1964 Plymouth Valiant Service Manual

2 INTRODUCTIUN AND GENERAL SPECIFICATIONS
m - r n
-
PLYMOUTH SPORT FURY CONVERTIBLE
VALIANT SIGNET 200 CONVERTIBLE COUPE
VALIANT V-100 TWO-DOOR SEDAN

64x551
Fig. 1-1964 Plymouth and Valiant Models
INTRODUCTION AND GENERAL SPECIFICATIONS 3
FACTORY CONTACT
The following outline of the proper procedure to use in obtaining assistance or advice on any matter
applying to Service will insure your inquiries receiving prompt attention and handling. Make certain
those members of your organization who might have the occasion to contact either your Regional Of-
fice or the factory, are thoroughly familiar with this procedure. All matters pertaining in any way to
Warranty Service Claims, or of a technical nature, should be handled by you direct with your Regional
Service Office. When in doubt as to the proper procedure to follow in the handling of a claim or com-
plaint, prompt results can be obtained through a letter, telegram or phone call to your Regional Serv-
ice Office-making certain to include all necessary information. If the aid of a Service Representative
is necessary, the Regional Office will arrange for his contact as promptly as circumstances permit.
Letters or telegrams to the Regional Service Office, should be confined to one subject only and
include the following information:
Car Serial Number Owner’s Name
Date of Sale Mileage
Complete description of difficulty, corrective action taken, your recommendations as to what should
be done and the reason for so doing.
Include Paint and Trim Code Numbers where finish, upholstery, body or sheet metal is involved, and
estimate of net cost of repairs.
CHRYSLER-PLYMOUTH D I V I S I O N
With the exception of orders for parts or parts literature, all requests for Imperial, Chrysler, Plym-
outh or Valiant Service literature such as Service Bulletins, Service Manuals, Owner Manuals, Time
Schedules, W.S.C.3 or other Chrysler-Plymouth Division Service Literature, should be addressed to:
(Letters) (Telegrams)
Chrysler Corporation Chrysler - Plymouth Division

Chrysler - Plymouth Division Attention,
Service Department (Name of person to whom sent)
P.O. Box 1658 a wux
Detroit 31,Michigan Detroit, Michigan
(Phone) 822-4700
NOTE: Please make certain to include the Code WUX on all telegrams to the Chrysler-Plymouth Divi-
sion as this insures delivery direct to our Teleprint Room thus eliminating delay.
MASTER TECHNICIANS SERVICE CONFERENCE

All correspondence concerning enrollment in the M.T.S.C. Program, issuance of awards, orders for
additional material, the return of reports, or any other matters relating to this program, should be ad-
dressed to:
Master Technicians Service Conference
Chrysler Corporation Training Center
P.O. Box 2119
Detroit 31,Michigan
(Phone) 539-3000
4 INTRbDUCTfON AND GENERAL SPECIFICATIONS
PARTS DIVISION
General
ALL orders for parts or accessories, emergency or otherwise, should be forwarded direct to your
usual source of supply or to the parts plant listed below serving the area in which you are located.
To insure your receiving the parts required by you more promptly, close attention should be given
to the procedure listed under “Ordering Information” and “Your Parts Orders” in the introductory
front part of all MoPar Parts lists and Price Lists. Particularly where parts are ordered for a specific
car, it is very essential that your order include the serial and engine numbers, and in the case of body
parts, the body number.
CENTER LINE, MICHIGAN SAN LEANDRO, CALIFORNIA
Mail Address: Mail Address:
Chrysler Motors Corporation Chrysler Motors Corporation
P.O. Bix 300 1955 Davis Street
Center Line, Michigan San Leandro, California
Telephone - 539-3000 Telephone -Neptune 8-6200
NEWARK, DELAWARE ATLANTA, GEORGIA
Mail Address: Mail Address:
Chrysler Motors Corporation Chrysler Motors Corporation
South College Avenue 1150 Murphy Avenue, S.W.
P.O. Box 120 P.O. Box 10786
Newark, Delaware Atlanta 10, Georgia
Telephone -Endicott 8-2521 Telephone -Plaza 5-2531
KANSAS CITY, KANSAS
Mail Address:
Chrysler Motors Corporation
Funston & Chrysler Roads
Kansas City 15, Kansas
Telephone -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 Motors Corporation
P.O. Box 1718
Detroit 31, Michigan
Attention: Parts Catalog Department
Shortage of Accessories or Other Equipment on New Cars
Before placing an order for missing accessories, other parts or equipment, on new cars received, ex-
amine the vehicle for the presence of a “back order” notice, which if present, will be found attached to
the bracket for the inside rear view mirror. Such back-ordered short items will be shipped from the
assembly plant as soon as stock is available, and should not be ordered from the Parts Division.
Emergency Orders---Car Down or Truck Down
1. When parts are not immediately available from your local MoPar source of supply, TELEPHONE,
TELEGRAPH or AIR MAIL your order to:
a. PARTS PLANT SERVINGYOUR AREA for parts coded “V”, “F”, “M” and “P”. Use Parts Or-
der Form No. 81-670-0139.
.
b. FACTORY PARTS PLANT AT CENTER LINE for all parts coded “D” . . and orders for “D”
parts combined with “V”,“F”, “M” and “P” parts required for an individual service job. Use
Parts Order Form No. 81-670-0190 (supersedes D-16712).
C. Quantities ordered should not exceed actual requirements for vehicle out of service.
Always supply car, vehicle serial number and Truck Parts Availability Number (1960-62 Mod-
els) in addition to Vehicle Serial Number.
2. Identify orders as “Emergency Car Down” or “Emergency,Truck Down”.
3. List part numbers in numerical sequence. Use your dealer code number on all orders. Assign only
one order number to the order regardless of size.
4. “V”, “F”, “M”, and “P” parts will be shipped transportation charges collect. “D” parts will be
shipped transportation prepaid when “Normal Prepaid Transporation” is specified; shipped col-
lect when “Premium Transportation”’ is specified.
INTRODUCTION AND GENERAL SPECIFICATIONS 5
VEHICLE AND ENGINE NUMBERS m---

VEHICLE NUMBER The vehicle number (serial nuin-
ber) is located on a plate attached to the left front
door hinge pillar post (Fig. 2).
All vehicle number contain ten digits. The vehicle .
number is a code which tells the make of car (1st dig-
it), model of car (2nd digit), year built (3rd digit), as-
sembly plant (4th digit) and vehicle sequence number
(last six digits.
Fig. 2-Vehicle Number Plate
1rt Digit 2nd Digit 3rd Digit 4th Digit

Make of Vehkle Model of Vehicle Year Built Assembly Plant
Valiant Plymouth 1964 1 and 3 Detroit

1. Valiant 1. v-100 Savoy 5. 10s Angeles
2. - Belvedere
2. Plymouth (6 Cyl.) 3. v-200 Fury 6. Delaware
4. Signet 200 Sport Fury
3. Plymouth (8 Cyl.) 5. V-100 Sta. Wagon Savoy Sta.-Wagon 7. St. Louis
6. - Belvedere Sta. Wagon
7. V-200 Sta. Wagon Fury Sta. Wagon
ENGINE NUMBER The 170, 225, 361, 383 and 426

engine numbers contain the model, cubic inch 'dis-
placement and manufacturing date, Figs. 3 and 5. The
318 engine number contains the model, cubic inch
displacement and serial number. (Fig. 4). The numbers S
are stamped on a boss on the cylinder block as shown.
Fig. 3-Engine Number location
(170 and 225 Cu. In. Eng.)
BODY NUMBER The body number plate is located

on the fender shield near the battery. The numbers
contain the body number, trim number and the paint
code. (F'ig. 6)
Fig. &Engine Number location (318 Cu. In. Eng.)
63x606
Fig. &Body Number Plate location Fig. 5-Engine Number location (361, 383 a n d 426)
6 INTRODUCTION AND GENERAL SPECIFICATIONS
GENERAL DATA AND SPECIFICATIONS
VP-1 Plymouth 6-Cyl. VP-2 Plymouth 8-Cyl. W - 1 Valiant.6-Cyl.
'Item Body Style

Two Door Sedan Savoy, Belvedere Savoy, Belvedere v-100 v-200
Two Door Hardtop Belvedere, Fury Belvedere, Fury, Sport Fury Signet 200
Convertible Coupe Sport Fury V-200, Signet 200
Four Door Sedan Savoy, Belvedere, Fury Savoy, Belvedere, Fury v-100, v-200
Four Door'tlardtop Fury
Station Wagon Savoy Savoy, Belvedere, Fury v-100, v-200
Wheelbase All Models 116" 116" 106"
Tread (Front) All Models 59.5" 59.5" 55.9"
Tread (Rear) All Models 59.6" 59.6" 55.6"
length with All Models except

Bumper Station Wagons 206.5" 206.5" 188.2*
Station Wagons 210.1" 210.1" 188.8"
Width with All Models except

Bumper Station Wagons 75.6" 75.A"- 70.1 "
Station Wagons 75.1" 75. 1 70.1"
Rear Axle
with Manual All Models except
Transmission Station Wagons 3.31" (3-Speed) 2.93" (1 Economy) 2.93"
3-Speed or (4-Speed) 3.23" (Perf,ormance) 3.23"
4-Speed Station Wagons 3.23" (3-Speed) 2.93" (1 Economy) 2.93"
(4-Speed) 3.23" (Perf1ormance) 3.23"
mar Axle All Models except

with TorqueFlite Station Wagons 2.93" 2.76" 3.23"
Transmission Station Wagons 3.23" 2.76" 3.23"
Tire Size All Models except

Station Wagons 7 . 0 0 ~ 1 4 ~Ply
2 7.00~14,2 Ply 6 . 5 0 ~13,2 Ply
Station Wagons 7 . 0 0 ~ 1 4 ~Ply
4 7 . 0 0 ~ 1 4 ~Ply
4 6 . 5 0 ~13,2 Ply
LUBRICATION AND MAINTENANCE 0-1
LUBRICATION AND MAINTENANCE CHART

NORMAL SERVICE
Engine Coolant-Check Ievol and/or Anti-Freeze Cmnkcare Dlprtlck . . . Check level when rofueling.
every 2 months. Cooling rystem pressure, 14
pounds; with air conditioning, 16 pounds. Carburetw Fuel Filter (Replace) 16,000 Miles or
Battory (Check Level) every 2 months.

Manifold Heat Control Valve treat with solvent
PSF Power Sfeerlng Rarorvolr (Check Level). Fill
to the bottom of the Aller neck (every 6 months). Crankcaao Ventilator Valve (Inspect) Every 6
EO Englne Oil (Chango) overy 2 months (net to Months. (Replace) Once a Year.
exceed 4,000 miles).
A Automatic Tranrmlrsion every 6 months. Chock
Multlgrader level, engine idling and thoroughly warm, NEU-
SAE lOW-30 Suitable year around for most parts of TRAL position. To overcome difficult starting below
the country may be used as low -10'. replace 1 % pints fluid with kerosene. Do
as 1O°F.- not dilute more than once during any one season.
SAE 5W-20 Recommended i f temperatures are MCC Carburetor Choke Linkage and Shaft
consistently below +1 O°F. (Every 6 months) Apply to choke shaft through the
Single grader
SAE 30 When temperatures are consistently Engine Oil F l l t r Element (Replace) every 6
above 32°F. months to coincide with an oil change.
SAE 10W When temperature ronges average
between 3 2 and -10°F. DCL Dlrtrlbufor (Every 10,000 Miles) Apply to cam
SAE SW When temperotures ore consistently and rubbing block.
below - 10°F. EO Dlrtrlbutor O i l Cup ond Wick under Rotor
(Every 10,000 miles.)
Carburetor Air Filter (Clean every 6 mo
Not to exceed 8,000 Miles (Replace Element Engine Tune-up every 10,000 Miles or once
Every 2 years, not to exceed 32,000 miles. each yeor.
MP M a n w l Stewing %or [Check Level) Above -30" Body Hardwan (every 6 months).
80; below -30", 75 (every 6 months). DPO Door and Tailgate Hingor and Rotwr.
HTF Broke Martor Cylinder (Check Level) Fill to % SL Striker Plator and Torsion Bw Roller Coma.
inch below top of reservoir (every 6 months).
ML Hood Hlnger and Lockr-Llcenre Plclt. Mount-
MML Front Surpenslon Ball Jolnh (every 6 mon ing Springs-Fuel Tank Cover.
Inspect seals for damage, replace i f necess
After replacing seal or when relubricating, rem EO Dock Lid Latch.
plug, use adapter. lnstoll plug. WB Front Brake Asromblier and Front Wheel
or Bearings. (Inspect) Every 20,000 miles or every
(Evny 32,000 Miler) Relubricate using specie AMO two years.
adapter. Fill until grease flows from upper bal
joint bleed holes or lower joint seal lower lip Tighten front wheel adjusting nut to 90 in.-lb.,
Do not rupture seals. Reinstall plug. position lock nut over odjusting nut so that one
set of slots on lock nut aligns with drilled hole
MML Steering Linkage Pivot Seals (every 6 months). in axle spindle. Back off adjusting and lock nuts
Inspect seals for damage, replace i f damaged one slot and install cotter key.
or worn. Relubricate every 32,000 miles.
Front Reor
AMO Clutch Torque Shaft (every 32,000 Miles). -14 . . . . _ . _ _ . . . . .__ ...., , . . _ . _24 22*
Relubricate shaft bearings and release fork.
on, 26; increase rear tire pressure A
A M 0 Clutch Roleare Fork Swivel Clean swivel and
swivel socket and Clutch releose fork and
lubricate when disassembling.
AA Manual Tranrmirrlon (Check Level) every 6
MCLSpeodometer Cable Lubricant

MHLMoPor Hypold Lubricant
CAPACITIES
Engine Oil 4 qts.
Position for lift adapter ML Lubriplate
(Add 1 qt. when replacing Alter ehment) A Prepacked bearing MMLMoPar Multi-Miloage lubricant
MP Multi-Purpore Geor Lubrlcanf
Cooling System 20 qts. Cooling system drain DPO Dripless Penetrating Oil
(Add 1 qt. for heater)
Rear Axle
Transmission (refill)
4 pts. PLYMOUTH PSF
s
SL
Power Steering Fluid
Manifold ~ o o Control
t valve Solwnt
Stoinlers Stick Lubricant
TorqueFlite 20 pts. WB Wheel Bearing Lubricant-Medium
Manual 3-Speed
4-Speed
4 % pts.
7 pts. i V- 8 6 4 x 660
MMC Mopar Carburotor Cleaner
0-2 LUBRICATION AND MAINTENANCE
LUBRICATION AN*D MAINTENANCE CHART

N O R M A L SERVICE
Engine Coolant-Check level and/or Anti-Freeze EO Engine Oil (Change) every 2 monthl (not to
every 2 months. Cooling system pressure, 14 exceed 4,000 miles).
pounds; with air conditioning, 16 poun Multlgrader
Eattory (Check Level) every 2 months. SAE 1OW-30 Suitable year ar3und for most parts of
the country may be used as low
PSF Power Steering Rerervoir (Check
to the bottom of the filler neck (eve
as -
1 O°F.
SAE 5W-20 Recommended if temperatures are
Carburetor Fuel Flitor (Replace) 16,000 Miles or consistently below 10°F.+
once each year.
Single grader
Crankcare Diprtlck ...Check level when refueling. SAE 90 When temperatures are consistently
above 32'F.
MCC Carburetor Choke Linkage and Shaft
(Every 6 months) Apply to choke shaft through the SAE 1OW When temperature ranges average
air horn. between 32 and - 10°F.
SAE 5W When temperatures are consistently
S Manifold Heat Control Valve treat with solve
every 6 months.
below -
1 O°F.
Dirtributor (Every 10.000 Miles) Apply to cam
Carburetor Air Fllhr (CledH every 6 month
and rubbing block.
Not to exceed 8,000 Miles (Replace Elemen
Every 2 years. not to exceed 32,000 miles. Diatributor Oil Cup and Wick under Rtitor
(Every 10,000miles.)
MP Manual Shoring O.ar (Check Level) Above -30°,
80; below -30°, 75 (every 6 months). Engine Oil F l k n Element (Replace) ev6ry 6
months to coincid6 with an oil change.
HTF Broke Martor Cyllndw (Check Level) Fill to %-
inch below top of reservoir (every 6 months). Crankcare Ventilator Valve (Inspect) Every 6
Month). (Rbplace) Once a Year.
Engine Tune-up every 10,000 Miles or once
each year. AA Automatic Tronrmlrrlon every 6 months. Check
MML Front Surpmnslon 8011 Jolnh (every 6 months). levbl, engine idling ond thoroughly warm, NEU-
Inspect seals for damage, repiace i f necessory. TRAL position. To overcome difficult starting below
After replacing seal or when relubricating, remove -loo, replace 1 Yz pints fluid with kerosene. DO
plug, use adapter. Install plug. not dilute more than once during any one season.
(Evory 32,000 Milea) Relubricate using special Body Hardwan (every 6 months).
\
adapter. Fill until grease flows from upper boll
DPO Door and Toltgah Hingor and Roton.
joint bleed holes or lower joint seal lower lip.
Do not rupture seals. Reinstall plug. SL Striker Plater
MML Stowing Llnkaga Ball Joints (every 6 months). ML Hood Hlnger and Lockr-Llcenre Plah Maunt-
Inspect seols for damage, replace i f damaged ing Springs
or worn. Relubricote every 32,000 miles. EO Deck Lid Latch.
AMO Clutch Torque Shaft (every 32,000 Miles).
Relubricate shaft bearings and release fork. WB Front Brake Arrembller and Front Wheel
or Bearingr. (Inspect) Every 20,000 miles br every
AMG Clutch Releare Fork Swivel Clean swivel and AMO two years.
swivel socket and Clutch release fork and
lubricate when disossembling. Tighten front wheel adjusting nut to 70 in.-lb. on
Valiant 6 and 90 in.-lb. on Plymouth 6, position
AA Manual Tranrmlrrlon (Check Level) every 6
lock nut over adjusting nut so that one set of slots
months. Maintain level to fill plug hole. Use MP
on lock nut aligns with drilled hole in axle spindle.
for 4-Speed Manual Transmission.
Back off adjusting and lock nuts one slot and
MML U n l v m a l Jointr every 6.months, inspect seals for install cotter key.
leakoge. Relubricate as necessary.
MP Rear Axle and SureOrip (Check. Level) every
6 months. Above -loo, 90; os low as -30°, 80;
below -30°, 75. Maintain level to All plug hole. KEY TO LUBRICANTS
(MHL can also be used on all axles.) AA Automatic Trona. Fluid Typo "A"
T i n a . . . , . , . . . . Prerrure Suffix "A"
AMG Automotive Mukl-Purpore Qreore
CL Charrir Lubricant
. . . . . . . . . . . . . . . ,. .
i- 24 DCL Mopar Cam Lubricant
increase rear tire pressure 4 EO Engine Oil
HTF High Tempomture Brake Fluid
MCL Speedometn CaMe Lubricant
A Prepacked bearing MHL MoPar Hypoid Lubricant
ML Lubriplate
Cooling system drain
MML MoPar Multi-Mileage Lubricant
MP Multi-Purpore Gear Lubricant
DPO Driplerr Penetrating oil
PSF Power Steering Fluid
Plymouth 6 4 pts. Manifold Heat Control Valve Solvent
VALIANT
S
TorqueFlite 6 18 pts.
Manual- 3-Speed-Valiant 7 pts.
, SL Stainleas Stick Lubricant
64 x 671 WB Wheel Bearing Lubricont-Medium
Plymouth 6-4.5 pts.
4-Speed-Valiant 7 DtS. - 2-Plvmouth, Valiant
Fig. MMC Mopar Carburetor Cleaner
I Plymouth 6-7pts. 1 6-Cylinder lubrication Chart .
LUBRICATION A N D MAINTENANCE 0-3
GROUP 0
CONTENTS
Page Page
Capacities, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication and Maintenance Service, . . . . . . . . . . . . . 5 Parts Requiring No Lubrication. . . . . . . . . . . . . . . . . . . 16
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Propeller Shafts and Universal Joints. . . . . . . . . . . . . . . 16
Selection of Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear Axle and Sure-Grip.. . . . . . . . . . . . . . . . . .
Frequency of Oil Change.. . . . . . . . . . . . . . . . . . . . . 6 Speedometer Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steering.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Carburetor Choke Linkage and Shaft. . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Crankcase Ventilator Valve. . . . . . . . . . . . . . . . . . . . . 8 n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hood Latch.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Manifold Heat Control Valve,, . . . . . . . . . . . . . . . . . . . 10 Passenger Car Maintenance Schedule
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 for Certified Car Care,, . . . . . . . . . . . . . . . . . . . . . . 20
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Recommended Services a t Mileage Intervals. . . . . . . . . 21
Body Maintenance, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Passenger Car Trailer-Towing Service. . . . . . . . . . . . . .
Brakes. . . . . . . . . . . . .... ............ 11 Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chassis Lubrication . . . . . . . . . . . . . . . . . . . 11 Certified Car Care-Engine Performance
Clutch and Gearshift Linkages. . . . . . . . . . . . . . . . . . . . 13 Evaluation Every 10,000 Miles. . . . . . . . . . . . . . . . . 22
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Certified Car Care-Semi-Annual Maintenance 22
Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Certified Car Care-Brake System Maintenance
Front Wheel Bearings. . . . . . . . ... ........ 14 every 20,000 Miles. . . . . . . . . . . . . . . . . . . . . . . . . . 22
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Certified Car Care-Front Suspension Alignment. . . . . 23
S U M M A R Y OF LUBRICATION AND MAINTENANCE SERVICES

