 1 Thoroughly inspect the motor parts for wear corrosion or damage 2 Clean the armature commutator w i t h 0...

Page 197: ...nstrument panel Connect a test lamp between B terminal of the switch and the negative battery post Connect a jumper wire from the positive battery terminal to the P terminal of the switch The lamp should light when the switch is i n the off position and go out when the switch is turned to the on position CUTTING TOOL UNDERCUTTING TOOL SPECIAL CHUCK COMMUTATOR 45x1018 Fig 48 Undercutting Commutator...

Page 198: ...talled Variable Speed Motor INTERMEDIATE CRANK ARM RIGHT LINK PARKING CAM ECCENTRIC 55P1071 Fig 51 Link Arm Installed Variable Speed Motor battery positive terminal to the motor ground strap Connect the red wire to the motor ground strap Momentarily touch the black wire to the yellow and blue wire The motor should park 100 ASSEMBLY OF WIPER M O T O l Make sure the gear box is y2 full of long fibre...

Page 199: ... Adjust the wiper parking position by moving the cam adjustment lever which projects from the switch cover 5 Connect the wires at the wiper motor 6 Install the glove compartment and the com partment door HORNS SERVICE DIAGNOSIS 104 HORNS WILL NOT BLOW a Improper adjustment b Broken or faulty wiring c Faulty horn relay 105 HORNS BLOW CONTINUOUSLY a Shorted wiring b Grounded horn button 108 TESTING ...

Page 200: ...tage regulator contained inside the fuel gauge case on Models PS 1 and PS 3 in the oil pressure gauge case on Models PC 1 2 3 and in the tempera ture gauge on Model PY 1 The terminals on the gauge that hoses the constant voltage regulator internally is marked as follows A i s the output terminal for the controlled voltage from the regulator I i s the 12 volt input voltage terminal to the voltage r...

Page 201: ...g 59 This unit like the fuel level tank unit operates on a principle of varying resistance d The Temperature Indicating System The operation of the temperature indicating system is identical in operation w i t h fuel system w i t h the exception of the method of varying the resistance of the sending unit When the engine is cold the resistance of the disc in the temperature sending unit is high Low...

Page 202: ...he ignition switch A reading of ap proximately 12 volts indicates a defective regulator No reading indicates an open circuit in wiring to the regulator c Condition Temperature gauge or oil pressure gauge indicates normal operation But the fuel gauge indicates a higher or lower fuel level than actually exists Cause Fuel tank sending unit or instrument panel fuel gauge is defective Test 1 Disconnect...

Page 203: ...lean and tighten all electrical connections 3 Make sure that the fuel tank sending unit is grounded to tank and that the tank is grounded to the frame g Condition No or low oil pressure PC 1 2 3 Cause Defective gauge sending unit wiring or engine oil ing system Test Measure oil level w i t h oil indicator stick 1 Disconnect the lead wire from the engine oil pressure sending unit and connect a jump...

Page 204: ...OFF CONTINUOUSLY AND WINDOW DOES NOT OPERATE a Disconnect the battery and remove wires from circuit breakers Do not remove battery feed wire Connect the battery and replace the feed wires one at a time until the grounded circuit is located When ground is located trace the wire to the particular door window i t controls Inspect the harness and wires behind the regulator control sector of each door ...

Page 205: ...TIRE UNIT INOPERATIVE Remove all wires from seat switch and connect to gether as shown in the following test chart for the six various control operations I f the operation is normal by connecting wires as shown in the chart replace switch POWER SEAT ELECTRICAL TEST CHART 117 MOTOR INOPERATIVE Check red wire at relay w i t h test light I f test light does not light check for continuity in number 10...

Page 206: ...ing a light coating of solder and then grinding to cable size 122 SEAT TRACK EXCESSIVELY LOOSE CAUSED BY LOOSE RIVET JOINTS a Disassemble upper track seat support B by removing the cotter keys and pins b Remove the seat support and tighten all the riveted joints J by peaning w i t h a ball peen hammer 123 LOOSE FRONT LEVERS a Arc weld the front levers K to prevent move ment between the two section...

Page 207: ...ed as an assembly only They cannot be adjusted and are not interchangeable 128 FRONT SEAT ASSEMBLY AND ADJUSTER a0 Removal 1 Disconnect the battery 2 Remove the four mounting stud nuts and tilt the complete seat back forward 3 Disconnect the control wires at the switch 4 Remove the front seat and cushion assembly 5 Disconnect the seat adjuster battery wire at circuit breaker in cowl 6 Remove the s...

Page 208: ...emove the flexible cables from the tubes b Installation 1 Place the three left cable tubes into the left slave unit Fig 67 2 W i t h the shortest tube on the inside and long est on the outside install the flexible cables in the tubes Make sure the cables seat in the slave unit 3 Position the drive unit on the left side tubes Make sure the flexible cables seat i n the slot in the drive unit 4 Bolt ...

Page 209: ...D W I R E C O I L PLATE I N S U L A T I N G W A S H E R 58x749 Fig 68 Solenoid and Coil Disassembled 7 W 7 COIL RELAY l C U l l w i p r INSU1AT1NG y W a s h e r PLATE S C R E W S E A T GUIDF A S S E M B L Y MOTOR f L COIL PLATE FRONT RISER CABLE SLAVE UNIT REAR RISER r 7 y HORi Oi 17 AL RISER w BLE BOLT t S V MOT OK Fig 69 Seat Track and Motor Disassembled Typical View 58x750 MyMopar com ...

Page 210: ...s and solder the coil ground wire to the tab and plate 6 Install the three solenoid springs and position the solenoids over the springs 7 Fasten the solenoids to the drive unit 8 Install the drive unit Refer to Paragraph 127 Removal and Installation of Flexible Cables H O R I Z O N T A L R A C K GLIDE ASSY KON AGC R A RACK SLAVE UNIT CAP SLAVE UNIT ScAT G U I D E CLEViS PIN 58x748 FRONT RACK CLEVI...

Page 211: ... locking lever into the lock Check to make sure the solenoid will pull the lever far enough out to unlock the door Install the t r i m panel PANELESCENT LIGHTING MODELS PC 13 PC 2 PC 3a PY 1 ONLY 132 OPERATION Panelescent panel lighting used i n all 1960 Chrysler and Imperial Models achieves a soft uniform glow that illuminates the panel instruments without ob jectionable intensity or annoying gla...

Page 212: ... Failure to do this might result i n your becoming startled by an electric shock from the high voltage i n the instru ment power unit The terminals are the protective type and this should not occur unless you inadvert ently touch the terminal of disconnected socket However due to the low wattage i t will not harm you POWER PACK To test the system to locate the cause of a failure use testing Tool C...

Page 213: ... additional short circuited lamps SERVICE PROCEDURE 135 1EMOVAL OF DOME A N D INSTRUMENT CLUSTER N O T E Removal of the steering wheel w i l l facilitate the removal of the electrical instruments and elim inate any possibility of damage to the steering wheel a Steering Wheel Removal 1 Press down on the steering wheel center orna ment and t u r n the unit l 4 t u r n counter clockwise to remove the...

Page 214: ...from the car for further disassembly or testing 7 Disconnect the speedometer cable and the or t I Fig 78 Removing or Installing the Speedometer Head Assembly nament lamp socket at the speedometer head remove the four screws and remove the speedometer head assembly Fig 78 8 The plastic dome is attached to the cluster by six slotted head machine screws N O T E Instruments can be removed to tester at...

Page 215: ...attery ground cable 136 INSTRUMENT CLUSTER OR SPEEDOMETER IMPERIAL a Removal 1 Disconnect the battery ground cable 2 Remove the chrome retainer ring retaining screw at the bottom of the retainer 3 Pull the bottom of the retainer forward and raise the retainer to release the upper tab located at the top of the retainer 4 Remove the screws attaching the instrument panel cluster 5 Disconnect the wire...

Page 216: ...ve b Installation 1 Starting at the parking brake side of the steering column place speedometer in a vertical position w i t h the numerals facing the steering column and the base toward the firewall 2 While raising the speedometer straight up from this position turn the assembly one half turn clockwise as the base passes the lower edge of dash panel then in the same motion rotate the lens to the ...

Page 217: ... CIRCUITS WITH AUTOMATIC DOOR SWITCHES DOME LIGHT 1 1 MALE FOUR DOOR SEDAN ROOF RAIL LIGHT CIRCUITS WITHOUT AUTOMATIC REAR DOOR SWITCH M 2 M 2 TO TOP LIFT SWITCH y r t M A L t M A L E St T l 1 T LEFT ROOF RAIL LIGHT M l p TO BODY HARNESS M ll TRUNK LIGHT I IF SO EQUIPPED M l 2 MALE TO SWITCH FEMALE M f F E M MALE TO CIRCUIT BREAKER FEED G 4 TO CHASSIS AND INSTRUMENT PANEL WIRING MALE MALEi FEMALES...

Page 218: ...MALE T 2 l5J FEMALE r TO CHASSIS A N D INSTRUMENT T O T O P LIFT M O T O R C O N N E C T O R 1 PANEL W I R I N G M A L E Fig 83 Body a n d Dome Lamp Wiring DeSoto TO RIGHT BACK UP LIGHT D 7 1 7 RIGHT TAIL STOP AND TURN SIGNAL LIGHT SYM GA COLOR B 2 18 WHITE D 7 18 BROWN D 8 18 DK GREEN G 4 18 LIGHT BLUE L 7 18 BLACK M l 18 PINK M 2 18 YELLOW M ll 18 PINK M l 2 18 YELLOW T 1 12 BLACK T 2 12 RED T 3...

Page 219: ...AREA SWITCH TYPICAL 2 DOOR HARDTOP 4 DOOR HARDTOP AND 4 DOOR SEDANS r M l I FEMALE TRUNK LIGHT AND SWITCH DOME LIGHT SWITCH MANUAL 1 J D T l f O p L _ T 2 a t M 2 I i M FEMALE TO CIRCUIT BREAKER FEED FEMALE MALE T l M 2 TO CHASSIS GROUND FEMALE TOP LIFT MOTOR CONNECTOR to L 7 M l 1 J TV FUEL GAUGE M ll G 4 G 4 FEMALE MALE M 2 Q TO CHASSIS WIRING D C LEFT REAR DOOR AUTOMATIC SWITCH D 8 D 8 JJ D D 6...

Page 220: ...K AND TURN SIGNAL LIGHT H i fBATT J GN GRD S 2 0 o O S 4 STARTER RELAY Q 5 GENERATOR REGULATOR RESISTANCE TYPE IGNITION CABLE J 2 IGNITION COIL STOP LIGHT SWITCH D 3 OIL PRESSURE SENDING UNIT H 3 H 3 H 3 STARTER MOTOR IGNITION RESISTOR GROUND TO MOUNTING SCREW Q 5 DASH GROMMET TO TOP LIFT 1 CIRCUIT BREAKER NOTE FOR TOP LIFT SWITCH CIRCUIT BREAKER FEED USE WINDOW LIFT OR SE ADJUSTMENT CIRCUIT BRE I...

Page 221: ...LOW L 5 18 RED L 4 16 BLACK L 3 16 RED L 2 16 LT GREEN J 3 18 DK BROWN J 2 18 DK BLUE J l 12 RED H 4 18 DK BLUE H 3 18 BLACK H 2A 16 DK GREEN H 2 14 DK GREEN H l 14 VIOLET G 5 18 DK BLUE G 4 18 LT BLUE G 3 18 BLACK G 6 18 GRAY G 2 18 VIOLET S 4 16 BROWN C 5 16 DK GREEN C 4 16 BROWN C l 16 BLACK M 4 18 BROWN M 3 18 PINK T l 10 BLACK Q 5 10 BLACK X 21 18 PINK E 2 18 ORANGE A 3 18 RED A 2 18 DK BLUE ...

Page 222: ...SIGNAL LIGHT 1 1 1 R T GENERATOR REGULATOR CIRCUIT BREAKER OR TERMINAL BLOCK NOTE ON SOME M WITHOUT WINDS WASHERS THIS INSUL WILL BE INSTALLED X ON WIPER SWITCH REAR SEAT CIGAR LIG s POWER ANTENNA k WINDOW LIFTS K SEAT ADJUSTER WINDS COORDIh Fig 87 Chassis and Instrument Panel Wiring Chrysler MyMopar com ...

Page 223: ... 741 L 7 D 8 G 4 3 1 LEFT FRONT LIGHT 2 FLASHER 3 RIGHT FRONT LIGHT 4 LEFT REAR LIGHT 5 STOP LIGHT 6 RIGHT REAR LIGHT 7 RIGHT CANCEL SWITCH 8 LEFT CANCEL SWITCH LEFT FRONT DOOR AUTOMATIC SWITCH SYM A COLOR A l 10 RED A 1A 12 RED B l 18 WHITE B 2 18 WHITE C l 16 BLACK C 4 16 BROWN C 5 16 DK GREEN D l 18 BLACK D 2 18 RED D 3 18 PINK D 4 18 WHITE D 5 18 TAN D 6 18 LT GREEN D 7 18 BROWN D 8 18 DK GREE...

Page 224: ... COIL RESISTOR F G BATp ALTENATOR TEMPERATURE GAUGE SENDING UNIT i TERMINAL j jBLOCK GENERATOR 2 FT H 2 HORN RELAY OIL PRESSURE SENDING UNIT oy G 6 j STOP LIGHT SWITCH D 3 STARTER MOTOR AND STARTER SOLENOID i 6 N S O L m RELAY S 5 S 5A WINI COOF WINDSHIELD WIPER MOTORR FEMALI L 3 r L 5 S 2 J ARM GRD FIELD BATl GENERATOR REGULATOR FEMALE CQD S 4A QHI MALE NEUTRAL SAFETY SWITCH R 2 REAR SEAT CIG POW...

Page 225: ...SWITCH SYM GA COLOR A l 10 RED A 1A 12 RED B l 18 WHITE B 2 18 WHITE C l 16 BLACK C 4 16 BROWN C 5 16 DK GREEN D l 18 BLACK D 2 18 RED D 3 18 PINK D 4 18 WHITE D 5 18 TAN D 6 18 LT GREEN D 7 18 BROWN D 8 18 DK GREEN D 9 18 TAN D 10 18 LT GREEN D 14 18 VIOLET D 15 18 ORANGE E 2 18 ORANGE E 20 WHITE G l 18 BLACK G 2 18 VIOLET G 3 18 BLACK G 4 18 LT BLUE G 5 18 BLACK G 6 18 ORANGE H l 16 VIOLET H 2 1...

Page 226: ...RICAL AND INSTRUMENTS DOOR LOCK CKT BREAKER SEAT ADJUSTMENT CKT BREAKER WINDOW LIFT CKT BREAKER CIGAR LIGHTER CKT BREAKER Fig 89 Window Lift Cigar Lighter and Electric Door Lock Imperial 2096829 MyMopar com ...

Page 227: ...W LIFT SWITCH W 4 OFEED W 24 ODOWN I RIGHT REAR DOOR WINDOW LIFT MOTOR CIRCUITS SYM GAUGE COLOR A 1 10 RED A 1A 12 RED X 2 10 BLACK X 3 14 LT GREEN X 32 12 LT BLUE X 32B 16 LT BLUE X 33 12 ORANGE X 34 12 PINK X 35 16 ORANGE X 36 16 PINK W 30 16 DK BLUE W 31 16 RED W 1A 16 TAN W 40 16 LT GREEN W 41 16 DK GREEN GAUGES FOR 4 DR SED 4 DR HT 2 DR HT CV CPE W l 12 12 12 TAN W 2 14 14 12 YELLOW W 3 14 12...

Page 228: ...N F E M A L E T T M A L E I W 1 4 C RIGHT REAR MOTOR UP COUNTER CLOCKWISE DOWN CLOCKWISE W 24C I MALE FEMALE CIRCUITS GAUGES FOR CIRC 4 DOOR SUB 4 DOOR SEDAN 4 DOOR SUB H T 4 DOOR H T 4 DOOR H T CV CPE CL SED COLOR W l 4 14 12 12 GRAY JW 14C 14 14 14 LT GREEN W 21 16 14 14 BROWN W 21C 14 14 14 LT GREEN W 22 16 14 14 VIOLET W 22C 14 14 14 BLACK 1 W 23 14 12 12 RED j W 23C 14 14 14 LT GREEN j j W 24...

Page 229: ...C P DOWN MOTOR CIRCUITS CKT GA COLOR W 55 18 YELLOW W 45 18 BROWN W 35 18 RED W 25 12 YELLOW W 15 12 BROWN W 9 10 BLACK W 5 12 RED TAIL GATE LIMIT SWITCH LOCK SWITCH SOL STARTER RELAY LIMIT b W H U I 1 E3 Ch rX UP W l FEED DOWN C j W 2 5 b 5 ri i UP TAIL GATE WINDOW LIFT SWITCH INSTRUMENT PANEL INCLUDED IN REAR BODY 2 DOOR WIRING HARNESS SUBURBAN T MOTOR D O W N 60x1126 Fig 91 Electric Tail Gate C...

Page 230: ...ng Cylinder Bores Cylinder Walls F i t t i n g Pistons F i t t i n g Rings Removal of Piston Pin Installation of Piston Pin Cylinder Heads 16 17 Removal Installation Distributor Drive Shaft Bushings 23 26 Removal Installation Camshaft Installation Distributor Timing Installation of Distributor Front Engine Mounts 34 34 Removal Installation Hydraulic Tappets 18 21 Preliminary to Checking Hydraulic ...

Page 231: ...om Vehicle 24 27 Removal Installation Removal of Engine Assembly From Vehicle 13 15 Replacement of Rear Main Bearing Oil Seal Crankshaft Removed 33 33 Removal Installation Rocker A r m s and Shaft Assembly 15 16 Removal Installation Service Diagnosis 1 9 Timing Chain Case Cover Oil Seal Replacement Cover Removed from Engine 21 24 Removal Installation of Oil Seal Installing Chain Case Cover Install...

Page 232: ...teel Backed Babbitt Journal Diameter PS 1 PS 3 2 6245 to 2 6255 PC 1 PC 2 PC 3 PY 1 2 7495 to 2 7505 Crank Pin Diameter 2 374 to 2 375 Maximum Out of Round Permissible 001 Number of Main Bearings 5 Diametral Clearance Allowed 0002 to 0025 Diametral Clearance Minimum 0005 to 0015 End Play 002 to 007 Thrust Taken By No 3 Main Bearing Finish at Rear Seal Surface Diagonal Knurling Interchangeability o...

Page 233: ... R I N G S Diameter after reaming No 1 2 000 to 2 001 No 2 1 984 to 1 985 No 3 1 969 to 1 970 No 4 1 953 to 1 954 No 5 1 750 to 1 751 T I M I N G C H A I N Adjustment None Number of Links 50 Pitch 50 Width 88 TAPPETS Type Hydraulic Clearance in Block 0005 to 0018 Body Diameter 9040 to 9045 Clearance Between Valve Stem and Rocker A r m Pad D r y Lash 060 210 PISTONS Type Horizontal Slot w Steel Str...

Page 234: ...Compression Oil W i d t h of Rings Compression Oil Piston Ring Gaps all R I N G SIDE C L E A R A N C E Compression Upper Intermediate Oil V A L V E S I n t a k e Material Head Diameter PS 1 PC 1 PC 2 PS 1 PS 3 PC 3 PY 1 Length to center of valve face Stem Diameter Stem to Guide Clearance Maximum Allowable Before Reconditioning Angle of Seat Adjustment L i f t 3 84 in 3 96 in 214 in 210 in 220 in 2...

Page 235: ... Used 2 Combustion Chamber Wedge Type Valve Seat Runout maximum 002 Intake Valve Seat Angle 45 Seat W i d t h finished 060 to 085 Exhaust Valve Seat Angle 45 Seat W i d t h finished 040 to 060 Cylinder Head Gasket Compressed thickness 022 E N G I N E L U B R I C A T I O N Pump Type Rotor Full Pressure Capacity qts 5 Pump Drive Camshaft Operating Pressure at 40 to 50 mph 45 to 65 lbs Pressure Drop ...

Page 236: ...ine Support Fixture C 3501 Cylinder Bore Surfacing Hone C 3506 Chain Case Cover Oil Seal Remover and Replacer C 3509 Camshaft Gear Installer C 3625 Rear Main Bearing Oil Seal Installer C 3626 Cylinder Head Holding Fixture C 3628 Piston Ring Remover and Replacer 361 cubic inch engine C 3648 Valve Stem Length Gauge C 3654 Oil Filter Remover and Replacer C 3661 Tappet Remover C 3662 Engine Repair Sta...

Page 237: ...aust Pipe Flange N u t 40 Exhaust Pipe Clamp Bolt 20 Exhaust Pipe Support Clamp Bolt 20 Fan Attaching Bolt 15 18 Fan Belt Idler Pulley N u t 45 Fan Belt Idler Pulley Bracket Bolt 30 Flywheel Housing to Cylinder Block Bolt 50 Flywheel Housing Cover Bolt 7 Fuel Pump Attaching Bolt 30 Generator Bracket to Manifold Bolt 50 Generator Mounting Nut 20 Generator Adjusting Strap Bolt 15 Generator Adjusting...

Page 238: ...ap g Improper timing ignition h Faulty ignition cables i D i r t or water i n the fuel line or carburetor j Carburetor flooded k Incorrect carburetor float setting 1 Faulty fuel pump m Carburetor percolating No fuel to carburetor n Faulty starting motor 2 ENGINE STALLS Possible Causes a Idle speed set too low b Idle mixture too lean or too rich c Incorrect carburetor float setting d Improper choke...

Page 239: ... a Oil level in crankcase too low or too high b Low oil pressure c D i r t in tappets d Bent push rods e Worn rocker levers f Worn tappets g Worn valve guides h Excessive runout of valve seats or valve face 7 CONNECTING ROD NOISE Possible Causes a Insufficient oil supply Inspect oil pump relief valve and spring Check filter for restrictions and by pass b Low oil pressure c Thin or diluted oil d Ex...

Page 240: ...ENGINE 11 3 m Mm 5 9 x 1 5 1 A Fig 1 413 Cubic Inch Engine Assembly y Fig 2 Front End Sectional View 59x54 MyMopar com ...

Page 241: ...ent on Models PS 1 and PC 1 A four barrel carburetor Is used on Models PS 3 PC 2 PC 3 and PY 1 A l l engines use premium fuel A periodic engine tune up will assure maximum engine perform ance and fuel economy ENGINE TUNE UP 11 MINOR TUNE UP 1 Check battery specific gravity add water I f necessary and clean and tighten battery connections 2 Clean and adjust the spark plugs 035 Inch gap Tighten to 3...

Page 242: ...MyMopar com ...

Page 243: ...14 ENGINE C A P 59 53 A Fig 5 Complete Engine Internal Parts Exploded View MyMopar com ...

Page 244: ... Compressed Air 3 Test the coil and condenser Inspect the pri mary and secondary cables Tighten terminal connec tions 4 Every 5 000 miles remove filter element and blow out d i r t gently w i t h air hose Direct air from inside out and keep nozzle 1 inch away from element to avoid damaging Clean the metal housing and replace the element Every 15 000 miles install a new factory recommended filter e...

Page 245: ...lines Connect throttle linkage 12 Install the hood using scribe marks for prop er alignment 13 Close all drain cocks and fill cooling system 14 Fill the engine crankcase and transmission Refer to Lubrication Group for quantities and lubri cants to use and check entire system for leaks and correct as necessary N O T E Whenever an engine is rebuilt and a new cam shaft and or new tappets are installe...

Page 246: ...emoval 1 Drain the cooling system INTAKE VALVES E3 EXHAUST VALVES 58x136 2 Remove generator carburetor air cleaner and fuel line 3 Disconnect the accelerator linkage 4 Remove the vacuum control tube at carburetor and distributor 5 Disconnect the distributor cap coil wires and heater hose 6 Disconnect the heat indicator sending unit wire 7 Remove spark plugs 8 Remove the intake manifold ignition co...

Page 247: ... h Tool C 3054 11 Install a new tappet chamber cover and tight er j k HrAD INTAKE PUSH RODS INSTALLING Fig 11 Push Rods Installed TOOL CYLINDER HEAD ASSEMBLY REPAIR STAND TOOL 58x141 Fig 12 Compressing Valve Spring Using Tool C 3422 en end bolts to 9 foot pounds 12 Install intake manifold carburetor and igni tion coil as an assembly and tighten manifold bolts to 50 foot pounds 13 Install the distr...

Page 248: ...aust valves Ream the guides for new valves w i t h over size stems i f dial indicator reading is excessive or i f the stems are scored or worn excessively 7 Service valves with oversize stems are avail able i n 005 015 and 030 inch oversizes Reamers to accommodate the oversize valve stem are as follows Reamer Tool C 3433 379 to 380 inch Reamer Tool C 3427 404 to 405 Inch 8 Slowly t u r n reamer by...

Page 249: ...le of Tool C 647 until surface is In line w i t h the 1 15 32 Inch mark on the threaded stud and the zero mark to the front Place spring over stud on table and lift the compressing lever to set the tone device Pull on torque wrench until a ping is heard Take the read ing on torque wrench at this Instant Multiply this reading by two This will give the spring load at the VALVE S P R I N G TOOL 58x14...

Page 250: ...appet noise is due to aeration i t may be i n termittent or constant and usually more than one tappet will be noisy When oil level and leaks have been corrected the engine should be operated at fast idle for sufficient time to allow all of air inside of tappets to be bled out b Tappet Noise Diagnosis 1 To determine the source of tappet noise op erate the engine at idle w i t h the cylinder head co...

Page 251: ...INING SPRING CLIP PLUNGER CAP TAPPET PLUNGER FLAT VALVE VALVE SPRING VALVE RETAINER PLUNGER SPRING TAPPET BODY 52x389B Fig 21 Hydraulic Tappet Assembly Exploded Vlvw 51x971D Fig 22 Testing Tappet Using Tool C 3160 4 Separate the plunger check valve retainer and check valve spring Place all parts in their respective place i n the tappet holder Tool C 3068 e Cleaning and Assembly 1 Clean all tappet ...

Page 252: ...timing indicator located on the chain case cover should read from 10 degrees BTDC to 2 degrees ATDC I f the reading is not within the specified limits Inspect the timing sprocket index marks inspect the timing chain for wear and check the accuracy of the DC mark on the timing indicator Turn crankshaft counter clockwise C A M S H A F S P R O C K E T C H A I N CASE COVER TIMING INDICATOR CYLINDER BL...

Page 253: ...on on crankshaft sprocket and the dowel holes i n the camshaft sprocket 4 L i f t the sprockets and chain keep sprockets tight against the chain in position as described 5 Slide both sprockets evenly over their respec tive shafts 6 Use a straight edge to check alignment of the timing marks Figure 24 7 Install the washer and camshaft sprocket bolt and tighten to 35 foot pounds torque PULLER BLOCKS ...

Page 254: ...W V C G L SEAL RETAINER INSTALLING PLATE TOOL CHAIN CASE COVER 58x155 HA N CASE COV CBX A Fig 30 Checking Seal for Proper Seating c Installing Chain Case Cover 1 Be sure the mating surfaces of chain case cover and cylinder block are clean and free from burrs 2 Using a new gasket slide the chain case cover oyer the locating dowels Install and tighten bolts to 15 foot pounds torque d Installing Vibr...

Page 255: ...Removal 1 Insert Tool C 3052 into old bushings and thread down until a tight fit is obtained Figure 33 2 Hold the puller screw and tighten puller nut until bushing is removed b Installation 1 Slide new bushing over burnishing end of Tool C 3053 and insert the tool and bushing into bore as shown in Figure 34 2 Drive bushing and tool into position using soft hammer BUSHING TOOL 58x159 B U S H I N G ...

Page 256: ...n stall the shaft so that after the gear spirals into place it will index w i t h oil pump shaft so that the slot i n TOOL Wm DISTRIBUTOR AND OIL 1 PUMP DRIVE GEAR SLOT mm l i t CENTER LINE OF CRANKSHAFT 58x163j Fig 37 Distributor Drive Gear Installed r f CRANKSHAFT MAIN BEARING OIL HOLE I f f W CAMSHAFT BEARING OIL HOLE 58x164 Fig 38 Removing Camshaft Bearing Using Tool C3132A top of drive gear w...

Page 257: ... h driver Tool C 897 3 Examine block for cracks or fractures c Checking Cylinder Bores The cylinder bores should be checked for out of round and taper w i t h Tool C 119 I f the cylinder bores show more than 005 inch out of round or a taper of more than 010 inch or i f the cylinder walls are badly scored scuffed or scored the cylinder block should be rebored and honed and new pistons and rings fit...

Page 258: ...58x165 A Fig 40 Measuring Piston Ring Clearance PISTON PIN CONNECTING ROD GUIDE LARGE TOOL 58x195 B Fig 41 Tool Arrangement for Removing Piston Pin and 040 inch i Fitting Rings 1 Measure the piston ring gap about two 2 inches from bottom of cylinder bore i n which i t is to be fitted A n inverted piston can be used to push the rings down to insure positioning rings squarely i n the cylinder wall b...

Page 259: ...pin as shown i n Figure 43 ANVIL TOOL SPRING TOOL PILOT TOOL PISTON PISTON PIN MAIN SCREW TOOL GUIDE SMALL c TOOL 0 CONNECTING ROD GUIDE LARGE TOOL 58x196B Fig 43 Tool Arrangement for Installing Piston Pin 4 Install the spring inside the pilot and install the spring and pilot i n the anvil Install the piston pin over main screw 5 Place piston w i t h front up over pilot so that the pilot extends t...

Page 260: ...LATION OF CONNECTING ROD BEARINGS N O T E Fit all rods on one bank until completed Do not alternate from one bank to another because when the rods are assembled to pistons correctly they are not interchangeable from one bank to another Each bearing cap has a small V groove across the parting face When installing the lower bearing shell make certain that the V groove in shell is in line w i t h V g...

Page 261: ...me guide connecting rod into position on crankpin journal 7 The notch or groove on the top of the piston must be pointing toward front of the engine and the larger chamfer of the connecting rod bore must be installed toward crankpin journal fillet 8 Install the rod caps tighten nuts to 45 foot pounds torque 30 CRANKSHAFT MAIN JOURNALS The crankshaft main bearing journals should be wBm 3 UPPER THRU...

Page 262: ...shaft while plastigage is installed Be sure to remove cardboard before reinstalling oil pan SEAL RETAINER SIDE SEAL _ 1 J GROOVfcS 5 8 x 2 3 7 Fig 51 Installing Rear Main Bearing Lower Oil Seal 58x238 Fig 52 Trimming Rear Main Bearing Lower Oil Seal I t is permissible to use one 001 inch undersize bearing shell w i t h one standard bearing shell or one 002 inch undersize bearing shell w i t h one ...

Page 263: ...nds torque BOLT LOCKWASHER WASHER ENGINE MOUNT L E F T ENGINE MOUNT FRAME BRACKET FRONT OF ENGINE BOLT LOCKWASHER WASHER ENGINE MOUNT RIGHT LEFT ENGINE MOUNT FRAME BRACKET R I G H T 60 x 1 BOLT X ENGINE REAR SUPPORT INSULATOR LOCKWASHER N U T WASHER NUT LOCKWASHER BACKING PLATE COIL SPRING CONTROL BUMPER STUD FRAME CROSSMEMBER BRACKET 60 x 4 Fig 54 Rear Engine Mounts 3 Connect throttle linkage to ...

Page 264: ... Pipe Flange Nut 40 Exhaust Pipe Support Clamp Bolts 10 Converter Housing Bracket Screw 15 SERVICE DIAGNOSIS EXCESSIVE EXHAUST NOISE a Leaks at the pipe joints b Burned or blown out muffler c Burned or rusted out exhaust pipe d Exhaust pipe leaking at the manifold flange e Exhaust manifold cracked or broken f Leak between manifold and cylinder block 2 LEAKING EXHAUST GASES a Same as paragraph l a ...

Page 265: ...nti rattle spring and make necessary repairs c Check shaft for looseness i n body and correct as necessary NUT SUPPORT SUPPORT PL AINW ASHER LOCKWASHER NUT U BOLT 17 NUT PLAINWASHER L O C K W A S H E R NUT MUFFLER PL At N WAS HER NUT LOCKWASHER PLAINWASHER SADDLE PIPE FLANGE NUT LOCKWASHER G BOLi PLAINWASHER SADDLE LOCKWASHER PIPE NUT J U BOLT PIPE U BOLT SINGLE O N L Y GASKET 1 PiPE BOLT FLAMGE N...

Page 266: ...DDLE Fig 2 Exhaust System Ram Manifold PLAINWASHER CLAMP PLAINWASHER SUPPORT SUPPORT r BOLT L O C K W A S H E R NUT ft j BOLT y NUT LOCKWASHER U BOLT U BOLT LOCKWASHER PLAINWASHER CLAMP PIPE BOLT f NUT MUFFLER PL A I N W A S H U BOLT PIPE v S A D D L E SUPPORT PIPE GASKET PIPE 7 SUPPORT L O C K W A S H E R NUT PLAINWASHER NUT L O C K W A S H E R 7 U B O L T SADDLE PLAINWASHER LOCKWASHER NUT PIPE M...

Page 267: ...2 3 and 4 6 INTAKE MANIFOLD Fig 5 Refer to Engine Group 9 for removal and installation of intake manifold 7 EXHAUST MANIFOLD a Removal 1 Disconnect spark plug cables at spark plugs 2 Remove generator from right exhaust mani fold 3 Disconnect exhaust pipes at exhaust manifold flanges 4 Remove nuts that hold exhaust manifolds to cylinder heads 5 Slide manifolds off studs and away from cyl inder head...

Page 268: ...e clamp nuts and bolts w i t h penetrating oil to loosen rust and dirt 2 Remove clamps from exhaust pipes mufflers and tail pipes 3 Disconnect exhaust pipe at exhaust manifold and remove exhaust pipe 4 Remove muffler extension pipe and tail pipe assembly N O T E i f only muffler is to be replaced cut extension at muffler w i t h a hack saw I t is unnecessary to re move the exhaust pipe The replace...

Page 269: ... shaft i n extreme counterclock wise position 2 Place the new coil i n position over shaft slot w i t h outer end tongue of coil i n lower right hand position as shown i n Figure 7 Press inner end of coil into slot of shaft and seat firmly 3 Move outer end tongue around and hook under pin as shown i n Figure 7 4 Place counterweight over shaft w i t h weight in upward position and insert lock i n s...

Page 270: ...FRAME 1 Group 13 FRAME CONTENTS Paragraph Page Alignment Gauge Adapter Chart 7 Body to Frame Alignment 3 6 Checking Frame Alignment 1 2 Frame Replacement 2 3 Removal Installation MyMopar com ...

Page 271: ...ts should be taken when straightening the frame Measure the distance between the points connected by line A i n Figure 5 This distance should agree within y4 inch w i t h the distance between the points connected by line B The diagonals shown in Figure 5 represent only one of a few that may be checked Many other di agonals may be measured in the same way N O T E Care should be taken to make sure t...

Page 272: ... radi ator the heater hoses the hood latch cable at the latch the head lamp wires and the horn wires 5 Remove the screws attaching the voltage regulator horn relay or starter solenoid from the fender splash shields 6 Remove the upper nuts and studs two at each side attaching the fender to the cowl panel Fig 6 7 Remove the bolts attaching the splash shields to the cowl F i g 7 NUTS SCREWS 60X205 Fi...

Page 273: ...ing studs at the cowl and remove all front end sheet metal and radiator as an assembly W i t h all front end sheet metal removed raise the car on a hoist 13 Disconnect the propeller shaft and the trans in r 7 k Vr dd Jody f rr h u n t i n g If FRONT WHBKSM WKSUm I A Ad I Fig 9 Splash Shield to Stub Frame Mounting mission push button cable from the transmission and the exhaust pipe at the front of ...

Page 274: ... 11 and 12 are removed N O T E Two bolts are located near the top of the curved portion of the body to frame crossmember 20 Remove the frame to body bolts Lower the stub frame and engine assembly and roll unit out from the body b Installation I f frame is to be replaced remove all serviceable units from the old frame and install them on the new frame 1 Position the frame and engine assembly under ...

Page 275: ...er steering unit w i t h oil i f so equipped 17 Bleed and refill the braking system 18 Check front end height and adjust as neces sary 19 Check front end alignment and adjust as necessary mmm mtWm Jm m P 6 0 x 2 5 5 Fig 16 Horizontal Checking Bars in Position Typical Installation 3 BODY TO FRAME ALIGNMENT Body to Frame Alignment checks should be per formed whenever the stub frame has been removed ...

Page 276: ... horizontal bars should be perfectly level across their combined surfaces where they meet however i f this condi tion is not prevailing raise both the long and short bar as a unit until they are perfectly level 7 Measure the space created by leveling the bars between the bars and center gauge F i g 17 The preferred spacing between the horizontal bars and the center gauge is 0 inch 1 1 6 inch The d...

Page 277: ...lerator Pump Fast Idle Adjustment Choke Unloader Wide Open Kick Bowl Vent Valve Adjustment Idle Speed Adjustment Curb Idle Carburetor Disassembly 15 9 Cleaning Carburetor 16 11 Inspection and Reassembly 17 11 Throttle Body Main Body Checking Float Setting A i r H o r n Service Diagnosis 8 7 Servicing the Carburetor 14 9 AFB SERIES CARBURETORS Automatic Choke Well Type 24 25 Carburetor Adjustments ...

Page 278: ...Servicing the Carburetor 20 18 FUEL TANK Fuel Tank A l l Models Except Town and Country and Imperial 26 28 Removal Installation Fuel Tank Imperial 27 29 Removal Installation Fuel Tank Town and Country 28 30 Removal Installation RAM MANIFOLD Adjusting the Anti Stall Device 32 36 Adjusting the Ram Manifold 33 36 A F B 2903S Series Carburetor Idle Speed and Mixture Adjustment On Vehicle Fast Idle Adj...

Page 279: ...ossible Causes a Cracked or deteriorated pull rod oil seal b Loose rocker arm pivot pin c Loose pump mounting bolts d Defective pump to block gasket 3 INSUFFICIENT FUEL DELIVERY Possible Causes a Vent i n tank filler neck restricted This also cause collapsed fuel tank E DIAGNOSIS b Leaks in fuel line or fittings c D i r t or restriction in fuel tank d Worn ruptured or torn diaphragm e Frozen gas l...

Page 280: ...sts should be made before removing the fuel pump f r o m the vehicle a Pressure Test I f leakage is not apparent test pump for pressure as follows 1 Insert a T fitting i n the fuel line at the carburetor as shown i n Figure 2 2 Connect a 6 inch piece of hose between the T fitting and gauge C 8411 The hose should not exceed 6 inches A longer hose may collect fuel and the additional weight would be ...

Page 281: ...ump on its side pivot pin hole down and tap gently to remove the pivot pin 4 Disengage the rocker arm from the dia phragm pull rod by the sliding rocker a r m out of the housing 5 Remove the screws attaching the valve body to the rocker a r m housing Separate the valve body and rocker a r m housing and lift out the diaphragm and pull rod assembly 6 Remove the screws that attach the valve body to t...

Page 282: ...aining screw securely 8 Place the pump in a vise with protector jaws and push on the rocker a r m until full travel is reached Hold i n this position while tightening the attaching screws This w i l l prevent tearing of the diaphragm when the pump is i n operation and the pump arm i n its full stroke 9 Test the fuel pump as described previously BBD SERIES CARBURETOR DATA AND SPECIFICATIONS C A R B...

Page 283: ... screws 1 Carburetor icing m Distributor advance vacuum leak n Loose distributor base plate bearing o Corroded wire ends or distributor towers p Incorrect distributor point gap q Fouled spark plugs r Incorrect ignition timing s Incorrect spark plug gap t Overheated spark plugs u Compression not within limits v Intake manifold leak w Internal coolant leak x Low boiling point fuel winter fuel in sum...

Page 284: ...d Worn needle valve and seat e Leaking float f Excessive fuel pump pressure N O T E Presence of fuel dye around carburetor gas kets does not necessarily denote a leak or a flooding condition Tighten air horn attaching screws secure ly to correct 13 POOR ACCELERATION Possible Causes a Step up piston stuck in down position lean mixture at wide open throttle b Accelerator pump piston or plunger leath...

Page 285: ...l T109 288S elevating legs through the carburetor throttle body stud holes These tools are used to protect the throttle valves from damage and to pro vide a suitable base for working 2 Remove the hairpin clip and disengage the fast idle connector rod from the throttle and fast idle levers 3 Remove the hairpin clip and disengage the accelerator pump rod from the throttle lever and the pump rocker a...

Page 286: ...seat and gasket from the main body 7 L i f t out the float fulcrum pin retainer and lift out the floats and fulcrum p i n as shown i n Figure 6 8 Remove the step up piston and retaining screw and slide the step up piston and rods out of ACCELERATOR PUMP SHAFT ACCELERATOR PUMP ARM CHOKE PISTON LINK CHOKE PISTON PLUG 58x246A STEP UP PISTON GASKET i 111 r w _ _ NEEDLE Ox VALVE 58x242 A Fig 6 Removing...

Page 287: ...may be used w i t h satisfactory results I M P O R T A N T If the commercial solvent or cleaner recommends the use of water as a rinse it should be HOT After rinsing all trace of water must be blown from the passages with air pressure It is further advisable to rinse all parts in clean kerosene or gasoline to be cer IDLE T R A N S F E R P O R T S S P A R K A D V A N C E A P O R T V T H R O T T L E...

Page 288: ... Testing Accelerator Pump Intake and Discharge Check Balls STEP UP RODS MUST MOVE FREELY 60x106 Fig 13 Step Up Rod Free Play the screws lightly against their seats w i t h the fingers Back off one full t u r n for approximate adjustment b Main Body 1 Invert the main body and place a new gasket i n position and place the throttle body on the main body and align Install screws and tighten securely 2...

Page 289: ... be 9 32 f r o m top of the crown of each float to top FLOAT UP HELD AGAINST NEEDLE VALVE FLOAT G A U G E 60x107 FROM TOP OF PUMP SHAFT TO BOTTOM OF AIR HORN FAST IDLE SCREW OFF FAST IDLE CAM Fig 7 1 4 Checking l at Setting THROTTLE VALVES SEATED 3 58x255B Fig 15 Measuring Accelerator Pump Travel of the main body Each float must be adjusted to this setting and should not touch the sides of the bow...

Page 290: ...e fast idle cam to the fast idle position b l f T i l UNLOADER GAUGE LIGHT FINGER PRESSURE AGAINST CHOKE VALVE THROTTLE VALVES IN WIDE OPEN POSITION 58x254B Fig 18 Checking Choke Unloader Setting 2 Hold i n this position and invert the carbure tor Slide wire gauge Tool T109 44 015 between the throttle valves and the bore side opposite ports Tighten the fast idle adjusting screw until a slight drag...

Page 291: ...a tachometer 575 r p m on air condi tion equipped cars 2 Adjust the idle mixture screws until the en gine operates smoothly Recheck the tachometer and again adjust the idle screw to give the correct engine r p m 19 AUTOMATIC CHOKE WELL TYPE To function properly i t is important that all parts C H O K E ROD DUST SEAL WASHER C O V E R C A L I B R A T I O N M A R K S THERMOSTATIC C O I L J t SPRING A...

Page 292: ...19 64 Secondary Throttle Lock Out Adjustment 020 020 Float Setting gasket to top of floats 7 32 9 32 Float Drop Idle Mixture both screws turns open 1 2 1 2 Automatic Choke U n i t Setting 2 Notches Rich 1 Notch Rich 550 r p m w i t h the transmission i n D or R and the air conditioning compressor on 725 to 750 r p m and constant w i t h the transmission in neutral N and the air conditioning compre...

Page 293: ... N BOSS AT CENTER OF CARBURETOR OPERATING LEVER PRIMARY THROTTLE SHAFT ARM OUTER ACCELERATOR PUMP CONNECTOR LINK f V ACCELERATOR PUMP SHAFT 7 PUMP CONNECTOR JLT ROD IN CENTER HOLE OF ARM SECONDARY THROTTLE DISTRIBUTOR VACUUM FITTING THROTTLE OPERATING ROD PRIMARY THROTTLE SHAFT D O G PRIMARY THROTTLE SHAFT ARM INNER 58x276 A Fig 21 Carburetor Assembly MyMopar com ...

Page 294: ...nstallation of new parts where required will return the carburetor to its originally designed performance When overhauling the A F B carburetor several items of importance should be observed to assure a good job The carburetor should be carefully disassembled and all parts should be cleaned i n a suitable solvent and inspected for wear or damage A i r pressure only should be used to clean the vari...

Page 295: ...a j a r of clean gasoline or kerosene to prevent the leather from drying out 5 Remove the fuel inlet fitting and filter screen from the air horn DISCHARGE CHECK NEEDLE IN HOLE MODEL NUMBER AND DATE STAMPED O N BOSS 58x283 Fig 23 Removing or Installing Accelerator Pump Jet Housing PRIMARY VENTURI CHOKE SIDE PRIMARY VFNTURI PUMP SIDE SECONDARY VENTURI CHOKE SIDE SECONDARY VFNTURI PUMP SIDE ACCELERAT...

Page 296: ...ure 26 6 Invert the main and throttle body casting and remove the accelerator pump intake check ball plug Using Tool T109 59 screwdriver bit remove the check ball seat as shown in Figure 27 Again invert the body casting and drop out the intake check ball 7 Remove the two idle mixture adjusting screws and springs from the throttle body portion of the main casting The carburetor now has been disasse...

Page 297: ...not tighten Be sure the idle speed adjusting screw is backed out Hold the valves i n place w i t h fingers fingers pressing on the high side of the valves 2 Tap the valves lightly w i t h a screwdriver to seat i n the bores Holding the valves i n this posi tion tighten the screws securely Stake screws by squeezing w i t h pliers 3 Install the two idle mixture adjusting screws and springs i n the t...

Page 298: ...SKET IN PLACE I 57 x 802 A Fog 3 ii Checking Float Height M I N I M U M C L E A R A N C E WITHOUT BINDING 57 x 801 Fig 30 Checking Float Alignment shaft and as the plunger is being depressed a clear straight stream should emit from each jet i f the streams are identical i f either one is diverted or restricted a new accelerator pump j e t housing should be installed After test pour the gasoline fr...

Page 299: ...hamber baffles or the air horn will not index correctly with the main body and can cause the floats to hang up Be sure the leather on the plunger does not curl or wrinkle Accelerator pump operation will be affected if this precaution is not observed 4 Install the 10 air horn attaching screws and tighten securely The t w o long screws should be installed i n the holes that are located at the air cl...

Page 300: ...ween the upper edge of the choke valve and the inner wall of the a i r horn as shown in Figure 35 2 I f an adjustment is necessary bend the un loader l i p on the throttle shaft lever using Tool T109 41 until correct opening has been obtained UNLOADER G A U G E INCH LIGHT FINGER PRESSURE AGAINST V CHOKE V A L V I M B E N D j UNLOADER LIP I 58x291 THROTTLE VALVES WIDE OPEN k Fig 35 Checking Choke U...

Page 301: ...s been obtained Secondary Throttle Lock Out Adjustment 1 Crack the throttle valves then manually open and close the choke valve The tang on the secondary throttle lever should freely engage I n the notch of the lock out dog 2 I f an adjustment is necessary bend the tang on the secondary throttle lever until engagement has been made Use Tool T109 22 for this opera tion 3 After adjustments have been...

Page 302: ...dle speed adjustment is made after the carbu retor has been installed on the engine 1 W i t h the throttle valves closed and the choke valve wide open engine at normal operating tem perature adjust the idle screw at 500 r p m 725 750 r p m on A F B 2903S Ram Manifold Carburetors using a tachometer 550 r p m on air conditioner equipped cars 2 Adjust the idle mixture screws until the en gine operate...

Page 303: ...kup in floor pan Is open I f this is not done a collapsed fuel tank will result The fuel tank on all models except the Town and Country has a 23 gallon capacity The Town and Country capacity is 22 gallons The filler tube on the conventional models is accessible through the center of the deck opening lower panel while the Town and Country fills at the left rear upper quar ter panel between the quar...

Page 304: ...cked or deteriorated install a new grommet at reassembly b Installation Before installing the tank gauge unit check the condition of the filter on the end of suction tube I f filter is corroded install a new filter 1 Position fuel tank gauge unit in tank using a new gasket Tighten securely using Tool C 3582 2 Slide the fuel tank under car Raise the tank far enough to engage the filler spout w i t ...

Page 305: ...ector hose Refer to F i g 43 Slide grommet off filler tube 4 Loosen the nuts that hold the ends of the fuel tank hold down straps until the button head studs can be disengaged from the floor pan brackets Dis engage studs from brackets and at the same time support the tank Drop the tank straight down and out from under car 5 Remove the gauge tank unit using spanner wrench Tool C 3582 Check the rubb...

Page 306: ... from the filler tube 6 Slide the tank down and out from under the quarter panel Reach up under the quarter panel and disengage the hold down strap from the bracket I f strap is to be replaced refer to Figure 41 7 Loosen the tank gauge unit using a spanner wrench Tool C 3582 Slide the unit up and out of the tank Check the condition of the rubber 0 ring I f cracked or deteriorated Install a new 0 r...

Page 307: ...es air fuel mixture f o r the left hand cylinder bank whereas the left hand carburetor supplies the r i g h t hand cylinder bank The passages between the r i g h t and left hand manifolds are inter connected w i t h a pressure equalizer tube to main tain balance of the engine pulsations The throttle linkage operates through a center mounted ball crank and controls both carburetors at the same time...

Page 308: ...l device vacuum line 6 Remove the high tension coil wire 7 Disconnect the throttle linkage at both car buretors and the bellcrank to the accelerator shaft 8 Loosen the clamps that attach the equalizer tube couplings to the manifolds and to the equalizer tube Slide either coupling inward on the tube far enough to clear the manifold tube opening L i f t the equalizer tube couplings and clamps up and...

Page 309: ...old and carburetor from the engine as an assembly RIGHT BANK CARBURETOR ROD BELL CRANK 3 16 x3 PIN WELDING ROD ADJUSTING LINK LOCKING BOLT AND NUT ADJUSTING LINK 5 LOCKING BOLT AND NUT D LOCKING NUT ACCELERATOR SHAFT TO TRANSMISSION ROD LEFT BANK CARBURETOR ROD TOP VIEW TRANSMISSION THROTTLE CONTROL LEVER KICKDOWN POSITION WIDE OPEN THROTTLE POSITION 0 LOCKING NUT BELL CRANK ANTI STALL UNIT D L E ...

Page 310: ... the intake manifold and engage the auto matic choke control rod w i t h the choke lever Se cure w i t h clip Install the carburetor mounting nuts and tighten 3 Place the intake manifold assembly in posi tion on the right hand bank cylinder head Place the exhaust crossover passage cover over the pas sage then install the manifold attaching bolts finger tight 4 Slide a new gasket between the left h...

Page 311: ...kage be set i n this order A t any time the throttle linkage is reset the anti stall device must be reset a Positioning the Accelerator Shaft To position the accelerator shaft refer to Figure 46 then proceed as follows 1 Loosen the adjusting nuts A and B ac celerator shaft to transmission rod and accelerator shaft to throttle shaft lever rod 2 Insert a piece of 3 16 inch drill rod 10 inches long i...

Page 312: ...tain i t is within specifications 5 BTC on the Chrysler Model C300F and 7y2 on the De Soto Ram Charge Adventurer engine as this also affects idle quality I f the ignition timing is not w i t h i n specifications disconnect the vacuum advance line at the distributor as there is full vacuum advance at idle and set the timing w i t h the engine idle speed below 600 r p m and transmission in neutral a...

Page 313: ...specification for engine rpm with both carburetors simultaneously set at the fast idle position 9 Connect both carburetor throttle rods to the bell crank c Indexing the Choke Piston Before indexing the choke piston be sure the igni tion system and t i m i n g are at the required specifica tions that the manifold heat control valves are oper ating properly this is very important for normal warm up ...

Page 314: ...1 2 Spring Maintenance 4 3 DATA AND SPECIFICATIONS SPRINGS Model PS 1 PS 3 PC 1 PC 2 PC 3 P Y 1 Type Semi Elliptic No of Leaves Sedans all 5 5 5 6 7 6 Hardtops all 5 5 5 6 7 6 Convertibles 5 5 6 7 6 Town and Country Wagon 6 7 W i d t h Inches 2 50 Length Inches 57 57 57 60 60 60 Shackle Silent Block Rubber Bushings Hanger Side Strapped w i t h Rubber Bushed Bolts SHOCK ABSORBERS Type Oriflow Doubl...

Page 315: ... 40 Rear Spring U U Bolt Nuts 60 80 Shock Absorbers Mounting N u t Rear 60 Front Upper 55 Front Lower 35 Shock Absorbers Stud Nut Lower 70 Upper 60 SERVICE DIAGNOSIS 1 SPRINGS S A G OR BOTTOM a Spring sagged or taken a set b Broken bent or weak spring leaves 2 SPRING NOISE a Loose U bolts b Loose rebound clips or clips rubbing edges of leaves c Loose or worn shackle bushings d Worn interliner butt...

Page 316: ... on both sides of the car I f these distances vary by more than inch i t is an indica tion that one of the rear springs may need re placing I t is normal for rear springs to show some reverse arch even w i t h no load so appearance alone should not be the reason for spring replacement Springs may bottom under abnormal loading conditions particularly when road dips and railroad crossings are encoun...

Page 317: ...l the silent block bolts and nuts finger t i g h t only Fig 3 Rear Spring Front Hanger 57x505 2 Install the spring shackles and nuts 3 Install the spring U bolts washers and nuts 4 Tighten the spring U bolt nuts 60 to 80 foot pounds torque and shackle bolt nuts 40 foot pounds torque 5 Connect the shock absorbers 6 Remove the car floor stands and w i t h the car weight on the wheels torque the sile...

Page 318: ...makes contact is clean and smooth 2 Insert the interliner between the spring leaves Fig 7 until the prongs of the metal fasteners are aligned w i t h the holes 3 Pry the prong end of the fastener through the hole i n spring leaf Fig 8 4 Position aligning clip Fig 9 and tighten re Fig 8 Installing Interliner Fastener Fig 9 Positioning Aligning Clip J S Fig 7 Positioning the Interliner SP O SP 3179 ...

Page 319: ... absorber cannot be refilled or disassembled When servicing is required the shock absorber must be removed and a new unit installed SHOCK ABSORBERS S H O U L D O N L Y B E R E P L A C E D I F T H E Y H A V E LOST T H E I R RESIST A N C E OR I F T H E Y D R I P O I L E V I D E N C E OF SLIGHT O I L MOISTURE O N OUTSIDE OF SHOCK ABSORBER IS N O T CAUSE TO R E P L A C E SHOCK ABSORBER 8 FRONT S H O C...

Page 320: ...ess against the steel sleeve to avoid damage to the assembly 4 Bleed the shock absorber Paragraph 8 then compress to its shortest length 5 Install the lower cup washer concave side up on the rod and into position 6 Hold the shock absorber i n the installed posi tion i n the frame Slide the upper cup washer concave side down over piston rod and down onto the bushing Install the nut finger tight 7 P...

Page 321: ...ervice Diagnosis 1 5 Steering Gear Alignment _ 8 10 Steering Knuckle Tie Rods _ 10 11 Removal Installation Steering Wheel Removal 5 6 POWER STEERING Column Jacket Support 25 22 Disassembly Assembly Cylinder Head 26 22 Disassembly Assembly Description and Operation 19 15 Final Test Adjustments and Specifications 32 28 Gear Shaft 28 24 Disassembly Assembly Gear Shaft Adjustment 21 18 Power Train Ass...

Page 322: ...Service Diagnosis 34 30 MANUAL STEERING DATA AND SPECIFICATIONS Worm and Three Tooth Roller 20 4 to 1 2 Needle Roller Bearings Tapered Roller Notch on Steering Column Tube Straight Up TIGHTENING REFERENCE Foot Pounds Steering Gear to Frame Bolt 50 Steering Gear Pitman A r m N u t _ 125 Steering Wheel N u t 40 Steering Knuckle Tie Rod Clamp Bolt 15 Steering Knuckle Tie Rod End Ball N u t 40 Interme...

Page 323: ...y Part Number 2084329 Power Steering Fluid Maximum Pump Pressure A l l Models 950 to 1050 psi Maximum Fluid Flow at 3000 rpm 2 Gallons TIGHTENING REFERENCE Foot Pounds Reservoir to Pump Body Bolts 10 15 Steering Wheel N u t 40 Steering A r m N u t 120 Steering Gear Housing to Frame Bolt 50 Steering Valve End Plug 25 Steering Valve Body Attaching Bolts 15 Steering Column Support N u t 110 to 200 St...

Page 324: ...428 Puller Steering Wheel C 3633 N u t Wrench Cross Shaft Retainer C 3634 Adjusting Wrench Gear Support N u t C 3638 Seal Remover Gear Worm Shaft C 3646 Puller Steering A r m C 3650 Seal Driver Gear Worm Shaft C 3676 Worm Piston Ring Remover and Installer C 760 Pliers Snap Ring MTU 36 Ounce Pull Scale POWER STEERING PUMP DATA AND SPECIFICATIONS Type Constant Displacement Maximum Pump Pressure 950 ...

Page 325: ... Steering arms loose at steering knuckles g Worn ball joints 2 HARD STEERING a Low or uneven tire pressure b Insufficient lubricant in the steering gear housing or i n steering linkage c Steering gear shaft adjusted too tight d Front wheels out of line e Steering column misaligned 3 PULL T O O N E SIDE Tendency of the car to veer in one direction only a Incorrect tire pressure b Wheel bearings imp...

Page 326: ...turns Use puller Tool C 3428 to loosen the steering wheel 5 Remove the tool steering wheel nut and steering wheel 8a MANUAL STEERING GEAR UNIT a Removal Disconnect the battery ground cable 2 Remove the steering wheel as outlined i n Paragraph 5 3 Disconnect the directional signal wires and the horn wire at connectors 4 Remove the t u r n signal switch Pig 1 held to jacket tube by two screws PITMAN...

Page 327: ... oil seal from the steer ing housing w i t h Puller Tool C 3350 I f the shaft is corroded or dirty clean the portion between the oil seal and the serrations to avoid binding i n the bear ings N O T E Position Tool C 3786 gear shaft bearing re mover and installer arbor over the gear shaft threads and while withdrawing the gear shaft follow with the arbor This arbor will keep the bearing rollers fro...

Page 328: ... rotate steering wheel i n one direction to the end of its travel Rotate the wheel i n the other direction to the end of its travel counting the turns Rotate the wheel back l 2 of the full number of turns This is the exact center of travel high point 7 T u r n the adjusting screw clockwise until all T O O L Fig 5 Installing Gear Shaft Housing Inner Bearing end play i n the gear shaft is gone Rotat...

Page 329: ...foot pounds torque 13 Install a wedge over the rear bolt Fig 6 between the housing and the frame so that the tapered surfaces match tapping i t lightly i n place and tighten the three attaching bolts to 50 foot pounds torque Tightening should be done by alter nately tightening 14 Install steering gear arm washer and nut Tighten to 125 foot pounds torque 15 Reinstall the brake line between the mast...

Page 330: ...e steering gear at the frame and the dash support bracket to allow the steering gear to move i n relation to the frame N O T E Make sure the pivot D bar at the front end of the steering gear housing is between the housing and the frame with the flat side of the bar against the frame and the concave side of the spherical washers must be against the housing Fig 6 3 Tighten the two front mounting bol...

Page 331: ...E A R I N G CUP B E A R I N G C O N E BEARING C O N E 57x309 Fig 12 Front Wheel Bearing Adjustment idler a r m and bushing are serviced only i n an as sembly 4 Measure the width of the idler bracket The distance between the bushing contact surfaces should be 214 inches Fig 10 5 Install the idler a r m protect bushing ends from being damaged from the sharp edges of the mounting bolt holes by using ...

Page 332: ...i t h compressed air Do not spin bearings w i t h air pressure Check the bearings for pits or brinelling Install new bearings as re quired c Installation of Front Wheel Bearing laces When installing new bearing races be sure to start the race evenly in the drum Drive down into posi tion alternately using i f possible the old race Be sure the race is seated evenly Pack the inner bearing with short ...

Page 333: ...oose pump belt c Oil on pump belts d Binding steering linkage e Engine idle too slow f Faulty power steering pump g A i r in system Work the steering wheel from right to left until the air is expelled h Gear malfunctions 1 External leakage 2 Improper gear shaft adjustment See Paragraph 21 3 Excessive internal leakage 16 EXCESSIVE STEERING WHEEL FREE PLAY a Improper gear shaft adjustment See Para g...

Page 334: ...E RAIL STEERING SHAFT FLEXIBLE COUPLING COLUMN JACKET SUPPORT WORM SHAFT BALANCING RING L E F T TURN REACTION RING CENTER THRUST BEARING RACE RIGHT TURN REACTION RING CYLINDER HEAD WORM SHAFT RIGHT TURN POWER CHAMBER CROSS SHAFT SECTOR GEAR STEERING GEAR CROSS SHAFT STEERING ARM ADJUSTING WEDGE 6Qx 11 Fig 13 Power Steering Complete Cross Section MyMopar com ...