Maintenance and lubrication services recommenda-
tions for the 1964 Chrysler Corporation cars have
been compiled (designed etc.) to provide maximum CERTIFIED CAR CARE
protection to vehicle owners against all types of
driving conditions. These, as well as driving habits,
are so varied that to prescribe the lubrication and Certified Car Care is a thorough servicing program
maintenance services on a mileage basis only did that helps make sure the vehicles you sell get the
not take care of those who drove fewer miles during regular attention you know they need.
equal length time periods, especially during adverse
weather conditions. Certified Car Care helps build business for you in
These recommendations, therefore, have been re- the surest way known - through customer satisfaction,
lated to the best of our ability to time intervals, yet not to mention the extra profits from the service de-
limited by mileage where necessary. In general, semi- partment. Tell your owner that the best approach to
annual lubrication and maintenance services have trouble-free driving is Certified Car Care . . .
been prescribed for most items. Exceptions to this
include two month intervals between engine oil chan- A practical plan to build sales and service for you,
ges (not to exceed 4,000 miles) opposed to the front providing for regular customer service at your dealer-
suspension lubrication every 32,000 miles. ships.
04 LUBRICATION AND MAINTENANCE
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LUBRICATION A N D MAINTENANCE 0-5
Service
Service Inspect InIpect

Interval Item Fluid and/or
Replace level Clean lubricate Service
2 Months Engine crankcase oil X

(not to exceed 4,000 Miles)
6 Months Engine oil filter X

Oil filler air cleaner X X
Manifold heat control valve X
Crankcase ventilator valve X
Carburetor choke shaft & linkage X
Transmission X
Rear axle X
Steering gear X
Steering linkage X
Universal joint X
Prop. shaft spline X
Brake master cylinder X
Brake hoses X
Carburetor air cleaner X
(not to exceed 8,000 Miles)
1 Year Engine Performance Evaluation

(not to exceed 10,000 Miles) X
Fuel filter
2 Years Brake linings

Carburetor air cleaner
32,000 Miles Ball joints, front suspension

& sttcring linkage X
Clutch release fork pivot X
Clutch torque shaft bearings X
When Body mechanisms X

Necessary Speedometer cable X
Manual gearshift linkage X
Front wheel bearing
(with brake service) X X
Parking brakes X
Clutch linkage & pressure plate
drive lugs X
1. ENGINE OIL the container should not be used. The pfoper viscosity
number should be selected based on the lowest
Lubricants are classified and graded according to
temperature expected during the coming period of
standards recommended by the Society of Automotive
usage.
Engineers (SAE),the American Petroleum Institute
(API) and the National Lubricating Grease Institute
(NLGI). 3. FREQUENCY O F OIL CHANGES
The SAE grade number indicates the viscosity of Chrysler Corporation recommends that engine oil
the lubricant (Example, SAE 30). Engine oils may be changed at least every two months. Cars driven
have a dual number, one of which is SAE 1OW-30. more than 2,000 miles per month should have the
This marking indicates that the oil is comparable to engine oil changed at a maximum of 4,000 miles.
SAE low,SAE 20W and SAE 30 grades. If the cars are operated under unusual conditions,
Both the SAE number and the MS designation the owner should consult the local dealer's Service
should be marked on the container. Manager to determine the best program to follow.
Complete information pertaining to the lubrication The two most important factors which effect oil
points, is shown in Figures 1 and 2, for the Plymouth life, aside from oil quality, are: Engine temperature
and Valiant Models. and type of driving.
At low engine temperatures harmful condensation
2. SELECTION O F LUBRICANT and sludge-forming impurities accumulate in the
engine oil. These cause corrosion of vital engine
For best performance and to provide for maximum
parts and harmful deposits. Highway driving pro-
protection of all engines, for all types of operation, duces higher engine temperatures which dissipate
only those lubricants should be selected which; con-
these impurities. Short trip driving at slower speeds
form to the requirements of the API Classification does not warm the oil sufficiently to drive off these
"For Service MS". Straight mineral or nondetergent
contaminants. Therefore, short trip driving at lower
oils never should be used.
temperatures decreases the effective life of the oil
Have the proper SAE grade number for the antic- while highway driving extends the effective lubricant
ipated temperature range. life.
Although all viscosity grades can be used safely at For example, highway driving, and longer trips per-
nearly all temperatures, light oils SAE 5 W and 1OW mit oil changes at 4,000 mile intervals. Short trips
increase oil consumption at high temperatures and
(less than 10 miles) and slow speeds, such as to the
heavy oils SAE 30 make engine starting more difficult store, school, work etc, and home again before the oil
in cold weather. The recommended viscosity grades warms up causes harmful condensation and sludge
are:
formation. This is typical of most city operation. Oil
changes should be made at intervals no longer than
Multigrades--SAE 1OW-30 Suitable year around for
most parts of the coun-
try may be used as low
as -10" F.
SAE 5W-20 Recommended if tem-
peratures are consistent- @.
BRAKE
ly below +loo F.
Single grades SAE 30 When temperatures are
consistently above 32" F.
SAE low When temperature
ranges average between
32 and -10" F.
SAE 5w When temperatures are
consistently below -10"
F.
Lubricants which do not have both an SAE des-

ignation and an MS service classification shown on Fig. 3-Engine Oil level Dipstick (64~1.)
every two months.
Severe operating conditions such as frequent
driving on dusty roads or in sandy geographic areas
or unusually short trips in cold weather will require
more frequent service.
During Break-In-The oil added to the engine at
the factory is a high quality lubricant, classified for
“Service MS”. It should be retained for two months
or 4,000 miles, whichever comes first. If it becomes
necessary to add oil during this initial period, an oil
for “Service MS” and of the proper viscosity grade
should be used (Fig. 3). “Non-Detergent” or “Straight
mineral” oils should not be used during the break-in
period.
Frequently a new engine will consume some oil
during its first few thousand miles of operation. This
should be considered as a normal part of the break-in,
and not interpreted as an indication of difficulty. Fig. 5-Engine Oil Filler Cap Air Cleaner (6-Cyl.1
4. AIR CLEANERS a new element should be installed every 2 years not

Oil Filler Cap to exceed 32,000 miles (Figs. 6 and 7).
After removing the air cleaner from the carburetor,
Engines require ventilation through the crankcase remove the cover and the filter element, clean the
to remove combustion products. Air enters the engine housing and cover with compressed air. Using com-
through the oil filler pipe which is equipped with a pressed air, gently clean the paper element by holding
combination cap and air cleaner to protect the engine the air nozzle at least two inches from the inside
from dust laden air. The oil filler cap should be washed screen. Examine the paper element for punctures.
in kerosene and re-lubricated with SAE 30 engine oil Discard an element that has a little as a pin-point
every 6 months (Figs. 4 and 5). Cars which are op- puncture. Examine the soft plastic sealer on both
erated in extremely dusty areas should be serviced sides of the element. These sealing surfaces must
more frequently. be smooth and uniform. Refer to Paragraph “Car-
Carburetor Air Cleaner buretor Choke” linkage and shaft for servicing at
this time.
The paper element carburetor air cleaner should
be inspected every 6 months, not to exceed 8,000
miles and cleaned as often as conditions warrant and
-
PI
63x373
Pig. 4-Engine Oil Filler Cap Air Cleaner (8-Cyl.) Fig; &Carburetor Air Cleaner (8-Cyl.)
W Run the engine at idle to clean out any excess

from the system. Refer to Paragraph “Carburetor Air
Cleaner” for servicing at this time.
6. CRANKCASE VENTILATOR VALVE
All models are equipped with a positive crankcase
ventilating system. This system is similar, but not
identical, to systems used on the previous .models
(Fig. 8).
The system must be kept clean to maintain good
engine performance and durability as deposits will
accumulate in the valve, hoses and the carburetor
parts, therefore, the ventilation system should be
inspected at least every six months and the valve
replaced once a year preferable to coincide with the
annual engine performance evaluation. This service
will be required more frequently if the vehicle is
used extensively for short trips - driving less than
10 miles - with frequent idling, such as city traffic.
0 63x372
With the engine running at idle, remove the ventil-
ator valve and cap assembly from the rocker cover. If
the valve is not plugged, a hissing noise will usually
Fig. 74arburetor Air Cleaner (6-Cyl.) be heard as air passes through the valve and a strong
vacuum should be felt when a finger is placed over
5. CARBURETOR CHOKE LINKAGE the valve inlet. Replace the ventilator valve and cap
A N D SHAFT assembly and remove the inlet breather cap. With
the engine still running at idle, loosely hold a piece
Every 6 months apply MoPar Carburetor Cleaner, of stiff paper or a parts tag over the oil fill pipe.
Part Number 1643273 to prevent the choke sticking It should be sucked against the oil fill pipe with a
from gum deposits on the choke shaft. noticeable force. If this occurs, a final test should be
Remove the air cleaner and apply the cleaner while made to be certain the valve shuttle is free. A
moving the choke blade back and forth until gum clicking noise should be heard when the valve is
formation is flushed out. Apply the cleaner to the shaken (engine not running). If the noise is heard,
choke shaft where it rotates in the air horn to remove the unit is satisfactory and no further service is nec-
gum and dirt from these surfaces. essary.
INTAKE MANIFOLD
CONNECTING TUBE
INTAKE MANIFOLD CONNECTING TUBE
FLOW CONTROL VALV
THIS WASHER IS COLOR CODED TO IDENTIFY VENT

VALVE ASSEMBLY SEE SPECIFICATIONS
61 x265A
SIX - CYLINDER ENQINES V-8 ENQINES
Fig. &Closed Crankcase Valve Schematic (6 & 8 Cyl.)

If the valve does not click when shaken or if the

paper is not sucked against the fill pipe, the valve
should be replaced and the system retested (Do not
attempt to clean the valve). On 170 cubic inch en-
gines use MoPar Ventilator Valve identified by a
stamped number 6 on the end, a step on the end
face, or a white end washer. On all other engines,
use MoPar Ventilator Valve, identified by a letter
“H”stamped on the end, a flat end or a black end
washer. With a new valve installed, if the vacuum can
be felt with the engine idling, the system is satis-
factory. If the vacuum cannot be felt, it will be nec-
essary to clean the ventilator hose and the passages
in the lower part of the carburetor. The carburetor
must be removed and cleaned by dipping the lower
part of the carburetor in solvent. A pipe cleaner or
small wire may be used in cleaning the passages. It is
not necessary to disassemble the carburetor for this
service. Fig. IO-Engine Oil Filter (6Cyl.)
7. ENGINE OIL FILTER

Efficient filtering yf the engine oil is very im-
portant to provide good engine protection (Figs. 9
and 10). The oil filter should be replaced at a maxi-
mum of 6 months to coincide with an engine oil P
change. Short trips, stop and go operation, or opera-
tion in dusty areas may require more frequent filter
changes. All engines are equipped with a full-flow
oil filter. Filters vary widely in quality, and it is rec-
ommended that MoPar Engine Oil Filter, Part Num-
ber 1851658 be used, to assure the most efficient
service.
8. FUEL FILTER
The fuel filter (Figs. 11 and 12) should be replaced L
Fig. 11-Fuel Filter (8-Cyl.)
at least every 16,000miles or once each year. Loss of

performance may occur if the filter traps an unusually
large quantity of foreign matter due either to opera-
TOOL
58x239
Fig. 9-Engine Oil Filter (8-Cyl.) Fig. 12-Fuel Filter (6-Cyl.)
Fig. 13-Manifold Heat Control Valve (8-Cyl.)

Fig. 14-Manifold Heat Control Valve (6-Cyl.)
ting conditions or contaminated fuel, restricting the
flow of fuel to the carburetor. If this occurs the filter trical” for complete servicing of the Alternator).
should be replaced as required.
11. BATTERY
9. MANIFOLD HEAT CONTROL VALVE I
Every 6 months or more often under adverse con- Refill the battery as necessary with distilled water
ditions, apply Manifold Heat Control Valve Solvent, and test the specific gravity. Clean and tighten the
Part Number 1879318 to each end of the valve shaft battery cable, terminals and the battery posts. Refer
when the manifold is COOL. Work the valve back and to Group 8,“Electrical” for complete servicing.
forth a few times to distribute the solvent to make
sure the lead deposits’are dissolved (Figs. 13 and 14). 12. BODY MANTENANCE
NOTE: Apply manifold heat control solvent only To maintain ease of operation and protection
when the exhaust manifold is COOL. against rust and wear, the body mechanism and
throttle linkages will require lubrication every 6
10. ALTERNATOR months. Prior to applying any lubricants, the parts
The alternator is equipped with pre-lubricated bear- should be wiped clean to remove dust and grit. The
ings, which require no periodic lubrication servicing. excess oil or lubricant should be removed.
The outside of the alternator should be wiped clean Particular attention should be given to external
and the ventilating holes inspected for an accumula- lock cylinders during fall and winter months to in-
tion of dirt which would obstruct the flow of air sure protection from water and ice.
(Servicing the Alternator, Refer to Group 8, “Elec- Lubricate the following:
Itern Type of Lubricant Remarks
All external lock cylinders MoPar Lubriplate Apply directly.

Door check arms, hood hinges MoPar Lubriplate Apply directly, use sparingly.
and lock
License plate mounting panel MoPar Lubriplate Apply directly, use sparingly.
springs and pin Plymouth only.
Engine exhaust manifold MoPar Lubriplate Apply directly to bearing surfaces.
mounted bellcrank Plymouth only.
Accelerator shaft sound insulator MoPar Lubriplate Apply to exterior surfaces of
located on the throttle shaft insulator. Valiant only.
Parking brake mechanism foot MoPar Lubriplate Apply a light film directly.
or hand operated
Tailgate locks MoPar Lubriplate Apply to inner surfaces through
access hole, use sparingly.
I tern Type of Lubricant Remarks
Ball joint at top of accelerator MoPar Lubriplate Apply directly to ball joint.
pedal rod-passenger side Valiant only.
of firewall
Throttle control bellcrank passenger MoPar Lubriplate Apply directly to bearing surfaces.
side of firewall
Plastic bushing on throttle linkage MoPar Lubriplate Apply between bushing and throttle
passenger side of firewall linkage rod. Valiant only.
Deck lid latch Engine Oil Apply to inner surfaces,
use sparingly.
Door hinges and other hard to Engine Oil Apply directly. Do not apply
lubricate places to ramp or outside of roller.
Door latch rotor Engine Oil Apply 2 or 3 drops to outside and
inside rotor bearing surface.
Tailgate hinges Engine Oil Apply directly, use sparingly.
Door lock striker plates MoPar Stainless Apply directly to upper edge of plate
stick lubricant on door frame.
Tailgate lock striker plates MoPar Stainless Apply directly.
and dovetail surfaces stick lubricant
Tailgate torsion bar and MoPar Stainless Apply directly, use sparingly
support arm guide pillars stick lubricant Plymouth and Valiant Station
Wagons.
13. BRAKES Hydraulic Brake System

All Models have self adjusting brakes so that major Master Cylinder (Fig. 751
brake adjustments are unnecessary. Inspect the fluid level in the master cylinder every
Brake linings should be inspected for wear every six months. Replenish with MoPar Hi-Temp Brake
20,000 miles or every 2 years or more frequently if Fluid for the best performance. Bring the level up to
severe brake use is experienced. At the time of brake within 34 inch of the top of the reservoir.
lining inspection, the contact area of the brake shoes
to brake backing plate should be lubricated with a Parking Brake Mechanism
very thin film of MoPar Sylglyde, Part Number The Valiant Models use a hand operated parking
1881923.For this operation, the brake shoes must be brake lever and the Plymouth Models continue with
removed, and the contact areas cleaned and smoothed the foot operated lever (Figs. 16 and 17). When the
with sandpaper before applying lubricant. foot lever can be depressed more than four and one-
Brake hoses should be inspected for cracking, half inches or the hand lever pulled out more than
abrasions, cuts or tears in the outer covering every four inches, refer to Group 5, “Brakes” for the ad-
6 months. justing procedures.
14. CHASSIS LUBRICATION
The front suspension ball joints should be inspected
every 6 months or whenever the vehicle is serviced.
The ball joints are semi-permanently lubricated
with a special lubricant at the factory. They should be
relubricated every 32,000 miles with MoPar Multi-
Mileage Lubricant, Part Number 2298947 (Figs. 18
and 19). Clean the accumulated dirt and grease from
the outside surface of the seal to permit complete
inspection. Remove the threaded plug from each ball
joint. Insert a standard grease fitting, however, if
high pressure dispensing equipment is used, care
must be taken to fill and flush the ball joint slowly to
avoid damaging the seal. If no grease fitting is used,
Fig. 15-Master Cylinder (6-Cyl.) an adapter will be necessary on the grease dispenser
INSTRUMENT
KNOB
SCREW
62x88 ASSEMBLY
Fig. 16-Foot Operated Parking Brake (Disassembled) (Plymouth)
to ensure proper filling and flushing of the units. Steering Linkage Ball Joints
Stop filling when the lubricant beans to flow freely The steering linkage ball joints should be inspected
from the bleed areas at the base of the seal or if the every 6 months or whenever the vehicle is serviced.
seals begin to balloon. Reinstall the plugs. Damaged joints or seals should be replaced to pre-
C L I P 4 rBODY
Fig. 17-Hand Operated Parking Brake (Disassembled) (Valiant)

Fig. 18-Steering linkage location of lubricating

Fittings
vent contamination of the grease or failure of the
component.
The tie rod and pitman arm linkage ball joints are
semi-permanently lubricated with a special lubricant
at the factory. All ball joints should be relubricated
every 32,000 miles with MoPar Multi-Mileage Lubri- Fig. 19-Upper and lower Ball Joints
cant Part Number 2298947. Clean any accumulated
dirt or grease from the outside surface of the seal to purpose Lubricant or MoPar Multi-Mileage Lubricant,
permit complete inspection. Remove the threaded Part number 2298947 to the points of contact and
plug from the ball joint. A standard grease fitting may relative motion on the clutch drive lugs, fork fingers
be screwed into the hole. If not used, an adapter is a d fork points. Care must be taken to avoid applica-
necessary to correctly fill and flush the unit. MoPar tion of lubricant to the clutch disc and pressure plate.
Multi-Mileage lubricant should be injected into each
unit until the grease flows freely from the seal bleed 16. COOLING SYSTEM
area, at the base of the seal. High pressure dispensing Inspect the level of the cooling system every 2
equipment may be used to flush and fill the unit. months. The cooling system should be drained, flushed
Re-install the plugs. and refilled with the proper coolant in the spring and
again in the fall. When necessary to remove accu-
15. CLUTCH AND GEARSHIFT LINKAGE& mulations of rust and other deposits, maximum clean-
(Manual Transmission 1 liness can be restored by using Cooling System
Clutch Torque Shaft - Every 32,000 miles, relubri- Cleaner according to the directions listed on the con-
cate the clutch torque shaft bearings on the clutch tainer. Always discard any old solutions removed.
release fork, with MoPar Multi-Mileage Lubricant, When ready for refilling refill with water and protect
Part Number 2298947 (Fig. 20). against corrosion by adding MoPar Rust Resistor, or
Clutch Release Fork Swivel-When disassembling refill with MoPar antifreeze and water, depending
the clutch torque shaft, clean the swivel and swivel upon the season.
socket on the clutch release fork and lubricate with When draining the system both plugs on the V-8
Automotive Multipurpose Grease, NLGI 2 at the time
of reassembly. TORQUE SHAFT A N D
CLUTCH LINKAGE
Floor-Mounted Gearshift Lever a LUBRICATION
Valiant Only I
Whenever the operation of the lever indicates that
lubrication is needed, remove the rubber boot from
the floor panel and apply engine oil to the pivots,
point and yoke selector mechanism.
Clutch Drive Lugs, Release Bearlng SIeeve,
Fork Fingers and Fork Pivots
If the effort required to depress the clutch pedal
becomes excessive, the inspection plate on the bottom INNERMATING S ~ R F A C E 6 4 x 172
of the clutch housing and the fork boot should be re-
moved to allow lubrication. Apply Automotive Multi- Fig. PO-Clutch Torque Shaft and Linkage
17. DISTRIBUTORS
Every 10,000 miles or 6nce each year apply three
drops of light engine oil to the felt rotor wick (Fig. 21).
Apply 5 to 10 drops of light engine oil in the oil cup.
Apply MoPar Cam Lubricant to the cam and rubbing
block.
Two or three drops of light engine oil in the felt
wick are required. Apply a thin coat of MoPar Cam
Lubricant on the cam and rubbing block after the old
lubricant has been wiped off.
18. FRONT WHEEL BEARINGS

The front wheel bearings should be cleaned and
repacked with Wheel Bearing or Automotive Multi-
purpose Lubricating grease whenever the brake
Fig. 21-Distributor lubrication Points linings are replaced or the brake drums are re-
surfaced.
engine or the singIe drain plug on the 6-cylinder The lubricant in the wheel bearings should be in-
engine should be opened, and the drain cock at the spected whenever the wheels are removed to inspect
bottom of the radiator opened. or service the brake system. Do not repack the
Sufficient permanent type antifreeze should be bearings if the grease is adequate in quantity and in
used in the cooling system at all times to prevent good condition..
freezing in the heater core on vehicles equipped with If the lubricant is low in quantity, contains dirt,
air conditioning. The coolant solution must contain or has been contaminated with water to produce a
20% glycol-type antifreeze during the summer milky appearance, the old lubricant should be re-
months to provide for protection against temperatures moved, the bearings cleaned and relubricated with
down to +15"F. at the heater core. In the winter, Wheel Bearing Lubricant, or Multi-purpose Lubricat-
protect for the lowest anticipated temperature range, ing grease. DO NOT ADD LUBRICANT TO THE
but never-use less than 20% glycol-type antifreeze WHEEL BEARINGS.
to ensure adequate protection against corrosion. Clean out the old lubricant thoroughly from the
All models are equipped with a 180" thermostat. bearings and the hubs and repack with the new lubri-
With this thermostat, permanent type antifreeze cant. The annular groove of the wheel inner hubs
must be used. Should an alcohol-type antifreeze be should be filled with lubricant (Fig.22).
used, a 160" thermostat must be installed. To adjust the front wheel bearings.
CAUTION: Chrysler Corporation does not rec- (1) Tighten the wheel bearing adjusting nut to 70
ommend the use of a 160" thermostat for vehicles inch-pounds on Valiant Models and 90 inch-pounds
equipped with air conditioning. torque on Plymouth Models while rotating the wheel.
r l
Fig. 22-Wheel Bearing (Schematic) Fig. %Front Wheel Bearing Installation

I
- 4 _I
26.5"
cAR
-ta
16'' 17.0"
'1
20 SQ. " MINIMUM
FOUR PADS
116"
i,Ii--,
I--- 3(y' c
c
PAD POSITION WITHIN
THESE LIMITS
SATISFACTORY
FROI 64x178
FRONT WHEELS $,REAR WHEELS
--2o.y'
SECTION A-A -32.7"-

c 23.7"-
PAD POSITION WITHIN THESE
LIMITS SATISFACTORY
LIFTING PAD MUST EXTEND
BEYOND THE SIDES OF
THE SUPPORTING STRUCTURE
181
Fig. 25-Support Location for Frame Contact Hoisting (Valiant)

0-1 6 LUBRICATION AND MAINTENANCE
(2) Position the nut lock on the adjusting nut so rubber bushings should not be lubricated, not only
one pair of the cotterpin slots aligns with the hole because lubricants will cause rubber to fail, but also
in the spindle (Fig. 23). will destroy their necessary friction characteristics.
(3)Back off the adjusting nut and lock assembly The following parts should not be lubricated:
to the next slot, and install the cotter pin. Accelerator Pedal Drive Belts
(4) Clean the lubricant cap, coat the inside with All Rubber Bushings Fan Belt Idler Pulley
wheel bearing lubricant (do not fill) and install the Alternator Bearings (With Air Conditioning)
cap. Brake Linkages (Passen- Rear Springs
(5) Install the wheel, tighten the wheel nuts to ger side of Dash Panel) Rear Wheel Bearings
65 foot-pounds torque and install the wheel cover. Carburetor Air Cleaner Starter Bearing
Clutch Pedal Push Rod Steering Gear Arm Pivot
Ends Upper and Lower Control
19. HEADLAMPS Clutch Release Bearings Arm Bushings
One of the most important contributions to auto-
motive safety, is the correct adjustment of the head- 22. PROPELLER SHAFTS A N D UNIVERSAL
lamp beams. Suspension geometry changes, or heavy JOINTS
loading often will change the headlamp beam pattern Every 6 months inspect for external leakage. The
and cause unsafe driving conditions. If a vehicle is universal joints should not be disassembled or re-
to be loaded abnormally, such as on a vacation trip, lubricated unless external leakage is noted.
or a salesman’s vehicle loaded with his products, the
headlamps should be adjusted. Refer to “Electrical”
Group 8 for service procedures.
20. HOISTING
Special care should be taken when raising the vehi-
cle on a frame contact type hoist. The hoist must be
equipped with the proper adapters in order that the
vehicle will be supported in the correct location, as
shown in Figures 24 and 25.
Conventional hydraulic hoists may be used after
determining that the adapter plates will make firm
contact with the lower control arms and the rear axle
housing.
A regular floor jack may be used under the rear
axle housing, or under the front suspension lower
control arms, however, a floor jack must never be Fin. 26-Universal Joint Ball and Trunnion
used on any other parts of the underbody.
CAUTION: Do not attempt to raise one entire
side of the vehicle by placing a jack midway between
a front and rear wheel. This procedure may result
in permanent damage to the body.
The bumpers are designed to accept a bumper jack
in an emergency, if it becomes necessary to change a
tire on the road. Notches are provided in the bumpers
for the purpose of raising the vehicle with the bumper
jack.
.
21 PARTS REQUIRING NO LUBRICATION
There are many points that should not be lubrica-
ted, some because they are permanently lubricated,
some because lubricants will be detrimental to their
operating characteristics, and some because lubri- 56r575A V
cants will cause component failures. In any event, Fig. 27-Universal Joint Cross and Roller
LUBRICATION AND MAINTENANCE 0-1 7
Relubrication of the universal joint is not required 2. Cross and Roller - Repack.
for normal vehicle usage. If the vehicle operation is
similar to any of the following, it is recommended 23. REAR AXLE A N D SURE GRIP
that the universal joints be disassembled, cleaned, and Multipurpose Gear Lubricant as defined by MILL
relubricated every 32,000 miles (Figs. 26 and 27).
2105B should be used in all rear axles. MoPar Hypoid
1. Police vehicles. Lubricant Part Number 1879414 is also used for all
2. Taxicab operation. rear axles.
3. Frequent towing of trailers.
4. Continuous operation at higher than normal Frequency of 011 Change
loading. The changing of all rear axle lubricant is not rec-
The universal joints should be relubricated with ommended for vehicles used in normal service, ex-
MoPar Multi-Mileage Lubricant, Part No, 2298947 as cept when the axle oil has been contaminated with
follows: water or to provide the correct viscosity grade for the
1. Ball and Trunnion - Repack with two (2) ounces anticipated temperature range as indicated by the
lubricant. following table:
\I
Anticipated Temperature Range Viscosity Grade

Above -10°F. SAE 90
As low as -3OOF. SAE 80
Below -3OOF. SAE 75
The lubricant level should be inspected every 6 months with the vehicle in a level position. The oil
level should be as follows:
Plymouth (All Models) The vehicle supported on The lubricant level should be between the bottom
a wheel or axle type hoist. of the filler plug hole to W inch below. (Fig. 28).
Valiant (All Models) The vehicle supported on The lubricant level should be between the botom
a wheel or axle type hoist-r of the filler plug hole to % inch below or-
The vehicle supported on The lubricant level should be at the bottom of
a frame type hoist. the filler plug hole. (Fig. 29).
9
-
62X: 7 62x78
c
,
Fig. 28-Removing lubricant with a Suction Tube Fig. 29-Removing lubricant with a Suction Tube
(8-Cyl.) (6-CyI.)
0-1 8 LUBRICATION AND MAINTENANCE
25. STEERING
Manual Steering
Every 6 months the lubricant level of the fluid
should be checked and if necessary replenish to the
level of the filler hole with Multipurpose Gear
Lubricant as defined by MIG2105B. Use SAE 80 for
temperatures ranging above -30°F. and SAE 75" for
temperatures below -30°F. If SAE 80 is not available
SAE 90 may be used (Fig. 30).
CAUTION: Do not use a pressure gun.
Power Steering
Inspect the level of the power steering pump reser-
voir every six months (Fig. 31).If necessary, replenish
to the bottom of the filler neck, with MoPar Power
Fig. 30-Manual Steering Gear lubrication Steering Fluid, Part Number 2084329.
24. SPEEDOMETER CABLE 26. TIRES

The speedometer cable should be removed, cleaned Tires should be rotated including the spare (Fig.
and relubricated with MoPar All-Weather Speedom- 32)every 5,000miles to provide long tire life, uniform
eter Lubricant, Part Number 1243632 if the operation wear, and to retain confortable riding qualities.
becomes noisy or erratic. The spare should be used so that all the tires will
wear at approximately the same rate.
Disconnect the cable at the speedometer housing,
and remove the shaft. Clean the shaft and coat with a The tires should be examined for unusual wear
very thin film of lubricant and reinstall the shaft. patterns, foreign material and proper inflation pres-
Clean the excess lubricant from the top one-foot of sure, each time the engine oil is changed. Such con-
core and from the ferrule before the shaft is inserted ditions, may reflect unusual driving habits or indicate
completely. mechanical corrections may be necessary.
See the capacities page for the recommended in-
CAUTION: Excessive lubricant may cause flation pressures.
speedometer malfunction.
LEFT F R O N T RIGHT F R O N T
57X 23
57x23
Fig. 31-Power Steering Rerervoir Fig. 32-Tire Rotation
27. TRANSMISSION
Manual Transmission
Every 6 months, remove the filler plug and inspect
the fluid level, and if necessary replenish to the level
of the filler hole. Use Automatic Transmission Fluid,
Type “A”, Suffix “A” for 3-speed and 4-speed manual
transmissions for all anticipated temperature ranges.
Multipurpose Gear Lubricant SAE 90 or SAE 140
may be used in warm climates. Use Multipurpose
Gear Lubricant SAE 80 with the 3-speed Warner T-
85 heavy duty manual transmission for temperatures Fig. 33-Converter Drain Plug
ranging above + 32°F. SAE 90 may be used if SAE 80 sene. This service should be performed only once
is not available. Automatic Transmission Fluid Type during the low-temperature season. Thereafter, any
“A”, Suffix “A” should be used when the temperature replenishment should be with Automatic Transmission
drops below + 32°F. Fluid, Type “A”, Suffix “A”.
Frequency of oil ihdhge+No change is recom-
mended for vehicles used in normal service. Frequency of Lubrication
The transmission fluid and oil filter will provide
Trailer Towing Service satisfactory lubrication and protection to the auto-
Drive line colrip&iieiitbtin fih&&ger vehicles used to matic transmission, therefore regularly scheduled oil
pull trailers or similar, heavy duty usage ,will require chahgks will not be required in vehicles used in nor-
dork freqiuent inspection and serdce than hose used mal service. Therefore, the oil changes will not be
in normal passenger, vehic1e.s. See “Passenger Car required except when the service is severe as
Special Towing Recommehdations”. described below. If the regular operation of the
Automatic Transmission vehicle is similar to any of the following, the trans-
Inspect the fluid level every 6 months with the mission should be adjusted and the oil and filter
engine and transmission at normal operating tem- changed approximately every 32,000 miles.
perature. 1. Police vehicles.
(1) With the parking brake on and the engine idling, 2. Taxicab operation.
depress each button momentarily, ending with the 3. Frequent towing of trailers.
“N” (Neutral) button pushed in. 4. Continuous operation at higher than normal
(2) The fluid level should be slightly below the full loading.
mark, but never above the “F” mark when the engine For extreme severe service, it may be necessary
is at its normal warmed condition described above. to change the fluid more frequently (Fig. 33).
Add or remove the fluid as necessary to bring to this Refer to Group 21, “Transmission” for the oil
level. change procedure.
CAUTION: To prevent dirt from entering the 28. WINDSHIELD WIPERS
transmission make certain that the dip stick cap is
If the windshield wipers are smearing or in general
reseated properly onto the filler tube.
poor wiping of the windshields, the rubber blade
If it is necessary to inspect the fluid level when the should be replaced with a new one.
transmission is cold, the fluid should be at, or slightly Depress the release on the top of the blade and
below the “Add One Pint” mark. If below the mark,
the rubber blade will slide off. Replace with the new
add one pint of fluid then recheck the level.
rubber blade. Slide the bade into the catch to fasten.
Chrysler Corporation does not recommend the addi-
Refer to MoPar Parts list for the correct blade.
tion of any fluids to the transmission other than
Automatic Transmission Fluid, Type “A” Suffix “A”. H O O D LATCH (Lock Stricker Plate)
The only exception to this policy are the uses of ( A l l Models)
refined kerosene to aid starting in very cold weather, Lubrication of the Hood lock assembly is of vital
the use of special dyes to aid in detecting fluid leaks importance to prevent any possibility of a binding or
and the use of MoPar Automatic Transmission Sealer, frozen lock or safety latch.
Part Number 2298923, in high mileage vehicles. If Every 6 months apply Automotive Multi-purpose
starting is difficult when the average temperature lubricant to all pivot points, springs and rubbing sur-
consistently ranges below -lO”F., drain 1% pints faces. Work the lubricant in the latch mechanism
of transmission fluid and replace with refined kero- until all functional areas are covered.
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0-22 LUBRICATION AND MAINTENANCE -
CERTIFIED CAR CARE -ENGINE PERFORMANCE E V A L U A T I O N
EVERY 10,000 MILES O R ONCE EACH YEAR
1. Spark Plugs usually can be cleaned. adjusted and 3. Carburetor-Iieniove the air cleaner filter and
re-used for 20.000 miles. They should be replaced clean properly. Check the fast idle speed at cam
whenever obvious physical deterioration is apparent index. Adjust the carburetor idle mixture and fast
or when a test indicates sub-standard performance. idle speed to proper settings. Tighten the carburetor
air horn to manifold nuts, also, inspect the crankcase
2. Distributor-Remove the distributor cap and ventilator valve. Be assured that the manifold heat
rotor. clean and inspect. Inspect the ignition braker control valve and the carburetor choke linkage and
points for pitting. bluing, and misalignment and ad- shaft are operating properly and are each re-treated
just (lubricate cam and wick). Assure that all dis- with their specified solvent.
tributor secondary wires and tower caps are clean 4. Electrical-Inspect the battery specific gravity.
and seated properly at all connections. Set ignition Clean and tighten the battery terminals and connec-
timing to proper factory specifications. Refer to Group tions. Test the battery line voltage at the starter. Test
8. "Electrical" for service procedures. the starter cranking ability.
CERTIFIED CAR CARE-SEMI-ANNUAL MAINTENANCE SERVICE