Page 335: ...e time oil from the right groove in the steering valve is directed to the left through a gal lery parallel to the w o r m shaft This oil flows to the TO RESERVOIR 4 PUMP PRESSURE IN CROSS SHAFT SECTOR GFAR i WER iSTON 5 8 X 1 9 8 A Fig 14 Steering Gear Housing Sectional View f TO PISTON 5 8 X 2 0 0 A Fig 15 Steering Gear Valve Neutral Position area below the power piston flange Part of this oil is...

Page 336: ...f the reac tion spring must be overcome before the center race can move to the right The force of the reaction spring provides positive returnability to the unit A t the instant when power assistance is no longer de sired by the driver the reaction spring and the oper ating oil pressure move the center thrust bearing race and the steering spool valve back to their neu tral center positions Equal o...

Page 337: ...ctually exerts Is only a small per centage of the total force that would be required to steer the car w i t h a manual gear I f oil pressure is Interrupted i n the steering gear It would operate with increased effort and there would be more steer ing wheel free play However complete steering control is retained by the driver i f a lack of power assist condition should ever arise 20 PBESSU1E TEST S...

Page 338: ... than 1050 Fig 19 Pressure Testing Pump and Steering Gear Fig 20 Jacket Tube installation PC 1 2 3 and P Y 1 psi the relief valve is faulty or the pump is equipped with the wrong relief valve b I f the pressure is less than 950 psi the pump is faulty c I f the pressure is within the specified range of 950 to 1050 psi the pump is operating properly and the trouble is in the steering gear d Open the...

Page 339: ...ber dust boot at firewall On Imperial cars remove the floor inspection panel 12 Loosen the jacket tube clamp at the steer ing gear housing 13 Remove the cotter key and nut at the drag link and disconnect the link from the steering arm 14 Remove the steering arm nut and washer at the steering gear shaft 15 Slide Tool C 3646 up on the steering arm and place the shoe of the puller behind the steering...

Page 340: ...cks or burrs provided i t is used carefully When used on the steering gear valve use extreme care not to round off the sharp edge portions of the two lands located between the valve drilled holes The sharp edge portion of these two lands is vitally i m portant to this type of valve Remove and discard all 0 seal rings and seals Use new ones lubricated w i t h petrolatum when re assembling 1 Drain t...

Page 341: ... retained in the cylin der head I t will also eliminate the possibility of the reaction rings becoming disengaged from their grooves in both the cylinder head and column jacket support 11 Remove the gear shaft assembly from the housing and remove the steering gear housing from the vise 24 DISASSEMBLY OF POWER TRAIN 1 Place the power train i n a vise equipped w i t h HOLDING FIXTURE JACKET TUBE SUP...

Page 342: ... shaft upper oil seal using SPANNER NUT y m 58x44 L e SI Installing Worm Shaft Upper Seal Tool C 3650 Fig 31 with the lip of the seal toward bearing 2 Lubricate and install the reaction seal i n the groove i n the face of the column jacket support w i t h the flat side of the seal out Fig 32 28 CYLINDER HEAD a Disassembly 1 Remove the two 0 rings i n the two outer grooves i n the cylinder head 2 R...

Page 343: ...trol valve assem bly 2 Compress the pressure control valve spring and remove retainer pin spring pressure control valve piston and back pressure valve cushion spring 3 Carefully shake out the steering valve piston Check the valve for nicks burrs and scores N O T E If the steering valve or valve housing is damaged replace the valve and housing assembly Do not remove the valve end plug unless inspec...

Page 344: ...I N G C R O S S S H A F T A D J U S T I N G S C R E W L O C K N U T O R I N G A D J U S T I N G C O V E R N U T O m R I N G u N G S S P A C I N G WASHER I T O O L H P 58x283 f i c j 36 Steering Gear Housing Sectional View 5 8 x 4 9 JSMMHMHHVV Fig 37 Removing Gem Shaft it 5eei over the adjusting screw into position at the top of the gear shaft cover 2 Lubricate an 0 ring and gear shaft cover w i t ...

Page 345: ...ows a Position Tool C 3676 i n the vise Fig 41 b Slide a new piston r i n g into place i n the piston groove c Place the piston and ring assembly i n Tool C 3676 w i t h the lower part of the piston and the r i n g resting on the land of tool d Press down on the piston to bottom the piston ring i n the piston groove forcing the open ends of the ring out for ease of locking the ring The r i n g sho...

Page 346: ... L S N A P R I N G RETAINER W O R M W PISTON I G RING RING TAINER RING EAL SEAL WASHER NUT C O U P L I N G NUT V A L V E A S S E M B L Y SUPPORT W BEARiNG 60x11 Fig 40 Steering Gear Exploded View MyMopar com ...

Page 347: ...I N G N U T CENTER BEARING RACrT C O R D SCALE ITOOL F E R R U L E 58x65 Fig 42 Checking Center Bearing Race Preload ADJUSTING NUT CENTER THRUST BEARING RACE CYLINDER EAD PISTON i 7 EARING RACE W O S M SHAFT 5 9 x 1 4 1 Fig 43 Staking Worm Shaft Bearing Adjusting Nut properly reading on the scale should be 8 to 16 ounces 12 ounces preferred while the bearing race is turning C A U T I O N Place a s...

Page 348: ...lding fixture Tool C 3323 in approximate car position lubricate the bore of the housing w i t h petrolatum and carefully install the power train assembly Fig 28 with the center bearing spacer valve lever hole in U P position to line up w i t h the control valve lever clearance hole in the steering gear housing N O T E Place a feeler stock 0015 inch to cover the aligning notch in the steering gear ...

Page 349: ...ATOR 60x19 BOLT NUT FLAT WASHER SPHERICAL SPACER FRAME RAIL FLAT WASHER Fig 46 Steering Gear Mounting WEDGE 60 x 16 Fig 45 Jacket Tube Installation the worm shaft either side of center the torque at the gear shaft required to turn the unit through center at 2 rpm i n each direction shall not exceed 25 foot pounds or vary more than 5 foot pounds from left to right Perform this operation carefully t...

Page 350: ...ck ring seats in the groove I M P O R T A N T This lock ring places the upper column tube In proper relation w i t h the worm shaft coupling pin 9 Install the steering wheel and the steering wheel nut Tighten the nut to 40 foot pounds torque 10 Install the turn signal cancelling mechanism on jacket tube Fig 1 Paragraph 6 Make sure column jacket does not restrict lever movement Chrysler models only...

Page 351: ... pump to the flow control valve Orifices i n the valve permit a flow of approximately two gallons per minute through the valve before the valve moves to the r i g h t to allow the excess to flow back to the inlet side of the pump Maximum pressure i n the system is limited by the pressure relief valve The valve opens into the reservoir when the pressure exceeds the maximum pressure specified 40 REM...

Page 352: ...control valve plug w i t h Tool C 3655 F i g 50 by threading the tap securely into the plug Place spacer and nut over the tap Hold the tap and tighten the nut to remove the plug C A U T I O N The valve is spring loaded 9 Remove the oil seal by threading Tool C 3642 IF VALVE ASSEMBLY s O RING 5 8 x 2 8 0 Fig 49 lei i lcii Relief Valve far enough to engage the metal portion of the seal Fig 51 T u r ...

Page 353: ...dy on the holding fixture Tool C 3643 w i t h the tool dowel pins i n the pump bolt holes so that the pressure w i l l be obsorbed by the lower end of the pump shaft F i g 54 C A U T I O N The pump must be supported i n a manner i n which all pressing force will be applied to the shaft only otherwise the pump body and rotor will be damaged 6 Install the pulley w i t h a heavy duty arbor press Pres...

Page 354: ...n bolts to 50 foot pounds torque 3 Connect the pressure and return hoses 4 Fill the pump reservoir w i t h No 2084329 Power Steering Fluid 5 Start the engine t u r n the steering wheel all the way to the left and back all the way to the right several times to expel the air from the system then t u r n off ignition switch to stop engine and recheck fluid in reservoir MyMopar com ...

Page 355: ...stallation 94 55 Removal 41 38 Band Adjustments 9 22 Kickdown Low Reverse Inspection 79 50 Installation Kickdown 92 55 Low Reverse 93 55 Removal Kickdown 40 37 Low Reverse 39 37 Clutch Front Assembly 78 49 Checking End Clearance After Assembly 103 58 Before Disassembly 31 34 Disassembly 76 48 Clutch Overrunning Disassembly 64 45 Clutch Rear Piston Retainer Assembly 69 47 Disassembly 65 46 Eccentri...

Page 356: ...ift Control Unit 12 26 Installation Removal Back Up L i g h t Switch Replacement Governor 24 31 Assembly 56 42 Disassembly 54 41 Installation 100 57 Removal Unit out of Vehicle _ _ 34 36 Servicing in Vehicle 24 31 Housing Face and Bore Runout Torque Converter 116 68 Bore Runout Face Runout Hydraulic Control System 5 18 Hydraulic Pressure Checks and Adjustment 11 24 Governor Line Lubrication Thrott...

Page 357: ...85 52 Removal 45 39 Oil Pump Rear 25 32 Installation 99 56 Removal 34 36 Servicing in Vehicle 25 32 Inspection 55 42 Operating Principles 3 13 Output Shaft Rear Oil Seal 22 29 Removal Installation Output Shaft Support 35 36 Inspection 57 42 Installation _ 98 56 Removal Parking Brake 32 35 Installation 102 57 Removal Power Flow in the Transmission 4 15 Power Train Unit No 1 Output Shaft Kickdown Pl...

Page 358: ...t No 3 Front Clutch Piston Retainer and Input Shaft Assemblies 38 37 Disassembly 76 48 Installation 95 55 Reassembly 78 49 Removal 38 37 Inspection 77 49 Push Button Lamp Replacement 13 26 Regulator Valve Assembly 17 28 Removal Installation Regulator Valve Body Inspection Includes Valves 86 52 Installation 88 53 Removal 46 39 Service Diagnosis Chart 9 Service Diagnosis Explanation 2 10 Servos Low ...

Page 359: ...r and Housing 113 66 Removal Installation Torque Converter H u b Runout 115 68 Checking Hub Runout Correcting Hub Runout Torque Converter Reaction Shaft Inspection 49 40 Installation 87 53 Removal 47 40 Torque Reference Transmission 26 33 Removal Installation 108 60 Transmission Case Inspection 50 40 Extension Housing 51 41 Valve Body and Transfer Plate 20 28 Assembly 111 63 Cleaning and Inspectio...

Page 360: ... inch Natural 097 to 099 inch Black 078 to 080 inch Red 059 to 061 inch Orange Front Clutch and Sun Gear 062 to 064 inch Output Shaft 062 to 064 Inch SNAP RINGS Kickdown Annulus Gear _ 060 to 062 inch 064 to 066 inch Rear Clutch 060 to 062 inch Low Reverse Planet Pinion Carrier 060 to 062 inch 064 to 066 Inch 068 to 070 inch Front Clutch 060 to 062 inch Front Clutch Accumulator Rear Clutch High En...

Page 361: ...mpensated Throttle Pressure Tap 120 Front Pump Housing to Transmission Case 180 Governor Body to Support 90 Locating Screw 70 Oil Pressure Take Off Plug 120 Line Pressure Take Off Plug _ 120 Oil Pan Bolts _ 175 Rear Clutch Pressure Tap 120 Pump Housing to Support 120 Oil Pressure Tap 180 Suction Pressure Tap 180 Servo Apply Pressure Tap 120 Transfer Plate to Transmission Case 180 Valve Bodies to T...

Page 362: ...lug 50 Converter Drain Plug 130 Drive Flange Stud 35 LUBRICATION PRESSURE INTERMEDIATE SUPPORT LOCATING f SCREW dm LINE PitESSL TAKE OFF P m i wm REAR CLUTCH U PRESSURE TEST P L U G m y y h MM i GOVERNOR PRESSURE TAKE OFF PLUG NEUTIAL STA 7 r S W I T C H 60x35 KICKDOWN BAND ADJUSTING SCREW Fig 1 Transmission Case Left Side INTERMEDIATE SUPPORT LOCATING SCREW LOW AND REVERSE BAND ADJUSTING SCREW y ...

Page 363: ...ats impossible to Push Start Starter Won t Energize A Oil L e v e l m B Throttle Link A d j m C Gearshift Control Cable A d j m D Pressure C h e c k s Line Lube etc o m E K D Band A d j m m F Low Reverse Band A d j m G Engine Idle H N e u t r a l Str S w I Parking Brake J R e g u l a t o r V a l v e S p r i n g m m m K Converter Control V a l v e m L Breather M O u t p u t Shalt Rear B u s h i n g...

Page 364: ...rt e Kickdown Band Adjustment the kickdown band adjustment screw is found on the left side of the transmission case Fig 1 Refer to Paragraph 9 a f Low and Reverse Band Adjustment The low and reverse band adjustment screw is found on the right side of the transmission case Fig 2 Refer to Paragraph 9 b g Engine Idle Adjust to 475 to 525 r p m in Neutral h Neutral Starter Switch I f the starter will ...

Page 365: ... air pressure to the kickdown apply compensated throttle pressure passage as shown in Figure 3 E Observe the operation of the kick down servo 6 Apply air pressure to the low and reverse servo passage as shown i n Figure 3 F Observe the operation of the low and reverse servo lever and band when air pressure is applied I f this usually occurs when line pressure fails an erratic or no upshift conditi...

Page 366: ... CASE j j KICKDOWN ANNULUS GEAR I I I OUTPUT SHAFT SUPPORT REAR OIL PUMP EXTENSION GOVERNOR ASSEMBLY SPEEDOMETER PINION S R E A R CLUTCH ASSEMBLY j FRONT CLUTCH PRESSURE PLATE OIL STRAINER REVERSE SUN GEAR TORQUE CONVERTER REACTION SHAFT LOW REVERSE PLANET PINION CARRIER ASSEMBLY FRONT OIL PUMP VALVE BODIES A N D TRANSFER PLATE ASSEMBLY TORQUE CONVERTER STATOR INTERMEDIATE SHAFT ASSEMBLY TORQUE CO...

Page 367: ...sets to provide three forward ratios and a reverse ratio a Gearshift Control Unit The transmission is operated by a gearshift control unit consisting of five push buttons identified by R reverse N neutral D drive 2 second and 1 first Mechanical connection between the gearshift con trol housing and the transmission manual control valve is obtained through the use of a single push pull cable as show...

Page 368: ...ted i n the Shift Pattern Summary Chart below As soon as the accel erator is depressed the vehicle will move forward i n the drive breakaway range Depending on the amount of accelerator is depressed and car speed the transmission will automatically upshift into second I f the vehicle speed falls before 8 M P H or if the accelerator is completely depressed provided vehicle speed is below 30 M P H t...

Page 369: ...as shown i n Shift Pattern Summary Chart wide open throttle 2 3 up shift are reached c Mountain Driving When driving i n the mountains w i t h either heavy 8 15 9 15 9 16 10 15 11 15 12 19 12 19 13 20 14 19 13 20 31 47 32 48 33 49 37 42 38 44 68 84 69 86 72 90 60 74 61 75 64 82 66 83 69 87 57 65 58 67 31 44 32 45 33 47 36 42 37 43 6 13 6 13 7 14 8 12 8 13 load or when pulling a trailer the 2 secon...

Page 370: ... flow is from the torque converter turbine 56x688 Fig 8 Power Flow in D Drive Position Direct the input shaft and front clutch retainer one u n i t The front clutch is applied and the drive continues through the clutch hub to the intermediate shaft and the kickdown annulus gear one u n i t The kick down annulus gear drives the kickdown planet pinion gears rotating them in the same direction The ki...

Page 371: ...d exert force through the kickdown planet pinion shafts to rotate the kickdown planet pinion carrier The carrier which is splined to the output shaft drive housing rotates at a slower speed than the annulus gear thus providing a gear ratio of 1 45 to 1 D Drive Position Direct see Fig 8 The power flow from the torque converter goes di rectly through the transmission because the plan etary elements ...

Page 372: ...ence there is no drive connection between the engine and the rear wheels Power Flow Summary The chart summarizes power flow conditions in the various ranges as regards to gear train elements in volved and the ratios obtained 5 THE HYDRAULIC CONTROL SYSTEM The hydraulic control system has four important functions to perform The pressure supply system the clutches and band servos the pressure regula...

Page 373: ...s accomplished by shutting off the source of line pressure to the regulator valve second ary reaction area w i t h the result that a line pres sure of 225 psi applied to the primary reaction area is required to overcome the force of the regulator valve spring Torque Converter Control Valve This valve maintains an oil pressure of approxi mately 30 psi within the torque converter Oil is fed from the...

Page 374: ...ted to the kickdown circuit of the 2 3 shift valve Pushing i n the 1 first button of the control unit positions the manual valve so that line pressure Is directed to the kickdown circuit of the 1 2 shift valve Pushing i n the N neutral button moves the manual valve to a position which shuts off oil flow to the valve body The torque converter and lubrica tion system remains pressurized Pushing i n ...

Page 375: ... firmly hold the R reverse button until the transmsision end of cable adjust ment has been completed THRO L I N K 3c O RING SEAL 4 CABLE GUIDE CABLE HOUSING Ifi 4f ADJUSTMENT WHEEL 60x34 Fig 12 Gearshift Control Cable and Adjustment Wheel 5 Back the adjustment wheel off on cable hous ing counter clockwise until only two or three threads are showing behind the wheel on the hous ing Fig 12 N O T E C...

Page 376: ...t still fail to light and the seat ing surfaces have been cleaned to obtain a good ground i t is recommended that the following mod ification be performed to the neutral starting switch INCORRECT CORRECT 5 8 X 16 Fig 14 Lever Alignment Fig 15 Neutral Starting Switch 1 Machine 1 32 from the seating surface of the switch as Illustrated in Figure 15 2 Clean the switch replace the concave cupped washe...

Page 377: ...ock nut to specifications 30 to 35 foot pounds torque ADJUSTMENT LOCK NUT A 60x171 Fig 16 Throttle Linkage Adjustments Fig 17 Checking Line Pressure 10 THROTTLE LINKAGE ADJUSTMENTS Refer to Fig 16 1 W i t h the engine at operating temperature carburetor off the fast Idle cam and transmission i n neutral adjust idle speed 475 to 500 r p m use ta chometer ram manifold 725 to 750 r p m 2 Loosen the t...

Page 378: ... i t h the engine at 1200 rpm w i t h wheel turning and transmission upshifted into direct speed A l l line pressure adjustments should fall within the limits specified i n the table shown for all other push button positions I f line pressure cannot be satisfactorily adjusted check Service Diagnosis Chart b Governor Pressure see Fig 18 1 Remove the pipe plug from the governor pres sure take off ho...

Page 379: ...ssion slowly towards full throttle Compensated throttle pres sure should begin to rise after approximately 5 de grees movement of the throttle lever I f compen sated throttle pressure rises immediately when the lever is moved or i f the pressure is above 16 psi but fails to rise after approximately 5 degrees movement the throttle pressure should be adjusted refer to Paragraph E 7 Before stopping t...

Page 380: ...g the cable bracket to the control housing b Installation 1 Insert the end of cable on the actuator and reassemble the clip Place the cable bracket on the control unit and install the screws securely 2 Carefully guide the unit into position from the rear of the instrument panel and install the attaching stud nuts from the front side of instru ment panel 3 Install the lamp built in the push button ...

Page 381: ...kwise until i t just contacts the transmission case 5 T u r n the wheel clockwise just enough to make the next adjustment hole i n the wheel line up w i t h the screw hole in the case 8 Counting this hole as number one continue turning the wheel clockwise until the fifth hole lines up with the screw hole in the case 7 Install the lock screw tighten 30 to 50 inch pounds torque 8 Install the neutral...

Page 382: ...er and tighten to 40 foot pounds torque 19 OIL PAN a Removal The oil pan may be removed after disconnecting the filler tube and draining the oil from the transmission Remove screws and drop pan b Installation Using a new gasket install the oil pan and tighten bolts 12 to 17 foot pounds torque Reconnect filler tube and refill transmission w i t h Automatic Trans mission Fluid Type A Suffix A Refer ...

Page 383: ...on properly centered so as not to damage rings tap lightly until piston bottoms in case 2 Place the kickdown piston rod assembly in piston and slide piston spring over kickdown piston rod 3 Install Tool C 3529 or C 3289 Modified on T O O L 4 57x98 Fig 23 Removing Handbrake Drum and Flange Assembly case and place kickdown piston rod guide over spring compress spring and install snap ring Remove com...

Page 384: ...haft Rear Bearing Oil Seal REAR E X T E N S I O N 6 0 x 2 9 Fig 26 Removing Output Shaft Rear Bushing 3 Remove the propeller shaft flange and park ing brake drum assembly using puller Tool C 452 if necessary 4 Disconnect parking brake and speedometer cables Remove the speedometer drive pinion sleeve assembly I f the output shaft rear bushing is to be replaced the oil seal must be removed at this p...

Page 385: ...ket 5 Start extension to case screws Due to inter ference of the mounting insulator i t will be neces sary to start the bottom extension housing to case screw as the extension is pushed into position against the support Remove the guide studs and install the remaining screws and tighten 25 to 30 foot pounds torque T u r n output shaft to make sure i t turns freely 6 Lower the transmission and inst...

Page 386: ...ernor Valve Shaft Snap Rings in Grooves 25 BEAR OIL PUMP a Removal 1 Remove the transmission extension and gov ernor assembly as outlined in Paragraph 24 2 Remove oil pump housing to output shaft sup port screws and install guide studs Tool C 3288 Remove pump housing and gear from output shaft Use dye or other suitable material to mark pump gears in relation to the pump housing face N O T E Do not...

Page 387: ... be left on transmission extension during transmission repairs When i t is necessary to replace the extension hous ing i t can be transferred on the bench 12 Remove the two transmission case to torque converter housing screws and lockwashers from the right side and install guide studs Tool C 3276 W i t h the transmission supported remove the two trans mission case to torque converter housing screw...

Page 388: ...TE REMOVAL 1 Remove the throttle valve lever and flat washer 2 Remove the cable adapter stud nut 3 Remove the oil strainer 4 Remove attachment nut from cable adapter stud at manual lever and remove the adapter 5 Remove the transfer plate bolts and remove the valve body assembly from the transmission Fig 33 Mating surfaces are machined Use ex treme care so as not to damage these surfaces Place valv...

Page 389: ...37 Removal and Installation of Governor Valve and Shaft extension I f a screwdriver or sharp instrument is used i n removal of this shield care must be exer cised not to damage the neoprene sealing surface at bottom of shield Note the indent on the grease shield for correct positioning on the extension 6 Using a suitable drift remove pin which at taches the brake shoe anchor in the extension hous ...

Page 390: ...the face of the pump gear in relation to pump housing for reassembly purposes DO N O T SCRIBE Remove oil pump pinion ball 35 OUTPUT SHAFT SUPPORT REMOVAL 1 Slide the output shaft rear support assembly UNIT N O 1 56x613 Fig 40 Removal and Installation of Unit No 1 and gasket from transmission case as shown in Fig ure 39 I f the rear support is stuck to the transmis sion case i t can be loosened by ...

Page 391: ...oses then compress ends of band 56x617A Fig 44 Removal and Installation f low Reverse Band sufficiently to remove the low reverse band strut 2 Remove the low reverse band assembly by rotating band ends through rear opening i n trans mission case as shown i n Figure 44 and remove low reverse band anchor from adjusting screw 40 1IC1DOWN BAND REMOVAL 1 Mark the band for reassembly purposes Com press ...

Page 392: ...n and low reverse servo levers 42 LOW REVERSE SERVO REMOVAL 1 Install Tool C 3529 or C 3289 modified and depress the reverse servo piston retainer to permit the removal of the snap ring w i t h a screwdriver Fig 48 2 Remove the tool f r o m the case 56x622A Fig 48 Removal a n d Installation of Low Reverse Servo Piston Spring Retainer Snap Ring TOOL SNAP RING mm i l l m 56x624A Fig 49 Removal and I...

Page 393: ...SPRING CU t Fig 53 Regulator Valve Assembly Disassembled View 3 Remove oil pump housing from transmission case by tapping the housing lightly w i t h a soft ham mer Fig 54 Using dye mark the pump gears in relation to face of oil pump housing for reassem bly purposes DO N O T SCRIBE 48 REGULATOR VALVE BODY REMOVAL 1 Remove the transmission regulator valve spring retainer gasket cup spring sleeve an...

Page 394: ... are seated properly I f mating parts do not go together properly always check reason Do not force parts unnecessarily 49 TORQUE CONVERTER REACTION SHAFT INSPECTION Inspect inside of torque converter reaction shaft for burrs Inspect splines on shaft for burrs and wear Inspect the reaction shaft seal ring neoprene for deterioration and hardness Inspect thrust surface for wear and heavy scoring Chec...

Page 395: ... hole in bushing w i t h the lubrication hole in the top side of the extension housing and drive bushing until tool bottoms Figure 27 3 While holding screw of tool w i t h a wrench to prevent turning use another wrench and t u r n nut on tool until burnisher of tool is pulled back out of bushing This operation correctly sizes the bushing Recheck the indexing of the lubrication hole in bush ing w i...

Page 396: ...nit No 1 Fig 61 Removal and Installation of Output Shaft Drive Housing Snap Ring the governor support seal rings w i t h fingers as sup port enters oil pump housing Do not force 57 OUTPUT SHAFT S U P P O R T I N S P E C T I O N Inspect all oil passages i n output shaft support for any obstructions Remove pressure take off plugs and clean passages w i t h compressed air Check the rear oil pump mati...

Page 397: ...racks and internal driving splines for exces sive wear or brinnelling The housing and output shaft are serviced as an assembly Inspect the interlocking seal rings L M on out put shaft K for wear or broken locks and make sure they t u r n freely i n the grooves Do not remove rings unless condition warrants When replacing rings use extreme care so as not to damage inter locking portion of ring Make ...

Page 398: ...gear teeth 63 UNIT NO 1 OUTPUT SHAFT I I C I D O W N PLANET PINION CARRIER AND INTERMEDIATE SHAFT ASSEMBLIES ASSEMBLY To aid in the assembly of Unit No 1 use the propel ler shaft flange and brake drum assembly as a stand 1 W i t h the output shaft assembly K in the upright position lubricate output shaft thrust wash er E w i t h Automatic Transmission Fluid Type A Suffix A and place into position ...

Page 399: ...x638 Fig 67 installation of Tool 3527 in Intermediate Support and Cam Assembly INTERMEDIATE SUPPORT AND CAM ASSY 56x639 Fig 68 Removal and Installation of Intermediate Support and Cam Assembly from Overrunning Clutch 2 Using two screwdrivers inserted between clutch and intermediate support remove the rear clutch retainer assembly from the sun gear as shown in Figure 65 3 Remove the two rear clutch...

Page 400: ...ease the compressor carefully Tool C 3575 and remove clutch return spring retainer P and spring Q from clutch piston retainer assembly The spring retainer may require guiding past snap r i n g groove as tool is released 7 Using a twisting motion remove the clutch piston assembly R from retainer Remove the inner and outer S and T seal rings from piston 66 CLUTCH D11V1NG DISC AND PLATE INSPECTION In...

Page 401: ...clutch will result 8 Install the pressure plate L and snap ring K Make sure the ring is properly seated 70 REVERSE SUN GEAR ASSEMBLY INSPECTION Inspect the gears for cracked or broken teeth I n spect the steel back bronze type bushing for scoring or excessive wear Bushing and reverse sun gear are serviced as an assembly Inspect intermediate support bearing surface of gear for wear and slight score...

Page 402: ...lace Tool C 3527 i n position in the inter mediate support and cam assembly and install cam spring and rollers as shown in Figure 72 Make definitely sure that cam springs and rollers are prop erly seated against cam otherwise damage to springs will result when overrunning clutch hub Is installed 5 W i t h the intermediate support and cam as sembly resting on bench lubricate bushing and in stall th...

Page 403: ...NG PISTON LEVER 58x753 Fig 75 Installing Piston Levers should be smooth free from scratches and excessive wear Do not unlock or remove rings except for re placement unless the condition warrants Seal rings should have sharp unbroken edges and unbroken lock ends The side clearance should not exceed 005 inch The outer surface should show no evidence of wear 2 Do not remove the reaction shaft for ins...

Page 404: ...tall the clutch hub G and input shaft C in retainer and install snap ring B 11 Install the thrust washer A over the input shaft against the flange of the shaft SERVOS BANDS AND MISCELLANEOUS INSPECTION 79 BAND INSPECTION A l l letters referred to in the inspection of these parts pertain to Figure 76 Make visual inspection of bands and lining for wear and bond to metal I f the lining is worn to the...

Page 405: ... Inspect the front seal ring neoprene for nicks deterioration and hardness Inspect the interlocking seal ring for wear or broken locks and make sure It v x DD E E fl CC Z P B B L G G HH C A LOW AND REVERSE BAND B REVERSE BAND STRUT C ANCHOi D KICKDOWN BAND E KICKDOWN BAND STRUT F ANCHOR G LEVER SHAFT PLUG H LEVER SHAFT SPACER I LEVER SHAFT J L O W AND REVERSE BAND LEVER K KICKDOWN BAND LEVER L L O...

Page 406: ...rs as o I D O L RONT O i l PL AP HOUSING 53x28 Fig 77 Installing Front Pump Housing Oil Seal m T O O L 56x650 Fig 78 Checking Clearance between front Pump Body and Gears shown i n Figure 78 Clearance limits are from 001 to 0025 After measuring pump gear clearance lubricate the pump rotors w i t h Automatic Trans mission Fluid Type A Suffix A Measure the tip clearance between the rotor lobes The ma...

Page 407: ...place as shown i n Figure 57 Remove the guide studs and install the bolts and washers Tighten the bolts down evenly to prevent any possible misalign ment of the shaft i n the case and tighten 30 to 35 foot pounds torque 4 Lubricate the torque converter reaction shaft seal neoprene and install on shaft GUIDE STUDS MARKS V A L V E BODY 56x652 Fig 79 Installing Front Oil Pump Assembly Fig 80 Installi...

Page 408: ...rings and install them on the kickdown piston 2 Compress outer ring and start assembly into TOOL SEAL RING DRIVE SLEEVE IS mm mmWm DRIVE SLEEVE Fig 81 Front Pump Drive Sleeve Installation Incorrect Installation Top View Correct Installation Bottom View KICKDOWN PISTON ROD KfaCDOWN PISTON SPRING K I C K D O W N PISTON ROD 56x625 A Fig 82 Removal and Installation of Kickdown Piston Rod Guide and Spr...

Page 409: ... over the adjusting screw compress band and install kickdown band strut 4 Position the low reverse band anchor over ad justing screw compress band and w i t h the aid of a screwdriver install the strut 95 UNIT NO 3 FRONT CLUTCH AND INPUT SHAFT ASSEMBLIES INSTALLATION I f when transmission was disassembled the end clearance was found to be incorrect correction can be made at this time by selection ...

Page 410: ...abs spaced between the webs on the front side of the output shaft support Ro THRUST WASHER Fig 85 Installing Thrust Washer on Output Shaft Support Fig 86 Removal and Installation of Rear Oil Pump Pinion tate the washer to find the location that will provide a minimum amount of rotation Fig 85 Lubriplate should be used to hold the washer in place 2 W i t h the guide studs Tool C 3283 installed in r...

Page 411: ...sitioning valve i n body and then install the governor valve shaft snap ring weight assembly end Fig 36 Make very sure snap rings on both ends of the governor valve shaft fit securely After snap ring installation apply sufficient pressure to both ends of the valve shaft to force snap rings to outer portion of snap ring grooves Check operation of governor weight assembly and 101 TBANSMISSION EXTENS...

Page 412: ...i n Figure 34 1 Install the dial indicator and p r y the clutch forward by carefully inserting screwdriver between the front and rear clutch 2 Remove the screwdriver and w i t h point of dial indicator contacting edge of front clutch retainer set the indicator to zero 3 Pry the front clutch assembly rearward against rear clutch and take indicator reading This clearance should be from 020 to 050 I ...

Page 413: ...r clockwise direc 4 60x9 Fig 91 Installing Cable Adapter T O R Q U E F L I T E T R A N S M I S S I O N 59 Fig 92 Installing Oil Strainer on Valve Body and Transfer Plate Assembly tion to center the bands on the drums prior to making band adjustments Low Reverse Rear Band Refer to Maintenance Adjustments Test Para graph 8 b Kickdown Front Band Refer to Maintenance Adjustments and Tests Paragraph 8 ...

Page 414: ...nd lockwashers in the left side do not tighten Remove the guide studs and install the two transmission case to housing screws and lockwashers in the right side Tighten the four down evenly to specifications 6 Place crossmember into position and install the crossmember to torsion bar bracket bolts Tighten to specifications Lower the engine and at the same time align mounting bolts in insulator brac...

Page 415: ...Location of Check Valve Balls in Valve Body valve spring C Remove the snap ring J and slide out shuttle valve I 6 Remove the 1 2 relay valve spring D and 1 2 relay valve E 7 Remove the 1 2 F and 2 3 G shift valve governor plugs 8 Remove the shift valve cover plate L Hold the cover plate while releasing the spring tension to prevent possible loss of springs while the cover is removed Refer to Fig 9...

Page 416: ...2 3 Shift Valve Governor Plug H Manual Valve I Shuttle Valve J Shuttle Valve Snap Ring K Valve Body V i u 60x6 L Shift Valve Cover Plate M 1 2 Shift Valve Spring N 2 3 Shift Valve Spring Fig 97 Shift and Throttle Valve Side of Valve Body O 1 2 Shift Valve R Throttle Compensating Valve P 2 3 Shift Valve S Throttle Valve Cover Q Throttle Compensating Valve Spring T Throttle Valve U Throttle Valve Sp...

Page 417: ...LVE BODY VALVE BODY PLATE A N D TRANSFER PLATE ASSEMBLY 1 While holding the valve body w i t h the oil passage ways facing downward insert the manual valve operating lever detent spring into the valve body recess followed by the detent ball Hold the ball against the spring w i t h the fingers to prevent loss 2 Slide the throttle lever shaft up through the valve body w i t h the smallest cam contac...

Page 418: ...valve bore and gov ernor pressure passage in the transfer plate 112 SERVICE INFORMATION a TorqueFlite Transmission Ram Manifold Engines The following information will acquaint the service technician with the procedures that differ from the standard TorqueFlite transmission and the one used on cars equipped with the ram manifold Disassembly inspection and assembly procedures are the same There is a...

Page 419: ...of rod either i n or out until an angle measurement of 114 degrees is ob RIGHT BANK CARBURETOR ROD BELL CRANK 3 16 x3 PIN WELDING ROD ADJUSTING LINK LOCKING BOLT AND NUT ADJUSTING LINK 6 LOCKING BOLT AND NUT D LOCKING NUT ACCELERATOR SHAFT TO TRANSMISSION ROD LEFT BANK CARBURETOR ROD TOP VIEW TRANSMISSION THROTTLE CONTROL LEVER KICKDOWN POSITION WIDE OPEN THROTTLE POSITION 0 LOCKING NUT BELL CRANK...

Page 420: ... housing and engine block or adapter plate Remove all burrs or rough spots w i t h emery cloth Remove all obstructions dirt etc from vent hole screens when so equipped 4 Using wrench Tool C 589 remove the stud nuts and lock washers which hold the converter unit to the crankshaft The torque converter assem bly is a welded unit and cannot be serviced except as an assembly b Installation 1 f a new to...

Page 421: ...e and direct the steam flow around the gear for approximately two minutes Flame Place the r i n g gear squarely on a flat surface Using a medium size tip direct a slow flame around the inner r i m of the gear being careful not to direct the flame onto the teeth of the ring gear Place a few drops of water on the face of the gear at intervals during the heating process When the gear is hot enough to...

Page 422: ...i m i Si iBiiB Bi R I K K i l l TOOL lllilw Fig H00 Checking Torque Converter Hub Runouft Typical i Fig 101J Heating Torque Converter Showing Heating Operation y2 inch diameter for 008 inch total indicator read ing Using an acetylene torch containing a No 3 tip and set to minimum heat apply i t to the selected spot until i t becomes a dull red Rapid heating of a local area is essential and i f the...

Page 423: ...16 inch i n a direction which approximates 2 o clock f l B TOOL INDICATOR 58x1 A Fig 104 Eccentric Dowel Schematic Diagram on engine block Refer to Fig 104 I n this case the housing is off crankshaft centerline 008 inch one half total indicator reading which is 003 inch greater than the allowable limit of 005 one half total indicator reading To correct an off center condition three off set dowels ...

Page 424: ...e dial indicator and re check the bore runout Small corrections can be made by loosening the housing mounting bolts and turning dowels with a screwdriver to shift the housing and bring the bore within limits SHIM THICKNESS LOCATION TABLE Location of Housing Location of Total Indicator Reading Total Shim Face Low Point Shim Observed on Housing Face Thickness a Near one of the a Place shim on bolt a...

Page 425: ... transmission as outlined in Para graph 108 Transmission Group POWERFLITE TRANSMISSION CONTENTS Paragraph Page Assembling the Transmission 9 95 Installing Kickdown Band Adjusting Screw Installing the Torque Converter Reaction Shaft Installing the Kickdown Piston Installing the Reverse Servo Piston Installing the Regulator Valve Body Installing the Front Oil Pump Installing the Kickdown Band and Le...

Page 426: ...e Body Removal of Reverse Servo Piston Removal of Kickdown Piston Removal of Torque Converter Reaction Shaft Explanation of Index Items Trouble Diagnosis Chart 1 77 Hydraulic Control Pressure Checks 3 80 Line Pressure Throttle Pressure Governor Pressure Direct Clutch Pressure Lubrication Pressure Installing the Transmission in Vehicle 11 105 Operation _ 2 78 Torque Converter Gearshift Control Push...

Page 427: ... Rear Band Adjustment Adjusting the Gearshift Control Cable Cable and Neutral Starting Switch Adjustment Road Testing Trouble Diagnosis Chart 76 POWERFLITE TRANSMISSION DATA AND SPECIFICATIONS Type Automatic Two Speed w i t h Torque Converter Torque Converter Diameter inches 1 1 Oil Capacity of Transmission and Torque Converter 20 pt Automatic Transmission Fluid Type A Suffix A Method of Cooling W...

Page 428: ...ings fails to provide m i n i m u m clearance use kickdown sun gear snap ring 058 060 SPECIAL TOOLS C 452 Puller C 3288 Pilots C 484 Pliers C 3292 Gauge C 589 Wrench C 3293 Gauge C 748 Puller C 3294 Stand C 760 Pliers C 3295 Pilots C 811 Wrench C 3297 Remover Installer C 3201A Jack C 3301 Pliers C 3202A Jack C 3335 Straightedge C 3204 Driver C 3339 Set Dial Indicator C 3205 Driver C 3380 Wrench C ...

Page 429: ...aft Support Bolt 2 5 Output Shaft Support Pipe Plug Rear Oil Pump Housing Bolt Regulator Valve Spring Retainer 50 Reverse Band Lever Adjusting Bolt N u t 3 5 Shaft Flange N u t 1 7 5 Speedometer Pinion Sleeve 4 5 Throttle Control Lever N u t 7 Throttle Oil Pressure Take Off Plug Throttle Valve Adjusting Bolt Plug 2 5 Torque Converter Control Valve Spring Retainer 4 0 Transfer Plate Cover Bolt Long...

Page 430: ...Range Moves Backward in Neutral Drags or Locks Grating Scraping Growling Noises Buzzing Noise Trans Hard to Fill Oil Blows Out Fill Tube Trans Overheats l Impossible to Push 1 Start Engine Starter Won t Energize A Oil Level m m B Throttle L i n k Adj C Gearshift Control Cable Adj D Pressure Checks Line Lube etc m m m m o E K D Band Adj m m F Reverse Band Adj G Engine Idle H Neutral Start SW I Hand...

Page 431: ...e taps have been provided to check the following pressures LATCHED POSITION LOCK SPRING UNLATCHED POSITION 57x430 Fig 1 Gearshift Control Unit Operational Sketch T O R Q U E C O N V E R T E R C O N T R O L 7 L V E T R A N S M I S S I O N REGULATOR V A L V E O L FILLER T U B E O P E N I N G DIRECT CLUTCH PRESSURE TAKEOFF PLUG 56x109 A KICKDOWN BAND ADJUSTING S C R E W LUBRICANT PRESSURE TAKEOFF THR...

Page 432: ...que valve body bolts to specifi cations S Speedometer pinion Check nylon teeth for wear shredding T Governor Clean assembly and check weight assembly and valve for burrs scratches or sticky operation Examine the governor valve shaft shaft snap rings and seal rings U Rear pump Clean and inspect assembly for side and diametral clearance Note whether rear oil pump pinion ball is in place Examine outp...

Page 433: ...ck prevents the driver from i n advertently pushing the R reverse button to the reverse position when the vehicle is traveling in the D drive position above 15 mph Should the reverse button be pushed i n at a speed in excess of 15 mph the manual valve lever will move to the neutral position The driver is then required to again select the proper gear range c Gearshift Control Housing Refer to Fig 1...

Page 434: ...e R reverse button to full limit of travel Upon depressing the accelerator the vehicle will move in reverse Do not depress the R reverse button when the car is moving forward at a speed above 5 mph 5 Kickdown or forced downshift A t speeds between 15 to approximately 55 mph in D drive after the transmission has upshifted to direct maxi mum acceleration can be obtained for passing or climbing a ste...

Page 435: ...ng from the lubrication pressure take off hole located on the left side of the transmission case Fig 2 Install gauge Tool C 3292 100 psi W i t h engine running at 800 r p m In neutral lubrication pressure should read not below 10 psi minimum I f the pressure Is Incorrect check line pressure and Trouble Diagnosis Chart 4 CHECKING FOR OIL LEAKS I f the transmission Is leaking oil check the following...

Page 436: ...iew of Gearshift Control Housing Typical mission assembly as outlined under Removal and Inspection of Cable Assembly Transmission End Paragraph 5 G steps 1 and 2 2 Remove gearshift control housing and cable as outlined under Servicing Gearshift Control Unit Removal Paragraph 5 3 From inside of vehicle pull cable assembly through rubber grommet or remove grommet in dash panel d Installing Gearshift...

Page 437: ...mbly 6 W i t h the carburetor throttle lever off the fast idle cam and against the idle stop screw move the rear half of the carburetor rod rearward until the stop i n the transmission is felt tighten lock nut B Figure 4 7 The accelerator pedal should be at an angle of 113 to 114 degrees to the horizontal I f necessary to correct adjust pedal angle by removing the accelera tor pedal end of the bel...

Page 438: ... Disregard multiplica tion factor on Extension C 3583 Use a refer ence mark of chalk or colored pencil on the corner of the adjusting screw square and the transmission case Using extreme care back the adjusting sc ew out exactly 2 turns Now hold the adjusting screw stationary w i t h wrench and tighten the locknut securely Extreme care must be exercised i n per forming this operation to insure cor...

Page 439: ...t assured and N neu tral button depressed make certain that switch is properly aligned i n center of neutral starting switch hole W i t h test leads connected to battery current and terminal of the switch screw switch into trans mission case until test light lights then t u r n switch an additional l s to y2 turn Do not exceed 75 foot pounds torque N O T E Excessive tightening may damage case and ...

Page 440: ...Support transmission w i t h a suitable jack Remove the two upper transmission case to con verter housing screws and lockwasher Install guide studs Tool C 3276 i Fig 10 Checking Transmission End Clearance 10 Remove the two lower transmission case to converter housing screws and lockwashers Slide jack and transmission straight back to avoid damag ing the front pump drive sleeve After removing trans...

Page 441: ... as shown in Figure 11 remove the transmis sion flange nut and washer 2 Install puller Tool C 452 to remove brake drum and flange assembly 3 Using a suitable drift remove pin which secures the brake shoe anchor i n extension Remove the brake support grease shield spring and remove shield I f a screwdriver or sharp instrument is used in removing shield care must be exercised to avoid damaging the n...

Page 442: ...OIL PUMP HOUSING GOVERNOR BODY SUPPORT GOVERNOR BODY GOVERNOR SUPPORT PISTON RINGS 53x14 Fig 16 Removal and Installation of Governor Body and Support weight assembly snap ring large one and remove the governor weight assembly from the governor body Fig 14 Remove governor secondary weight snap ring Fig 15 using pliers Tool C 3229 4 Remove governor secondary weight and spring and the intermediate we...

Page 443: ... When removing pinion do not lose the ball Inspect keyway i n pinion and ball pocket i n output shaft for wear and also the gear for pitting 56 x 156 Fig 20 Removing or installing Reverse Band or scoring 3 Using straightedge Tool C 3335 and feeler gauge check clearance between pump housing face and face of gears as shown in Figure 18 Clearance limits are from 001 to 003 inch f Removal of Output Sh...

Page 444: ...ft as shown in Figure 21 Wrap towel around sun gear to protect hands Re sure to remove direct clutch retainer thrust washer fiber from reaction shaft g Removal and Inspection of Planet Carriers Refer to Fig 22 Fig 23 Removing Kickdown Planet Pinion Carrier Housing Snap Ring r 4 57x42 Fig 24 Removing or Installing Input Shaft and Kickdown Planet Pinion Carrier Assembly 1 Using a feeler gauge check ...

Page 445: ...e kickdown planet pinion carrier assembly is serviced only as a complete assembly 53x56A Fig 28 Removing Kickdown Sun Gear Snap Ring 6 Remove the reverse planet pinion carrier from the carrier housing as shown in Figure 27 Remove the output shaft and reverse annulus gear assembly and fiber thrust washer from the carrier housing Using pliers Tool C 3301 remove the reverse annulus gear snap ring and...

Page 446: ...amaged Inspect the steel clutch plates for evidence of burn ing scoring and damaged splines 4 Using compressor Tool C 3575 or C 3533 compress the direct clutch spring sufficiently to un seat the direct clutch spring retainer snap ring w i t h pliers Tool C 3301 as shown in Figure 30 Release compressor Tool C 3575 or C 3533 and remove the direct clutch spring retainer snap ring spring re tainer and...

Page 447: ...er or a piece of welding rod inserted in end of valve Valves are so constructed that they will not drop into front housing when removing 3 Remove the front oil pump housing to trans mission case bolts and washers 4 Using a soft hammer tap on the circumfer ence of the housing to loosen Pull oil pump housing assembly and gears from the transmission case Fig 31 Using dye mark front side of gears Do n...

Page 448: ...tainer spring and servo piston and plug assembly 4 Remove the servo piston seal lip type neo prene from piston 5 Remove reverse servo piston plug snap ring 6 Remove plug and cushion spring from piston Inspect servo bore for scoring Light scores may be removed w i t h crocus cloth Check plug for scoring and wear at lever contact point Check plug snap ring and groove for burrs wear n Removal of Kick...

Page 449: ... KICKDOWN OFF PRESSURE 7 PRESSURE TO REGULATOR VALVE FRONT PUMP S U C T I O N FRONT PUMP CHECK VALVE GOVERNOR I PRESSURE REAR PUMP CHECK VALVE UPSET PRESSURE TO REGULATOR VALVE DIRECT CLUTCH PRESSURE TO PRESSURE GAUGE FOR SERVICE 57x161 Fig 34 Removal of Torque Converter Reaction Shaft Fig 35 Transmission Oil Passages refer to F i g 35 to make sure they are open Check oil pressure take off plugs f...

Page 450: ...nd install on kickdown piston rod guide Make sure ring rotates freely i n land 5 Install compressor Tool C 3289 or Tool C 3529 on transmission case Using extreme care compress the kickdown piston spring to the point that piston guide seal ring slightly binds on case Using a piece of brass rod flattened on end work seal ring into position gradually compressing spring un t i l seal ring enters case ...

Page 451: ...ng Lugs of drive sleeve should extend not more than from y2 to inch beyond face of oil pump housing 8 Using a new gasket install the torque con verter control valve spring and retainer Tighten 35 to 40 foot pounds torque 7 Using a new gasket install the transmission regulator valve spring and retainer Tighten from 45 to 50 foot pounds torque g Installing the Kickdown Band and Levers 1 Place kickdo...

Page 452: ...inch 082 to 084 inch and 086 to 088 inch Make sure snap ring seats properly 3 Coat output shaft seal ring w i t h transmission fluid and install on shaft Interlock the seal ring into position and make sure ring rotates freely in land 4 Coat the planet pinion carrier housing fiber thrust washer w i t h lubriplate slide washer over out put shaft and against thrust surface on reverse annulus gear 5 P...

Page 453: ... sure pump gears are free to rotate If they are not remove pump to determine cause m Installing the Governor on the Output Shaft 1 Coat the two governor support piston rings w i t h transmission fluid and install on the governor support Stagger ring gaps and make sure they are free to rotate i n lands Position governor on support and install the four screws and lockwashers Do not tighten screws at...

Page 454: ...asket over SCREW 25 LOCK WASHER 2 s TRANSFER PLATE COVER SCREW SERVO RESTRICTOR VALVE LOC C W A S H LP 0 S C P P A 4 L O 1 W A S H E R 4 SCREW 3 AND LOCK WASHER 3 TRANSFER PLATE PUMP CHECK VALVE SPRING THROTTLE PRESSURE C H E C K B A L L S C R E W L O N G 3 SCREW SHORT 1 END COVER PLATE SERVO BLEED VALVE SCREW SHORT 1 it mtSm S H U T T L E V A i V F ASSEMBL END COVER K I C K D O W N ROD BALL AND S...

Page 455: ... and 112 114 inch TRANSFER PLATE ASSCAABLY GUIDE STUDS I STAND _ T O O 56x160 Fig 43 Valve zns 2H SiaIid P U M P CHECK VALVE G U I D E STUD SERVO RESTR1CTOR VALVE OPERATING PLUG 1 VALVE BODY PLATE rie Assembly Pig 44 Removing Transfer Plate Assembly 1 Remove the screws and lockwashers from the transmission extension and install guide studs Tool C 3283 2 Remove the output shaft support to case scre...

Page 456: ...ing lever out of the way and re move the throttle valve spring from throttle valve Remove the throttle valve from the valve bore 8 Check the distance from valve body to end of throttle valve operating adjusting screw Using wrench Tool C 3279B remove the throttle valve ad justing screw lever assembly Normally i t is not necessary to remove this assembly unless damaged parts are to be replaced 9 Hol...

Page 457: ...e sure i t slides freely into valve body Fig 48 Servo Restrictor Valve POWERFLITE TRANSMISSION 103 Fig 49 Holding Manual Valve Lever Detent Ball Inspect staking of control cable adapter to detent plate and cable adapter clip to valve body Inspect the staking of valve lever and throttle valve cam to their respective shafts Inspect the throttle valve operating lever roller to make sure i t rolls fre...

Page 458: ...tent plate when finger pressure on detent ball is released 5 W i t h finger pressure holding manual valve shoulder i n bore insert sleeve short end in bore up to stop r i n g 6 Position throttle valve cam in sleeve as shown in Figure 51 and lock i n place w i t h retainer I f re tainer is not placed i n position at this time the Tf 0 56x163 Fig 52 Indexing Throttle Valve Cam Shaft with Throttle Va...

Page 459: ...uide studs and into position on valve body 25 Place transfer plate cover into position and install two of the transfer plate cover screws and lockwashers one each side finger tight Make sure pump check valves remain i n position in body plate 26 Remove guide studs and install the remain ing transfer plate cover bolts and lockwashers Tight en the bolts 45 to 50 inch pounds torque Avoid over tighten...

Page 460: ...r to torsion bar spring bracket bolts Tighten bolts securely 7 Install the rear engine mount to the trans mission and tighten bolts to 35 foot pounds torque Install rear engine crossmember to frame and tight en bolts to 75 foot pounds torque Remove the trans mission jack Install the rear engine mount to cross member bolts and tighten to 35 foot pounds torque Lower the ear and remove holding fixtur...

Page 461: ... GK Town and Country Number of Wheel Nuts 5 Stud Hole Circle W Stud Size y2 20 TIRES Type Super Cushion Tubeless Size 8 x 14 8 00 x 14 8 50 x 14 Optional 8 50 x 14 Town and Country Ply 4 Standard Tread Twin Grip T I R E PRESSURES COLD Pounds Rear 24 Town and Country Rear 22 24 Front 22 W i t h Town Country fully loaded increase rear tire cold pressure to 28 pounds Captive Air tires are optional eq...

Page 462: ... GK Town and Country Number of Wheel Nuts 5 Stud Hole Circle W Stud Size y2 20 TIRES Type Super Cushion Tubeless Size 8 x 14 8 00 x 14 8 50 x 14 Optional 8 50 x 14 Town and Country Ply 4 Standard Tread Twin Grip T I R E PRESSURES COLD Pounds Rear 24 Town and Country Rear 22 24 Front 22 W i t h Town Country fully loaded increase rear tire cold pressure to 28 pounds Captive Air tires are optional eq...

Page 463: ...R e a r 22 22 24 R e a r 24 Town Country F r o n t 22 22 24 W i t h T o w n Country fully loaded increase r e a r tire cold pressure to 28 pounds C a p t i v e A i r tires a r e optional equipment on T o w n C o u n t r y Wagons 3 seat Models only 8 50 x 14 on Model P C 1 and 9 00 x 14 on Model PC 3 SERVICE DIAGNOSIS 1 SIDE WEAR Figs 1 and 2 a Outside A l l wheels excessive cornering speed b Outsi...

Page 464: ...ive cornering speed 5 HEEL AND TOE WEAR a High speed driving b Severe use of brakes ca Continuous rapid acceleration M IS Fig 4 Toe in Wear Fig 5 Spotty Wear 6 UNIFORM SPOTTY WEAR Fig 5 a Lack of tire rotation b Wheel unbalance 7 IRREGULAR SPOTTY WEAR a Wheel unbalance b Under inflation c Loose or worn parts 57x33 57x31 MyMopar com ...

Page 465: ...he car is lubricated the air pressure of all tires should be checked to the following speci 54 A 364A Fig 6 Safety Type Rim fications They should also be inspected for damage and embedded foreign matter at the same time T I R E PRESSURES C O L D P R E S S U R E M O D E L S F R O N T R E A R DE SOTO A l l 22 22 CHRYSLER Windsor Except Town Country 24 22 Windsor Town Country 24 24 Saratoga 22 22 New...

Page 466: ...ER SURFACE Fig 7 Tire Rotation TOTAL RUNOUT MUST NOT EXCEED 0 4 5 55x115 Fig 8 Run Out Checking Areas A and B This should not exceed 060 inch Position dial indi cator against side of tire to check lateral runout The dial indicator should be attached to a firm base so that i t will be held steady while taking the runout readings I f radial runout exceeds 060 inch mark the relative location of the t...

Page 467: ... Fig 9 i t will pull out of the needle as the tool is pushed to full depth 7 Insert additional plugs as found necessary i n step 4 8 Cut the plug 1 8 inch above the surface of the tire 13 DISMOUNTING AND MOUNTING TIRES a Removing Tire with Car Jack The bumper jack provided i n the car may be used to remove a tire from the r i m 54 x 386A Fig 9 Plug and Needle Inserted in Tire Fig 10 Removing Tire ...

Page 468: ...eel bearing lubri cants containing either sodium or l i t h i u m soaps either of which is satisfactory Since the t w o types do not m i x satisfactorily lubricant should never be added to that already i n the bearings a Removal Hub Assembly Off 1 Using a brass drift i n the slots i n the hub drive out the inner oil seal bearing cone and cup 2 Invert the hub and drive out the outer bearing cup b C...

Page 469: ...ent permits driving 100 miles or more at speeds up to 50 mph w i t h no stopping no inconvenience and no danger from changing wheels on the road a Inflation Procedure 1 Through the r i m valve inflate inner chamber first to 30 pounds pressure VISIBLE M O U N T I N G GUIDE RIM VALVE SIDEWALL VALVE STEEL C O R D SAFETY SHIELD 59x80 y 8 Fig 15 Inserting Inflating Needle in Side Wall Valve 2 Lubricate...

Page 470: ...tall tubeless tire valve i n hole i n r i m 4 Spread contents of a capsule of anti friction fluid lubricant uniformly over inside crown of tire 5 Insert safety shield i n tire and position H mark on shield i n alignment w i t h L mark on tire 1 m mWm 5 9 x 8 3 Fig 137 Positioning Shield Over Tire lead Fig 17 Apply shield bead channels over tire beads and smooth out wrinkles by hand 6 Coat outer be...

Page 471: ...ed and both compartments inflated see Paragraph 15a remove inflating needle and store in case 16 THREE SEAT TOWN AND COUNTRY SPARE TIRE REMOVAL The spare tire for the three seat Town and Country will be carried beneath the t h i r d seat I t is neces sary to remove the t h i r d seat to allow the tire to be removed Slots i n the t h i r d seat pivot brackets line up w i t h the flats on the hinge ...

Page 472: ... 29 14 Paint Finish Care 30 15 Major Body Servicing Aligning Doors 32 24 Front Doors F i t t i n g 35 25 Front Doors Moving F o r w a r d or Back 34 25 Hood Lock Hood and Hinge Removal 38 27 Front Doors Raising or Lowering 33 24 Rear Door Adjustments 37 26 Replacement of Body Panels 31 23 Striker Plate Adjustment 36 25 Windshield and Windows Convertible Windshield Glass 40 33 Removal Installation ...

Page 473: ...al Installation Rear Door Glass Four Door Sedan 44 37 Removal Installation Rear Door Window Glass Hardtop 49 41 Removal Installation Rear Quarter Window Glass 48 41 Removal Installation Rear Quarter Window Glass Hardtop 50 42 Removal Installation Rear Window Glass 41 34 Removal Installation Windshield Glass 39 29 Removal Installation Headlining Headlining Removal A l l Models 52 43 Plastic Mouldin...

Page 474: ...l Installation Hinge Assist Spring Assembly 67 52 Removal Installation Nylon Rollers 63 51 Removal Installation Seat Assembly 57 47 Removal Installation Seat Back Assembly 62 51 Removal Installation Seat Pivot Assembly 61 51 Removal Installation Six Way Manual F r o n t Seat 54 46 Swivel Seat 56 47 Doors Door Hinge A l l Models 77 57 Removal Installation Door Inside Hardware and T r i m 68 52 Remo...

Page 475: ... Reservoir 75 56 Removal Installation BODY SEALING Leakage at Deck L i d 84 62 Luggage Compartment Sealing 83 61 Permagum Sealer 81 58 Seam Sealing Material 80 58 Town and Country Tail Gate Sealing 85 67 Town and Country Tail Gate Glass Run Channel 86 67 Town and Country Tail Gate Weatherstrip 87 67 Town and Country Tall Gate Glass 88 68 Water and Dust Leakage Areas 82 58 Weatherstrip Adhesive 78 ...

Page 476: ... 103 77 Deflector Imperial Models 96 73 Deflector Chrysler Models 69 Removal Installation Fender Alignment 98 75 Fender Splash Shield 99 75 Removal Installation Fender Rear Quarter Panel 100 75 Fender 97 73 Removal Installation Grille Chrysler and De Soto Models 92 69 Removal Installation Grille Imperial Models 95 72 Removal Installation Rear Deck L i d Hinges and Locks 101 76 Convertible Coupe To...

Page 477: ...unit The Imperial Models use a conventional type body in which the body is bolted to the frame Fig 2 To achieve greater terminal rigidity and improve overall strength of the body shell on the Unibody construction two heavy duty crossmembers one under the rear seat area and the other at the extreme rear end of the body are welded to the box side rails extending from under the rear seat over the bod...

Page 478: ...ach immersion covers the entire underbody inter nally and externally extending up to body and door sides On the Imperial models heavier section center pillars box section and roof rails are added to i m prove the overall strength of the upper body struc ture I n the new body diagonal braces are welded to underside of floor pan to minimize flexing Improved floor pan design includes metal to metal w...

Page 479: ...8 B O D Y A N D S H E E T M E T A L R E N FORCED FRONT DOOR HINGE PILLAR Fig 2 Basic Body Construction Imperial Fig 3 Underbody Construction Chrysler DeSoto MyMopar com ...

Page 480: ...ide of the radiator yoke 3 SIX WAY ADJUSTABLE FRONT SEAT WITH MANUAL SEATS A new six way adjustable front seat Is now stand ard equipment on all models equipped w i t h manual seats W i t h one new custom positioned front seat each individual driver may decide the position and angle desired for the front seat The seat can be positioned vertically i n any one of the locations regardless of Its hori...

Page 481: ... mechanism Handle slug gish but shows no interference i n handle mechanism and spring is operating correctly d Remove hardware and t r i m panel Remove handle to lock link I f handle is still sticky remove and replace w i t h new handle e I f handle is all right remove and check for lack of lubricant or interference i n pivot and spring of lock release lever 1 and attached levers and links I f lub...

Page 482: ...y is i n the lock check for lack of lubrication bent levers and loose pivots I f lock is damaged replace w i t h a new assembly 12 KEY WILL NOT LOCK OR UNLOCK FRONT DOOR Possible Causes a Key cylinder to lock link attachment off at lock or handle I f key will neither lock or unlock the lock but inside remote control handle will remove the t r i m panel and check for key cylinder to lock link attac...

Page 483: ... switch in lock or un lock position if there is no vacuum on hose connec tion replace distributor h Plugged or pinched hose 19 FAILURE TO LOCK UNLOCK OPERATION SATISFACTORY Possible Causes a Hose off Red connection on switch b Hose off Red connection on distributor c Faulty distributor lock valve stuck remove door feed hose off Red connection on distributor push switch to lock position if no vacuu...