Replace-Engine Oil Filter element. Throttle Control Bellcrank (passenger side of firewall),
Lubricate-Manifold Heat Control Valve with Engine Exhaust Manifold Mounted Bellcrank, All
special MoPar solvent, carburetor choke shaft and Station Wagons as noted: Tail Gate Hinges, Tail Gate
throttle linkage. Locks, Tail Gate Lock Striker Plates and Dovetail
Wipe clean and Lubricate, if necessary-Door Surf:ices, Tail gate Torsion Bar and Support Arm
Hinges and other Hard-to-lubricateplaces, Door Latch Guide Pillars.
Rotor, Door Lock Striker Plates, Door Check Arms,
Chheck Levels and Add Fluids, if Necessary-Trans-
Hood Hinges and Lock, All External Lock Cylinders,
missiion - (conventional or automatic), Rear Axle Dif-
Parking Brake Mechanism, (foot and hand operated),
License Plate Mounting Panel Springs and Pin, Deck terential, Steering Gear Pump (Power Steering), Man-
ual Steering Gear, Engine Coolant - Check Antifreeze
Lid Latch, Accelerator Shaft Sound Insulator (located
on throttle shaft), Ball Joint at top of Accelerator Brake Master Cylinder, Battery.
Pedal Rod (passenger side of firewall), Plastic Bushing Inspect-Condition of ball joints and steering link-
on Throttle Linkage (passenger side of firewall), age pivot and the ventilator valve.
-
CERTIFIED CAR CARE BRAKE SYSTEM MAINTENANCE SERVICE
EVERY 20,000 MILES O R EVERY TWO YEARS
1. Remove both front wheel, tire and drum as- (5)Inspect the brake drums for excessive out of
semblies. round, score marks, hard spots, and spider webbing.
NOTE: Front brakes do 60% of the braking. The (6) Safety inspect all brake lines, brake tees and
condition of the front brakes will Serve as an indicator hoses. Safety check all conditions. Inspect the lower
of the condition of the rear brakes. outside portion of the rear brake backing plates,
leakage inside will usually show at this point.
(2) Blow out any accumulated dust or dirt.
(7) Fill master cylinder reservoir to the proper
(3) Inspect lining wear pattern and determine re- level,
maining lining life. ( 8 ) Adjust service brakes, on Models without auto-
(4) Inspect condition of shoe return springs, inspect matic brake adjusters.
freedom of shoe movement, wheel cylinders, dust (9) Inspect and, if necessary, adjust the parking
boots and backing plates. brake.
CERTIFIED C A R CARE -FRONT SUSPENSION A L I G N M E N T

I1J Iktermine if vehicle needs the front suspension 13) Inspect, if necessary. adjust front suspension
system aligned. Three important reasons can indicate height at torsion bars.
this need,
(4) Inspect. if necessary. adjust camber, caster. and
a. Tire wear pattern
and or toe-in.
b. Car pl,lls in one direction on brake application ( 5 ) Inspect the condition Of the Steering linkage
and or and inspect the seal condition of suspension parts.
c. Car leads, left or right, in normal driving. ( 6 ) Inspect the steering gear lubricant level.
2. Inflate all tires to the same pressure. (7 J Aim all headlamps.
ACCESSORIES 1-1
GROUP 1
ACCESSORIES (RADIOS, HEATERS, MIRRORS)

CONTENTS
ELECTRIC CLOCK
Page
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H O T WATER HEATER ( PLYMOUTH 1
Page Page
Heater Blower.. . . . . . . . . . . . , . . . . . . . . , . . . . . . . . . . 3 Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Heater Vacuum Actuator. . . . . . . . . . . . . . , . . . . . . . . . . 3 Rear Window Defroster. . . . . . . . . . . . . . . . . . . . . . . . . 5
H O T WATER HEATER (VALIANT)
Page Page
Heater Assembly. . . . . . . . . . . . . . . . . . , . , . , . . . . . , . . 5 Heater Core Replacement. . . . . . . . . . . . . . . . . . . . . . . 7

Heater Control Cables (Adjustment). . . . . . . . . . . . . . . . 7 Fresh Air Ducts. . , , , . . . . , . . . . . . . . . . . . . . . . . . . . . . 7
Heater Motor or Fan Replacement. . . . . . . . . . . . . . . . 7
R A D I O AND ANTENNA
Page Page
Radio Removal and Installation. . . . , . . . . . . . . . . . , . . 8 Antenna Trimmer.. . . . . . , , , . . , , . . . . . . . . . . . . , , . .

, 10
Speaker Removal and Installation, . . . . . . . . . . . . . . , . 9 Antenna Replacement. . , . . . , , . , . . . . . , . . . . , . . , . . . 10
Push Button Adjustment. . . . . . . . . . , . . . . . . . . . . . . . . . 9 AM-FM Radio. . . . . . , . . , , . . . . . . , , , . . . . , . . . . . . . . 11
On-Off Switch and Volume Control., . . . . . . . . . . . . . . 9 Radio Speaker Reverberator.. , . . , , . . . . . . . . . . . . . . 11
Interference Elimination, . . . . . . . . . . . . , . . . . . . . . . . . . 9 Radio Wiring Diagrams, , . . . . , , . . . . . , . . . . , . , , , . . 16
Fader Control. , . , , . . . . , . . , . . . . . . . . . . . , . . . . . . . . 9
WINDSHIELD WASHER
Page Page
Nozzle Adjustment. . . . . 16 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . 17

1-2 CLOCK-HEATER-PLYMOUTH
ACCESSORIES (RADIOS, HEATERS, MIRRORS)

A disc type, solenoid actuated, self regulated elec- the Plymouth Models.
tric clock is available as additional equipment on
ELECTRIC CLOCK
SERVICE PROCEDURES
1. CLOCK the instrument cluster and carefully remove the
clock.
Removal
(1) Disconnect the battery ground cable. lnstallatton
(2) Remove the instrument cluster from the in- (1)Install the clock into the instrument cluster
stmment pan& &e “Elect&at” Group 8 - Ifistru- and install the two attaching screws.
ments. I , (2) Connect the wiring to the clock.
(3) Remove the d o c k reskt RnUb. (3) Install the clock reset knob.
(4) Disconnect the wiring from the clock., (4) Install the instrument cluster.
(5) Remove the two screws that attach the clock to (5) Connect the battery ground cable.
H O T WATER HEATER-PLYMOUTH
The hot water heating system, shown in Figure 1, Heating-air enters through the cowl air intake,
incorporates forced air ventilation. Forced air ven- passes through the heater core into the blower and
tilation is accomplished by the use of an axial flow distribution duct through the opened shut-off damper.
blower which provides ventilation irrespective of Def rosting-is controlled by the .defroster damper.
vehicle speed. The speed of the blower is controlled For maximum defrosting or deicing the temper-
by a three speed switch. ature control lever must be set in the full warm
position.
The Temperature Control Lever-operates the Temperature Control Lever-selects the tempera-
water valve through a bowden cable. It is important ture of the air discharged through the lower and
that the bowden cable be adjusted to provide full upper outlets. When the lever is to the top, air is
Opening and of the water valve for efficient not being heated. Air temperature is increased by
functioning of the system. moving the lever toward “WARM” down position.
Summer Ventilationis controlled by the opening Off Button-When the “OFF” button is pushed in,
of the ventilator air damper. the system will not operate. The OFF button cuts
DEFLECTOR AND
CHE VALVE ASSEMBLY
FAN ASSEMBLY
DEFROSTER
TUBES ACTUATOR/ 62x537A
Pig. 1-hrh Button Heater (Plymouth)
HEATER-PLY MOUTH 1-3
off the current from the control lever switch. The to eliminate objectional drafts and permit maximum
ventilation doors are closed, preventing outside air air flow to the rear of the vehicle. When the heat
from entering the vehicle. button is pushed in, sufficient warm air will be forced
Cool button-opens the ventilation door to allow onto the windshield through the upper air outlets
outside air to enter the vehicle directly. for adequate defogging during average driving con-
Defrost Button-causes a major portion of the air ditions.
to be forced against the windshield through air out-
lets on top of instrument panel for defrosting or Defrosting or Defogging the Windshield
defogging. Push in the “Defrost” button for maximum de-
Heat Button-causes major portion of air to be frosting, move the temperature control lever to the
directed toward the floor of the vehicle. “WARM“ position. Under particularly severe fog-
ging conditions, opening the front vent wings tem-
Heating the Vehicle porarily, will speed up the removal of fog from the
Until the engine warms up, make sure the “OFF” windows.
button is pushed in and the temperature control lever
is in the “WARM” position. Then, push in the “Heat” Summer Ventilation
button and leave the temperature control lever in Push in the “COOL” button to open the ventilation
the “WARM” position. After warm-up, the “LO” door. Move the temperature control lever to the ex-
button can be used and the temperature control treme up position. The ventilation door may be left
lever adjusted to maintain the desired temperature. open during rain.
At lower outside temperatures and particularly to
obtain maximum rear seat heating performance, it Rear Window Defroster f If s o Equipped)
may be necessary to use the “HI” button to provide A toggle switch (at left and under the instrument
maximum air circulation. It is important to keep the panel) operates a blower which circulates air over
windows closed, particularly the front vent wings, the rear window to prevent fogging.
SERVlCE PROCEDURES
1. HEATER BLOWER (4) Connect the heater ground wire.

Removal (5) Connect the battery ground cable.
(1) Disconnect the battery ground cable. (6) Test the operation of the heater blower.
(2) Disconnect the heater ground wire.
2. HEATER VACUUM ACTUATOR
(3) Loosen the fresh air intake duct clamp (at the
blower end) and remove the duct from the blower (1) To remove, disconnect the vacuum hoses.
assembly. (2) Remove the two nuts and lockwashers attaching
(4) Remove the screw attaching the blower to the
plenum.
(5) Remove the heater blower assembly from the
heater housing.
(6) From inside the heater housing, disconnect the
blower assembly wires.
HOT WATER TO
Inst allation HEATER INLET HOSE
(1) Connect the heater blower wires to their con-
nectors inside the heater housing.
(2) Position the blower assembly in the rubber
grommet in the heater housing with the blower RETURN HOSE FRO
mounting bracket positioned against the plenum HEATER OUTLET
bracket and install the mounting bracket screw. 64 x 131
(3) Install the fresh air duct on the heater blower Fig. 2-Heater Hose Connections-170 and 225
assembly and tighten the clamp. Cu. In. Engines
1-4 HEATER--PLYMOUTH
TURN HOSE FROM
HEATER INLET HOSE

RETURN HOSE FROM
HEATER OUTLET
64 x 134
Fig. 3--C(eater Hose Connection with Air Fig. +Heater Hose Connections-All 8-Cylinder
Condition-170 and 225 Cu. In. Engines Engines Except 318 Cu. In. Engine
the vacuum unit to the housing, and the one clip (10)Remove the defroster tubes from the heater
attaching the vacuum unit rod to the actuated unit. housing.
(11) From the engine compartment remove the
3. HEATER CORE three nuts and washers attaching the heater assembly
Removal f Flgs. 2 , 3 , 4 , 5 and 6J to the dash panel.
(1) Disconnect the battery ground strap. (12) Remove the heater to dash panel attaching
(2) Drain the cooling system. screws.
(3) Disconnect the heater hoses at the heater. (13)Remove the heater assembly.
(4) Remove the fresh air intake duct from the (14) Remove the heater control valve screws and
blower assembly. remove the valve by pulling the valve straight out
(5) Remove the blower to plenum bracket screw. from the housing. The valve is held into the heater
(6) Disconnect the actuator lines.
core by the use of an “0”ring only.
(15) Remove the screws attaching the heater
(7) Disconnect the heater wires receptacle from
the heater (left side). housing to the heater core and remove the heater
core assembly.
(8) Disconnect the heater ground wire.
(9) Remove the control lever cable from the heater
control valve.
HOT WATER TO
HEATER INLET HOSE a 133
64 x 136
Fig. 4-Heater Hose Connections-318 Cu. In. Fig. 6-Heater Hose Connections with Air
Engine Conditioning -All 8 Cylinder Engines
HEATER-VALIANT 1-5
lnstallat ion (9) Connect the heater control lever cable to the
(1) Position the heater core in the heater housing heater control valve.
and install the attaching screws. (10) Connect the heater wire receptacle to the
(2) Position the heater control valve into the heater assembly.
heater core and install the two screws attaching the Connect the heater ground wire.
valve to the heater housing. Connect the actuator lines to the actuators.
(3) Position the heater assembly on the dash panel Connect the battery ground cable.
and install the heater bracket to dash panel attaching Start the engine dnd operate the heater.
. screws.
Inspect for water leaks.
(4) From the engine compartment, install the three
nuts and washers attaching the heater to the dash
panel. 4. REAR WINDOW DEFROSTER
(5) Install the heater hoses and fill the cooling The rear window defroster (optional on all models)
system. Make certain the hoses are connected correct- is located on and under the rear shelf panel of the
ly (See Figures 2, 3, 4, 5 and 6). vehicle, and consists of a blower, flexible hose and
nozzle. A switch, located on the instrument panel,
(6) Install the defroster tubes.
controls the blower for defrosting the rear window.
(7) Connect the intake air duct to the heater blower The rear window defroster operates independently
assembly. . from the heater. The air forced against the rear
(8) Install the heater blower bracket to plenum window glass is drawn by the defroster blower from
bracket screw. the air inside the vehicle.
HOT WATER HEATER-VALIANT

The heater assembly (Fig. 7) used on Valiant motor is used in conjunction with the heater. The
models incorporates a “Ram-Air” feature. The heater “ T ~ control
~ ~ ”knob controls the amount of heat
(Fig’ 8, are located in the instrument pane’
desired. The “Def?7 knob controls the air flow to the
directly above the radio opening. Two fresh air ducts
(Figs. 9 and lo), for warm weather use, are located windshield for defrosting- Two manually operated
at each end of the instrument panel. A two speed freshair ducts areprovided
SERVICE PROCEDURES
1. HEATER ASSEMBLY (2) Disconnect the heater hoses from the heater
Removal and remove the heater hoses to dash panel seal and
retainer plate (Figs. 11 and 12).
DEFROSTER GRILLE-2 (3) Disconnect the wires from the heater motor.
WITH CONTROLS IN OFF POSl

AFTS IN DIRECTION
TO THAT EXTREME
CABLES TO DOOR
CABLE HOUSINGS
G BRACKETS AS S
HTR-DEF TEMP. DEF.
Fig. 7-Heater Assembly (Valiant) Fig. 8-Heater Controls (Valiant)

1-6 HEATER-VALIANT
63x531
Fig. 9-Fresh Air Duct-Driver's Side (Valiant) Fig. 11-Heater Hose Connections (Valiant)
(4) Remove the heater motor seal retainer plate (3) Remove the fan from the heater motor.
and seal from the dash panel (Fig. 12).
(4) Remove the mounting support plate from the
(5) Disconnect the heater and defroster control heater motor.
cables from the heater assembly (Fig. 8). (5) Remove the heater motor resistor assembly
(6) Remove the heater motor resistor wire from from the heater housing (Fig. 7).
the resistor (Fig. 7). (6) Remove the fresh air door seal from either the
(7) Remove the defroster tubes from the heater inner or outer heater housing half only.
assembly. (7) Remove the retainer clips attaching the heater
( 8 ) Disconnect the heater housing support rod housing halves together.
from the fresh air duct (Fig. 7). (8) Separate the heater housing halves.
(9) Remove the heater assembly. (9) Remove the screw attaching the seal retainer
and seal around the heater core tubes.
Disassembly (10) Remove the heater core tube support clamp.
(1) Remove the seal from around the heater motor (11) Remove the screws attaching the heater core
in( Wing studs. to the heater housing and remove the core.
( 2 ) Remove the spring clips holding the spacers (12) Remove the seal retainer and seal from the
and heater motor to the heater housing. heater core.
SUPPORT ROD
RETAINER
x530
Fig. 10-Fresh Air Duct-Passenger Side (Valiant) Fig. 12-Heater Mounting-Engine Side (Valiant)
HEATER-VALIANT 1-7
Assembly (20) Connect the wire to the heater motor resistor.

(1) Position the heater core in the heater housing. (21) Connect and adjust the defroster control cable.
(2) Slide the seal retainer and seal over the heater (22) Connect the defroster tubes to the heater.
core tubes and up against the housing. Install the (23) Fill the cooling system, start the engine and
attaching screw. operate until the normal engine operating temper-
( 3 ) Install the heater core to housing screws. ature is obtained.
( 4 ) Position the support clamp over the heater core (24) Test the operation of the heater assembly.
tubes and install the attaching screw.
(5) Install the support plate on the heater motor. 2. HEATER CONTROL CABLES-
ADJUSTMENT (Fig. 8 )
16) Install the fan on the heater motor. Turn the
fan to make certain it does not hit the motor support TEMP. (Temperature Control Cable 1
plate. To adjust the TEMP cable, remove the glove com-
( 7 ) Position the heater motor and support plate partment box to gain access to the cable adjusting
over the mounting studs on the heater housing. clamp.
(8)Install the spacers and retainers on the heater
HTR-DEF ( Heater-Defroster Control Cable 1
motor mounting studs.
To adjust the HTR-DEF cable, remove the glove
(9) Position both housing halves together and in- compartment box to gain access to the cable adjusting
stall the retainer spring clips. Add sealer between clamp.
the two halves before reassembly.
(10) Install the heater motor resistor assembly. DEF ( Defroster Control Cable 1
(11) Position and cement the seal around the fresh The DEF cable .may be adjusted without re-
air door opening. moving any parts.
(12) Position the heater housing to dash panel
seal around the heater housing mounting studs. 3. HEATER MOTOR OR F A N REPLACEMENT
(13) Connect and adjust the heater-defroster cable (Fig. 1 2 )
and the temperature control cable to their respec- To replace either the heater motor or fan assembly,
tive control arms. remove the complete heater assembly (see Para-
114) Position the heater assembly on the dash graph 3).
panel by sliding the four mounting studs into
their respective holes in the dash panel. 4. HEATER CORE REPLACEMENT
(15) In the engine compartment side, install the To replace the heater core assembly, remove the
heater to dash panel seal. seal retainer and complete heater assembly (see Paragraph 5).
mounting nuts.
f 16) Connect the wires to the heater motor. 5. FRESH AIR DUCTS (Figs. 9 and 1 0 )
(17) Position the seal and seal retainer over the Passenger Side-The fresh air duct on the passen-
heater tubes and install the attaching screws. ger side is an integral part of the heater.
(18) Connect the heater hoses to the heater. Drivers Side-The fresh air duct on the driver’s
(19) In the passenger compartment side, connect side is attached to the plenum chamfer by two sup-
the heater support rod to the heater housing. port rods.
1-8 RADIO
RADIO AND ANTENNA

Plymouth Models are equipped with a fully tran- Models 220 and 218 feature a single-ended audio
output. Also available, as optional equipment, on
sistorized A.M. radio model 220. Valiant Models are Plymouth Models is a fully transistorized A.M.-F.M.
equipped with a fully transistorized radio model 218. radio model 335.
SERVICE PROCEDURES
1. RADIO REMOVAL A N D INSTALLATION Installing the Radio f Plymouth J