Page 484: ...n missing or stretched seat opening assist spring replace or shorten spring as described above j Nylon stabilizer on seat cushion frame 16 sticks to steel ramp on rear seat frame rail check for broken spring inside nylon wedge clean and lubricate mating surfaces of wedge and ramp 26 SEAT DOES NOT CLOSE INTO COMPLETELY LATCHED POSITION WHEN DOOR IS SHUT Possible Causes a T r i m or ramp interferenc...

Page 485: ...ining matter can only be guessed at and a dry cleaning fluid does not remove the stain it should then be cleaned w i t h one cup per gallon of laundry type detergent i n water When using a detergent do not use one contain ing a bleach as this could discolor the fabric As most detergents contain a certain amount of bleach caution should be exercised as to the amount used Some of the more common uph...

Page 486: ...the air and settle on the flat surfaces of the paint I f any of this foreign substance containing acid like particles is allowed to remain on the paint for any length of time i t may result i n a spotting condi tion This spotting condition is caused by the reac tion of such particles w i t h the aluminum used in all metallic paints causing the aluminum flakes to disappear leaving the base color Th...

Page 487: ...of vehicle The marks made on the floor will represent the various Fig 5 Aligning Body of Centerline of Front Pillar Saratoga New Yorker Fig 6 Aligning Body at Centerline of Center Pillar Windsor PeSoto points which can be checked diagonally Use a meas uring t r a m for these measurements Take the meas urements between reference points such as crease lines or weld joints which are diagonally opposi...

Page 488: ...BODY AND SHEET METAL 17 Fig 8 Frame to Underbody Alignment Windsor DeSoto MyMopar com ...

Page 489: ... O U L D I N G N A M E P L A T E M O U L D I N G LETTER S A R CAP M O U L D I N G M O U L D I N G H I M O U L D I N G P A N E L M O U L D I N G M O U L D I N G PANEL HANDLE C Y L I N D E R A N D K E Y S 4 E X T E N S I O N EXTENSION j M O U L D I N G j P A N E L A N D P I L L A R COVER W H E E L D E F L E C T O R P A N E L M O U L D I N G 60x1143 Fig 10 Body Nomenclature DeSoto MyMopar com ...

Page 490: ...60x1151 Fig 11 Body Nomenclature New Yorker MyMopar com ...

Page 491: ...Fig 12 Body Nomenclature New Yorker MyMopar com ...

Page 492: ...E N T UNIT F R A M E O R E X T E N S I O N M O U L D I N G OR C O V E R F R A M E O R E X T E N S I O N P A N E L M O U L D I N G G L A S S GUARD GRILLE N A M E P L A T E C O V E R P A N E L A N D P I L L A R D E F L E C T O R B A S E LENS D O O R M O U L D I N C HANDLE M O U L D I N G C O V E R 7 i CYLINDER A N D K E Y S W H E E L G L A S S 60X1 59 Fig 13 Body Nomenclature Imperial MyMopar com ...

Page 493: ... A 4 B A R J M O U L D I N G 1 NAME PLATE MOULDINC J SILL PANEL M O U L D I N G GLASS 1 MOULDING B A S E REPLtCTOk SEAL BEZEL 1 LENS LIFT CYLINDER AND KEYS LETTERS LID 4 A M O U L D I N G MOULDING H A N D L E CYLINDER A N D K E Y S PANEL M O U L D I N G j C O V E R j WHEEL PANEL AND PILLAR DEFLECTOR j H A N D L E M O U L D I N G BAR P A L f M O U I D I N G utNS BEZEL BAR MOULDING 60X1260 Fig 14 Bo...

Page 494: ...e area is extensively damaged I f a complete panel requires replacement refer to Figures 10 11 12 13 and 14 which show some of the hidden weld joints and sealer locations The following procedure is one of several methods that can be used for cutting out and replacing a portion of the quarter panel Rough out and shape as much of the damaged area as possible Measure the piece of metal to be cut out ...

Page 495: ...ne the actual point of engagement between the door lock rotor and the lower portion of the striker plate 6 Each hinge is attached to two floating plates one located at the front pillar and the other at the door panel 7 U p or down adjustment of the door can be made at the front pillar or i n the door itself Forward or Rearward adjustment can be made only at the door I n or out adjustment can be ma...

Page 496: ... or push the lower portion of the door i n the desired direction SEAL SPRING 60x1146 6 Tighten hinge bolts and check the fit 7 When correct reinstall the door t r i m panel 35 FITTING THE FRONT DOOR FLUSH WITH ADJACENT PANELS 1 I f the door is not flush w i t h adjacent panels correct by loosening the four hinge bolts on front door pillar or three hinge bolts on rear door pillar 2 I t should be re...

Page 497: ...nt 8 The door weatherstrip seal can be checked by holding a heavy piece of paper similar to a shipping tag against the lock pillar and then closing the door 9 A slight drag should be felt as the paper is being pulled out Refer to Fig 17 10 I f no drag is felt move the striker plate i n closer 11 This paper test should be made all around the door at about six inch intervals 12 I f no drag is felt o...

Page 498: ... tion before hood latch adjustment is made Shorten or lengthen wire as the case may be to release or lock hood assembly To adjust the striker to lengthen or shorten loosen the locknut and t u r n the striker i n or out w i t h a screwdriver until the correct adjustment has been obtained After making new adjustment that requires a shifting of the hood or fender always check the hood striker for cor...

Page 499: ...OTE Do not remove the prop from under the hood until the attaching nuts have been tightened f Unequal Spacing Between Hear of Hood and Fenders 1 Loosen the four hinge to hood attaching bolts on each side of hood 2 Shift the hood at rear i n the direction of the wide space until spacing appears to be equal on each side 3 Tighten the hinge to hood bolts lower hood and check for correct fit I f the s...

Page 500: ...n tighten locknut NOTE Do not adjust the striker too short as diffi culty will be experienced when closing hood j Hood Side Contour Does Not Follow Fender When the side contour of the hood does not follow the curve of the fender the hood should be reshaped 1 Insert a small block of wood about 1 inch square between fender flange and hood just oppo site the low spot on the hood 2 Close the hood slow...

Page 501: ...nd remove moulding Fig 27 5 W i t h a suitable tool carefully raise the ex treme end of the upper and lower moulding from clips and remove mouldings 6 On Imperials remove the upper and lower center clips 7 Carefully remove the sealing compound from around the weatherstrip and body opening 8 Pry the lip of the weatherstrip apart insert fibre tool twist tool slightly to unlock while moving the tool ...

Page 502: ...This Is enough to support the windshield i n place 3 Check the clearance between glass and fence A properly centered glass has 2 4 to 3 4 Inch clear ance on all sides and to 14 inch distance between 5 21 64 TO 33 64 1 INCH 1 BODY 1 i 8 TO 1 4 INCH 56 x 515 Fig 29 Checking Windshield Clearances the outer edge of the glass and the centerline of the fence as shown i n Figure 29 A n y spot on the body...

Page 503: ...lass w i t h a wedge shaped tool of hardwood or fibre Fig 32 inserted between the weatherstrip and glass at either corner to strip glass into weather strip Slide the tool across the top bottom and around the sides of the weatherstrip to properly seat glass i n place Fig 32 N O T E Always work the tool across the top down each side and over the bottom Fig 31 Sealing Windshield Weatherstrip IB Fig 3...

Page 504: ...ible Coupe f 4 1 6 0 1 2 6 5 Fig 36 Removing or Installing A Post Outer Side Moulding 5 P r y the header moulding up slightly to clear the moulding f r o m the weatherstrip then disengage from the header and remove as shown i n Figure 34 6 Remove the screws attaching inner and outer side A post side mouldings Figs 35 and 36 7 Remove the sun visors 8 Remove the screws attaching the header t r i m c...

Page 505: ... Moulding Imperil 41 1EA1 W I 1 D O W GLASS a Removal 1 Cover the rear deck rear window and quarter panel areas w i t h protective covering 2 Remove the upper lower and center mould ings retaining clips 3 Remove the side upper lower and center weatherstrip mouldings Figs 37 38 39 and 40 4 Use a fibre wedge to unlock weatherstrip 60x1297 Fig 40 Removing or Installing Lower Rear Window Lower Mouldin...

Page 506: ...ect and reposition moulding retaining clips Figs 41 and 42 2 Apply weatherstrip adhesive i n the glass groove 3 Position the glass at the lower outside cor ners as shown i n Figure 43 4 Work the lip of the weatherstrip over the glass along the lower edge 5 After the glass is entered along the top and the lower corners w o r k the lip of the weatherstrip over the lower edge of the glass as shown i ...

Page 507: ...e glass and pull the glass r u n channel free at the top F i g 50 4 Pull the glass r u n channel up until the upper and lower clips are disengaged 5 Remove the glass r u n channel f r o m the door 60x1182 60x1165 v Fig 49 Removing or Installing Trim Panel b Installation 1 To install the glass r u n channel first lower the glass 2 Slide the channel down and engage the upper and lower clips Fig 50 3...

Page 508: ...nnel and the divisional bar so that window does not bind when raised or lowered Fig 51 Removal and Installation of Front Door Glass Typical 60x1299 Fig 52 Removing or Installing Window Ventilator 44 REAR DOOR GLASS FOUR DOOR SEDAN a Removal 1 Remove the garnish moulding and remote control handles 2 Remove t r i m panels and water curtain 3 Roll the glass down and pull the glass r u n channel out a...

Page 509: ...ventilator as sembly F i g 52 WASHER RETAINER b Installation 1 Install ventilator assembly and tighten attach ing screws 2 Adjust anchor screw for proper operation of ventilator and seal 3 Install t r i m panel door hardware and garnish moulding SPRING R I V E T PDT H O U S I N G PLATE _ R y E T S P R I N G S H A F T L O C K D R I V E C U P B U S H I N G X P I N I O N 60x1201 Fig 54 Rear Door Wind...

Page 510: ...le so that a r m is i n the raised position Fig 56 Removing or Installing Front Window Glass Regulator Assembly Manual DeSoto Chrysler Fig 57 Removing or Installing Window Glass Regulator Imperial 3 Engage the regulator arm i n the door glass lower channel Lower the glass and install regulator a r m retainer and clips 4 Install the t r i m panel and inside door hard ware 5 Install garnish moulding...

Page 511: ... the assembly i n order that the end of D O O R L O C K A S S E M B L Y the remote control arm can be connected to the lock lever 4 Install the attaching screws 5 Check the assembly for proper operation and adjust i f necessary 6 Install t r i m and water curtain 7 Install garnish moulding 8 Install arm rest i f so equipped U P P E R G L A S S S T O P A D J U S T I N G B O L T S G U I D E T R A C ...

Page 512: ...lower glass frame 5 Install the regulator a r m attaching clips 6 Install the up stops 7 Check up and down and radial movement of regulator for proper adjustment 8 Replace shower curtain t r i m panel and install hardware 9 Adjust the track i n and out and fore and aft to attain correct adjustment 49 REAR DOOR WINDOW GLASS FOUR DOOR HARD TOP Fig 6 or 62 a Removal 1 Remove the door inside hardware ...

Page 513: ... channel off glass w i t h hardwood block and mallet b Installation 1 When installing quarter window slide seal and lower channel on glass 2 W i n d regulator arm up until the end pro trudes above window opening 3 Connect arm to lower channel 4 Guide glass in rear portion of glass run chan nel and carefully lower glass 5 Install top and forward portion of felt run channel 6 Make certain that upper...

Page 514: ...door post and roof rail 4 Retighten attaching screws and divisional bar nut 5 Check ventilator for proper alignment 6 Raise window and check alignment w i t h roof rail and weatherstrip 7 Adjust rear guide upper adjustment to align window w i t h outer edge of weatherstrip so that only light contact is maintained w i t h lip of weatherstrip 8 Adjust the rear track Fig 63 i n and outer adjustment t...

Page 515: ...r taut F i g 65 5 A f t e r pulling the headlining from the wind shield and rear window opening remove the head lining bows from the roof rail retainers Use care not to damage lining 6 Remove bow retaining springs and remove Fig 67 Marking Center of Each End of Headlining with Shaped Cyts Chrysler DeSoto the headlining from the roof the rear quarter and lower section under the package shelf Instal...

Page 516: ...screws Visor Attaching Screw Holes v Fig 70 Visor Attaching Holes Chrysler DeSoto Fig 71 Trimming Excess Material From Windcord Chrysler DeSoto 9 Install garnish mouldings N O T E I n most cases the listing is longer than nec essary Cut the material at the ends to prevent wrinkling at the seams when i t is tucked or cemented in place F i g 71 Cut the listing from the end up to the clip Use care to...

Page 517: ...ERS REAR WINDOW WEATHERSTRIP Fig 74 Plastic Mouldings Removed From Retainers 4 Remove the damaged section by pulling i t downward to release i t from the retainer 5 To remove the plastic headlining at the side pull towards the center of the car and this will release the plastic headlining from the small spring type clips at the outer edges b Installation 1 Push the plastic headlining onto the smal...

Page 518: ...n the door to Its widest position 2 Remove the plastic royalite covers on the front and rear frame rails 3 Remove the nut 3 Figure 76 securing the swivel seat pivot assembly to seat base 4 Raise the seat cushion and back assembly at the rear out of pivot assembly remove opening assist spring 4 Figure 77 from tab on bottom of seat cushion and pull the seat straight back to remove the C channel from...

Page 519: ...48 BODY AND SHEET METAL MyMopar com ...

Page 520: ...MyMopar com ...

Page 521: ...ALF a Removal 1 Remove the seat cushion and back assembly 2 W i t h the door closed remove the r e t u r n spring 3 Unscrew the ferrule on this cable from the door half cable NOTE L H Thread 4 Remove the retaining rings from the other end of the seat half cable and the pulley 5 L i f t the pulley off of the pivot pin and re move the cable b Installation 1 Place the cable in the pulley install the ...

Page 522: ...l 1 Remove the seat assembly Paragraph 57 and Invert the seat 2 Remove the screws holding the retarder springs In place 3 The screws are located on the bottom of the seat frame and under the seat back hinges 4 Remove the retarder springs 5 Turn seat assembly r i g h t side up remove the two hinge bolts and lift the seat back assembly straight up to remove b Installation 1 Insert the seat back supp...

Page 523: ...ot i n lower door hinge brackets b Installation 1 W i t h door fully open install torsion springs in slot i n lower door hinge bracket 2 From the inboard side of the car insert the notched end of the special Tool C 3800 on the springs slightly below the upper spring retainer bracket 3 Twist the springs clockwise right side coun terclockwise left side to rotate and install them in the upper slot 4 ...

Page 524: ...isconnect link D f r o m handle to lock by pulling away from lock release lever I The link clip will snap off over the ball on which the link pivots On front door only disconnect the link from the key cylinder F to the lock G by removing formed wire clip from the rod and removing rod from lock lever L 4 Back off the two nuts on the studs at the back of the handle Pull handle out of door 5 To remov...

Page 525: ...ch the remote control assembly to the door inner panel 6 Connect the key cylinder link to the lock 7 Connect the outside handle link to the lock 8 When reinstalling the metal glass r u n chan nel with glass lowered be sure i t is retained i n the clip at the bottom bracket and that the top clip hooks into the slot provided 9 After this channel is secure push the felt channel down the edge of the g...

Page 526: ...engine is not running 72 MANUAL LOCKING SWITCH a Removal 1 Unscrew lock nut to loosen switch from switch plate 2 Disconnect three hoses one large and two small from distributor 3 Remove manual switch and hose from back of instrument panel b Installation 1 Install the three hoses leading from the dis tributor to the switch slipping them on the switch connections and making sure the small hose w i t...

Page 527: ...d remove the reservoir b Installation 1 Install the vacuum reservoir on the radiator yoke attaching both ends of the support clamp to the yoke w i t h two metal screws 2 Install the large hose leading to the vacuum distributor valve by slipping i t over the tank connection 3 Install the large hose leading from the engine manifold by slipping i t over the tank connection 76 HOSES a Removal 1 The la...

Page 528: ...ace the shower curtain and reinstall the door t r i m panel 8 Reinstall the window regulator handle i n side door handle a r m rest and garnish moulding Reinstall the cowl kick pad 9 Install the two large hoses to either rear door by first slipping one end of each over the con nections on the vacuum actuator unit i n the door 10 Secure the hoses i n place w i t h two 2 clips on the inside door pan...

Page 529: ...MATERIAL Body caulking gray putty sealer Permagum used for body seam and joints requires areas for sealing to be free of dirt moisture and foreign matter Sealer must be pressed firmly into seam to effect a proper seal 81 GASOLINE RESISTANT PERMAGUM SEALER Used i n areas subject to gasoline spillage such as filler housing door ROOF PANEL WINDSHIELD WEATHERSTRIP Fig 82 Windshield Weatherstrip Sealin...

Page 530: ...p has caused a leak remove the windshield finish moulding and apply sealer as far down as possible between the inner weatherstrip and the glass for a considerable distance on each side of the leakage point Fig 31 Clean off excess sealer w i t h a rag Reinstall the finish mouldings and check for proper seal d Door Hinges at Center Pillar Fig 85 Check the sealer where rear door hinge enters through ...

Page 531: ...from rubber shim stock and place between the upper vent pivot bracket and the outside of the vent glass Application of black mastic or body sealer to the corners of the vent weatherstrip generally corrects the leak i n this area i f the weatherstrip overlaps I f the weatherstrip Is severely damaged Install a new vent window weatherstrip Leaks around the pivots can be corrected by the use of black ...

Page 532: ...e mating window weatherstrip 83 LUGGAGE COMPARTMENT SEALING Leaks may occur f r o m medallions or clip holes tail lamps or the rear quarter panel which w i l l generally appear i n the luggage compartment floor extensions near the quarter panel Before attempting to correct luggage compartment leaks carefully determine the real source of the leak C A U T I O N JjjjEB Do not confuse condensation on ...

Page 533: ...g the weatherstrip Clean surface prior to installation of new deck l i d weather strip and brush an even coat of rubber cement to weatherstrip cementing surface Care should be taken not to stretch the weatherstrip during replace ment especially at the corners Note Reseal the metal weatherstrip retainer joints or burnt spot welds i f required w i t h body caulking sealer a Housing Fuel Filler Fig 8...

Page 534: ...lange and the drip rail Clean the roof drip rail thoroughly before applying the putty caulking sealer Wipe sealer into areas where skips occur Clean off the excess putty Seal may be painted I t is advisable to inspect the seam joint sealing under the drip rail Occasionally this seal is incomplete or broken Use procedure as out lined above for repair When correcting a water leak at the front end of...

Page 535: ...er test or w i t h the use of slips of paper trace blue carpenter s chalk or the use of trace powder and testing bulb Fig 94 When using chalk or tracepowder a good seal will be indicated by an unbroken chalk line A weakness i n the seal w i l l be indicated by passing or blowing through of the powder Rolled kinked or creased weatherstrip as well as breaks and openings or gaps between the ends of t...

Page 536: ...eatherstrip on the door opening by installing closed cell rubber shim stock under the weatherstrip To obtain greater com pression of the weatherstrip against the door open ing install the closed cell rubber shim between the weatherstrip and the flange of the door or the ex truded aluminum frame Be sure to taper off the ends of the shim stock since blunt ends w i l l cause water leaks Loosen the we...

Page 537: ...In stalled Seal off all holes In the door or quarter Inner panel using a waterproof masking tape Pull wind cord from forward edge of quarter panel and run wide tape over access holes and windcord clip holes Cement the plastic watershield In place using rubber cement and reinstall windcord The cement pattern must funnel any water leakage Into the slot at the bottom of the door Be sure to tuck In th...

Page 538: ... as shown i n Figures 96 and 97 1 Deck Lid Lock Cylinder and Bezel Apply body caulking sealer into seam of bezel and 60x1172 mm 1 W 9F3 Fig 96 Sealing Booster Brake Assembly to Dash Panel Fig 97 Sealing Plenum Chamber Housing to Dash Panel deck l i d lock make sure sealer is all around the outer periphery of bezel m Tail Lamps Water test the tail lamp area for possible leakage into the luggage com...

Page 539: ...to remove the weatherstrip and after cleaning shim the weather strip surfaces and reinstall 88 TAIL GATE GLASS Check glass for proper fit Be sure to adjust lift so that when glass Is raised i t fits squarely into top channel and compresses against the glass run I f glass does not seat i n r u n when i n closed position It is possible for dust water and carbon monoxide gas to be pulled i n around t...

Page 540: ...toga EXTENSION BRACKET Fig 101 Rear Bumper Assembly Exploded View Chrysler DeSoto sions and the extensions on the bumper face bar 2 Using extreme care not to damage the paint on the quarter panel position the bumper assembly on the support arms and install the mounting bolts loosely 3 A f t e r obtaining the bumper to the quarter panel alignment tighten the bumper to support the a r m bolts 4 Inst...

Page 541: ...70 BODY AND SHEET METAL Fig 103 Grille Assembly Exploded View Chrysler MyMopar com ...

Page 542: ...move the bumper to the support bar bolts and remove the bumper assembly PLAINWASHER NUT WASHES BOLT A S H E P SUPPORT w H f P W PLAINWASHER LOCKWASHER BOLT Fig 105 Rear Bumper Exploded View Imperial 3 W i t h the bumper removed remove the bump er center section and the parking lamps b Installation 1 Position the parking lamps on the bumper and install the mounting bolts securely 2 Install the bump...

Page 543: ...s b Installation 1 Install the bumper center section and the license lamp and back up lights on the bumper 2 Feed the stud in the upper part of bracket through supports tighten finger tight assemble the nuts to exposed bolts through the lower face bar finger tight 3 Align the bumper w i t h the rear quarter panels and tighten all bolts securely 4 Connect the back up light wires 5 Install the licen...

Page 544: ...ve the bolts attaching the grille brack ets to the stone shield 3 Remove the stone shield to the fender splash shield bolts 4 Remove the grille to support bracket bolts and the screw attaching the shield to the yoke and carefully remove stone shield b Installation 1 Slide the stone shield into position and install the screws attaching the shield to yoke and the support brackets 2 Install the stone...

Page 545: ...leading edge of the front doors and cowl to fender area to avoid damage to the finish 3 Remove the fender to splash shield radiator yoke grille bar and fender to body attaching bolts 4 Remove outside rear view m i r r o r and an tenna lead i f so equipped 5 Remove head lamp horns and wires Re move the fender assembly b Installation 1 Install the splash shield yoke grille body brackets attaching bo...

Page 546: ...en retighten the attaching bolts f Fender too Far Forward at Upper Door Loosen the fender to cowl attaching bolts Apply pressure to the forward section of the fender until correct alignment is obtained Then tighten fender to cowl attaching bolts 89 FENDER SPLASH SHIELD Figs 107 108 and 109 a Removal 1 Disconnect the battery 2 Jack up the front of the car and remove the front wheel and tire assembl...

Page 547: ... should be installed A l l the necessary inside mounting and supporting brackets less wheel houses are welded to the outside panel to make up the service replacement quarter panel assembly N O T E I f difficulty is experienced in separating spot welds where the damaged panel is attached the panel can be cut away from its flange leaving the old flange intact The new panel can then be welded over th...

Page 548: ...60x1177 Fig 114 Deck Lock and Latch Assembly 5 Disengage the hinge from the bracket and remove from the rear compartment b Installation 1 Slide the hinge into position i n t r u n k rear compartment Install the bolts Do not tighten just snug down 2 Install the bolts that hold the hinge to the deck lid Do not tighten just snug down 3 Remove prop and lower the l i d to check fit 4 Make the necessary...

Page 549: ...corners are too low open the deck l i d and loosen the bolts that hold the hinge bracket Insert small fiber block under the low corner between the l i d and side panel Slightly lower the l i d Tighten the bolts and check the fit To lower Raise the deck l i d and loosen the bolts as i n the paragraph above Press down on top of the deck l i d at the high corner until correct fit has been obtained Ti...

Page 550: ...d how ever when removing or installing the mouldings on all models to avoid damage to paint and other finishes C O N V E R T I B L E C O U P E T O P CHRYSLER AND IMPERIAL MODELS ONLY 107 OPERATING THE CONVERTIBLE COUPE TOP a To Lower the Top Release the safety catch on the locking handle located i n the center of the header pull the handle down and to the rear Push header free of wind shield Be su...

Page 551: ...or not enough shims or overtightening of the body bolts may result in distortion of the body sill and cause misalignment of the doors and top fit at the header Therefore before any adjustments are performed to correct the door or the top misalignment be sure that all the body bolts are tightened to 18 foot pounds torque I n some cases i t may be advisable to loosen the body bolts and drive the car...

Page 552: ...u r n the front side rail hinge adjusting screws counter clockwise until the joints are closed I f after mak ing this adjustment the clearance between the door glass and the side rail is increased or decreased adjust the rear adjusting screws to obtain the de sired clearance c Power Link Adjustment Chrysler Only W i t h the top and all door and quarter window glasses in raised position carefully i...

Page 553: ...stem Always check the fluid level when the top is lowered 111 TOP WILL NOT RAISE OR LOWER Hook one wire of a test lamp to a good ground and the other wire of the test lamp feed to terminal on control switch The test lamp should light I f test lamp does not light test on each side of the circuit breaker and replace the faulty wire or the circuit breaker as necessary 112 TESTING THE TOP CONTROL SWIT...

Page 554: ...le is located i n the center of the upper inside garnish moulding to unlatch the tail gate The tail gate is held closed by two rotary type locks mounted on the sides of the tail gate These rotary locks engage two stage strikers attached to the pillar post a Removal Tail Gate 1 Remove the rear bumper face bar to enable the tail gate to be removed down and out of the body opening B B yoT PIN A N C A...

Page 555: ...the tail gate glass removed remove the channel attaching bolts Fig 126 and remove the channel b Installation 1 Position r u n glass channel into the tail gate and install the attaching bolts only finger tight 2 Install the tail gate glass into the r u n chan nel and engage the regulator arms and install the retaining clips c Adjustment 1 Run the tail gate glass to the bottom stop and close the tai...

Page 556: ...e glass weatherstrip and moulding assembly on a padded table w i t h inside of glass up 8 Starting at the lower center of the weather strip insert a pull cord i n the flange groove w i t h the ends of the cord crossed 9 W i t h an assistant holding the glass weather strip and moulding assembly i n approximate posi tion i n the window opening slowly work the weatherstrip over the window fence by pu...

Page 557: ...Installation Crankshaft and Ball Bearing Removal Inspection Installation Crankshaft Bearing Housing and Gas Seal Removal Installation Cylinder Head and Valve Plate Assembly Removal Inspection Installation Drive Belt Adjustment Oil Pump Removal Installation Piston and Connecting Rod Removal Inspection Installation Compressor Capacity Test 15 44 Discharge the System Test Preparations and Connections...

Page 558: ...lator Valve Test 14 43 EPR Valve Test Conditions Expansion Valve 30 58 Removal Installation Expansion Valve Test 16 46 Test Preparations and Connections M a x i m u m Flow Test Thermal Bulb W a r m M i n i m u m Flow Test Thermal Bulb at 32 F Test Results and Corrections Functional Description of the 1960 Refrigeration System 7 17 Gauge Set Manifold 9 25 Handling Tubing and Fittings 18 50 Heater C...

Page 559: ...Performance Safety Precautions 17 49 Servicing the Compressor 22 52 Servicing the Magnetic Clutch 29 57 Testing Electromatic Current Draw Removal Disassembly Assembly Installation Sweep Test Charge 37 63 Testing the System for Leaks 38 63 Test Precautions 39 64 Trunk Unit Performance Test 12 33 Test Preparations Determination of Trunk U n i t Performance DATA AND SPECIFICATIONS C O M P R E S S O R...

Page 560: ... air per minute at high speed Current D r a w Approximately 14 17 amps at 14 Volts SPECIAL TOOLS Tool No Tool Name C 590 STUDS C 744 L I G H T C 804 TOOL SP 2922 T E S T C A P C 3128 P L I E R S C 3355 _ GOGGLES C 3358 W R E N C H SET C 3361A R A T C H E T C 3362 B E N D E R SET Tool No Tool Name C 3429 SCALE C 3478 C U T T E R C 3499 T E S T E R C 3569 TORCH C 3616 R A T C H E T C 3620 SOCKET C 3...

Page 561: ... Group 24 AIR CONDITIONING Three types of original equipment air conditioning installations are available for the 1960 models The first option is a combination air conditioning and heating unit I t is a dash mounted unit operated by push buttons conveniently located on the instrument panel A dual installation consisting of the combina tion front unit and a rear mounted evaporator assembly is also ...

Page 562: ...nd medium speed between these two extremes Operation of the doors and damper which direct air flow through the combination heater and air conditioning unit is by means of vacuum diaphragm units called vacuum actuators The vacuum source is the engine intake manifold Vacuum lines connect JPfl Fig 1 Air Conditioning Controls to each side of the vacuum actuator diaphragm w i t h the push button servin...

Page 563: ...ntrol the per centage of air directed to the instrument panel out let grilles and spot cooler and the percentage of air delivered through the central floor outlet deflector In the extreme down position i t will direct most of the air upward and to the spot cooler the balance to the central floor outlet I n the extreme up position the damper directs most of the air to the floor outlet the balance t...

Page 564: ...duct damper The defroster outlet i n the distribution is at the left adjacent to the spot cooler outlet I t is equipped w i t h a door The defroster outlet door is mechanically linked to a bell crank at the left end of the central deflector The defroster door should be fully open for defrosting and heating I t should be closed for all other push button positions I t is operated by the vacuum actua...

Page 565: ... Grilles are normally directed back toward the passengers for cooling They are angled forward and toward the sides of the windshield for effective defrosting The spot cooler grilles can be adjusted manually to change the direction of air delivered or close completely When the spot cooler grilles are closed all air deflected to the upper part of the distribution duct will be delivered to the instru...

Page 566: ...10 AIR CONDITIONING Fig 7 Air Flow Maximum Cooling DeSoto FRESH AIR DOOR OPEN EVAPORATOR Fig 8 Air Flow Fresh Air Cooling Chrysler and Imperial MyMopar com ...

Page 567: ...at is bypassing the heater core Fresh air is then drawn in conditioned and discharged through the outlets in the same proportion as for maximum cooling The temperature of the discharged air can be regulated by moving the temperature control lever This regu lates the temperature control valve which controls water circulation through the heater core On De Soto models figure 9 air flow is similar Sin...

Page 568: ...12 AIR CONDITIONING FRESH AIR DOOR OPEN EVAPORATOR Fig 10 Air Flow Defrosting Chrysler and Imperial Fig 11 Air Flow Defrosting DeSoto MyMopar com ...

Page 569: ...AIR CONDITIONING 13 FRESH AIR DOOR OPEN EVAPORATOR Fig 12 Air Flow Heating Chrysler and Imperial FRESH AIR DOOR OPEN EVAPORATOR Fig 13 Air Flow Heating DeSoto MyMopar com ...