Removing the Radio f Plymouth J NOTE: For vehicles equipped with air-condi-
NOTE: For vehicles equipped with air-condition- tioning the radio is serviced through the glove box
ing the radio is serviced through the glove box opening in the instrument panel.
opening in the instrument panel. (1) From under the instrument panel position the
(1) Disconnect the battery ground cable. radio into the instrument panel opening.
(2) Remove the control knobs from the front of (2) From the front of the radio install the two nuts
the radio. that attach the radio to the instrument panel. Tighten
(3) From under the instrument panel disconnect the nuts securely.
the radio feed and radio illumination wires at the (3) Position the top of the radio mounting bracket
fuse block. under the mounting screw on the back of the radio.
(4) Disconnect the antenna and radio speaker Tighten the screw securely.
leads. (4) Install the screw that attaches the bottom of
( 5 ) Remove the screw attaching the radio mounting the radio mounting bracket to the instrument panel
bracket to the instrument panel lower reinforce- lower reinforcemerIt.
ment.
( 5 ) Connect the radio fe!ed and radio illumination
( 6 ) Loosen the top screw on the radio mounting wires at the fuse block on the instrument panel
bracket and remove the mounting bracket. lower reinforcemerIt.
(7) From the front Of the radio remove the two ( 6 ) Connect the antenna and radio speaker leads.
nuts attaching the radio to the instrument panel and
remove the radic ' ~
, 1 1 . 1 17) TnctQll tho rQrlin rnntrnl lrnnhc
de.
Removing the
(1) Disconnect
(2) Remove th, under the in-
the radio. idio power feed
(3) Remove tf
mounting brackel istrument panel.
(4) Remove the
( 5 ) Loosen the . . - - ..-- ...- - ._
_ _ ._
0
(4) Install the mounting nuts on the front of the
bracket and remove ;he bracket.
radio.
(6) Disconnect the speaker and antenna leads.
(5) Connect the speaker and antenna leads.
(7) Remove the mounting nuts from the front of
the radio. (6) Install the radio mounting bracket. Tighten the
(8) Remove the radio Bezel.
screws securely.
(9) Lower the radio and disconnect the radio (7) Connect the left defroster tube.
power feed cable. (8) Install the control knobs on the radio.
(10) Remove the radio from under the instrument (9) Connect the battery ground cable and test the
panel. operation of the radio.
RADIO 1-9
2. SPEAKER REMOVAL A N D INSTALLATION (4) Repeat the operation on the other push buttons
as necessary.
Removing the Speaker t Plymouth I
NOTE: For vehicles equipped with airtondition-
4. ON-OFF SWITCH A N D VOLUME
ing the radio speaker is serviced through the glove
CONTROL
box opening in the instrument panel.
The on-off switch and volume control are combined
(1) Remove the radio as outlined in Paragraph 1. and operate from the left-hand radio knob.
(2) From under the instrument panel remove the
four nuts that attach the speaker mounting plate to 5. INTERFERENCE
the instrument panel. As an aid to service, use a ELIMINATION
flexible drive socket wrench to remove the mount-
ing nuts. When installing any suppression item, make cer-
(3) Remove the radio speaker and speaker mount- tain that all paint and dirt is removed from the
ing plate as an assembly. grounding area between the capacitors and the engine
or body components. Tighten all nuts and bolts
Removing the Speaker t Valiant I securely.
(1) Remove both defroster hoses. The high tension circuit of the engine ignition
(2) Remove the speaker leads. system uses radio resistance wire as standard equip-
(3) Remove the two nuts mounting the speaker ment. The balance of the suppression equipment is
and adapter plate assembly to the instrument panel. installed as follows:
Install the ignition coil capacitor, as shown in
(4) Remove the speaker and adaptor assembly
Figure 1.
from under the instrument panel.
(5) Remove the screws mounting the speaker to NOTE: The alternator is equipped with an
the adaptor plate. internal capacitor which is integral with the output
stud.
lnstalling the Speaker t Plymouth 1 Install the thermal gauge suppression capacitor on
NOTE: For vehicles equipped with air-condi- the back of the instrument cluster.
tioning the radio speaker is serviced through the
glove box opening in the instrument panel. NOTE: Voltage regulator suppressors should be
used to assist in curing stubborn cases of radio inter-
(1) From under the instrument panel positio the
radio sd6aker and speaker mounting plate as “a, ference.
assembly on to the four mounting studs on the in-’
strument panel. 6. FADER CONTROL
(2) Install the four speaker mounting nuts. Tighten This control is used only when the vehicle is
the nuts securely. equipped with a rear seat speaker. Full “counter-
(3) Install the radio as outlined in Paragraph 1. clockwise” position allows operation of the front
speaker. Full “clockwise” position allows the opera-
lnstalling the Speaker t Valiant I tion of the rear seat speaker. Rotation between either
(1) Install the adapter plate on the speaker. position will allow both speakers to operate with
(2) Position the speaker and adapter plate on the
instrument panel and install the two mounting co< ’ POST
screws.
(3) Connect the speaker leads.
(4) Connect both defroster leads.
(5) Test the operation of the radio and speaker.
MOU
3. PUSH BUTTON ADJUSTMENT BRAC
(1) Extend the antenna fully and turn the radio on
for fifteen minutes.
MOU
(2) Unlock the push button by pulling it out. BOLT
57x439 B
(3) Manually tune in the desired station and
relock the push button by pushing it all the way in. Fig. l-lgnition Coil Capacitor
1-10 RADIO
12-7/8” w
g-J t
+1-7/16”-+
I
ALIGN WITH DOOR OPENING
RIGHT FRONT FENDER DRILLING TEMPLATE
\
NTER PUNCH AND DRILL 1” HOLE
1-5/8”
n 12-1/2”
ALIGN WITH SIDE RIDGE
6” -1
L
HOOD OPENING
PEAK LINE
c--------- -~ /SIDE RIDGE
64 x 129
Fig. 2-Antenna Mounting location-Plymouth
varying volume as desired, or with equal volume at (1) Operate the radio for 15 minutes.
the mid-position. If the vehicle is equipped with (2) Extend the antenna to 40 inches.
a radio speaker reverberator the reverberator control
(3) Manually tune the radio to noise or a weak
on the instrument panel replaces the fader control.
signal between 1400 and 1600 K.C.
Pull the control knob “OUT” to turn “ON” the
reverberator. Push the control knob “IN” to turn (4) Increase the,x’adio volume to full volume and
“OFF” the reverberator and give normal fader con- the tone control ’to maximum treble (fully clock-
trol operation. wise).
(5) Adjust the antenna trimmer by carefully turn-
7. ANTENNA TRIMMER ing it back and forth until the position is found that
giv s a peak response in volume. Maximum output
All radios are pre-trimmed at the factory and u/dicates the proper point of antenna trimmer
should require no further trimming adjustment.
adjustment.
However, whenever a radio is removed from the
vehicle for repair, after the radio is re-installed,
the antenna trimmer should always be adjusted as 8. ANTENNA REPLACEMENT
follows: When installing the antenna, care should be taken
*
4 8-1 64“- -b
* 3”-q
7
4
t
31 132”
LINE UP WITH RIGHT FRONT HOOD OPENING
1-31 32”
1-31/32” I
I
LINE UP WITH DOOR OPENING FORWARD I
Fig. 3-Antenna Mounting location-Valianl

RADIO 1-1 1
FRONT SPEAKER TERMINALS

to route the “lead-in” cable over the glove box com- I m
partment to allow for ample cable length when
plugging the “lead-in” cable into the radio receptacle.
Refer to Figures 2 or 3 for the antenna mounting
points on initial installations.
Removal
(1) Unplug the antenna lead from the radio re-
ceiver.
(2) Remove the splash shield cover plate. (If
so equipped.)
(3) Remove the antenna attaching nut, retainer,
and gasket.
(4) Withdraw the antenna assembly from the fen-
der, splash shield and body opening.
lnstallation
(1) Install the antenna body, mast and lead.
(2) Install the antenna gasket, adaptor and at-
taching cap nut.
RIBBED LEAD
ON AM \ SMOOTH LEAD
ON A M
(3) Install the “lead-in” cable in the fender splash

shield and the body opening.
(4) Plug in the “antenna lead-in” cable in the
radio receptacle. 64 x 143
(5) Test the radio for proper operation. Fig. 5-Reverberator Installation
9. “AM-FM” RADIO (If so equipped) (2) The antenna should be extended to a height of
The “AM-FM” radio allows reception of both 31 inches for maximum “FM” reception.
“AM-FM” broadcast frequencies. To select “AM” or (3) The radio push button adjustment is the
“FM” reception move the selector slide bar (Figure same as the standard “AM” radio. It should be noted
4) to the desired position. The tuning knob, the “On- that a push button adjustment is only good fop one
Off” and “Volume” control knob operate in the same station (either “AM” or “FM”) not both at the same
manner as the standard AM radio. time.
The following items should be noted for proper (4) Should a malfunction occur, the repair proce-
“AM-FM” radio operation: dures are the same as for the standard “AM” radio.
(1) If the antenna trimming is required, tune the
radio dial below 1000 K.C. (about 960 K.C.) with the 10. RADIO SPEAKER REVERBERATOR
selector slide bar in the “AM” position. Proceed with ( If so equipped 1
the antenna trimming procedure as outlined in The radio speaker reverberator is used to produce
Paragraph 7. a time delay of .025 to .030 seconds in the radio
AM-FM SELECTOR SLIDE BAR output to the rear seat speaker. The reverberator
\
does not cause any time delay in the radio output
to the front speaker. Due to the “time ifference”
of the radio output between the front and rear
speakers an “echo” is produced which gives the 4
effect of “Stereo” sound reproduction in the vehicle.
The reverberator consists of the reverberator unit
(mounted in the luggage compartment), the instru-
ment panel switch and the wiring from the switch to
the reverberator unit (Figure 5). The reverberator is
an independently powered unit and has its voltage
RADIO CONYROLKNOBS 64 x 169
supply separate from the voltage supply to the
Fig. 4-AM-FM Radio radio.
1-12 RADIO
N
c
! -
!
!
!
!
!
!
!
!
!
!
!
!
!
I
!
!
!
!
!
!
!
!
!
!
!
!
"Ll,
!
!
!
!
01 E'* !
!
!
!
!
!
!
I
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"2
3
'
RADIO 1-13
I A
8
c
X
3
v
0
0
0
0
A
1-14 RADIO
XOZZ 918
0
F
0
I
00
RADIO 1-15
m
I I d
1
I
I
I
I
I
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I
L-
i
-Q
\
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L-
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1-1 6 WINDSHIELD WASHER
To operate the reverberator turn the radio “ON” parts (Fig. 6):
and tune the radio to the desired station. Pull the
(1) Delay Line. This item cannot be repaired, it
instrument panel reverberator switch “out” and
then rotate the switch until the desired volume level must be serviced as an assembly.
between the front and rear speakers is achieved. (2) Amplifier Section. This item is serviced using
With the switch “in” normal fader operation exists normal radio trouble shooting procedures.
between the front and rear speakers by rotating the
switch knob until the desired volume level is es- 11. RADIO W I R I N G DIAGRAMS
tablished between the speakers. Refer to Figure 7 for radio model 218, Figure 8 for
For service the reverberator unit is divided in two radio model 220, Figure 9 for radio model 335.
WINDSHIELD WASHER
The windshield washers are operated by an electric a plastic reservoir. The motor is operated by depres-
motor driven pump to which fluid is gravity fed from sing a small button in the center of the windshield
wiper knob.
CENTER LINE OF
WINDSHIELD
3 INCH
7 INCHES TARGET
UPPER SPRAT AREA
MEASURE DOWN FROM

MEASUREDOWN FROM BOTTOM OF WINDSHIELD
BOTTOM OF WINDSHIELD MOULDING MOULDING 6 4 x 152
6 4 x 149
Fig. 1-Washer Aiming Instructions (Plymouth) Fig. 2-Washer Aiming Instructions (Valiant)
1 NOZZLE ADJUSTMENT Figures 1and 2.

Adjustment of the nozzle may be made by inserting
NOTE: The oval pattern formed by the stream
a small screwdriver into the cowl opening grille and
bending the nozzle. striking the windshield glass is not “centered“ on
Adjust the nozzles so that the centers of the the center of the stream. The stream center is toward
streams contact the windshield glass, as shown in the bottom of the oval pattern.
ACCESSORIES 1-17
SERVICE DIAGNOSIS
ELECTRIC CLOCK
Condition Possible Cause Correction
Clock Does N o t Operate (a) Wire loose or off of terminal. (a) Install connector on the terminal.
(b) Internal short. (b) Replace the clock.
HEATER
Insufficient H e a t (a) Temperature control valve not opening (a) Adjust or replace valve as
(Plymonth only). necessary.
Engine thermostat opening too soon, too (b) Replace thermc, '
wide, or at low temperature.
Faulty push button controls (Plymouth (c) Replace push button switch.
only).
Vacuum line to shut-off damper (d) Connect or replace vacuum line.
disconnected or broken (Plymouth only).
Faulty vacuum actuator or broken or (e) Replace the vacuum actuator
cracked nipple (Plymouth only). or nipple.
Insufficient coolant in radiator. (f) Fill radiator to the correct level.
Collapsed water hose on the return (g) Replace hose or remove
side, or partially plugged hose on the obstruction as necessary.
pressure side.
Heater system airbound; needs bleeding. (h) Bleed the heater system.
Blower motor not operating, fuse blown, (i) Replace the fuse or wiring, or
faulty wiring or loose connections. install the connections securely.
Improper control cable adjustment. (j) Adjust the control cables.
Too M u c h H e a t (a) Temperature control valve stuck in open (a) Adjust or replace the valve.
position (Plymouth only).
(b) Disconnected or broken bowden cable (b) Connect or replace the control
wire. cable.
(c) Engine thermostat controlling at too (c) Replace the thermostat.
high a temperature.
(d) Thermostat stuck in closed position. (d) Replace the thermostat.
(e) Temperature control valve not closing (e) Adjust the control cable.
properly, cable needs adjusting
(Plymouth only).
Blower M o t o r N o t (a) Fuse blown. (a) Replace the fuse.

Operating (b) Faulty motor. (b) Replace the motor.
(c) Faulty electrical connections. (c) Repair the connections as
necessary.
(d) Push button not completing circuit (d) Replace the switch.
(Plymouth only).
1-1 8 ACCESSORIES
SERVICE DIAGNOSIS
RADIO
Radio is Inoperative (a) Blown fuse. (a) Replace the fuse.

(b) Broken, loose or shorted (b) Test with an auxiliary antenna and
antenna lead-in. replace lead-in if necessary.
(c) Loose battery cable. (c) Test the voltage a t the fuse and
tighten all connections.
(d) Burned out transistor. (d) Test all transistors and replace
weak ones.
(e) Faulty speaker. (e) Replace the speaker.
(f) Faulty antenna. (f) Test the antenna and repair.
Radio Reception i s Weak (a) Unbalanced antenna trimmer. (a) Adjust the antenna trimmer.
(b) Loose antenna lead-in. (b) Tighten the antenna lead-in.
( c ) Shorted antenna lead-in. (c) Test with an auxiliary antenna and
replace lead-in if necessary.
(d) Weak radio transistor. (d) Test and replace weak transistors.
(e) Faulty antenna. (e) Test the antenna and correct.
Radio Reception is (a) Outside electrical (a) Move the car or eliminate
Noisy (Engine Running) interferences. interference.
(b) Insufficient or faulty radio (b) Install capacitors in ignition system.
capacitors.
Radio Reception is (a) Static build up in tires. (a) Ground the tires to the wheels with
Noisy (Vehicle in Motion) powdered graphite.
(b) Loose antenna or lead-in wire. (b) Tighten the antenna attaching nut.
Inspect the fit of the antenna lead-in
plug in the socket.
Radio is Noisy When (a) Loose antenna ground. (a) Clean and tighten the antenna
Equipment is Operated connections.
Radio Reception is (a) Speaker coil rubbing on (a) Install an auxiliary speaker and
Distorted voice core. compare. Replace if improved.
(b) Torn speaker cone. (b) Replace the speaker.
(c) Faulty radio transistors. (c) Test and replace any faulty transistors.
Intermittent (a) Broken lead-in wire. (a) Test with a substitute antenna.
Reception Repair the lead-in wire.
(b) Ground lead-in wire. (b) Test with a substitute antenna.
Repair the lead-in wire or replace.
(c) Faulty radio transistor. (c) Test the radio transistors and
replace as necessary.
ACCESSORIES 1-19
SERVICE DIAGNOSIS
WINDSHIELD WASHER
Motor Does Not Run (a) Loose wiring terminals. (a) Tighten the terminals.
(b) Corroded terminals. (b) Clean and tighten the terminals.
(c) Broken wires. (c) Repair or replace the wires.
(d) Faulty switch. (d) Replace the wiper switch assembly.
(e) Faulty motor. (e) Replace the motor and pump assembly.
(f) Poor ground. (f) Clean the pump housing and tighten
the mounting screws.
Pump Does Not (a) Broken coupling. (a) Replace the motor and pump assembly.
Operate Motor Runs
(b) Faulty pump. (b) Replace the motor and pump assembly.
FRONT SUSPENSION 2-1
GROUP 2
CONTENTS
Page Page
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Lower Control Arm and Shaft. . . . . . . . . . . . . . . . . . . . 6
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lower Control Arm Strut.. . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Ball Joints.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preparation for Inspecting the Upper Control Arm.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front Wheel Alignment.. . . . . . . . . . . . . . . . . . . . . . . 4 Upper Ball Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Front Suspension Height Adjustment. . . . . . . . . . . . . . . . 4 Sway Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front Wheel Alignment.. . . . . . . . . . . . . . . . . . . . . . . . . 5 Front Suspension "K" Member. . . . . . . . . . . . . . . . . . . . 12
Torsion Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPEC IFlCATlONS
Plymouth Valiant
VP-2, VP-1 w-1
CAMBER
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +%"to +%" (+%" preferred)
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0" to + !42" (+'/4 preferred)
CASTER
Manual Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0" to -1"
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + % " t o +1%"
(Drivers side should be less positive)
HEIGHT
Standa rd Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 % inch 2 inch
+ % inch k!h inch
Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2% inch 2 % inch
Side to Side Difference (Max.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . !h inch
TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . % inch l%z inch
TOE-OUT ON TURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner Wheel 20" when

Outer Wheel i s 17%" (k1")
TREAD
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.4 inches 55.94 inches
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.5 inches 55.56 inches
WHEEL BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 inch3s 106 inches

2-2 FRONT SUSPENSION
TOOL LIST
C-3466. . . . . . . . . . Engine Lifting Fixture (8-Cylinder Engine)

C-3560. . . . . . . . . .Ball Joint Remover or Installer (Upper) (Plymouth)
C-3710. . . . . . . . . .Upper Control Arm Bushing Remover or Installer
SP-3828. . . . . Adapter-Used on Police and Taxi Units-Remover
SP-3827. . . . .Adapter-Used on Police and Taxi Units-Installer
C-3711 . . . . . . . . . .Ball Joint Stud Remover (Upper)
C-3713. . . . . . . . . .Upper Ball Joint Seal Installer (Valiant)
C-3714. . . . . . . . . .Ball Joint Remover or Installer (Valiant)
C-3728. . . . . . . . . .Torsion Bar Remover
C-3736. . . . . . . . . .Upper Ball Joint Seal Installer (Plymouth)
SP-3208. . . . .Stud Make Tool C-3736
SP-3307. . . . .CUP {
C-3804. . . . . . . . . . Engine Lifting Plate (6-Cylinder Engine)
C-3809. . . . . . . . . . Engine Lifting Fixture (6-Cylinder Engine)
C-3846. . . . . . . . . . Ball Joint Stud-Lower-Remover
C-3848. . . . . . . . . .Lower Control Arm Shaft and Bushing Installer
C-3894. . . . . . . . . .Tie Rod End Stud Remover
Foot-Pounds
Ball Joint-(Upper) ................................... .............................. 125 (minimum)

Ball Joint-(Lower) Stud Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ball Joint-(Upper) Stud Nuts (Plymouth). . . ............................................ 100
(Valiant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control Arm (Lower) Shaft Nut.. . .................................................. 180
(Rebound Bumper). . . . . . . . . . . . . . . . . . . . . . . . .............................. 200 (inch-pounds)
Front Suspension ("K") Crossmember Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Idler Arm Stud Nut (at Mounting Bracket). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
(at Center Link). . . . . . . . . . . . . . . . . . . . . ............................ 40
Steering Knuckle to Bracket Bolt Nuts (Upper). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Plymouth (Lower). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... ............... 120
Valiant (Lower). . . . . . . . . . . . .............................................. 100
Strut-Front Bushing Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... 40
Strut-To Control Arm Nuts (Rear) ............................................ 110
Tie Rod Clamp Bolt Nuts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 15
Tie Rod Stud Nuts (to steering knuckle arms). . ............................................ 40
Shock Absorbers
Front-Upper . . . . . . . . . . . . . ....................................... 25
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 55
Wheel Mounting
(Plymouth) . . . . . ............................................... 65
(Valiant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................... 55
Sway Bar (When so equipped)
Cushion Housing Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 35
Link Nuts. . . . . . . . . . . . . . . . . . . . ...................................... 100 (inch-pounds)
Lower Control Arm Shaft Nut.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
FRONT SUSPENSION
Construction of the fully unified body employs a end assemblies is required it is necessary to remove
bolted-on engine and front suspension support the plugs and install a grease fitting. After the lu-
member (“K” member), which is attached to the brication is completed, remove the grease fittings
body horizontals (side rails) at four points. The and reinstall the plugs.
lower control arm pivot shafts and struts are at- All service replacement ball joints are equipped
tached to the legs of the “K” members, as shown with a “Knock-Off” type lubrication fitting. After
in Figures 1and 2. the ball joint has been lubricated with the specified
The torsion bar rear anchors are integral with lubricant, knock off that portion of the lubrication
the engine rear support member in the body. The
fitting over which the grease gun was installed. A
torsion bar front anchors, which are part of the special ball check is installed in the remaining
lower control arms, provide the means of adjustment portion of the fitting to prevent foreign materials
or setting of vehicle front height. The lower ball from passing through the fitting.
joints are integral with the steering arms.
All ball joints and the torsion bars at the front The tie rod end seals and protectors should be
of the rear anchors are effectively sealed against inspected at all oil change periods. The tie rod end
road splash by tightly fitted balloon type flexible seals and seal protectors are serviced separately.
seals. The ball joints are of the semi-permanent Caster and camber adjustments are made by cams
lubricated type and should not under normal on the upper control arm pivot bolts.
operating conditions require lubrication with the Rubber bushings should not be lubricated at any
specified lubricant before 32,000 miles. time. When replacement of a bushing is necessary,
When re-lubrication of the ball joints and tie rod water may be used to aid in installation.
62 x 51
62 x 50
Fig. 1-Front Suspension Mounting Points Fig. 2-Front Suspension Mounting Points
(PIy mout h) (VaIiant)
SERVICE PROCEDURES
1. PREPARATION FOR INSPECTING THE prior to taking each measurement (Height-Caster-
FRONT WHEEL ALIGNMENT Camber and Toe): Grasp the bumpers at the center
(rear bumper first) and jounce up and down several
Front wheel alignment is the mechanics of ad- times. Release the bumpers on the down cycle after
justing all the interrelated factors affecting the jouncing both rear and front ends an equal number
running and steering of the front wheels of the of times.
vehicle. Incorrect alignment of front wheels will
result in hard steering, abnormal tire wear as well
2. FRONT SUSPENSION
as braking problems. HEIGHT ADJUSTMENT
The method of inspecting the alignment will vary
depending on the type of equipment being used. Standard suspension (including all Station W a g
The instructions furnished by the manufacturer of ons)
the equipment should always be followed, however, (Plymouth 1%inches kYs inch)
the specifications as recommended by the Chrysler (Valiant 2 inches kYs inch)
Corporation should always be used. Heavy Duty Suspension
All inspections and adjustments should be made
in the following order: (Plymouth 2% inches kv8 inch)
(Valiant 2% inches -+-%inch)
Front Suspension Height
Caster and Camber Side to Side Difference v 8 inch for all Models.
Front suspension heights must be held to speci-
Toe-In fications for a satisfactory ride, correct appearance,
Steering Axis Inclination proper front alignment and reduced tire wear.
Toe-out On Turns The heights should only be measured when the
An inspection of the steering axis inclination and vehicle has the recommended tire pressures, a full
toe-out on turns is valuable in determining if parts tank of fuel, no passenger load and is placed on a
are bent or damaged particularly when adjustments level floor or alignment machine.
will not bring camber and caster within specifica- (1) Clean all foreign material from the bottom of
tions. DO NOT ATTEMPT TO MODIFY ANY OF the steering knuckle arm assemblies and from the
THESE PARTS BY HEATING OR BENDING. lowest area of the height adjusting blades directly
Before any attempt is made to change or correct below the center of the lower control arm inner
caster, camber and toe-in; the following preliminary pivots.
inspections and necessary corrections must be made (2) Jounce the vehicle several times releasing it
on those parts which influence the steering of the on the downward motion.
vehicle.
(3) Measure the distance from the lowest point of
(1) Inflate the tires to the recommended pressure. one adjusting blade to the floor (measurement A)
All tires should be the same size, in good condition and from the lowest point of the steering knuckle
and have equal wear. Note the type of wear to aid arm, on the same side (measurement B) to the floor
in diagnosing. See Group 22, “Wheels, Bearings and (Fig. 3). Measure only one side at a time. The dif-
Tires”. ferential between measurement A and B should be:
(2) Inspect the suspension and steering linkage
pivot points for excessive looseness, rear springs
for proper tightness of “U” bolts and height differ-
ential between the left and right sides of the vehicle.
(The vehicle shall be on a level floor or alignment
rack) and should have a full fuel tank but no
luggage or passenger load.
(3) Inspect the front wheel bearing adjustment.
See Group 22, “Wheels, Bearings and Tires”. Meas-
ure the front wheel and tire assembly runout
(follow the Equipment Manufacturers Instructions).
(4) To obtain accurate readings, the vehicle
should be jounced in the following manner just Fig. 3-Measuring Front Suspension Heights
Standard Suspension (including all Station Wag- should be replaced if they are found to be bent.
ons) Do not attempt to straighten any bent part.
(Plymouth 1%inches +1/8 inch)
Camber and Caster
(Valiant 2 inches +?A8 inch) Access holes to loosen the upper control arm cam
Heavy Duty Suspension bolt nuts have been provided for in the fender side
(Plymouth 2% inches +1/8 inch) shields (Fig. 4) of the Plymouth vehicles. The front
(Valiant 2?48 inches +Ysinch) access hole is made available by removing splash
(4) Measure the other side in the same manner. cover tapping screws and cover. When adjusting the
The maximum allowable difference in suspension right front cam bolt on Plymouth vehicles equipped
height from side to side is 34 inch on all Models. with the 318 cubic inch engine, it i s necessary to
loosen the alternator and move it out of the way.
(5) Adjust if necessary by turning the torsion bar
adjusting bolt to increase the height and backing (1) Hemove all foreign material from the exposed
off the bolt to decrease the height. threads of the cam adjusting bolts.
(6) After each adjustment jounce the vehicle be- (2) Prepare the vehicle for inspection as outlined in
fore rechecking measurements. Both sides should be Paragraph 1.
measured even though only one side has been ad- (3) Take the initial camber and caster readings
justed. before loosening the cam bolt nuts.
Camber-Left Wheel + % " to %Io (preferred + V2").
3. FRONT WHEEL ALIGNMENT Right Wheel 0" to + V2" (preferred + % O).
(Camber-Left wheel + G o to +%Io (preferred Caster -Power Steering + %O to 1%".

+ V2O)
Manual Steering 0" to -1".
(Right Wheel 0" to + V2' (preferred + %") (5) Camber settings should be held as close as
(Caster -Power Steering + Vi" to 1%') possible to the "preferred" setting. Caster should
be held as nearly equal as possible on both wheels.
(Manual Steering 0" to - 1")
Toe-% + or - 1/32 inch. Toe-in ( 3 / 3 2 to 5 / 3 2 inch)
Front wheel alignment settings must be held to (Preferred '/e inch)
specifications to hold tire wear to a minimum and to The toe setting should be the final operation of
maintain steering ease and handling of the vehicle. the front wheel alignment adjustments. The front
Wheel alignment measurements should only be wheels must be in a straight ahead position. Fol-
measured with the tires inflated to the recommended low the equipment manufacturers procedure. The
pressure, no passenger load, correct vehicle height, steering wheel should be centered during this opera-
full tank of fuel, and with the full weight of the tion.
vehicle on the wheels. The equipment manufac- Turning the tie rod sleeve will "center" the steer-
turers recommended procedure should always be ing wheel spokes. If the steering wheel was center-
followed. Any parts of the front suspension system ed, make the toe-in adjustment by turning both
sleeves an equal amount. Be sure and tighten with
a clamp rotated such that the bolts are on the
bottom, otherwise interference with the torsion bars
in jounce may result.
4. TORSION BARS
The torsion bars are not interchangeable side for
side. The bars are marked either right or left by an
"R" or an "L" stamped on one end of the bar.
Removal
(1) Remove the rebound bumper from its mount-
ing bracket located under the upper control arm.
(2) If the vehicle is to be raised on a hoist, make
!8 sure it is lifted on the body only so that the front
suspension is in full rebound (under no load). If the
Fig. rl-hcess Openings in Fender Shield vehicle is to be raised on jacks, placed under the
balloon seal off of the anchor to facilitate removal

of the torsion bar.
(7)Remove the torsion bar by sliding the bar out
through the rear of the rear anchor. Use care not to
damage the balloon seal when it is removed from
the torsion bar.
lnstallation
(1)Inspect the balloon seal for damage and replace
if necessary.
(2)Inspect the torsion bar for scores and nicks.
62 x 52A
Dress down all scratches and nicks to remove the
Fig. 5-Torsion Bar Spring sharp edges, then paint the repaired area with a
good rust preventative.
center of the “K” member, it will be necessary that (3)Remove all foreign material from the hex
a support first be placed under the “ K member. openings in the anchors and from the hex ends of
the torsion bars.
CAUTION: Under no circumstances should the
(4)Inspect the torsion bar adjusting bolt and
front end of the vehicle be raised with a jack unless
swivel for corrosion or other damage and if nec-
a support is first positioned under the ”K” member.
essary replace. Lubricate for easy operation.
(3)Release the load from the torsion bar (Fig. 5) (5) Insert the torsion bar through the rear
by backing off the anchor adjusting bolt (Fig. 6). anchor.
(4) Remove the lock ring from the rear of the tor-
(6) Slide the balloon seal over the torsion bar
sion bar rear anchor (Fig. 5). (cupped end toward rear of bar).
(5) Using Tool C-3728, remove the torsion bar
(7) Coat both hex ends of the torsion bar with
(Fig. 6 ) from its anchors. It is advisable to place MoPar Multi-Mileage Lubricant, Part Number
Tool C-?728 toward the rear of the torsion bar to 2298947.
allow sufficient room for striking the striking pad
of the tool. Do not apply heat to the torsion bar, (8)Slide the torsion bar into the hex opening of
front anchor or rear anchor. On Valiant models the lower control arm.
equipped with the 225 cubic inch engine it may be (9)Install the lock ring in the rear of the torsion
necessary to remove the exhaust pipe from the bar rear anchor.
manifold when using Tool C-3728 on the left bar. (10)Pack the annular opening in the rear anchor
(6) Remove the tool and slide the rear anchor completely full of multi-purpose grease.
(11)Position the balloon seal on the rear anchor
so the lip of the seal engages with the groove in the
anchor.
(12)Tighten the adjusting bolt to place a load on
the torsion bar.
(13)Lower the vehicle to the floor and adjust the
front suspension height (Paragraph 2).
(14)Install the upper control arm rebound bum-
per on its mounting bracket.
5. LOWER CONTROL A R M A N D SHAFT

(Fig. 7 )
Removal
(1) Remove the upper control arm rebound bum-
per.
(2)Raise the vehicle so the front suspension is in
full rebound (under no load) and remove the wheel
Fig. 6-Removing Torsion Bar and drum assembly.
SHAFT YONTRoL ARM
\
STRUT KNUCKLE ARM
\
62 x 538
Fig. 7-lower Control Arm Assembly
(3)Disconnect the shock absorber from the lower

control arm and push it up out of the way.
(4) Remove all load from the torsion bar by back-
ing off the adjusting bolt. Fig. 9-Removing Lower Ball Joint Stud
(5) Remove the torsion bar from the lower control
arm (Paragraph 4). (9)Remove the strut nut and bushing retainer
(6)Remove the cotter pin and slide the tie rod (Fig. 7) from the forward end of the “K” member.
and seal protectors up on the steering knuckle arm. (10)Remove the cotter pin, nut and washer from
Remove the tie rod end from the steering knuckle the lower control arm shaft (Fig. 7).
arm using Tool C-3894 (Fig. 8) Use care not to (11) Tap the end of the lower control arm shaft
damage the seal.
with a “soft end” hammer to aid in removal of
(7) Remove the steering knuckle to brake support the shaft from the “K” member.
plate bolts and remove the steering knuckle arm. (12) Remove the lower control arm, shaft and
Move the brake support assembly out of the way. strut as an assembly from the “K” member.
(8)Remove the ball joint stud from the lower (13) Remove the strut rubber bushing from the
control arm using Tool C-3846(Fig. 9). “K” member only if damaged.
(14)Remove the strut bushing inner retainer
from the “K” member, if it did not come out with
the strut.
Dlsassern bly
(1) Place the strut portion of the lower control
arm assembly in a vise and remove the nut from
the strut.
(2) Remove the strut from the lower control arm.
(3) Remove the jounce bumper from the lower
control arm.
(4) Remove the torsion bar adjusting bolt and
swivel.
(5) Place the lower control arm assembly in an
Y ‘ 62x329
arbor ‘press with the torsion bar hex opening up.
Fig. 8-Removing l i e Rod End Stud (6) Place a brass drift into the hex opening and
(5)Position the strut in the lower control arm
and tighten the nut 110 foot-pounds torque.
Installation
(1) Install the new strut bushing if necessary (in
“K’ member), with a twisting motion. Water may be
used as a lubricant to aid in installation.
(2)Position the lower control arm shaft and strut
into their respective mountings in the “K” member.
The strut bushing inner retainer should be placed
over the shaft before the strut is inserted into the
bushing.
(3) Install the strut bushing outer retainer and
nut finger tight only.
(4) Install the lower control arm shaft washer and
nut finger tight only.
(5) Position the lower ball joint stud into the
lower control arm and tighten the nut 100 foot-
pounds torque. Install the cotter pin.
(6)Position the brake support plate on the steer-
ing knuckle and install the two upper bolts and nuts
finger tight only.
(7) Position the steering knuckle arm on the
steering knuckle and install the two lower bolts and
Fig. 10-Removing Bushing Shell from Control Arm nuts.
(8) Tighten the upper bolt nuts 55 foot-pounds
torque. Tighten the lower bolt nuts to 100 foot-
press the shaft out of the lower control arm. The pounds torque on Valiant and 120 foot-pounds on
bushing inner shell will remain on the shaft. Plymouth.
(7) Cut and remove the rubber portion of the
(9) Inspect the tie rod seal for damage and replace
bushing from the control arm. the assembly if damaged. Connect the tie rod end
(8) Insert a 1% inch NF 12 tap into the pivot of the steering knuckle arm and tighten the nut
shaft bushing outer shell approximately one half the 40 foot-pounds torque. Slide the tie rod end seal
depth of the bushing. protector over the tie rod end. Install the cotter pin
(9) Using a hand press and a blunt drift, force the over the outer tie rod stone shield.
bushing out of the control arm (Fig. 10). (10) Connect the shock absorber to the lower con-
(10) Remove the bushing shell from the tap. trol arm and tighten the nut 55 foot-pounds torque.
(11) Remove the bushing inner shell from the (11)Install the torsion bar (Paragraph 4).
pivot shaft. (12)Install the wheel and drum assembly and
adjust the front wheel bearing. (See Group 22,
Assembly “Wheels, Bearings and Tires”).
(1) Position the new bushing on the shaft (flange (13) Lower the vehicle to the floor.
end of bushing first) and seat bushing on the shoul-
der of the shaft. (14)Tighten the strut nut, at the “K” member,
40 foot-pouny torque.
(2) Press the shaft and bushing assembly into the
lower control arm using Tool C-3848 and an arbor (15)Adjust the front suspension height (Para-
press. graph 2).
(3) Install the torsion bar adjusting bolt and (16)Tighten the lower control arm shaft nut 130
swivel. foot-pounds torque and install the cotter pin.
(4) Install the jounce bumper on the control arm (17)Measure and adjust the front suspension
and tighten the nut 200 inch-pounds torque. alignment as necessary (Paragraph 3).
6. LOWER CONTROL A R M STRUT (4) Install the stud retaining nut and tighten to
100 foot-pounds torque. Install the cotter pin. Re-
Removal move the plug from the ball joint housing and install
(1)Remove the lower control arm, shaft and strut a grease fitting in the plug hole. Repack joint with
as an assembly (Paragraph 5). the specified grease until seal passes grease or the
(2) Remove the nut holding the strut to the lower seal swells showing fullness. Replace grease fitting
control arm. with plug.
(3) Remove the strut from the lower control arm. (5) Inspect the tie rod seal for damage and re-
place if damaged. Connect the tie rod end to the
installation steering knuckle arm and tighten the nut 40 foot-
(1) Position the strut into the lower control arm pounds torque. Slide the tie rod end seal protector
and tighten the retaining nut 110 foot-pounds tor- over the nut and install the cotter pin.
que. (6) Place a load on the torsion bar by turning in
(2) Install the lower control arm, shaft and strut the adjusting bolt.
assembly, as outlined in Paragraph 5. (7) Install the wheel and drum assembly.
(8) Adjust the front wheel bearing (See Group 22,
7. LOWER BALL JOINTS “Wheels, Bearings and Tires”).
Removal (9) Lower the vehicle to the floor and install the
The lower ball joint is integra! with the steering upper control arm rebound bumper.
arm and is not serviced separately. (10) Measure and adjust the front end height if
(1) Remove the upper control arm rebound bum- necessary (Paragraph 2).
per. (11) Measure the front end alignment and adjust
(2) Raise the vehicle so the front suspension is in if necessary (Paragraph 3).
full rebound (under no load). If jacks are used to
raise the vehicle, it is essential that a support be 8. UPPER CONTROL A R M
used between the “K” member and the jack.
Removal and Disassembly
(3) Remove the wheel and drum as an assembly.
(1) Place a jack under the lower control arm as
It may be necessary to back-off the brake shoes to
facilitate removal of the drum assembly. close to the wheel as possible. Raise the vehicle
until the wheel clears the floor.
(4) Remove the two lower bolts from the backing
plate that attach the steering arm and ball joint
assembly to the steering knuckle.
(5) Remove the tie rod end from the steering arm
using Tool C-3894. Use care not to damage the seal.
(6) Using Tool C-3846, remove the ball joint stud
from the lower control arm (Fig. 9), and remove the
steering arm and ball joint assembly.
/nstallatlon
NOTE: The lower ball joint seal incorporates a
convex toothed retainer.
(1) Place a new seal over the ball joint (if nec-
essary) and press the retainer portion of the seal
down on the ball joint housing (using a 1% inch
socket) until it is securely locked in position.
(2) Position the steering arm and ball joint assem- I
bly on the steering knuckle and install the two
mounting bolts. Tighten the nuts to 100 foot-pounds
torque on Valiant and 120 foot-pounds torque on
Plymouth.
(3) Insert the ball joint stud into the opening in
the lower control arm. Fig. 1 1-Removing Upper Ball Joint Stud
2-10 FRONT SUSPENSIOK
0
‘I BALL JOINT
t----l
A. REMOVE 1/16 INCH FROM LOWER PART OF TOOL.
B. ROUND OFF PORTIONOF THE rooL THAT IS
POSITIONED NEXT TO THE STEERING KNUCKLE ARM,
62x 127
Fig. 12-Tool C-3711 Modified
(2)Remove the wheel and tire as an assembly.