Page 570: ... spot cooler grille must be closed by the driver to eliminate a hot air blast and to make maximum use of available heated air for defrosting On De Soto models figure 13 the defroster outlet door is fully open to provide air to the left hand defroster outlet Close the spot cooler grille to make maximum use of available heated air for defrosting e Ventilation P u s h i n g e i t h e r t h e D E F R ...

Page 571: ...nly when the ignition is on and any push button other than off is depressed The High Speed Blower Circuit from the speed con trol switch to the blower motor is energized when the temperature control lever is pulled all the way out the ignition is on and any push button other than off is depressed The Medium Speed Blower Circuit from the speed control switch to the blower motor is energized when th...

Page 572: ...O FUSE BLOCK 60x1188 BLOWER MOTOR Fig 17 Roof Unit Wiring Diagram Chrysler and Imperial s w i t c h c i r c u i t f o r a l l models except T o w n and Country Figure 17 Roof Unit Wiring Diagram provides the necessary information for tracing the blower circuit on Chrysler models Town and Country 6 OPERATING INSTRUCTIONS FOR OWNERS The purchaser of an air conditioning equipped car should be instruc...

Page 573: ...time after the winter s operation w i t h the cooling system protected w i t h permanent type antifreeze for the temperatures of the area it is suggested the system be drained and flushed out w i t h water When draining flushing and refill ing have the temperature control lever i n the ex treme hot position so the heater core is drained flushed and refilled Install a gallon of permanent type antif...

Page 574: ... dried and temporarily stored i n the Receiver Driver Strainer until i t is needed by the Evaporator On some installations the relatively hot liquid refrigerant leaving the receiver drier strainer passes through a special Sub Cooler on its way to ine evaporator The sub cooler gets r i d of some of the heat remaining in the liquid refrigerant The liquid refrigerant is metered into the Evapor ator b...

Page 575: ...tor Pressure Regulator incorporated into its design to insure proper oper ation under the most difficult operating conditions Service parts are available so that the compressor can be repaired i n the field Detailed instructions for servicing the compressor are contained i n Para graph 22 A complete procedure for testing com pressor capacity output will be found i n Para graph 15 One of the first ...

Page 576: ... the diaphragm A vapor pressure of 22 to 31 psi exerted on the diaphragm will overcome the pressure exerted by the spring above the diaphragm Thus the pres sure of the vapor leaving the evaporator lifts the valve off its seat The open valve allows vapor to enter the compressor inlet The compressor performs its normal pressurizing function The Compressor Inlet Service Port located on the compressor...

Page 577: ... electromagnet is through collector rings and brushes Complete instructions for servicing the clutch are contained in Paragraph 29 The Condenser The condenser is constructed of tubing and fins The tubing is made of soft annealed copper I t is hydrau lically expanded into the aluminum fins This insures good thermal contact between the fins and tubing Both copper and aluminum are excellent conductor...

Page 578: ...s to increase heat dissipation When a sub cooler is used i t is connected i n series between the Receiver Drier Strainer outlet and the refrigerant liquid line to expansion valve at the evaporator The function of the sub cooler is to cool the liquid refrig erant flowing to the evaporator The tubing used i n the sub cooler is steel The tubing is solder bonded to the aluminum fins to i n sure good t...

Page 579: ...rce controlling the operation of the expansion valve The super heat spring keeps the valve cup closed preventing liquid from passing through the expansion valve to the evaporator When the engine and air conditioning are started the compressor starts pumping refrigerant gas from the w a r m evaporator out through the suction mani fold w i t h the expansion valve closed This lowers the pressure i n ...

Page 580: ...ousing The purpose of this housing is to direct air flow through the core for maximum transfer of heat and humidity to the core The evap orator core assembly i n its cast housing is i n turn attached to the Engine Side evaporator housing forming a completely sealed evaporator assembly Refer to F i g 27 The evaporator core is also constructed of annealed copper tubing hydraulically expanded into al...

Page 581: ... and 0 to 150 psi This gauge and the evaporator suction gauge must be accurately0 calibrated so that the needles of both gauges are exactly at 0 before making tests The compressor inlet gauge is connected to the com pressor inlet service port by a special service port adapter Center Manifold Outlet provides the necessary con nection for a long service hose used when discharg ing the system using a...

Page 582: ...e next test and adjustment TEMPERATURE PRESSURE R E L A T I O N S H I P C H A R T FOR R E F R I G E R A N T 12 Temp Pressure Temp Pressure Temp Pressure Temp Pressure Temp Pressure F PSI P PSI F PSI F PSI F P S I 0 9 1 2 10 1 4 11 2 6 12 3 8 13 4 10 14 6 12 15 8 14 17 1 16 18 3 18 19 7 20 21 0 21 21 7 22 22 4 23 23 1 24 23 8 25 24 6 26 25 3 27 26 1 28 26 8 29 27 6 30 28 4 31 29 2 32 30 0 33 30 9 3...

Page 583: ...r windows 3 Move the temperature control lever to the O F F position 4 Start the engine and adjust engine speed to 1250 RPM Use a reliable tachometer 5 Push the F R E S H COOL button i n 6 Test blower operation at all three speed posi tions I f blower does not operate correctly refer to E L E C T R I C A L CONTROLS A N D CIRCUITS Paragraph 5 Leave the blower H i g h position 7 The compressor clutc...

Page 584: ...ded as i t too will decrease the free flow of air Check condenser and sub cooler for bent or dam aged fins Bent fins on the condenser and or sub cooler de flect air flow across the bent portions decreasing the condenser area B y careful use of the condenser comb Tool C 3663 Fig 33 the fins can be straight ened to their original shape and efficiency Be sure the fan shroud is properly positioned f R...

Page 585: ...illustrations in A I R F L O W FOR E A C H B U T T O N Paragraph 4 I f all controls operate i n the proper sequence but action of dampers and doors is slow or incomplete inspect for mechanical misalignment binding or i m proper linkage adjustment as outlined below Heater Bypass Boor Adjustment Press the D E FROST or H E A T button The bypass door should be fully closed and the vacuum actuator shou...

Page 586: ...tion determines whether or not the vacuum and electrical circuits are properly connected and the controls are functioning properly However i t is possible that a vacuum control system that operates perfectly at the high vacuum provided at engine idle speed may not function properly at high engine speeds Before starting this test stop the engine Make certain that the vacuum source hose at the engin...

Page 587: ...operly position the connector plug all the way on the switch prods put a drop or two of clean water i n the holes of the connector plug This will allow the plug to slide completely on switch prods Retest I f vacuum drop is now w i t h i n limits pro ceed w i t h over all performance test I f vacuum drop is still i n excess of inch remove connector plug from switch Insert the vacuum test prod alter...

Page 588: ...dds mate rially to the comfort of the passengers However an owner may expect too much from his air conditioning 60 295 r Fig 42 Gauge Set Manifold Installed H V NBBQflHB Fig 43 Psychrometer and Thermometer system on humid days A performance test is the best way to determine whether or not the system is performing up to standard This test also provides valuable clues to the possible cause of troubl...

Page 589: ...ature for the prevailing D r y and Wet bulb temperatures recorded I f the car s discharge air temperature is at or below the temperature given on the Performance Chart the air conditioning is delivering its rated cooling capacity However to assure trouble free operation continue w i t h the Evaporator Pressure Regulator Test Paragraph 13 I f the EPR valve has been tampered with i t may have been a...

Page 590: ...0 0 W O CO M O CO WO CO MO Os MO Os MO Os wo o sO o sO o sO o sQ sO CN sO CN sQ CO sO CO sO CO sO sO sO sO sQ W O sO wo sO sO sQ sO sO o h s sO W O o W 0 sO W O WO sO wo sQ M O sQ W O sO WO sQ W O K M O K hs WO K MO CO WO 0 0 MO CO W O 0 0 MO Os wo Os MO Os wo o sO o sO sO CN sO CN CN sO CO sO CO sO CO sO t sO sO sQ wo sO M O SO sO sO sO sO O o W 0 W O WO WO wo W O W O WO W O W O MO W O wo W O wo ...

Page 591: ...9 59 60 60 61 61 62 63 64 64 65 66 67 68 69 69 70 71 72 73 73 74 75 76 92 58 58 58 58 59 59 59 59 59 59 59 59 60 60 61 61 62 62 63 64 65 65 66 67 68 69 69 70 71 72 73 73 74 75 76 93 59 59 59 59 59 59 59 59 59 60 60 60 61 61 62 62 63 64 64 65 66 66 67 68 69 69 70 71 72 73 73 74 75 76 94 60 60 60 60 60 60 60 60 60 60 60 60 61 61 62 63 63 64 64 65 66 66 67 68 69 69 70 71 72 73 73 74 75 76 95 60 60 60...

Page 592: ...5 56 56 56 57 57 58 58 59 60 61 61 62 63 64 65 66 66 67 68 69 70 70 71 72 73 92 55 55 55 55 56 56 56 56 56 56 56 56 57 57 58 58 59 59 60 61 62 62 63 64 65 66 66 67 68 69 70 70 71 72 73 93 56 56 56 56 56 56 56 56 56 57 57 57 58 58 59 59 60 61 61 62 63 63 64 65 66 66 67 68 69 70 70 71 72 73 94 57 57 57 57 57 57 57 57 57 57 57 57 58 58 59 60 60 61 61 62 63 63 64 65 66 66 67 68 69 70 70 71 72 73 95 57...

Page 593: ... 60 61 62 63 63 64 65 66 67 68 68 69 70 71 72 72 73 74 75 92 57 57 57 57 58 58 58 58 58 58 58 58 59 59 60 60 61 61 62 63 64 64 65 66 67 68 68 69 70 71 72 72 73 74 75 93 58 58 58 58 58 58 58 58 58 59 59 59 60 60 61 61 62 63 63 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 94 59 59 59 59 59 59 59 59 59 59 59 59 60 60 61 62 62 63 63 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 95 59 59 59 59 59 59 59 ...

Page 594: ...58 59 59 60 61 62 63 64 64 65 66 67 68 68 69 70 71 92 53 53 53 53 54 54 54 54 54 54 54 54 55 55 56 56 57 57 58 59 59 60 61 62 63 64 64 65 66 67 68 68 69 70 71 93 54 54 54 54 54 54 54 54 54 55 55 55 56 56 57 57 58 59 59 60 61 61 62 63 64 64 65 66 67 68 68 69 70 71 94 55 55 55 55 55 55 55 55 55 55 55 55 56 56 57 58 58 59 59 60 61 61 62 63 64 64 65 66 67 68 68 69 70 71 95 55 55 55 55 55 55 55 55 55 5...

Page 595: ... 57 58 58 59 60 61 62 63 63 64 65 66 67 67 68 69 70 92 52 52 52 52 53 53 53 53 53 53 53 53 54 54 55 55 56 56 57 58 59 59 60 61 62 63 63 64 65 66 67 67 68 69 70 93 53 53 53 53 53 53 53 53 53 54 54 54 55 55 56 56 57 58 58 59 60 60 61 62 63 63 64 65 66 67 67 68 69 70 94 54 54 54 54 54 54 54 54 54 54 54 54 55 55 56 57 57 58 58 59 60 60 61 62 63 63 64 65 66 67 67 68 69 70 95 54 54 54 54 54 54 54 54 54 ...

Page 596: ...5 66 67 67 68 69 70 71 72 72 73 74 75 76 76 77 78 79 92 61 61 61 61 62 62 62 62 62 62 62 62 63 63 64 64 65 65 66 67 68 68 69 70 71 72 72 73 74 75 76 76 77 78 79 93 62 62 62 62 62 62 62 62 62 63 63 63 64 64 65 65 66 67 67 68 69 69 70 71 72 72 73 74 75 76 76 77 78 79 94 63 63 63 63 63 63 63 63 63 63 63 63 64 64 65 66 66 67 67 68 69 69 70 71 72 72 73 74 75 76 76 77 78 79 95 63 63 63 63 63 63 63 63 63...

Page 597: ... 61 62 62 63 63 64 65 66 66 67 68 69 70 71 71 72 73 74 75 75 76 77 78 92 60 60 60 60 6 61 61 61 61 61 61 61 62 62 63 63 64 64 65 66 66 67 68 69 70 71 71 72 73 74 75 75 76 77 78 93 61 61 61 61 61 61 61 61 61 62 62 62 63 63 64 64 65 66 66 67 68 68 69 70 71 71 72 73 74 75 75 76 77 78 94 62 62 62 62 62 62 62 62 62 62 62 62 63 63 64 65 65 66 66 67 68 68 69 70 71 71 72 73 74 75 75 76 77 78 95 62 62 62 6...

Page 598: ...e Per formance Chart test the t r u n k unit expansion valve 13 ROOF UNIT PERFORMANCE TEST The method used to test the roof unit of a dual i n stallation is essentially the same as for a front unit The front unit should be tested before testing the roof unit When testing the roof unit of a dual sys tem t u r n the front unit off by pushing the O F F button Connect a jumper from the positive termin...

Page 599: ...Performance Test The gauge set manifold will be connected as illustrated i n Figure 28 Adjust engine speed to 1250 rpm Close the hood for this test Close the car windows and t u r n the blower on H I G H Push the F R E S H COOL but ton The heat load on the evaporator will soon call for continuous operation of the refrigeration system The EPR valve will open and the pressure at both the suction por...

Page 600: ...tem failed to pass the Over All Per formance Test but passed the EJPR Valve Test proceed w i t h the Compressor Capacity Test 15 THE COMPRESSOR CAPACITY TEST The Over All Performance Test and the Evaporator Pressure Regulator Valve Test should be performed before testing compressor capacity These tests are made w i t h the system fully charged w i t h refrigerant I t is necessary to discharge the ...

Page 601: ...ge slowly C A U T I O N Bo not open the valve fully and allow the system to discharge rapidly since this would sweep some of the refrigerant oil out w i t h the refrigerant 4 Allow system to discharge until discharge pres sure gauge registers zero 5 Open the suction left hand gauge valve to release any vapor trapped at the suction side b Test Preparation and Connections After the system is complet...

Page 602: ...st Pressures and Results 1 Start the engine and adjust speed to exactly 500 rpm 2 Slowly close the left hand gauge valve Refer to Figure 49 A l l air delivered by the compressor w i l l now be discharged through the metering orifice i n the test cap Pressure registered at the discharge gauge should build up to at least 190 psi 3 The load on the compressor may affect engine speed I f necessary read...

Page 603: ...etween the discharge and suction side of the compressor will upset the expansion valve test results a e Test Preparations and Connections 1 Close both the left and right gauge set mani fold valves Open the manifold needle valve 2 Install a 14 connector and a 4 tee fitting at the left side of the gauge manifold _ Install the test cap Tool SP 2922 on the tee fitting and connect the test hose to the ...

Page 604: ...a r m the thermal bulb by holding i t i n your hand This will produce the same effect as a w a r m evaporator i t will open the expansion valve for maximum flow 2 Open the refrigerant manifold valve fully counterclockwise to allow refrigerant vapor to flow to the gauge set manifold 3 Adjust the right hand gauge set manifold valve to maintain exactly 70 psi on the discharge gauge 4 The suction gaug...

Page 605: ...ps of min eral oil to wash them out Refrigerant 12 is rapidly absorbed by the oil Next wash the eyes w i t h the weak solution of boric acid Call your doctor imme diately even though irritation has ceased after first aid treatment C A U T I O N Do not heat Refrigerant 12 above 125 degrees F In most instances moderate heat is required to bring the pressure of the refrigerant i n its container above...

Page 606: ...nt distorting of lines and components When connecting the flexible hose lines the swaged fitting the flare nut and the flare coupling should be held to prevent rotation of the swaged fitting and possible damage to the seat The internal parts of the refrigeration system will remain i n a state of chemical stability as long as pure moisture free Refrigerant 12 and refrigerant oil is used Abnormal am...

Page 607: ... S E M B L Y 8 C O M P R E S S O R D I S C H A R G E SERVICE A D A P T E R G A S K E T 9 E P R V A L V E G A S K E T 10 C O M P R E S S O R V A L V E PLATE T O C R A N K C A S E G A S K E T 11 C O M P R E S S O R C Y L I N D E R H E A D G A S K E T 12 C O M P R E S S O R C Y L I N D E R H E A D LEFT 13 C O M P R E S S O R C Y L I N D E R H E A D R I G H T 14 E P R V A L V E C A P 15 C O M P R E S ...

Page 608: ...ned specifically for the Chrysler Air Condition ing System Service parts are available so that the compressor can be repaired in the field Fig 53 is a disassembled view of the compressor w i t h a key to the parts serviced individually and in service packages Nomenclature key numbers 1 through 17 designate parts which are serviced indi vidually Numbers 18 through 24 designate service packages whic...

Page 609: ... A U T I O N When replacing the compressor assembly the crank shaft should be rotated by hand at least two complete revolutions to clear oil accumulation from com pressor head before the clutch is energized to avoid damaging the compressor reed valves 1 Install compressor to bracket and tighten attaching bolts 2 Install compressor pulley belts 3 Connect magnetic clutch to control unit wire 4 Remov...

Page 610: ... S S E M B L Y moi STUDS C 5 9 0 UNDER H E A D J P v HEAD RH i GASKET FG 56 Installing Valve Plate and Cylinder Head PILOT STUDS C 590 SUMP RELIEF SPRING l b 60x889 Fig 57 Installing Sump 3 Separate the sump from the case by tapping w i t h a plastic hammer being careful not to distort the oil pressure relief spring 4 Remove the oil relief spring and rubber ball from the crankcase 5 Remove cylinde...

Page 611: ...lacement package con sists of the crankshaft gas seal assembly and the crankshaft bearing housing seal face plate Two types of crankshaft seals are supplied for service as shown in F i g 59 I f the replacement package contains the cartridge type seal follow the entire installation pro cedure given below I f the replacement package con tains the unitized type seal steps 1 2 and 4 will not apply 1 B...

Page 612: ...an i t carefully w i t h mineral spirits and shake dry Saturate bearing w i t h clean refrigerant oil and assemble immediately I f a new bearing is to be installed leave i t wrapped in its protective package until ready for installation DO N O T W A S H A N E W B E A R I N G A S S E M B L Y B E F O R E I N S T A L L A T I O N c Installation 1 Press crankshaft ball bearing on crankshaft using a sle...

Page 613: ...pping against the cap screw w i t h a hammer 3 Remove both bearing snap rings f r o m field assembly 4 Place the field assembly w i t h the coil side on an arbor press Place Tool C 3807 against the bear i n g and press bearing out of field assembly N O T E I t is strongly recommended that a new bear ing be installed every time the magnetic clutch is disassembled H U B AND S H O E A S S E M B L Y C...

Page 614: ...mal contact between the bulb and its well THERMAL BULB Clean parts and a t i g h t fit of the bulb i n the well will insure good thermal contact 1 Install the thermal bulb i n its well using brass wedging strips to insure a tight mechanical fit 2 Lubricate all expansion valve and line fittings w i t h clean refrigerant oil Install the expansion valve using two flare wrenches to prevent rotation an...

Page 615: ...itized evaporator assembly The unitized evaporator assembly must be removed and installed as a complete assembly Refer to F i g 65 a Removal 1 Remove the heater core and cover assembly from the evaporator engine side housing Remove the temperature control valve capillary from its well in the engine side housing 2 Discharge the refrigerant from the system and disconnect the expansion valve and the ...

Page 616: ... of the evaporator assembly 33 BLOWER AND DISTRIBUTION DUCT a Removal 1 Disconnect the battery ground cable 2 Disconnect the heater ground wire at wind shield wiper motor mounting bracket and disconnect blower and clutch circuit wires from the harness connectors 3 Disconnect the vacuum hoses and actuator rods from each vacuum unit Remove hoses from their attaching clips 4 Disconnect the distributi...

Page 617: ... 1960 air conditioning system Refrigerant 12 is available i n bulb tanks or in sealed 15 ounce cans The use of canned refriger ant is preferred by most technicians because i t pro vides a very quick and simple means of adding re frigerant or charging the system completely A l l 1960 models equipped w i t h front end units only require 2 to 2 pounds of refrigerant Three 15 ounce cans of Refrigerant...

Page 618: ...rate scale C 3429 so that the amount of refrigerant added can be weighed Open the refrigerant manifold valve 8 Purge all air from test hoses A i r i n the sys tem will be trapped in the condenser causing ab normally high discharge pressures and interfering w i t h condensation of the refrigerant a Loosen the test hose adapters at both the suc tion service port and the discharge service port b Loos...

Page 619: ...ee end of the long hose used for d i s c h a r g i n g to the r e f r i g e r a n t dispensing manifold 3 Attach a single can of Refrigerant 12 to the dispensing manifold Place refrigerant in 125 degree water For detailed instructions on attaching refrig erant can for charging see Charging the System Paragraph 42 4 Operate the engine at 1250 rpm car windows open F R E S H COOL button pushed in and...

Page 620: ... burner shield not through the top of the shield I f the flame remains bright yellow when the tester is removed from a possible leak point insufficient air is being drawn i n through the sampling tube or the reaction plate is dirty Remove Sweep Test Charge I f the system is free of leaks or after correcting a leak remove the sweep test charge Close the refrig erant manifold valve so that any refri...

Page 621: ...O N Replacement receiver drier strainer unit must be sealed while i n storage The drier used i n these units is so hungry for moisture that they can satu rate quickly upon exposure to the atmosphere When installing a drier have a l l tools and supplies ready for quick reassembly t o avoid keepng the system open any longer than necessary 41 EVACUATE THE SYSTEM Whenever the system has been opened to...

Page 622: ...refrigerant at one time On dual installations a single can must be added after the three cans have been charged into the system N O T E Keep the r e f r i g e r a n t m a n i f o l d valves capped when not in use Keep a supply of extra refrigerant can to refrigerant manifold gaskets on hand so that gaskets can be replaced periodically This will insure a good seal without excessive tight ening of t...

Page 623: ......

Page 624: ...a copies of this Supplement are available at 2 00 each plus any local taxes under Part Number 81 071 0057 Order from Chrysler and Imperial Division P O Box 1658 Detroit 31 Michigan C H R Y S L E R A N D I M P E R I A L D I V I S I O N Chrysler Corporation DETROIT 31 MICHIGAN Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its product wit...

Page 625: ...2 GENERAL DATA AND SPECIFICATIONS Fig 1 1961 Imperial and Chrysler Models MyMopar com ...

Page 626: ...100001 Fig 2 Vehicle Nymber The vehicle number is stamped on a metal plate at tached to the left front door body hinge pillar as shown in Figure 2 The engine numbers will provide the following in formation R represents the 1961 M o d e l 36 represents the 361 cu in displacement 38 represents 383 cu in displacement 4 1 represents 413 cu in displacement The next digit is the month built and the last...

Page 627: ...n Convertible Coupe Two Door hard top Town and Country Four Door hard top 59 7 59 7 59 7 59 7 59 7 59 7 59 7 59 7 60 0 60 0 60 0 60 0 60 0 62 2 62 2 62 2 Length with Bumper Four Door Sedan Convertible Coupe Two Door hard top Town and Country Four Door hard top 215 6 215 6 215 6 216 1 215 6 215 6 215 6 215 6 219 6 219 6 219 6 220 1 219 6 227 3 227 3 227 3 Width with Bumper Four Door Sedan Convertib...

Page 628: ...oint Lubricant WB Wheel Bearing Lubricant Medium IMPERIAL Distributor Oil Cup 2 000 Miles Wick under Rotor 10 000 Miles Distributor Cam 1 0 000 Miles Clean Carburetor Air Cleaner 6 000 Miles Install New Carburetor Air Cleaner Element 1 5 000 Miles Manifold Heat Control Valve 2 000 Miles Part No 1879318 MoPar Manifold Heat Control Valve Solvent Automatic Transmission Check Fluid Level 2 000 Miles E...

Page 629: ...ainless Stick Lubricant Wheel Bearing Lubricant Medium Universal Joint Lubricant AA AF AP C CL DCL EO HTF MCL ML MP PDO PSF RR S SGL SL WB UJ2 Distributor Oil Cup 2 000 Miles Wick under Rotor 10 000 Miles Distributor Cam 10 000 Miles Clean Carburetor Air Cleaner 6 000 Miles Install New Carburetor Air Cleaner Element 1 5 000 Miles Manifold Heat Control Valve 2 000 Miles Automatic Transmission Check...

Page 630: ...alifornia where the system is standard equipment There is a better method of cleaning the carbu retor air cleaner assembly Lubriplate can be easily applied on door lock cylinders and door lock intrusion guards There is also a change i n tire rotation All other components are basically the same as outlined in the 1960 Chrysler and Imperial Service Manual KEY T O L U B R I C A T I O N A N D M A I N ...

Page 631: ...al Steering Gear Check Level M L License Plate Mounting Panel Springs and EO Parking Brake Linkage Manual Trans Pin M P or Rear Axle Check Level DPO Tail Gate Hinges GL 4 M L Tail Gate Locks SGL Rear Axle Sure Grip Check Level SSL Tail Gate Striker Plates Dove Tail Surfaces A A Automatic Transmission Check Level EO Engine Oil Change M P or Manual Transmission Check Level SC 10 Point Safety Check G...

Page 632: ...ld be replaced every 15 000 miles or every t h i r d removal 1 Remove the air cleaner from the carburetor as an assembly 2 Remove the cleaning element from the housing 3 Gently blow the dirt from the element by holding the compressed air nozzle at least two inches from the inside screen and blowing outward 4 Blow the dirt out of the housing 5 Check the element for punctures using a bright light Di...

Page 633: ...k of the lubricant level cannot be made LEFT F R O N T RIGHT F R O N T Fig 3 Tire Rotation The approved lubricants are Multi Purpose lubri cants designated for A P I Service GL 4 as defined by MIL L 2105B SAE 90 for temperatures above 10 F SAE 80 for temperatures below 1 0 F SAE 75 for temperatures below 30 F Drain and refill at 20 000 mile or two year intervals TIRE ROTATION Tires should be rotat...

Page 634: ...k of the lubricant level cannot be made LEFT F R O N T RIGHT F R O N T Fig 3 Tire Rotation The approved lubricants are Multi Purpose lubri cants designated for A P I Service GL 4 as defined by MIL L 2105B SAE 90 for temperatures above 10 F SAE 80 for temperatures below 1 0 F SAE 75 for temperatures below 30 F Drain and refill at 20 000 mile or two year intervals TIRE ROTATION Tires should be rotat...

Page 635: ...ting a small screw driver Into the opening of the grille and rotating the nozzle In the direction the spray Is desired OPERATION Depressing a small button In the center of the wind shield wiper knob actuates the motor and pump and a continuous stream of fluid Is ejected as long as the button Is depressed and fluid remains i n the reser voir The windshield washer operates Independently of the winds...

Page 636: ...ill accelerate the car to the selected speed to the point where the reaction pressure is felt i n Fig 2 Auto Pilot Controls Imperial Fig 3 Auto Pilot Controls Chrysler the accelerator pedal then by pulling out the button located i n the center of the speed control selector knob will place the Auto Pilot into full automatic regulation of the accelerator when on level road The Auto Pilot will howeve...

Page 637: ...T SWITCH AUTO PILOT UNIT SIDE VIEW SPEEDOMETER CABLE BRAKE MECHANICAL CUT OUT SWITCH ACCELERATOR PEDAL AUTO PILOT UNIT FRONT END VIEW ACCELERATOR PEDAL EXTENSION 60x1119 Fig 4 Auto Pilot Operation Schematic View MyMopar com ...

Page 638: ... ARM 1 GOVERNO s S P R I N G ASSEAA3L GOVERNOR ASSEMBLY GUIDE CLAMP NUT BALL SOCKET 61x278 CONTACT s li f KING figgjl AM M PLATE w 3 ijj M HI Mm WORM NUT Fig 5 Governor Assembly Operation Cut A View 61x279 Fig 6 Driving Magnet Assembly with Worm and Worm Nut set of points make contact The electric motor rotates the worm moving the assembly to raise the acceler ator pedal and close the carburetor T...

Page 639: ...adjust ment 3 locking arm latch adjustment 4 point ad justment 5 brake switch check and adjustment LINKAGE ADJUSTMENT C A U T I O N Carburetor must be on slow idle for this adjustment 1 Remove the nut from the link ball joint and pull the link ball joint from the armature lever Fig 7 2 Insert the sleeve gauge Tool C 3844 over the gauge bolt and hold the armature lever securely against the sleeve g...

Page 640: ...to Pilot drive mechanism cover 3 Turn the ignition O N Do not start the engine 4 Move the locking arm against the magnet and push the latching cap down to lock the magnet as sembly and locking a r m together 5 Use a feeler gauge to measure the clearance between the locking arm and latching cap Fig 10 The clearance should be 001 to 006 I f less than 001 clearance loosen the lock nut T u r n the adj...

Page 641: ... the sleeve gauge and checking gauge N O T E If the checking gauge tends to jump out of the weights roughen the two angled surfaces of the gauge with emery cloth 9 Turn the ignition switch ON do not start engine 10 Push the locking arm up against the magnet and push down on the latching cap to latch the magnet and locking arm together Fig 13 Point G a p Setting 11 With the contact arm point agains...

Page 642: ...ns 7 Hold the motor i n one hand and repeat steps 4 and 5 8 I f the motor operates i n both directions and the drive mechanism does not operate the drive screw is damaged and must be replaced 9 I f the motor does not operate i n both direc tions replace the motor BRAKE SWITCH TEST 1 Turn the ignition O N but do not start the engine Fig 16 Elecfrical Test Terminal 2 2 Ground one lead of a test lamp...

Page 643: ...tton knob Remove both knobs from the shaft 3 Disconnect the ground wire and also the double plug connected to the w i r i n g harness 4 Unscrew attaching nut Remove selector head from instrument panel 5 Pull cable through dash panel from passenger side 1 Selector Control A s s e m b l y I m p e r i a l Repeat steps 1 2 3 under Chrysler 2 Unscrew attaching nut 3 Remove the steering column lower dus...

Page 644: ...lamping nut at the lower end of the dust shield 4 Hold the guide clamp nut at the top of the dust shield and unscrew the dust shield Slide the cable clamping nut and dust shield down the control cable Slip the ball end of the control cable out of the socket 5 Disconnect the accelerator link ball joint from the armature lever 6 Remove the brace nut Remove the t w o mount ing bracket bolts and remov...

Page 645: ...2 13 L i f t the pintle assembly out of the housing C A U T I O N B e careful not to lose the gasket from the groove in the housing N O T E T h e finger assembly will come out w i t h the pintle assembly 14 Remove the locking a r m and spring w a s h e r f r o m the pintle shaft 15 Remove the snap r i n g f r o m the end of the pintle shaft and remove the contact a r m f r o m the s h a f t F i g ...