(3)Remove the upper and lower ball joint stud
nuts. On Valiant models, it may be necessary to add 62 x 548
approximately 7/ls inch of flat washers over the
lower ball joint stud to allow the use of Tool (2-3711 Fig. 14-Upper Control Arm Assembly (Valiant)
without damaging the threads on the lower ball joint
stud. Place Tool (2-3711 over the stud. Turn the (6)Remove the ball joint using Tool C-3560
threaded portion of the tool locking it securely (Plymouth) Tool C-3714 (Valiant) (Fig. 15). The seal
against the upper stud (Fig. 11). will come off as the ball joint is removed.
To use Tool C-3711 as outlined, it may be nec- (7)Assemble Tool C-3710 over the bushing and
essary to modify the tool, as shown in Figure 12. press the bushing out of the arm (from the inside
(4)Spread tool enough to place upper stud under out) (Fig. 16).
a logd, then strike the steering knuckle sharply
with a hammer to loosen stud. Do not attempt to NOTE: To remove the upper control arm rear
force stud out of the steering knuckle with the tool bushing support sleeve (used on Police and taxi
alone. application) assemble Tool C-3710, using adaptor
SP-3828 in place of adaptor SP-3088, over the
(5) Remove the nuts, lockwashers, cams and cam
bushing and press the bushing out of the arm
bolts that attach the upper control arm and bushings (Fig. 16).
(Fig. 13 or 14) to the front and rear support
brackets. Lift the upper control arm up and away Assembly
from the support. When installing new bushings, be sure the con-
trol arm is supported squarely at the point where
the bushing is being pfessed in. Do not use oil or
grease to aid in installation.
~
CONTROL ARM
%
FWD. KNU CKLE
62 x 558
Fig. 13-Upper Control Arm Assembly (Plymouth) Fig. 15-Removing 0.r Installing Upper Ball Joint
FRONT SUSPENSION 2-1 1
adaptor SP-3827 in place of SP-3233A cup on the

tool and install the support sleeve on the bushing
(Fig. 17).
(2) Install the ball joint into the arm using Tool
C-3560 (Plymouth) Tool C-3714 (Valiant). Tighten
until seated (125 foot-pounds minimum). The ball
joint will cut threads into a new arm during the
tightening operations.
(3) Install a new ball joint balloon seal using Tool
C-3736 or Tool SP-3307 cup and SP-3208 stud.
SP-3208 stud is part of Tool C-3713 (Plymouth). On
Valiant Models, use Tool C-3713.
lnstallatlon
(1) Slide the upper control arm into position and
install the control arm cam bolts (Figure 13 or 14),
and nuts. Tighten nuts in preparation for final ad-
justments.
(2) Slide the upper ball joint stud into position
62x64
in steering knuckle and install nut. Tighten the nut
55 foot-pounds torque on Valiant and 100 foot-
Fig. 16-Removing Upper Control Arm Bushing pounds torque on Plymouth and install cotter pin.
Remove the plug from the ball joint housing and
(1) Position the flange end of the new bushing install a grease fitting in the plug hole. Repack the
in Tool (2-3710, support the control arm squarely, joint with the specified grease, until seal passes
and force the bushings into the control arm (from grease or the seal swells showing fullness. Remove
outside) until the tapered portion of the bushing the grease fitting and reinstall the plug. Tighten the
seats on the arm. lower stud nut 100 foot-pounds torque.
NOTE: On police and taxi application (using (3) Install the wheel and adjust the bearing (See
the bushing support sleeve) remove Tool C-3710 Group 22, “Wheels, Bearings and Tires”).
after the bushing has been installed and install (4) Measure and adjust the vehicle height and
alignment (Paragraphs 2 and 3).
SLEEVE
9. UPPER BALL JOINTS
Removal
(1) Raise the vehicle by placing a jack under the
lower control arm as close as possible to the wheel.
(3) Remove the upper and lower ball joint stud
nuts. On Valiant models, it will be necessary to add
approximately x6 inch of flat washers over the
lower ball joint stud to allow the use of Tool C-3711
without damaging the threads on the lower ball
joint stud. Place Tool C-3711 over the studs. Turn
the threaded portion of tool locking it securely
against the upper stud (Fig. 11). To use Tool C-3711
as outlined, it will be necessary to modify it, as
shown in Figure 12.
(4) Spread the tool enough to place the upper
64 x 153 stud under a load, then strike the steering knuckle
sharply with a hammer to loosen stud. Do not at-
Fig. 17-Installing Upper Control Arm Bushing tempt to force stud out of the steering knuckle with
Support Sleeve tool alone.
2-1 2 FRONT SUSPENSION
(5) Remove the tool, then remove the ball joint
stud from the steering knuckle.
(6) Using Tool C-3560 (Plymouth) Tool C-3714
(Valiant) unscrew the ball joint from the upper con-
trol arm (Fig. 15). The seal will come off as the ball
joint is being removed.
Installat ion
NOTE: When installing a ball joint, it is very
important that the ball joint threads engage those of
the control arm squarely. Balloon type seals should
always be replaced once they have been removed.
(1) Screw ball joint squarely into the control arm 62x56
as far as possible by hand. Fig. 18-”K” Member (Plymouth)
(2) Using Tool C-3560 (Plymouth) Tool (2-3714
(Valiant) tighten the ball joint until it bottoms on from the frame bracket. If the bushings are worn or
the housing. Tighten to a minimum of 125 foot- deteriorated install new bushings.
pounds torque.
lnst allation
NOTE: If the ball joint cannot be torqued to (1) Using a twisting motion, install the sway bar
125 foot-pounds, inspect the threads on the ball link bushings. Water may be used as a lubricant to
ioint and also in the control arm and replace the aid in installation.
ball joint or control arms as necessary.
(2) Position the sway bar cushion housings on the
(3) Position a new balloon seal over the ball joint struts and install the lock plates.
stud and install seal using Tool C-3736 or Tool SP- (3) Insert the bolts, washers and nuts and tighten
3307 cup and SP-3208stud. Tool SP-3208stud is part
to 35 foot-pounds torque.
of Tool C-3713 (Plymouth). On Valiant models, use
To01 C-3713. (4) Install the washers over the ends of the links
(concave side up). Slide the links up through the
(4) Position the ball joint stud in the steering
bushings and install the washers (concave side
knuckle and install a retaining nut.
down). Install the nuts and tighten to 100 inch-
(5) Tighten the nut 55 foot-pounds torque on Val- pounds torque.
iant and 100 foot-pounds torque on Plymouth and
install the cotter pin. Remove the plug from the ball 11. FRONT SUSPENSION “K” MEMBER
joint housing and install a grease fitting. Repack the (Figures 18 and 19)
joint with the specified grease until grease passes
through seal or the seal swells showing fullness. Removal
(1) Remove the engine mount to “K” member
(6) Install the lower ball joint stud nut and tight-
mounting bolts.
en the 100 foot-pounds torque. Install the cotter pin.
(7) Install the wheel and drum assembly.
(8) Adjust the front wheel bearings (See Group
22, “Wheels, Bearing and Tires”).
(9) Lower the vehicle and adjust the front sus-
pension height as necessary (Paragraph 2).
10. SWAY BAR (if so equipped)

Removal
(1) Remove the two sway bar link retaining nuts
and washers.
(2) Remove the two sway bar cushion retaining
nuts, washers, and bolts (one to each strut) and
62 x 57
remove the sway bar assembly.
(3) Remove the sway bar link insulating bushings Pig. 19-”K” Member (Valiant)
(2) Remove the carburetor air cleaner. into the “K” member using only water as a lubri-
(3) Attach engine lifting plate, Tool C-3804 to the cant.
cylinder head on vehicles equipped with 6 cylinder (2) Position the “K” member on the body side
engines. Position engine lifting fixture Tool (2-3809 rails, install the four mounting bolts. Tighten the
over the engine and attach the fixture to the lifting bolts 150 foot-pounds torque.
plate. Raise the engine until the motor mounts (3) Lower the engine and install the engine
clear the “K” member. mounting bolts and tighten to 85 foot-pounds
(4) On vehicles equipped with 8 cylinder engines, torque.
remove the carburetor and install engine holding (4) Position the steering gear on the “K” member
fixture Tool C-3466 to support the engine while the and install the mounting bolts and washers. Tighten
“K” member is being removed. bolts 50 foot-pounds torque.
(5) Remove the lower control arm assemblies, (5) Connect the idler arm to its mounting bracket
both sides (Paragraph 5). and tighten the nut 45 foot-pounds torque. Install
(6) Remove the idler arm at the “K” member the cotter pin.
mounting. (6) Install the lower control arms, shafts and
strut assemblies (Paragraph 5). (Do not tighten.)
(7) Disconnect the steering gear from the “K”
member and support it to relieve all tension. (7) Remove the engine lifting fixture and plate
and install the carburetor if removed.
(8) Install frame stands under the body side rails.
(8) Install the carburetor air cleaner.
(9) Remove the “K?’member mounting bolts and
(9) Measure and adjust the front suspension
remove the “K”member.
height if necessary (Paragraph 2). Tighten the pivot
(10) Remove the strut bushings from the “ K ’ shaft to “K” member nuts and insert cotter pins.
member. Tighten the strut nuts (front - 40 foot-pounds)
(rear - 110 foot-pounds).
installation (10) Measure and adjust the front suspension
(1) Install the lower control arm strut bushings alignment, Paragraph 3 (if necessary).
SERVICE DIAGNOSIS
Ball joint needs lubrication. (a) Lubricate ball joint (see Lubrication
Group “0”).
Shock absorber or bushings. (b) Replace bushings.
Worn strut bushings. (c) Replace bushing.
Loose struts-Lower control (d) Tighten all bolts and nuts.
arm bolts and nuts.
Loose steering gear on frame. (e) Tighten the steering gear mounting bolts.
Worn upper control arm (f) Replace the worn bushings.
bushings.
Worn lower control arm shaft (g) Replace the worn bushings.
bushings.
Excessively worn upper ball (h) Replace the ball joint.
joint.
Excessively worn lower ball (i) Replace the ball joint.
joint.
Worn tie rod ends. (j) Replace the tie rod end.
Loose or worn front wheel (k) Adjust or replace the bearings as
bearings. necessary.
2-1 4 FRONT SUSPENSION
SERVICE DIAGNOSIS--. (Continued1
Poor Directional (a> Low or uneven tire pressure. Inflate the tires to correct pressure.
Stability
(b) Loose wheel bearings. Adjust the wheel bearing.
(c> Improper steering cross shaft Adjust the steering cross shaft.
adjustment.
Steering gear not centered. Adjust the steering gear.
Worn idler arm bushing. Replace the bushing.
Loose or failed front strut Replace the bushings.
bushings.
Weak or broken rear spring. Replace the spring.
Incorrect front suspension Measure and adjust the front end
alignment or heights. alignment and heights.
Shock absorber inoperative. Replace the shock absorber.
Hard Steering (a> Ball joints-insufficient Lubricate the ball joints.

lubrication.
Low or uneven tire pressure. Inflate the tires to the recommended
pressures.
Low power steering fluid level. Fill the power steering pump reservoir to
(On Power Steering equipped level with MoPar Power Steering fluid.
vehicles).
Lack of assist of power steering Inspect and test the power steering pump
system. and steering gear. Service the power
steering pump or gear as required.
Low front suspension height. Adjust heights to specifications.
Incorrect front end alignment Replace the bent part, and align
(particularly caster) resulting suspension.
from one of the following:
(a) Upper control arm bent.
(b) Lower control arm bent.
(c) Steering knuckle or
steering knuckle arm
bent.
Steering gear low on lubricant. Fill the steering gear to the correct level.
Steering gear not adjusted Adjust the steering gear.
properly.
Idler arm binding. Free-up the idler arm.
Excessive Play in (a, Worn or loose front wheel Adjust or replace the wheel bearings as
Steering bearings. necessary.
(b) Incorrect steering gear Adjust the steering gear.
adjustment.
Loose steering gear to frame Tighten the steering gear to frame bolts.
mounting bolts.
Worn tie rod ends. Replace the tie rods as necessary.
Worn steering gear parts. Replace worn steering gear parts and
adjust steering gear as necessary.
Worn upper control arm ball Replace the ball joints.
joints.
SERVICE DIAGNOSIS--. ( Continued1
(g) Worn lower control arm ball (g) Replace the ball joints.
joints.
(h) Worn idler arm bushings. (h) Replace the bushing.
Front Wheel Shimmy (a) Tire, wheel out of balance. (a) Balance the wheel and tire assembly.
(b) Uneven tire wear, or extremely (b) Rotate or replace the tires as necessary.
worn tires.
(c) Worn or loose wheel bearings. (c) Replace or adjust the wheel bearings as
necessary.
(d) Worn tie rod ends. (d) Replace the tie rod ends.
(e) Strut mounting bushings loose (e) Replace the strut mounting bushings.
or worn.
(f) Incorrect front end alignment (f) Adjust the front end alignment and car
and car hekht (particularly height.
caster).
Vehicle Pulls t o (a) Low or uneven tire pressure. (a) Inflate the tires to the recommended
One Side pressure.
(b) Front brake dragging. (b) Adjust the brakes.
(c) Grease, lubricant or brake fluid (c) Replace brake shoe and lining as
leaking onto brake lining. necessary and eliminate all leaks.
Loose strut bushings. (d) Adjust or replace the strut bushings.
Power steering control valve out (e) Adjust the steering gear control valve.
of adjustment.
Incorrect front end alignment (f) Adjust the front end alignment.
(particularly caster).
Broken or sagging front or rear (g) Replace the spring as necessary.
spring.
Failed suspension pivot (h) Replace the bushings as necessary.
bushings.
REAR AXLE-PLYMOUTH 3- 1
GROUP 3
CONTENTS
PLYMOUTH
Page Page
Specifications-Plymouth . . . . . . . . . . . . . . . . . . . . . . . . 1 Differential-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications-Valiant . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pinion Bearing Cup.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Axle Ratios.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Differential Bearing Preload-Pinion
Special Tools.. ............................... 3 with Bearing Spacer.. . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque Reference.. ............................ 4 Gear Tooth Contact Pattern. . . . . . . . . . . . . . . . . . . . . . 15
Rear Axle Assembly-Removal . . . . . . . . . . . . . . . . . . . 5 Welding Rear Axle Housing. . . . . . . . . . . . . . . . . . . . . . 15
Axle Shaft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Carrier Assembly-Installation. . . . . . . . . . . . . . . . . . . . 15
Differential-Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALIANT
Page Page
Rear Axle-Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pinion Installation and Bearing Preload. . . . . . . . . . . . . 27
Axle Shaft-Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Drive Gear and Pinion Backlash. . . . . . . . . . . . . . . . . . 28
Differential-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Differential Preload Spacer Selection Chart.. . . . . . . . 28
Pinion Bearing Cup-Installation . . . . . . . . . . . . . . . . . . 26 Axle Shaft-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drive Pinion Depth of Mesh Axle Assembly-Installation . . . . . . . . . . . . . . . . . . . . . . 29
(Using Tool C-3715). . . . . . . . . . . . . . . . . . . . . . . . . . 26 Service Diagnosis, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SURE-GRIP DIFFERENTIAL
Page Page
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS
P L Y M O U T H MODELS VP-1, VP-2
TYPE
Gear Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi-Floating Hypoid
Ring Gear Diameter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6-Cyl.) 8.25 inch
(8-Cyl.) 8.75 inch
PINION BEARINGS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tapered Roller
Number Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Shims
Pre-Load Torque (Seal Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 30 inch-pounds
DIFFERENTIAL BEARINGS
Number Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Nut
3-2 REAR AXLE--PLYMOUTH
SPECIFICATIONS--. ( Continued 1
RING GEAR AND PINION
Serviced in.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Matched Sets
Ring Gear Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005” Max.
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Washers
Back Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 to .008”
DIFFERENTIAL SIDE GEAR CLEARANCE
With Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001 to .012”
WHEEL BEARINGS
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Shims
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .013 to .023
LUBRICATION
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pints
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-purpose Gear Lubricant as
defined by MIL-L-2105B is used in all
rear axles. MoPar Hypoid Lubricant Part
No. 18794 14 is also recommended.
Anticipated Temperature Viscosity Grade
Range
Above - 10°F SAE 90
As low as -30°F SA€ 80
Below -30°F SAE 7 5
SPECIFICATIONS
V A L I A N T MODEL VV-1
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi-Floating Hypoid
Number of Differential Pinions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Axle Ratio
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard-3.55
Optiona1-3.2 3
Automatic Transmission. ......................................... Standard-3.23
Optional-3.55
Differential Bearings
Adjustment by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spacer Washer
.254-.284 inch in .002 inch graduations
Carrier Bearing Preload Spread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003-.006
Lubrication
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pints
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants Designated for API Service GL-4
as defined by MIL-L-2105A
SAEViscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summer-Above - 10” SAE 90
Winter-Below - 10°F. SAE 89
Extreme Cold-Below - 30°F. SAE 75
Pinion and Drive Gear Back Lash.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004-.007” at point of minimum back lash
Pinion Bearing Preload Adjustment by. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spacer Washers
.074-.lo6 inch in .001 variations
Pinion Bearing Drag Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25 inch-pounds
Pinion Depth of Mesh Adjustment b y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spacer Washers
.Oq4-.100 inch in .002 inch graduations
Runout-Case and Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005 inch Maximum
Wheel Bearing Type ................................................
i
I
Single Row Sealed Ball
REAR AXLLPLYMOUTH 3-3
AXLE RATIOS
Plymouth VP-1 Plymouth VP-2 Plymouth VP-2
225 Cu. In. Engine 318 Cu. In. Engine 361 Cu. In. Engine
PASSENGER CAR
Manual Transmission . . . . . . . . . . . . 3.23 3.23 3.23
Optional ..................... 3.55 3.55 3.55
Automatic Transmission . . . . . . . . . . 2.93 2.76 2.76
Optional ..................... 3.31 -3.55 2.9 3 -3.2 3 2.93-3.23
Sure Grip*. . . . . . . . . . . . . . . . . . . 3.23 2.76 2.76
Plymouth VP-1 Plymouth VP-2 Plymouth VP-2
170 Cu. In. Engine 225 Cu. In. Engine 318 Cu. In. Engine
TAXI**
Manual Transmission . . . . . . . . . . . . 3.91 3.55 3.55
Optional. .................... 3.55 3.9 1 -
Automatic Transmission . . . . . . . . . . 3.55 2.93 2.93
Optional . . . . . . . . . . . . . . . . . . . . . 3.55 -
Sure G r b * . . . . . . . . . . . . . . . . . . . -
Plymouth VP-1 Plymouth VP-1 Plymouth VP-2 Plymouth VP-2
170 Cu. In. 225 Cu. In. 318 Cu. In. 361 Cu. In.
Engine Engine Engine Engine
POLICE**
Manual Transmission. . . . . . . . . . . . 3.9 1 3.55 3.23 3.23
Optional ..................... 3.55 3.23 3.55 3.55
Sure Grip*. . . . . . . . . . . . . . . . . . . - 3.23 3.23 3.23
Automatic Transmission . . . . . . . . . . 3.55 3.23 3.23 3.23
Optional . . . . . . . . . . . . . . . . . . . . . - 2.93 2.93 2.93
- 3.55 - -
Sure Grip*. . . . . . . . . . . . . . . . . . . - 3.23 3.23 3.23
*8% inch Ring Gear-Standard on Sure Grip Axles **a% inch Ring Gear-Standard on Taxi 8t Police Cars
SPECIAL T O O L ~ P L Y M O U T H
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle, Pinion and Differential Case Roller Bearing Puller Set
C-406-A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Bearing Adjusting Wrenches
C-413. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Shaft Outer Bearing Cup Driver
C-430. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-496 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion and Transmission Companion Flange or Yoke Puller
c-499 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle Shaft Puller
C-637. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle Shaft and Inner Oil Seal Puller
C-685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inch-Pounds Torque Wrench
c-745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Shaft Oil Seal Installing Sleeve
C-758. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion Setting Gauge Set
C-839 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Shaft Inner Oil Seal Driver
C-3281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Companion Flange Holding Wrench
C-3339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-3565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle Shaft Outer Seal Driver
C-3656. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion Oil Seal Driver
DD-996. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Bearing Installer
DD-999.. ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flange or Yoke Installer
DD- 1005. .............................................. Differential Case Side and Cross Shaft Roller Bearing Driver
DD-1014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Stand-Differential Carrier
SP-3639. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spacer-Part of Gauge Tool C-758-D3
3-4 REAR AXLLPLYMOUTH
SPECIAL TOOLS--VALIANT
C-293. ................................................ Bearing Removing and Installing Kit