Page 646: ... STUD SCREW i OCiC NG SEAL I DRIVE SCREW ASSEMBLY N U M B COMPRESSOR ROD HOUSING ASSEMBLY FINGER ASSEMBLY MOTOR NYLON GEAR SPEEDOMETER ADAPTER GUIDE GUIDE CLAMP NUT TERMINAL BLOCK DUST SHIELD CABLE CLAMPING NUT 6 1 X 2 1 5 Fig 24 Auto Pilot Disassembled View MyMopar com ...

Page 647: ...h the plate and drive screw WORM 61x298 Fig 27 Assembling the Locking Arm on the Pintle Shaft assembly with the three screws B o not overtighten the screws 3 Install the pintle shaft In the collar end of the bushing In the magnet assembly 4 Install the contact a r m on the end of the pintle shaft and attach w i t h the snap ring 5 Install the locking a r m on the pintle shaft Fig 27 6 Install the ...

Page 648: ...ntil the magnet is in an upright position Install the motor on the hous ing Make certain that the end of the motor shaft engages In the slot of the drive screw Install the motor mounting nuts and tighten C A U T I O N Bo not tighten by the use of a screwdriver on slotted bolt heads as this may result i n binding of the motor bearings 14 Route the black motor wire over the pintle shaft between the ...

Page 649: ...BLE 61x303 Fig 32 Installing the Drive and Speedometer Cable ball socket on t h e bottom of t h e drive mechanism Install t h e dust shield A d j u s t t h e control cable 4 Connect t h e drive cable a n d t h e speedometer cable F i g 32 5 Connect t h e terminal plug SERVICE DIAGNOSIS N O T E It is recommended that the diagnosis be performed in the sequence outlined Do not dis assemble the Auto P...

Page 650: ...d 5 Automatic control does not a Driver riding the brake pedal a Instruct the owner of Auto Pilot engage when button is pulled Driver does not hold accelera operation and demonstrate out tor against back pressure when pulling the button b No current at 2 terminal b Perform electrical test and correct as required c Loose or disconnected ground c Tighten or connect the ground wire between the select...

Page 651: ...age 10 Speedometer does not regis ter or unit does not operate a Speedometer drive pinion i n the transmission damaged b o Broken speedometer cable c Faulty speedometer d Broken drive cable from trans mission to the drive mecha nism e Damaged drive gear or nylon gear i n the drive mechanism a Replace the speedometer d r i v e pinion b Replace the speedometer cable c Remove and repair the speedom e...

Page 652: ...RONT SHOCK ABSORBERS Upper Mounting Nuts 25 Lower Mounting N u t 55 Steering Knuckle to Bracket Support Bolt 55 Steering Knuckle to Steering Knuckle A r m N u t 50 Service Information for Front Suspension remains the same as described i n the 1960 Chrysler and Imperial Service Manual w i t h the following excep tions Front Suspension height has been changed to 2 inches on Town and Country models a...

Page 653: ...age 10 Speedometer does not regis ter or unit does not operate a Speedometer drive pinion i n the transmission damaged b o Broken speedometer cable c Faulty speedometer d Broken drive cable from trans mission to the drive mecha nism e Damaged drive gear or nylon gear i n the drive mechanism a Replace the speedometer d r i v e pinion b Replace the speedometer cable c Remove and repair the speedom e...

Page 654: ...RONT SHOCK ABSORBERS Upper Mounting Nuts 25 Lower Mounting N u t 55 Steering Knuckle to Bracket Support Bolt 55 Steering Knuckle to Steering Knuckle A r m N u t 50 Service Information for Front Suspension remains the same as described i n the 1960 Chrysler and Imperial Service Manual w i t h the following excep tions Front Suspension height has been changed to 2 inches on Town and Country models a...

Page 655: ...Serviced i n Matched Sets Only 005 inch Maximum Select Washer 006 to 009 Inch 001 to 012 inch 3V2 pints 3 58 to 1 2 93 to 1 Tapered Rollers Select Shims 013 to 018 inch TIGHTENING REFERENCE Foot Pounds Axle Shaft Nuts 145 Min Brake Support Plate to Housing Mounting Bolt Nuts 30 35 Differential Carrier to Axle Housing Bolt Nuts 45 Rear Axle Drive Gear to Case Bolts 45 Differential Bearing Cap Bolts...

Page 656: ...es should be used when as sembling the 1961 Chrysler Newport RC 1 carrier PMION BEARING CUP INSTALLATION 1 Place the bearing cups squarely In position Assemble Tool C 758 by placing the spacer SP 2919 followed by the rear pinion bearing cone over the main screw of the tool and Inserting It Into the carrier from the gear side 2 Place the front pinion bearing over the main screw followed by compress...

Page 657: ...lat portion of the spacer should be facing the differential bear ing pedestals and the offset of the spacer or the large portion toward the center of the carrier Tighten the screw w i t h an Allen wrench 2 Position the arbor SP 561 part of Tool C 758 In the differential bearing pedestals of the carrier Center the arbor so that an approximate equal dis tance Is maintained at both ends Position the ...

Page 658: ... the same marking and if the original bearing is being reused use a thrust washer of same thickness But i f old pinion is marked zero 0 and new pinion is marked 2 t r y a 002 thinner washer I f new pinion is marked 2 t r y a 002 inch thicker washer I f the bearing cups are to be replaced place the bearing cups i n position i n the carrier and drive the cups in place w i t h suitable drift After pr...

Page 659: ... of the washer facing the drive pinion gear Posi tion the rear bearing on the pinion shaft Make sure the contacting surfaces of the washer pinion gear and rear bearing are perfectly clean and free from dirt or foreign particles Install the rear bearing cone onto the pinion shaft w i t h Tool DD 955 Install the selected shim pack Lubricate the front and rear bearing Insert the pinion and bearing as...

Page 660: ...lowers the oper ating pedal closer to t h e floor w i t h t h e results of easier setting B o t h pedal and lever assemblies will be serviced a s a unit a n d will require only periodic lubrication BRAKE CABLE APJPSIMQfT A change i n t h e p a r k i n g brake cable adjustment f u r t h e r increases p a r k i n g brake efficiency W i t h t h e p a r k i n g brake pedal i n t h e fully released pos...

Page 661: ... contact w i t h the drum Inspect the brake support plate for evidence of high or low areas at the point of brake shoe contact that might indicate a bent support plate This might cause misalignment of brake shoe to drum and create erratic brake operation Replace the brake support i f bent BRAKE BLEEDING All Models 1 Clean all dirt from around the master cylinder reservoir cover and from the bottom...

Page 662: ... the brake shoe is firmly seated and wheel is locked Back off the adjusting cam until no drag is felt when the wheel is rotated 2 Rotate the rear brake shoe adjusting cam i n the direction the wheel rotates when i n a backward motion until the brake shoe is firmly seated and the wheel is locked Back off the adjustment until no drag is felt when wheel is rotated 3 On the opposite rear wheel repeat ...

Page 663: ... the brake shoe is firmly seated and wheel is locked Back off the adjusting cam until no drag is felt when the wheel is rotated 2 Rotate the rear brake shoe adjusting cam i n the direction the wheel rotates when i n a backward motion until the brake shoe is firmly seated and the wheel is locked Back off the adjustment until no drag is felt when wheel is rotated 3 On the opposite rear wheel repeat ...

Page 664: ...al Trans mission Group 21 f o r detailed procedure 2 Remove the clutch housing pan and dust seal 3 Disconnect the release fork rod at the release fork 4 Remove the release fork pull back spring 5 Detach the release fork from its pivot and remove the fork dust seal sleeve and bearing 6 Mark the flywheel the clutch cover and one pressure plate l u g to maintain their same relative positions during r...

Page 665: ... h e w e a r circle should show no more than 003 inch runout throughout a com plete rotation of t h e flywheel 3 T h e friction face of t h e flywheel should also be free f r o m discolored burned areas small cracks and excessive grooves or ridges 4 T h e bushing i n t h e end of t h e crankshaft should be smooth a n d show no excessive wear A new transmission m a i n drive pinion or bushing drive...

Page 666: ...dal is operated a slight move ment of internal clutch parts must take place Normally any moving parts should be lubricated but i n lubricating a dry disc type clutch a very m i n i m u m amount of lubricant must be used When the clutch pedal is depressed the disc moves on the splines of the transmission main drive pinion shaft The pressure plate also moves i n the slots of the cover and on the eye...

Page 667: ...e bushing 3 Turn the center screw i n through the outer portion to remove the bushing b Installation Soak a new bushing in engine oil prior to installation 1 Remove the nut and cup from installing and burnishing Tool C 3181 2 Place the new bushing on the tool shaft and drive the bushing flush w i t h the end of the crank shaft Use a soft hammer to prevent damage to the tool 3 To remove the driver ...

Page 668: ...utch pedal after oper ating the clutch several times The pedal should return completely I f the pedal hangs up i n the free play distance 1 1 4 inch initial travel screw the bumper out and tighten the lock nut I f the initial effort to start the pedal moving breakaway load is more than 5 to 7 pounds screw the bumper i n and tighten the lock nut This adjusting screw is located below and at a right ...

Page 669: ...oken pressure c Recondition the cover assembly springs D I F F I C U L T GEAR S H I F T I N G a Excessive pedal free play a Adjust the release fork rod b Worn or damaged disc assembly b Replace the disc assembly c Improperly adjusted cover c Remove and recondition assembly d Clutch disc splines sticking d Remove the disc assembly and free up splines or replace the disc C L U T C H NOISY a D r y cl...

Page 670: ...oken pressure c Recondition the cover assembly springs D I F F I C U L T GEAR S H I F T I N G a Excessive pedal free play a Adjust the release fork rod b Worn or damaged disc assembly b Replace the disc assembly c Improperly adjusted cover c Remove and recondition assembly d Clutch disc splines sticking d Remove the disc assembly and free up splines or replace the disc C L U T C H NOISY a D r y cl...

Page 671: ...ollowing exceptions TESTING THE SILENT FLITE FAN DRIVE Cooling Problems I f the fan drive operates below its m i n i m u m design speed engine overheating may result at low car speeds Test the fan drive as follows 1 Cooling system must be at room temperature for test 2 Mark one fan blade w i t h white or yellow chalk or crayon 3 Attach a timing light to spark plug wire Start and operate the engine...

Page 672: ...C 65 100 Fan Idler Bracket 35 50 A C A i r Conditioning BELT DEFLECTION METHOD Deflection Inches to be Applied at Midpoint of Belt Segment Under a 5 Pound Load See Figure 1 ALL MODELS Accessory Belt in Use New Belt Power Steering 6 e Fan B e l t I d l e r 1 U Alternator Without A C Vg W i t h A C 14 A C A i r Conditioning Fig 1 Belt Deflection Location AC Air Conditioning CS Crankshaft I Idler WP ...

Page 673: ...W i t h the engine running the pump load reaction will move the pump mounting bracket away from the stop TORQUE METHOD The power steering belts are tightened by using Tool C 3832 and torque wrench Tool C 3005 Fig 2 The alternator belts are tensioned by using a special Tool C 3841 and torque wrench Tool C 3005 Fig 3 The special tool should be hooked at the heavily ribbed section of the alternator r...

Page 674: ...W i t h the engine running the pump load reaction will move the pump mounting bracket away from the stop TORQUE METHOD The power steering belts are tightened by using Tool C 3832 and torque wrench Tool C 3005 Fig 2 The alternator belts are tensioned by using a special Tool C 3841 and torque wrench Tool C 3005 Fig 3 The special tool should be hooked at the heavily ribbed section of the alternator r...

Page 675: ...imum Free Running Test Voltage 11 Amperage Draw 78 Amps Maximum Minimum Speed r p m 3800 Minimum Stall Torque Test Torque Foot Pounds _ 8 5 Voltage 4 Amperage Draw 350 Pinion to Housing Clearance W plus or minus y 3 2 be tween Pinion Stop and End of Pinion Solenoid Switch Pull in Coil 20 0 22 2 Amps at 6 Volts Hold In Coil 11 2 12 4 Amps at 6 Volts ALTERNATOR Standard Equipment Special Equipment S...

Page 676: ...t Gap 015 Inch plus or minus 001 Inch A i r Gap 048 to 052 Inch Measure gap w i t h gauge back of stop Contacts close w i t h 052 inch gauge installed Contacts open w i t h 048 inch gauge Installed Temperature I n Degrees 75 95 118 140 Minimum Setting 13 7 to 13 6 to 13 5 to 13 4 to Maximum Setting 14 3 14 2 14 1 14 0 Start and operate the engine at 1250 rpm Turn on the lights and electrical acces...

Page 677: ...w i t h 2 Barrel Carburetor 0 250 to 450 0 to 2 450 2 5 to 4 5 700 10 to 12 2050 0 6 to 8 1 6 to 9 12 10 5 to 13 16 014 to 019 27 to 32 17 oz to 21 5 oz 10 BTC 25 to 285 mfd 000 to 003 003 to 010 Counterclockwise A 42 14 M M 035 1 8 4 3 6 5 7 2 Chrysler Essex 2095223 62 160 2 1 41 to 1 55 ohms 9200 to 10600 ohms Ballast Resistor 2095501 Resistance 70 to 80 F 0 6 ohms Current Draw Coil and Ballast ...

Page 678: ...ms Secondary Resistance 70 to 80 F 8000 to 9200 ohms Chrysler Essex 2095223 62 160 2 1 41 to 1 55 ohms 9200 to 10600 ohms Ballast Resistor 2095501 Resistance 70 to 80 F 0 6 oms Current Draw Coil and Ballast Resistor i n Circuit Engine Stopped 1 3 0 Amperes Engine Idling 1 9 Amperes When distributor is new or after rebuilding new bushings and or shaft installed service wear tolerance should not exc...

Page 679: ...ead and the bat tery terminal post 4 Connect a test voltmeter w i t h a 10 volt scale divisions between the battery positive post and the starter switch terminal at the starter 5 Crank the engine and observe the readings on the voltmeter and the ammeter The voltage should not exceed 12 volt per 100 amperes of current The current should not exceed 150 to 250 amperes A reading of voltage that exceed...

Page 680: ...battery voltage adjusted to 4 D I S A S S i M l t l N G THE STAHTE1 Fig 1 volts the stall torque should be 8 5 foot pounds m i n i m u m w i t h a current draw of 350 amperes 61x18 1 Remove the through bolts and tap the com mutator end head from the field frame w BRUSH PLATE Fig 2 Removing or Installing Brush Ritig SERIES COIL LEAD SHUNT COIL L E A D mm 61x20 rsg 3 FisM H i ds Disconnected from So...

Page 681: ...d remove the snap ring 11 Slide the overrunning clutch drive from the armature shaft Fig 5 Removing or Installing Shifter Fork Pivot Pin SPACER WASHER 61x23 Fig 6 Removing or Installing Shifter Fork 12 I f necessary to replace field coils remove the ground brushes terminal attaching screw and raise the brushes w i t h terminal and shunt wire up and away from field frame Fig 7 Remove the pole shoe ...

Page 682: ...e brush spring tension w i t h a spring scale hooked under the spring near the end Pull the scale on a line parallel to the edge of the Fig 8 Testing Armature for Short Fig 9 Testing Armature for Ground brush and take a reading just as the spring end leaves the brush Spring tension should be 32 to 48 ounces Replace the springs that do not meet speci fications TESTING THE ARMATURE Testing the Armat...

Page 683: ...hat are 180 degrees apart should cause the test lamp to light as they are intentionally grounded The other two brush holders Fig 12 should not cause the lamp to light when tested as they are insulated I f the insulated brush holders cause the lamp to light when tested it indicates that the brush holders on the brush r i n g are grounded Replace the brush ring assembly i f the brush holders are gro...

Page 684: ...nclosed behind the brush holder ring and that they do not interfere w i t h the brush operation 12 Install thrust washers on commutator end of armature shaft to obtain 010 inch minimum end play 13 Install the commutator end head 14 Install through bolts and tighten 40 to 50 inch pounds torque ADJUSTING STA1TE1 DUVE GEAH PINION CLEARANCE 1 Place the starter assembly i n a vise equipped ELECTRICAL A...

Page 685: ...r ance c Broken teeth on flywheel drive gear d Armature shaft rusted dirty or dry due to lack of lubrica tion a Battery discharged b Defective wiring a Test specific gravity and check for dead cell Replace or recharge bat tery as required b Replace switch c Clean terminals and clamps replace i f necessary Apply a light film of vasoline to t e r m i n a l s T i g h t e n clamps securely d Inspect a...

Page 686: ...old weather conditions a Broken solenoid plunger spring or spring out of position b D e f e c t i v e i g n i t i o n s t a r t e r switch c Defective solenoid d P i n i o n clearance i m p r o p e r l y adjusted e Solenoid plunger stuck in sole noid m a t i c t r a n s m i s s i o n o n l y Also check open circuit wire between ignition starter switch and ignition terminal and starter relay c Repl...

Page 687: ...ed 60 degrees apart I n assembly the six protruding fingers of each end pole piede are alternately spaced providing twelve poles Since the end pole pieces have different polarity this i n effect provides a 12 twelve pole rotating electro magnet The ends of the field coil winding are connected to the slip rings at the rear end of the rotor The field coil is externally excited by means of battery cu...

Page 688: ...lled a heat sink The heat sink is electrically insulated and is large enough to absorb the heat from the positive case rectifiers The heat sink contains the output B A T terminal Three of the rectifiers have negative polarity cases and Fig 17 Alternator Rotor Assembly are pressed into the rear die cast aluminum end shield providing a ground i n the circuit The silicon rectifiers have a very high r...

Page 689: ...o site direction prevents the flow of battery current to the alternator their use eliminates the need of a circuit breaker cut out relay For this reason the battery must always be connected w i t h the nega tive terminal to the ground END HOPSMGS The two die cast aluminum end shields Fig 21 support and contain the internal parts The housings are vented at both ends and around the circumfer ence Tw...

Page 690: ...the selection of the correct size and number of windings the correct air gap between the rotor poles and stator and other design features the Chrysler Cor poration Alternator permits inductive reactance to limit output current therefore no current regu lator is needed VOLTAGE REGULATOR The only function of the regulator is to limit the FIELD TERMINAL Z IGNITION TERMINAL V O L T A G E REGULATOR 161...

Page 691: ...ber one and number two through the F L D terminal and through the rotor field to ground The two resistors i n series w i t h the field circuit reduce field current and rotor field strength w i t h a corresponding reduction i n alternator output voltage This momentarily reduces battery line voltage ap plied to the regulator voltage coil The regulator UPPER FUSIBLE WIRE FUSIBLE WIRE SOLDIERING POINT...

Page 692: ... excessive resistance 4 Disconnect the test instruments Connect the B A T lead to the alternator B A T terminal and tighten securely Current Output Test Fig 28 1 Disconnect the battery ground cable output B A T terminal 3 Connect a 0 50 ampere scale D C ammeter in series between the alternator B A T terminal and the disconnected B A T lead 4 Connect the positive lead of a test voltmeter to the out...

Page 693: ...minutes of operation will stabilize the regulator temperature Measure the temperature at the regulator by holding a reliable thermometer two 2 inches from the regulator T u r n off the lights and other electrical load T u r n on the instrument panel lights Read the test volt meter W i t h a fully charged battery and 15 amperes flowing in the circuit the voltmeter reading should be w i t h i n the ...

Page 694: ...r e not the contact spring until it contacts the wire gauge T h e upper contacts should j u s t open IFog 3 CheckSrrag Go N O T E A 12 volt battery and test light connected i n series to the I G N and F L D terminals m a y be used to accurately determine the contact opening W h e n the contacts open the test light will go d i m 4 Insert a 052 inch wire gauge between the a r m a t u r e and the cor...

Page 695: ...etained i n a holder that is integral w i t h the end housing Remove the retaining screw and lift the clip spring and brush assembly from the end shield Fig 32 C A U T I O N Stator is laminated do not burr stator or end housing 3 Remove the through bolts and p r y between the stator and drive end shield w i t h a t h i n blade screwdriver Carefully separate the drive end shield pulley and rotor as...

Page 696: ...ry and a test lamp equipped w i t h a number 67 bulb 4 candle power as follows a Connect one side of test lamp to the positive battery post The other side of the test lamp to a test probe w i t h the other test probe connected to the negative battery post b Contact the outer case of the rectifier w i t h one probe and the other probe to the wire i n the center of the rectifier See F i g 37 c Rever...

Page 697: ...ould l i g h t when the prod contacts each of the three leads I f the test lamp does not light the stator winding Is open See Fig 39 7 Install a new stator I f the one tested Is grounded or open I f the rectifiers must be re placed proceed as follows a Cut rectifier wire at point of crimp b Support the rectifier shield on Tool C 3771 See Fig 40 N O T E This tool Is cut away and slotted to fit over...

Page 698: ...i t h Tool SP 3381 Fig 43 N O T E New bearings are pre lubricated additional lubrication is not required 6 Insert the drive end bearing i n the drive end shield and install the bearing plate washers and nuts to hold the bearing i n place 7 Position the bearing and drive end shield on the rotor shaft and while supporting the base of the rotor shaft press the bearing and shield into position on the ...

Page 699: ...nstall the insulated brush lockwasher i n sulating washer and terminal attaching screw 17 Install the ground brush and attaching screw 18 Rotate the pulley slowly by hand to be sure that the rotor fans do not h i t the rectifiers and stator connectors 19 Install the alternator and adjust the drive belt according to the instructions i n ACCESSORY B E L T D R I V E Group 7A of this Supplement 20 Con...

Page 700: ...istance and cor low battery ing circuit rect as required b Low regulator setting b Adjust the voltage regulator c Shorted rectifier Open recti fier c Perform current output test Remove and dis assemble the alternator Test the rectifiers Install new rectifiers as required d Grounded stator windings d Remove and disassemble the alternator Test the stator windings Install a new stator i f necessary E...

Page 701: ...ry IGNITION SYSTEM The Ignition system consists of two separate circuits The battery ammeter ignition switch primary winding of the ignition coil distributor contacts and condenser vehicle frame and the primary w i r i n g make up the voltage primary circuit The secondary high voltage circuit includes the coil secondary wind ing the distributor cap and rotor the spark plugs the high tension wiring...

Page 702: ...pection service testing and calibration IDLE 1PM TEST The engine Idle r p m setting should be tested and recorded as i t is when the vehicle Is first brought into the shop for testing This will assist i n diag nosing complaints of engine stalling or complaints of creeping and hard shifting on vehicles equipped w i t h automatic transmissions 1 T u r n the selector switch to the calibrate posi tion...

Page 703: ...74 ELECTRICAL AND INSTRUMENTS Fig 47 Distributor Exploded View Typical MyMopar com ...

Page 704: ...lamp screw and rotate the distributor housing so that the specified timing mark and pointer are i n alignment Moving distrib utor housing against shaft rotation advances t i m i n g and w i t h shaft rotation retards t i m i n g 6 Tighten the distributor clamp screw after the t i m i n g has been set and recheck t i m i n g adjustment w i t h a Power Timing Light 7 When the spark timing is correct...

Page 705: ...ng and remove the lower bushing In the same manner CAM AND YOKE Fig 49 Checking Distributor Shaft Side Play I 0 i f TOOL 60x697 A Fig 50 Removing Distributor Shaft Upper Bushing f Soak the new bushings i n light engine oil for approximately 15 minutes g Position the new upper bushing w i t h slot in bushing up and i n line w i t h oil hole i n housing then press the bushing into the distributor ho...

Page 706: ...er thrust washers for Auto Lite distributors or a single flat thrust washer for Chrysler built distributors Position the washers on the distributor shaft and slide the shaft Into the distributor body Position the lower thrust washer and drive the collar on the lower end of the shaft and Install the retainer pin 6 Install the oiler wick and oiler 7 Install the breaker plate assembly align the j 61x...

Page 707: ...eck the model number on the distributor base and refer to the specifications before making this test N O T E Clamp around the r i b section of the distrib utor housing The bottom section of the distributor housing is not a machined surface and concentricity would be affected causing a wobble Mount the distributor assembly less cap i n a reliable stroboscope type distributor tester and pro ceed w i...

Page 708: ...make sure all high tension wires snap firmly i n the cap towers and distributor hold down clamp screw Tighten the screw finger tight 6 Connect the secondary lead of a Power Timing L i g h t to the No 1 spark plug the red primary lead to the positive terminal of the battery and the black primary lead to the negative battery terminal 7 Start the engine Idle the engine at 475 500 rpm Rotate the distr...

Page 709: ...der head and crank engine w i t h the ignition switch on I f the spark jumps the 1 4 inch gap the coil can be considered satisfactory IGNITION SYSTEM SERVICE DIAGNOSIS Condition Possible Cause Correction Burned or pitted dis a D i r t or oil on points a I f oil is on contact face determine cause and tributor points correct condition Clean distributor cam of dirt and grease apply a light film of di...

Page 710: ...el System b Oil entering cylinders due to w o r n rings or worn valve guides Refer to Group 9 Engine for corrective measures c Install correct plugs d Set spark plug gap to 035 Inch a Replace spark plugs Install new gaskets Tighten spark plugs to 30 foot pounds torque b Adjust carburetor Refer to Group 14 Fuel System c Install correct plugs d Adjust ignition timing Refer to Group 8 Electrical INST...

Page 711: ...hing the dome and cluster assembly to the dome support These screws are located just behind the steering tube collar attaching screws See Fig 58 8 Remove the four screws attaching the plastic dome to the instrument panel 9 Carefully release the base of the dome from the supports at each side and w i t h a pointed Instru ment carefully move the dome away from the open ing i n the Instrument panel s...

Page 712: ... of the Steering Group 19 of the 1960 Chrysler and Imperial Service Manual 11 Connect the battery ground cable INSTRUMENT REMOVAL 1 Disconnect the battery ground cable 2 Remove the steering jacket tube cover Fig 56 3 Disconnect the wires at the instrument to be replaced F i g 61 4 Oil Pressure Gauge When removing the oil pressure gauge remove the ground wire and the two screws from the speedometer...

Page 713: ...ring jacket tube 4 Remove the five screws securing the instru Fig 62 Removing or Installing Instrument Cluster Panel Fig 63 Disconnect oil Electrical Connections ment cluster to the instrument panel Carefully re move the instrument cluster Fig 62 by tilting the lower end of the cluster outward N O T E For speedometer or complete cluster removal disconnect all electrical connections and disengage t...

Page 714: ... AND R E A R Left B a n k 1 3 5 7 R i g h t B a n k 2 4 6 8 C R A N K S H A F T T y p e F u l l y Counter Balanced Bearings Steel Backed Babbitt Journal Diameter R C 1 R C 2 2 6245 to 2 6255 R C 3 R Y I 2 7495 to 2 7505 C r a n k P i n Diameter 2 374 to 2 375 M a x i m u m Out of Round Permissible 001 Number of M a i n Bearings 5 Clearance Desired Bearing Installed I D M i n u s Journal O D 0005 t...

Page 715: ...AFT B E A R I N G JOURNALS Diameter No 1 1 998 to 1 999 No 2 1 982 to 1 983 No 3 1 967 to 1 968 No 4 1 951 to 1 952 No 5 1 748 to 1 749 C A M S H A F T B E A R I N G S Diameter after reaming No 1 2 000 to 2 001 No 2 1 984 to 1 985 No 3 1 969 to 1 970 No 4 1 953 to 1 954 No 5 1 750 to 1 751 T I M I N G CHAIN Adjustment None Number of Links 50 Pitch 50 Width 88 T A P P E T S Type Hydraulic Clearance...

Page 716: ...0075 Interference in Rod 0007 to 0012 Piston Pins for Service Standard Only Direction Offset in Piston Toward Right Side of Engine P I S T O N RINGS Number of Rings per Piston 3 Compression 2 Oil 1 Width of Rings Compression 0775 to 0780 Oil _ I860 to 1865 Piston Ring Gaps all 013 to 025 R I N G S I D E C L E A R A N C E Compression Upper 0015 to 0030 Intermediate 0015 to 0030 Oil 0010 to 0030 VAL...

Page 717: ...t Angle 45 Seat W i d t h finished 040 to 060 Cylinder Head Gasket Compressed thickness 022 E N G I N E L U B R I C A T I O N P u m p T y p e Rotor F u l l Pressure Capacity qts 5 P u m p Drive Camshaft Operating Pressure at 40 to 50 m p h 45 to 65 lbs Pressure D r o p Resulting from Clogged Filter 7 to 9 lbs When Filter I s Replaced A d d 1 Quart O I L P U M P I N S P E C T I O N L I M I T S F O ...

Page 718: ...ust Pipe Clamp Bolt 20 Exhaust Pipe Support Clamp Bolt 20 Fan Attaching Bolt 15 18 Fan Belt Idler Pulley N u t 45 Fan Belt Idler Pulley Bracket Bolt 30 Fuel Pump Attaching Bolt 30 Alternator Bracket to Manifold Bolt 50 Alternator Mounting Nut 20 Alternator Adjusting Strap Bolt 15 Alternator Adjusting Strap Mounting Bolt 30 Intake Manifold Bolt 50 Manifold Heat Control Counterweight Bolt 50 in lbs ...

Page 719: ...ine B o l t 50 7 16 14 15 5 16 18 9 M 20 30 30 M 16 30 16 GROUP 9 E N G I N E Three V 8 engines are used for 1961 They are RC 1 361 cu in Displacement RC 2 383 cu in Displacement RC 3 and RY 1 413 cu in Displacement The service procedures will remain the same as out lined in the 1960 Chrysler and Imperial Service Manual except for the closed crankcase ventilation system which follows Fig 1 Closed ...

Page 720: ...id accumulations of harmful fumes may be present In the engine Under these condi tions of operation the valve and tube must be cleaned more frequently than speclied above No speclic mile age recommendation however can be made under these conditions Frequency of cleaning must be dic tated by experience Disassemble the valve Fig 2 and clean the valve parts with any good solvent cleaner and blow dry ...

Page 721: ...indsor RC 2 and New Yorker RC 3 and the Newport RC 1 Town and Country Wagon have single exhaust systems A dual exhaust system is optional at extra cost on the New Yorker Model RC 3 The Imperial Model RY 1 and the New Yorker RC 3 Town and Country Wagon have a dual exhaust system Service procedures remain the same as outlined in the 1960 Chrysler and Imperial Service Manual GROUP 13 F R A M E The fr...

Page 722: ...indsor RC 2 and New Yorker RC 3 and the Newport RC 1 Town and Country Wagon have single exhaust systems A dual exhaust system is optional at extra cost on the New Yorker Model RC 3 The Imperial Model RY 1 and the New Yorker RC 3 Town and Country Wagon have a dual exhaust system Service procedures remain the same as outlined in the 1960 Chrysler and Imperial Service Manual GROUP 13 F R A M E The fr...

Page 723: ...3 188 Bore 1 6 V e n t u r i l l i o M a i n Metering Jet Standard 068 One Step L e a n 066 T w o Steps L e a n 064 Power Jet 040 to 063 A D J U S T M E N T S Idle Mixture B o t h Screws Yz to T u r n Open Idle Speed r p m 500 W i t h C a r Cooling rpm 550 F a s t Idle Speed rpm 1375 to 1425 F a s t Idle Speed C a m Index Choke Blade Opening W D r i l l 3 1 2 T u r n s Accelerator P u m p T r a v ...

Page 724: ...d Cars Fast Idle Speed R P M 1875 to 1425 CHOKE Control Type Setting For use w i t h closed crankcase vent system mandatory for California cars Ball and Ball Dual Throat BBD 2923SA BBD 3132S l9 ie l e l5 ie Wie No 120 249S No 120 249S 75 1526 75 1525 026 x 032 026 x 031 1 1 64 1 i 6 4 2 060 060 l 1 500 500 575 575 1375 to 1425 1375 to 1425 Thermostatic Coil Spring Well Well On Index On Index SPECI...

Page 725: ...USTING SCREWS 2 VACUUM PASSAGE DISTRIBUTOR CHOKE VALVE ACCELERATOR PUMP LEVER B O W L VENT VALVE ACCELERATOR PUMP ROD FAST IDLE LEVER AIR HORN FAST IDLE C A M i I FAST IDLE ROD MAIN BODY THROTTLE BODY FAST IDLE SPEED ADJUSTING SCREW IDLE MIXTURE ADJUSTING SCREWS 2 THROTTLE LEVER I v A IDLE SPEED ADJUSTING SCREW CURB IDLE 60x331 Fig 1 Carburetor Assembly WWC3 Series MyMopar com ...

Page 726: ...aintain a constant level of fuel in the float chamber at all times and under all conditions of operation Fuel enters the carburetor at the fuel inlet flowing through the float chamber as shown in Figures 2 and 3 When the fuel reaches a given level the float shuts off the supply of fuel at the needle valve The float chamber is vented internally by a vent passage which connects the float chamber w i...

Page 727: ...e is also dis charged from the upper idle discharge holes to sup ply the additional fuel reguired for increased engine speed as shown in Figure 3 VACUUM POWER PISTON THE M A I N METERING SYSTEM The main metering system controls the flow of fuel during the intermediate or part throttle range of operation With the throttle valves in a partially open posi tion fuel flows from the float chamber throug...

Page 728: ...y pass jet When the demand for power is satisfied and the throttle opening is decreased the manifold vacuum PUMP LEVER Fig 6 Accelerating System Discharge Stroke Fig 7 Accelerating System Return Stroke again builds up to raise the power piston As soon as the manifold vacuum exceeds 7 Hg the lower second stage valve closes cutting off the supply of fuel through the bottom hole When the manifold vac...

Page 729: ...oil spring however is unable to close the choke valve until the throttle valves are opened sufficiently to move the fast idle stop screw away from the fast idle cam The tension on the thermostatic spring will then close the choke valve according to the prevailing temperature As the engine begins to operate man ifold vacuum exerts a pull on the vacuum piston to open the choke valve just enough to s...

Page 730: ...ER MAIN TO THROTTLE BODY GASKET THROTTLE BODY AIR HORN FAST IDLE ROD HAIR PIN CLIP AIR HORN TO MAIN BODY GASKET HAIR PIN CLIP ACCELERATOR PUMP ROD THROTTLE LEVER 60x330 Fig 11 Carburetor Assembly Exploded View CENTER SLOT IN ACCELERATOR PUMP ARM X Vrft ACCELERATOR PUMP R O D x tiv it FAST IDLE ROD HAIR PIN CLIP FAST IDLE CAM HAIR PIN CLIP THROTTLE LEVER 60x332 Fig 12 Removing or Installing Pump Ro...

Page 731: ...or kerosene to prevent the leather from drying out 7 Remove the vacuum power piston from the air horn using an open end wrench and wood block as shown i n Figure 16 Exert sufficient pressure on end of wrench to force piston out of its well i n air horn This assembly is staked i n the air horn and 60x335 Fig 15 Removing or Installing Accelerator Pump Plunger care should be used at removal Discard a...

Page 732: ...ixture adjusting screws and springs from the throttle body 2 The carburetor now has been disassembled into three units namely the air horn main body and throttle body and the component parts of each disassembled as far as necessary for cleaning and inspection N O T E I t is usually not advisable to remove the throttle shaft or valves unless wear or damage neces sitates installation of new parts CL...

Page 733: ...ide the valves down into position w i t h the notches in the valves at the ports Install new screws THROTTLE VALVES IDLE TRANSFER PORTS S P A R K A D V A N C E PORTS THROTTLE VALVES I D L E SPEED ADJUSTING SCREW 3 60x341 IDLE SPEED ADJUSTING SCREW IDLE MIXTURE SCREWS THROTTLE VALVE SCREWS 6 0 x 3 4 2 Fig 22 Throttle Body Exploded View but do not tighten Hold the valves i n place w i t h the finger...

Page 734: ...mp passage 2 Using a small clean brass rod hold the dis charge check ball firmly down on Its seat Raise the pump plunger and press downward N o fuel should be emitted from either the Intake or discharge pass age as shown In Figure 26 3 I f any fuel does emit from either the Intake or discharge passages i t Indicates the presence of dirt or a damaged check ball The passages should be recleaned and ...

Page 735: ...float lip is perpen dicular to the needle or slanted not more than 10 degrees away from the needle when the float is set correctly Install float needle and seat and tighten seat se curely Slide the float baffle down into position and install the fulcrum pin spring Fig 14 Remeasure as described i n Step 2 above AIR HORN ASSEMBLY Fig 29 1 Slide the choke shaft and lever into the air horn w i t h the...

Page 736: ... long screws and tighten securely 4 Install the fast idle rod and secure w i t h the hairpin clip Fig 13 5 Install the pump rod and secure w i t h hairpin clip Be sure rod is i n the center slot of arm Fig 12 Work the accelerator pump plunger several times to be sure i t operates smoothly CARBURETOR ADJUSTMENTS I t is very important that the following adjustments be made on a reconditioned carbure...

Page 737: ...avel should be 6 inch as shown 3 I f an adjustment is necessary bend the pump rod at the point shown using Tool T109 213 until correct travel has been obtained BOWL VENT VALVE SETTING Fig 34 This setting is made after the pump travel setting 1 W i t h the idle speed screw set at closed throttle hold the throttle i n the closed position and choke valve wide open 6 0 x 3 5 PUMP ROD Bend as Required ...

Page 738: ... t off the a i r horn Check the float setting as follows 1 Seat the float fulcrum pin b y pressing finger against t h e fulcrum p i n spring There should be enough fuel i n the bowl t o raise the float so t h a t t h e l i p bears firmly against t h e needle Additional fuel may be admitted b y slightly depressing the float I f the fuel pressure i n the line is insufficient to force additional fuel...

Page 739: ...emble the components for servicing If however the setting has been disturbed refer to Figure 36 then reset as follows 8 Loosen locknut A and t u r n part w i t h screw driver until index mark on disk B coincides w i t h the first mark to the right of center mark on the bracket Hold i n this position w i t h screwdriver while tightening nut N O T E After adjustment is made and the choke unit instal...

Page 740: ... accelerator pump inlet check ball for poor seat or release I f part is faulty replace e Test fuel or float level i n carburetor Adjust as necessary to obtain correct float level f Clean and inspect needle valve and seat I f found to be in questionable condition replace assembly Then test fuel pump pressure Refer to Data and Specifications for correct fuel pump pressure g Disassemble Carburetor Re...

Page 741: ...Refer to Data and Specifications for recommended pressure I f pres sure Is In excess of recommended pressure re place fuel pump assembly e Disassemble carburetor Replace worn metering jet using a new j e t of the correct size and type ACCELERATOR PUMP ARM ACCELERATOR PUMP PLUNGER CHOKE VALVE BOWL VENT AIR HORN CHOKE PISTON CYLINDER PAST IDLE SCREW IDENTIFICATION TAG AST IDLE CAM FAST IDLE LEVER MA...

Page 742: ...t performance and fuel economy 1 To correctly set the float height when the carburetor is being overhauled install the floats w i t h the fulcrum pin and pin retainer i n the main body 2 Install the rubber tipped needle seat and gasket i n the body and tighten securely See Figure 39 Fig 38 Carburetor Assembly BBD 3132S Closed Crankcase Vent System Fig 39 Rubber Tipped Needle Seat and Gasket 3 Inve...

Page 743: ...ause a false setting which will affect correct level of fuel in the bowL N O T E After being compressed the rubber tip is very slow to recover its original shape I t is very important that the float lip be perpendicular to the needle o r slanted not more than 10 degrees away from the needle when the float is set correctly 6 After the float has been correctly set re assemble the air horn IDLE SPEED...

Page 744: ... ventilator valve is located i n the crankcase vent tube cap and is connected to the carburetor throttle body w i t h the use of a rubber tube The function of the valve is to regulate the flow of unburned hydrocarbons from the crankcase and return them to the intake manifold F r o m here they enter the combustion chamber and then exit through the exhaust system as completely burned exhaust product...

Page 745: ... A M F A S T IDLE A D J U S T I N G S C R E W 7 F A S T IDLE C O N N E C T O R R O D M A I N A N D T H R O T T L E B O D Y T H R O T T L E L E V E R 61x169 Fig 41 Carburetor Assembly AFB Series S T E P U P P I S T O N C O V E R P L A T E V E N T T U B E F U E L INLET C O N N E C T O R C H O K E P I S T O N LINK R O D I N C E N T E R H O L E O F P U M P A R M R E T A I N I N G C L I P S E C O N D A...

Page 746: ...ithout sacrificing perform ance i n the intermediate speed range To do this there is a new step up piston and spring assembly STEP UP PISTON SPRING 2 STAGE STEP UP PISTON COVER I I 3 STEPS JET OLD TYPE STEP UP ROD E M SCREW JET NEW TYPE 61x171 new metering rods w i t h three diameters and a new style primary metering jet as shown i n Figure 43 SYNTHETIC RUBBER TIPPED FUEL INLET NEEDLE The carburet...

Page 747: ...mp stem 3 When reassembling make sure the large CARBURETOR ASSEMBLY Fig 45 Closed Crankcase Vent System NIPPLE MANIFOLD EQUALIZER TUBE Fig 46 Closed Crankcase Vent System torn Manifold diameter of the pivot screw enters the hole i n the pump arm and that the shoulder on the screw has not pinched the pump arm INSTALLING THE AIR HORN 1 Before installing the air horn slide the accel erator pump plung...

Page 748: ...eed was originally set using the speed screw the speed obtained after find ing the leanest smooth idle setting will probably be too fast 5 Readjust the speed screw to obtain correct idle speed Repeat steps 2 and 4 above i f necessary CHOKE VALVE OPEN f 1 FAST IDLE l j JC CONNECTOR ROD A N TO ADJUST BEND AT THIS ANGLE SECONDARY LOCKOUT PAWL THROTTLE VALVE INDEX CLOSED I M A R K O N CAM V l FAST IDL...

Page 749: ...RELEASE FAST IDLE CAM THEN RETURN THROTTLE TO CURB IDLE 7 MOVE REAR O F CARB ROD ASS Y REARWARD UNTIL THE STOP IS CONTACTED TIGHTEN CARB ROD LOCK N U T WITH MANUAL TRANSMISSION 1 ASSEMBLE THROTTLE LINKAGE IN PLACE 2 WITH THE LOCK NUT LOOSE IN THE CARB R O D INSERT A W DIAMETER R O D APPROX 10 LONG THRU HOLES PROVIDED IN ACCELERATOR SHAFT BRKT AND LEVER 3 OPEN CHOKE VALVE AND OPEN THROTTLE SLIGHTLY...

Page 750: ... 2 UNI mSAL JOINTS Model RY 1 Front Center Rear Cross Type TIGHTENING REFERENCE Foot Pounds Inch Pounds Front Companion Flange Nuts Rear Clamp Bolts 35 170 The servicing procedures for the Propeller Shaft Manual There are changes i n the Data and Specifi and Universal Joint Group remain the same as out cations Tightening Reference and Service Diagnosis lined i n the 1960 Chrysler and Imperial Serv...

Page 751: ... 2 UNI mSAL JOINTS Model RY 1 Front Center Rear Cross Type TIGHTENING REFERENCE Foot Pounds Inch Pounds Front Companion Flange Nuts Rear Clamp Bolts 35 170 The servicing procedures for the Propeller Shaft Manual There are changes i n the Data and Specifi and Universal Joint Group remain the same as out cations Tightening Reference and Service Diagnosis lined i n the 1960 Chrysler and Imperial Serv...

Page 752: ...loose b Lack of lubrication c W o r n universal j o i n t p i n or housing h Loosen the spring clamps and reset the spring center bolt i Replace the broken spring j Install the correct spring k Recondition the universal joint Install a new trunnion pin 1 Using Tool C 3567 replace trunnion pin m Recondition the universal joint n Recondition the universal joint Install a new housing o Install a new ...

Page 753: ...loose b Lack of lubrication c W o r n universal j o i n t p i n or housing h Loosen the spring clamps and reset the spring center bolt i Replace the broken spring j Install the correct spring k Recondition the universal joint Install a new trunnion pin 1 Using Tool C 3567 replace trunnion pin m Recondition the universal joint n Recondition the universal joint Install a new housing o Install a new ...

Page 754: ... for t h e 1961 m a n u a l steering gear assembly a r e essentially t h e same a s outlined in the 1960 Service Manual w i t h the exception of the removal and installation of the w o r m s h a f t oil seal T h i s procedure will be covered i n this Supplement DISC COUPLING LIP SEAL S W CLAMP 30LT 61X237 STEERING G E A 1 I M O f l L 1 Disconnect the battery cable a t battery nega tive terminal 2 ...

Page 755: ...E A rubber lip type seal is positioned between the upper hub of the flexible coupling and the jacket tube The outer groove of seal must be firmly in stalled on jacket tube and the two nylon rings F i g 5 and lip of the seal must be well lubricated w i t h a wheel bearing grease 3 Hold the steering column so i t is centered plus or minus Vs inch on the tube while aligning the column support bracket...

Page 756: ...ve ground cable from the battery 2 Remove the two screws from the underside of the steering wheel and remove the horn ring re tainer and attaching screws 3 Disconnect the horn wire at horn switch re move the horn switch screws and bushings and horn switch 4 Loosen the steering wheel n u t several turns install puller Tool C 3428 and remove steering wheel nut and wheel 5 Disconnect the directional ...

Page 757: ...the steering column shaft lower groove install a new snap ring i f old ring will not fully seat in the groove 7 Install spring and tapered spacer tapered end up 8 Carefully install the steering column shaft assembly into the column jacket tube 9 Support the column tube lower hub on a block of wood place the upper snap ring on the steering column shaft pull down on the jacket tube to com press the ...

Page 758: ...w service tools C 3783 Oil Seal Remover and C 3782 Oil Seal Installer Service procedures are the same as outlined i n the 1960 Chrysler and Imperial Service Manual w i t h the following exceptions The larger capacity pump is mounted on a flexible swivel type mounting Fig 10 which enables torque reaction of the pump acting through the mounting bracket and adjustment bracket to move the pump outward...

Page 759: ...ING BRACKET RUBBER STOP ADJUSTMENT MOUNTING BRACKET Fig 13 Pump Bracket and Rubber Stop 61x257 Fig 14 Horn Switch and Horn Wire 2 Remove the two screws from the underside of the steering wheel and remove the horn blowing actuator and steering wheel cover 3 Disconnect the horn wire at the horn blowing switch 4 Remove the four screws and insulators and remove the horn blowing switch Fig 14 5 Remove ...

Page 760: ...ect the horn wire 7 Install the horn blowing actuator steering wheel cover and attaching screws Fig 17 Directional Switch and Lever Steering Wheel Removed 8 Connect the battery cable at the battery neg ative post m Fig 18 Removing Directional Switch SERVICE DIAGNOSIS Condition Cause Remedies NOISE Knocking condition at the a Rubber stop worn or missing from a Replace rubber stop bracket stop when ...

Page 761: ...LOCKWASHER GROMMET 61x325 Fig 1 Heavy Duty Transmission Exploded View MyMopar com ...

Page 762: ...h 004 inch 007 to 012 inch 004 to 011 inch TORQUE REFERENCE Foot Pounds Inch Pounds Front Bearing Retainer Bolts Extension Housing Bolts Nuts Gearshift Operating Lever Nuts Mainshaft Flange N u t Transmission to Clutch Housing Bolts 50 50 175 50 200 180 SPECIAL TOOLS Tool Name Tool No Tool Name Tool No Brake D r u m Holding Wrench C 3281 Cluster Gear Arbor C 3834 Detent Ball Holding Tool C 3765 En...

Page 763: ...sconnect the gearshift control rods and the parking brake cable from the transmission 4 Remove the transmission to clutch housing bolts 5 Pull the transmission back until the pinion shaft clears the clutch disc and release levers 6 Lower the transmission and remove i t f r o m the vehicle EXTENSION HOUSING Removal 1 Apply parking brake and use flange holding Tool C 3281 while removing the flange n...

Page 764: ...ft rear bearing snap ring from the groove i n the mainshaft rear bearing bore in the case 2 Slide the mainshaft and rear bearing assembly to the rear until the rear bearing is out of the case 3 Remove the synchronizer assembly Fig 4 from the mainshaft and out of the case 4 Remove the second and t h i r d speed shift fork 5 Remove the synchronizer clutch gear snap ring using Tool C 484 6 Remove the...

Page 765: ... i n the bores 4 Inspect the bearings shaft and case for wear I f installation of a new bearing does not correct con ditions install a new shaft or repair case as required 5 Inspect the mainshaft splines for galling or scoring Inspect bearing mounting surfaces and snap ring groove Slight nicks or burrs can be stoned off Replace the damaged parts 6 Inspect the gear teeth and threads on the inner sy...

Page 766: ...r thrust washer on the arbor against the rear of the cluster gear w i t h the tabs positioned In the grooves provided In the cluster gear 8 Install the remaining rear thrust washer plate on the rear of the gear and arbor w i t h the step i n the washer facing upward as viewed from rear N O T E Rear thrust washer must be installed w i t h step on O D facing clockwise as viewed from rear In order to...

Page 767: ...3765 F i g 7 to depress t h e detent ball against spring tension push t h e lever s h a f t firmly into posi tion so i t prevents t h e detent ball f r o m escaping 6 Remove t h e detent ball installing tool 7 Install t h e low a n d reverse lever shaft lock I TOOL Fog 7 flnsftesllaflng Defied M i s UsGcugj Tool C 3F65 Fig 8 Gearshift Forks and Shafts pin i n t h e case driving i t down firmly f r...

Page 768: ... the pinion shaft and against the transmission case While holding the retainer w i t h hand pressure against the transmission case measure the clearance between the retainer and case using a feeler gauge 5 Select a gasket 003 to 005 inch thicker than the clearance found This eliminates end play of the front bearing i n the transmission case and also elim inates the distortion of the bearing outer ...

Page 769: ...Fig 9 Gearshift Controls MyMopar com ...

Page 770: ...r rear on the rod until the stud shaft on the block can be inserted into its lever Split the backlash of the rod then install the lever Install the remaining flatwasher and spring clip and tighten to 100 inch pounds torque 11 Remove the wedge Slide the upper boot down into position and install the retaining r i n g and screws Tighten screws securely W i t h the linkage properly adjusted the cross ...

Page 771: ...shift fork retaining screw and lockwasher front Do not tighten at this time SPECIAL SCSsW FLATWA SPRING ENC IN HOLE LOW AND REVERSE LEVER CROSSOVER PIN SPRING LOOPED A R O U N D FORK SHAFT FLATWASHER TORSION SPRING LOWfeR BOOT 60x1340 k SECOND AND HIGH LEVER Fig 11 Lever Torsion Spring Installed 7 Engage the loop of the torsion spring w i t h the gearshift fork shaft and slide the other end into t...

Page 772: ...ct the mainshaft and syn spline fit on mainshaft chronizer hub and replace parts as necessary c Loose spline fit on low speed c Inspect the low speed sliding gear sliding gear to mainshaft and mainshaft Replace parts as spline necessary d Loose spline fit of rear main d Inspect the mainshaft and flange shaft flange splines Replace parts as neces sary e Damaged broken or exces e Replace the worn ge...

Page 773: ...025 inch 001 to 0025 inch 005 to 008 inch 008 inch maximum 115 to 117 inch Natural 097 to 099 inch Black 078 to 080 inch Red 059 to 061 inch Orange 062 to 064 inch 062 to 064 inch 060 to 062 inch 064 to 066 inch 060 to 062 inch 060 to 062 inch 064 to 066 inch 068 to 070 inch 060 to 062 inch Model Engine Cu In Kickdown Band Front Clutch Cushion No Spring Discs Accumula tor Spring Rear Clutch No Dis...

Page 774: ...e 55 Body End Cover 25 Band Lever Shaft Plug 35 Extension to Transmission Case 25 Filler Tube N u t 40 Intermediate Support Locating Screw 25 Case to Converter Housing 40 Kickdown Band Adjusting Screw N u t 35 Line Pressure Regulator Valve Retainer 50 Low Reverse Band Adjusting Screw N u t 35 Manual Valve Control Cable Housing 200 Neutral Starter Switch Initial Electrical Contact Plus 1 3 to V2 Tu...

Page 775: ...63 80 64 82 66 83 69 87 3 1 Kickdown L i m i t 30 43 31 44 32 45 33 47 Closed Throttle Downshift 6 13 6 13 6 13 7 14 LINE PRESSURE CHART Push Engine Line Button Speed Pressure Position Rear Wheels rpm P S I R Free to Turn 1600 200 240 N 1200 85 95 D Shifted into Direct Free to Turn 1200 89 91 2 Free to T u r n 1200 85 95 1 Free to T u r n 1200 85 95 D Free to Turn 3500 95 100 GOVERNOR PRESSURE CHA...

Page 776: ...lows Rear Clutch The rear clutch piston retainer and pressure plate have been modified by decreasing the clearance between the pressure plate drive lugs and the grooves i n the piston retainer The new pressure plate is also used in the front clutch assembly Servicing procedures for the clutch assembly remain the same however the new parts are not inter changeable w i t h earlier transmissions GROU...

Page 777: ...lows Rear Clutch The rear clutch piston retainer and pressure plate have been modified by decreasing the clearance between the pressure plate drive lugs and the grooves i n the piston retainer The new pressure plate is also used in the front clutch assembly Servicing procedures for the clutch assembly remain the same however the new parts are not inter changeable w i t h earlier transmissions GROU...

Page 778: ...re to 28 pounds Captive Air tires are optional equipment on Town and Country Wagon models only G I O U P 22 W H E E L S B E A R I N G S A N D T I R E S There are changes i n the tire and wheel specifica TIRE ROTATION tions The tire rotation plan has been revised The Tires should be rotated after the first 3 000 miles servicing procedures for the Wheels Bearings and and at 6 000 mile intervals ther...

Page 779: ...es and door lock system BUMPER FRONT NEWPORT WINDSOR MODELS Fig 1 Removal 1 Remove the bumper assembly to frame mount ing bolts and remove the bumper E X T E N S I O N Installation 1 Position the bumper against the frame and install the mounting bolts loosely 2 Align the bumper for correct spacing from side to side w i t h the front fenders and tighten the mounting bolts securely BUMPER FRONT NEW ...

Page 780: ... and tighten the mounting bolts securely BUMPER REAR RC 1 RC 2 A N D RC 3 MODELS Removal 1 Remove the bumper bar to frame mounting bolts and remove the bumper assembly 2 Remove the extension to frame reinforcement plates 3 W i t h the bumper removed from vehicle re move the bumper guards stabilizers extensions and bumper guards Installation 1 Install the bumper bar to frame extension bumper stabil...

Page 781: ...R GRILLE ATTACHING STUD HOLES Fig 3 Radiator Grille Chrysler Fig 4 Hood Lock Assembly install the attaching stud nut and washers Make sure the grille is centered properly i n the grille open ing before tightening the attaching nuts HOODLOCK HOOD AND HINGE ASSEMBLY CHRYSLER The hoodlock is manually operated w i t h the safety release catch located under the leading edge of the hood above the grille...

Page 782: ...ble knob enough to allow hood to snap up to the safety catch F r o m the outside of the car push down slightly on the hood to unlock the safety catch Removal 1 Remove the striker assembly mounting bolts from the hood assembly and remove the striker assembly 2 Remove the latch assembly to grille bar and yoke bracket attaching bolts 3 Remove the latch lever cable and wire lock ing screw and remove t...

Page 783: ...a plastic wedge above the rotor which slides on the top of the striker plate to prevent up and down movement of the door when i t is latched FRONT DOOR The front doors are locked from the outside w i t h a key and locking the front doors from the inside can be accomplished by pushing the handle forward I n effect both operations disconnects the outside door handle control linkage from the lock mec...

Page 784: ... Y C Y L I N D E R TO LOCK rtj LINK DOOR LOCK REMOTE Jj LEVER DOOR LOCK R E L E A S E jj L E V E R R E A R DOOR LOCK BLOCKING K L E V E R D E T E N T ACTUATOR L LOCKING L E V E R jV T R A N S M I T T I N G L I N K A C T U A T O R T R A N S M I T T I N G L I N K jp L O C K L O C K I N G CONTROL L I N K IMPERIAL 51X318 Fig 8 Door Lock and Linkage MyMopar com ...

Page 785: ...rvice procedures remain the same as outlined i n the 1960 Chrysler and I m perial Service Manual DOOR LOCK AND LINKAGE SERVICE DIAGNOSIS Condition Possible Cause Correction Door hard to open or sticks Door Is hard to close a a Striker rubbing on the door face or on the back rotor hous ing b Lock striker not set at the correct angle or position Door mouldings or t r i m inter fere w i t h the door ...

Page 786: ...i m panel away from the remote control handle Interference i n the remote con trol mechanism Adjust the t r i m panel to provide proper clear ance Remove the tapered coil spring from the re mote control handle shaft Inspect for an excessively tight anti rattle clip on the inner panel at the middle of the remote to lock link Properly lubricate the remote con trol mechanism and the lock assembly usi...

Page 787: ...y a Connect the link b Properly lubricate the lock Co Straighten the levers a Properly adjust the link b Properly lubricate and free up the levers c Free up the handle d Connect the link a Free up and adjust the handles as required Lock does not latch i n e x t r e m e c o l d weather Front door lock does not unlock when the door is closed after locking the door Front door locks auto matically whe...

Page 788: ...onnected f M a l f u n c t i o n i n g or f a u l t y switch c d f g Faulty vacuum distributor g Inspect the main vacuum hoses from the intake manifold to the vacuum tank and from the vacuum tank to the vacuum distributor Refer to Figure 9 Inspect the hoses for short bends kinks or being pinched Correct as required Install new hoses i f necessary Connect the manifold to vacuum tank hose Connect th...

Page 789: ...MyMopar com ...

Page 790: ...Fig 10 Vacuum Door Lock Tubing Diagrams Passenger Compartment MyMopar com ...

Page 791: ... the engine Move the control switch to the lock position I f no vacuum is felt at the red connection the switch is at fault Install a new switch d Remove the distributor to main tee hose marked red from the distributor connection Start the engine Operate the switch to the lock position I f no vacuum is felt at the connection the distributor is at fault Install a new dis tributor e Inspect all the ...

Page 792: ...Fig 11 Front Door Vacuum Lock MyMopar com ...

Page 793: ...MyMopar com ...

Page 794: ...the cowl side panel l o c k o f t h e o t h e r Hoses improperly connected at b Connect the hoses at the actuator correctly doors the door lock actuator Refer to Figure 11 and Figure 12 One door vacuum lock a Binding or malfunctioning door a Remove the door inside t r i m panel Inspect the fails to operate Man lock actuator linkage actuator and linkage correct as required See ual operation satis F...

Page 795: ...the cowl side panel l o c k o f t h e o t h e r Hoses improperly connected at b Connect the hoses at the actuator correctly doors the door lock actuator Refer to Figure 11 and Figure 12 One door vacuum lock a Binding or malfunctioning door a Remove the door inside t r i m panel Inspect the fails to operate Man lock actuator linkage actuator and linkage correct as required See ual operation satis F...

Page 796: ...Set C 3363 Wrench Set C 3420 Adapter C 3429 Scale C 3478 Cutter SP 3496 Tool C 3499 Tester C 3569 Torch C 3616 Ratchet C 3620 Socket C 3621 Socket C 3622 Extension C 3623 Thermometer C 3644 Test Hose C 3645 Test Hose C 3652 Vacuum Pump C 3663 Condenser Comb C 3704 Psychrometer C 3707 Gauge C 3740 Tester C 3741 Adapter K i t C 3787 Puller C 3788 Tool C 3807 Sleeve C 3822 Tool C 3825 Tool These numb...

Page 797: ... factory to provide maximum cooling and is not adjustable The functioning however is the same as the external valve described i n the 1960 Chrysler and Imperial Service Manual except that the service port valves are i n different locations Refer to Figure 2 which shows the new gauge set manifold connections A revision was also made i n the valve plate assemblies Refer to Paragraph Servicing the Co...

Page 798: ...e EPR Valve the disassembly and assembly of the compressor is the same as described in the 1960 Chrysler and Imperial Service Manual The removal and installation of the Cylinder Head and Valve Plate assemblies however are the same except that there is no etxernal oil return tube The valve plate and reed valve are different as shown in Figure 6 EPR Valve Removal 1 Remove the EPR Valve suction line ...

Page 799: ...the current draw is not w i t h i n these limits install a new field coil assembly Removal 1 Disconnect the field coil lead wire and remove drive belts 2 Remove special locking bolt and washer from compressor crankshaft at front center of clutch 3 Insert a 11 x 2 1 cap screw into the threaded portion of the hub and shoe assembly 4 Support clutch w i t h one hand then tighten the cap screw until th...

Page 800: ...shoe assembly F i g 9 Tighten the 11 hex head bolts down until the drive hub is removed from the bearing R V A L V E P L A T E G A S K E T K V A L V E P L A T E A S S E M B L Y C Y L I N D E R H E A D A G A S K E T 4 TOOL PILOT STUDS Iv3 Ptoe and Cylinder Head R E E D V A L V E ASSEMBLY V A L V E P L A T E CYLINDER HEAD 61 x 95 Hp 61 x 94 Fig 6 Valve Plate Installed Position MyMopar com ...

Page 801: ...h Stationary Field Type PULLER C 3787 60x896 Fig 9 Removing Hub and Shoe Assembly 3 Start drive hub into inner bearing race then press hub into position w i t h an arbor press 4 Install bearing snap ring and hub snap ring C A U T I O N The pulley assembly and hub assembly are mated parts They are burnished at the factory before shipment I t is recommended they be replaced i n matched pairs Replace...