No. 39.. .............................................. .Carrier Bearing Plates
No. 40.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion Bearing Plates
C-452. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion Yoke Remover
C-485. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy Duty Foot-Pound Torque Wrench
C-685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch-Pound Torque Wrench
C-748. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pinion Oil Seal Remover
C-328 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Yoke Holding Tool
C-3288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pilot Stud
C-3339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-37 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Setting Gauge Kit
C-37 16 ....................................... Differential Side Bearing Driver
C-3717. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Bearing Installer
C-37 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Yoke Installing Tool
......................................... .Pinion Oil Seal Installer
C-3721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing Spreader
C-3725. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axle Shaft and Bearing Remover and Installer
............................................ .Axle Shaft Inner Oil Seal Driver
TORQUE REFERENCE
PLYMOUTH MODELS Foot-Pounds
Axle Shaft Nuts. . ................................................................. 145 (Min.)

Brake Support Pla Housing Mounting Bolt Nuts. . ............. .......... 30 to 35
Differential Carrier to Axle Housing Bolt Nuts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Rear Axle Drive Gear to Case Bolts. . . . . . . . . . . . . . . . . ...... ........................ 60
Differential Bearing Cap Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Rear Axle Drive Pinion Companion Flange Nut.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 (Min.)
Rear Spring "U" Bolt Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
VALIANT MODELS
Axle Shaft Retainer Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Differential Bearing Bolts. . . . . . . .................................................... 40
Wheel Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Carrier Cover Bolts.. . . . . . . . . . . . ................................................... 20
Pinion Yoke Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 (Min.)
Propeller Shaft Bolts-Front. . . . . . . . . . . . . . . . . . . .... ............ 32
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Gear Bolts (Left Hand Thread). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Spring Clip (U Bolts) Nuts ............................................................. 45 (Max.)
REAR AXLWLYMOUTH 3-5
REAR AXLE
PLYMOUTH MODELS VP=ll VP-2
The rear axle assembly, shown in Figure 1, may the weight of the new unitized body from the rear
be divided into four subassemblies; axle drive shafts axle.
with related parts, differential with drive gear, drive
pinion with carrier, and axle housing. It is not neces- Gear ratio identification numbers are stamped on
sary to remove the entire assembly to service any of the front face of the pad at the bottom of the carrier.
the above parts with the exception of the axle housing Refer to Page 21 for Valiant Models Rear Axle s e w
itself. Conventional methods are used for relieving ice procedures.
SERVICE PROCEDURES
1. REMOVING THE REAR AXLE ASSEMBLY (7) Remove the rear spring (U Bolts) and the shock
Should it become necessary to remove the rear absorbers.
axle for overhaul or repair, refer to Figure 1, then (8) Remove the axle assembly from the vehicle.
proceed as follows:
(1)Raise the rear of the vehicle until the rear 2. AXLESHAFT
wheels clear the floor. Support the body at the front Removal
of the rear springs. (1) Clean the axle shafts, bearings, cups, shims and
(2) Block the brake pedal in the “Up” position. hub and drum assembly using puller Tool C-845.
(3) Remove the rear wheels. (2) Block the brake pedal to prevent its being de-
(4) Disconnect the hydraulic flexible line. pressed and disconnect the brake lines at the wheel
(5) Disconnect the parking brake cable support at cylinders.
the transmission. (3) Remove the axle drive shaft key and remove
(6) Disconnect the propeller shaft at the differential the brake support plate assembly using Tool C-745 to
yoke. protect the outer seal.
THRUS
..,.e*,-
Fig. 1-Rear Axle (Pinion with Spacer)

3-6 REAR AXLWLYMOUTH
(3) Inspect each axle shaft for signs of fatigue,

worn or scored oil seal contacting surfaces, wear or
accumulated metal deposits on the thrust block end
of shaft, damaged threads, or excessively worn splines.
Machine surfaces can usually be satisfactorily cleaned.
If abnormal conditions are noted, the shafts should
be replaced.
(4) Inspect the shims for distortion or other visible
damage. Discard any shims unfit for further service.
(5) Inspect the shim contacting surfaces of both
the brake support and axle housing for burrs. Remove
the burrs with crocus cloth if possible.
(6) If ?he inspection reveals that replacement of
either the axle shafts or bearings were necessary,
install new bearings on either the original shaft or
46x140 the new shaft if such is being used.
Make certain the bearing and axle shaft contacting
surfaces are thoroughly cleaned so the bearing when
Fig. 2-Removing Axle Drive Shaft and Bearing installed bottoms against the shoulder of the axle
shaft (tapered portion of bearing must face axle
(4) Carefully remove the shim pack from each end shaft threads).
of the axle housing. Identify each shim pack as to
location, to aid in reassembly. Axle Drive Shaft End Play
(5) Remove the axle shaft and bearing assembly
with Tool C-499, as shown in Figure 2. If necessary Where the original axle shafts and/or bearings are
the bearing may be removed from the axle shafts with used, start the adjustment of the axle end play with
the bearing puller Tool (2-293-13, as shown in Figure 3. the original shim pack.
(6)Remove the axle shaft inner oil seals with puller (1) Install a new axle shaft inner oil seal (Fig. 4).
Tool C-637.Remove the brake support plate. (2) Lubricate both axle shaft bearings and install
axles and bearing cups. (Fig. 5)
Cleaning and Inspection (3) With the axle assembled and the brake support
(1) Clean the axle shafts, bearings, cups, shims and plates removed, proceed as follows.
shim contacting surfaces as well as the counterbores
(4) Push both axle shafts and bearing cups in to-
of the axle housing, with mineral spirits or dry
cleaning solvent. With the exception of the bearings, ward the center of the housing as far as they will go.
dry all the parts with compressed air. NOTE: Rotate axles to insure seating of both
(2) Inspect the bearing cones and cups for pitting, bearings and cups.
spalling or other visible damage. If either the bearing (5) After pushing the left axle in as far as it will
cone or cup is unfit for further service, always replace go, measure the amount the right axle shaft bearing
both. cup protrudes out of the axle housing (using feeler
gauge stock).
TOOL
r 34A
Fig, 3-Removing Bearing from Axle Drive Shaft
1 -Axle Drive Shaft 2 -Tool 3 -Bearing Fig. rl-Installing Axle Shaft Inner Oil Seal
REAR AXLE-PLYMOUTH 3-7
Fig. Llnstalling Axle Drive Shaft Bearing Cup Fig. &Checking Drive Gear Run-Out
(6) If the protrusion of the right bearing cup is as shown in Figure 6. Make certain there is no
less than .052inch (Standard Differential) or .081inch end play in the differential side bearings. If the end
(Sure-Grip Differential), no shims are needed on the play is evident, remove the adjuster lock and slightly
right side. If the protrusion is beyond the above loosen the bearing cap on the gear tooth side. Tighten
specifications, that is the amount of shims to add to the adjuster sufficiently to eliminate the end play.
the right side. (6) Rotate the drive gear several complete revolu-
(7) Install the gasket, shims and brake support tions while noting the total indicator reading. This
plate to the right side of the axle housing. Tighten reading must not exceed .005 inch runout. If the in-
the attaching nuts to 30-35foot-pounds torque. dicator reading exceeds the .005 inch runout, it will
be necessary to take a second reading after the drive
(8)Push the left axle shaft and bearing cup in as
gear has been removed. This operation is covered
far as possible while rotating the axle shaft to insure during the differential disassembly.
seating of the axle bearing and cup.
(7) With the companion flange up, hold the flange
(9) Measure the distance the bearing cup protrudes with holding Tool C-3281and remove the pinion shaft
beyond the housing face. nut and belleville washer.
(10)Add .016 inch to this measurement in order to (8) Install the companion flange puller Tool C-542
insure proper end play. and remove the flange, as shown in Figure 7.
(11)Install the gasket, shims and brake support (9) Install oil seal puller Tool C-748by screwing it
plate. Tighten the brake plate attaching nuts to 30-35 securely into the pinion oil seal, as shown in Figure 8.
foot-pounds of torque. Tighten the puller screw to remove the seal.
(12) Measure both axle shaft end play after assem- (10)While holding one hand over the companion
bly. Preferred end play (.013to .023inch). If necessary flange end of carrier, invert the carrier in the stand.
to correct, change shims on the left side. The oil slinger, front bearing cone shim pack and
3. D l F F E R E N T l A L 4 E M O V A L
A N D DISASSEMBLY
(1)Remove the axle drive shafts, Paragraph 2.
(2)Disconnect the rear universal joint and drop
-FLANT ”
the propeller shaft.
(3)Remove the lubricant from the axle housing,
using a suction gun.
(4) Remove the attaching nuts and lift the rear
axle carrier assembly from the axle housing.
(5) Mount the differential in stand DD-1014 and
secure the dial indicator Tool C-430 to the differ-
ential carrier flange so the pointer of the indicator
squarely contacts the back face of the drive gear, Fig. 7-Removing Companion Flange
3-8 REAR A X L M Y M O U T H
Fig. &Removing Pinion Bearing Oil Seal
bearing spacer (where used) will drop from the carrier.

(11) Apply identifying punch marks on the bearing
Fig. 10-Removing Bearing from Pinion Shaft
supports of the differential carrier, differential bear-
ing caps, and bearing adjusters for reassembly pur-
(17) The bearing cups can be removed from the
poses, as shown in Figure 9.
carrier with a blunt brass drift and hammer.
(12) Remove each of the differential bearing ad-
juster lock screws and locks. Differential Case Disassembly
(13) With a W inch socket wrench, loosen the (1) Secure the drive gear in an upright position
bearing cap bolt (one each side) and back off the using brass jaws in a vise. With a % inch socket
bearing adjusters slightly with spanner wrench Tool wrench, remove the drive gear to differential attach-
C-406, to remove the differential case bearing pre- ing cap screws. The drive gear attaching screws have
load. Remove the bearing cap bolts, caps and bearing left hand threads; turn clockwise to loosen.
adjusters. (2) Remove the assembly from the vise and with
(14) Remove the differential assembly with bearing a fibre mallet, tap the drive gear off the case.
cups. Make certain that each bearing cup remains with (3) If the drive gear runout was found to be more
its respective bearing. than .005 inch, test the case as follows: Install the
(15) Withdraw the pinion and rear bearing cone differential with bearing cups in the carrier.
from the carrier. (4) Install the bearing caps, attaching bolts and
(16) With puller Tool (2-293 and four No. 36 adaptor bearing adjusters. Snug the bearing cap bolts down
plates, remove the rear bearing cone from the pinion lightly and screw in both adjusters with spanner
shaft, as shown in Figure 10. Remove the pinion wrench Tool C-406A.
locating washer. (5) Tighten the support cap bolts and adjusters
Fig. 9-Marking Bearing Caps and Adjusting Nuts Fig. 1 1-Checking Drive Gear Flange Run-Out
REAR AXLWLYMOUTH 3-9
sufficiently to prevent any end play in the bearings. spirits or a dry cleaning solvent and with the excep-
(6) Secure dial indicator Tool C-430 or C-3339 to tion of the bearings, dry with compressed air.
the differential carrier flange so pointer of indicator (2) Inspect the differential bearing cones and cups
squarely contacts the drive gear surface of the dif- for pitting or other visible damage. If replacement is
ferential case flange between the outer edge of the necessary, remove the bearings from the differential
flange and the drive gear bolt holes, as shown in case with puller Tool C-293-F2 and adaptor plates
Figure 11. No. 18, as shown in Figure 13.
(7) Rotate the differential several complete revo- (3) Inspect the differential case for elongated or
enlarged pinion shaft holes and the side gear counter-
lutions while noting the total indicator reading. This
bores and the four thrust washer contacting surfaces
reading must not exceed .003 inch runout. If the for galling, metal deposits or raised portions of metal.
runout is in excess of .003 inch, the differential case If any of the above conditions exist, satisfactory cor-
must be replaced. rection must be made or the case replaced. Inspect
(8) Measure the side gear clearances between the the case for cracks or other visible damage which
gear and the case, as shown in Figure 12. Clearances might render it unfit for further service.
should be from .001 to .012 inch. If the clearance (4) Inspect the differential pinion shaft for exces-
exceeds .012 inch, install new thrust washers. sive wear. Replace as necessary.
(9) From the back side of the drive gear flange, (5) Inspect the differential pinion gears for exces-
(8% inch gear) drive the differential pinion shaft sive wear, cracks, chipped teeth or other visible dam-
lock pin out of the case with a flat nose drift and age. Replace the pinion gears or thrust washers as
hammer. (On the 8% inch gear, the lock pin is driven necessary.
out from the opposite side.) The lock pin is a v4 (6) Inspect the differential side gears for cracks,
inch hollow split type pin. (The hole is reamed only chipped teeth or other visible damage. Replace the
part way through, making it necessary to remove differential side gears or thrust washers as necessary.
the lock pin from one direction.)
(7)Inspect the axle shaft thrust block for excessive
(10) Drive the pinion shaft out with a brass drift wear or other visible damage. The thrust block is
and remove the axle drive shaft thrust block. usually damaged by using a "knock off" type axle
(11) Rotate one differential side gear until each
pinion appears at the large opening of the case. Re-
move each pinion and thrust washer at that time.
(12)Remove the two differential side gears and
the thrust washers.
4. CLEANING AND INSPECTION

(1) Clean all parts in fast evaporating mineral
Fig. 12-Checking Differential Gear Clearance Fig. 13-Removing Differential Bearings

drive shaft remover. The wear surface, on opposite (5) Install the thrust block between the two pMon
sides of the block, must be smooth. If inspection re- gears. The thrust block must be installed so the hole
veals that replacement of the thrust block is n e w - in the block is aligned with the pinion shaft and with
sary, the axle shaft end play must be reset. the ground sides facing the two side gears.
(8) Inspect the differential pinion shaft lock pin (6) While keeping all of these parts in proper align-
for damage or looseness in the case. Replace the pin ment, push the pinion shaft on through until the
or case as necessary. locking pin hole in the pinion shaft is in exact align-
(9) Inspect the drive gear for worn or chipped teeth ment with its respective hole in the case and install
or damaged attaching bolt threads. If replacement the pinion shaft lock pin through the hole in the case
of the drive gear is necessary, replace both the drive from the pinion shaft side of the drive gear flange,
gear and drive pinion as they are furnished only in (8Y4 inch gear). (On the 8% inch gear, install the pin
matched sets. from the opposite side).
(10) Inspect the drive pinion bearing cones and the (7) Make certain the contacting surfaces of the
cups which may have been left in the carrier for drive gear and the case flange are clean and free
pitting, excessive wear, or other visible damage. If from any burrs and position the drive gear on the
inspection reveals that either are unfit for further case, aligning the threaded holes of the drive gear
service, replace the cup and the cone. with those in the case flange.
(11) Inspect the differential carrier for cracks or (8) Insert the drive gear cap screws through the
other vibible damage which would render it unfit for case flange and into the drive gear. After all cap
further service. Raised metal on shoulders incurred screws are properly started, tap the gear onto the
in removing pinion cups should be flattened by use flange.
of a flat nose punch. (9) Position the unit .between the brass jaws of a
(12) Inspect the drive pinion for damaged or ex- vise and alternately tighten each cap screw to 60
cessively worn teeth, damaged bearing journals or foot pounds torque.
splines. If replacement of the pinion is necessary, a (10) Position each differential bearing cone on the
new drive gear must also be used as they are fur- hub of the case (taper away from ring gear) and with
nished only in matched sets. Also inspect the pinion installing Tool DD-1005, install the bearing cones.
bearing spacer (where used) for distortion and dam- An arbor press may be used in conjunction with the
age. installing tool.
(13) Inspect the companion flange for cracks, worn
splines, pitted, rough or corroded oil seal contacting 6. PINION BEARING CUP INSTALLATION
surface. Repair or replace the companion flange as (1) Place the bearing cups squarely in position.
necessary. Assemble Tool (2-758 (shown in Figure 14) by placing
(14) Inspect the pinion bearing shim pack for dam- spacer (SP-2919) (8% inch gear with spacer only.)
aged or distorted shims. Replace the shims with (Spacer SP-3639 for the 8% inch gear) followed by
correct ones during establishment of the pinion bear-
ing preload.
5. ASSEMBLING THE DIFFERENTIAL
(1) Install the thrust washer on each of the dif-
ferential side gears and position the gears in the case.
(2) Through the large side opening of the case,
insert each of the two pinions and thrust washers
exactly 180 degrees opposite each other, so the pinion
shaft holes of the two gears and thrust washers are
properly aligned.
(3) Rotate the gears 90 degrees so the pinion shaft
holes of the case are in exact alignment with the
holes in the two thrust washers and pinions.
(4) From the pinion shaft lock pin hole side of the
ATING SPACER SP-2919 57x438
case, insert the slotted portion of the pinion shaft
through the case, the conical thrust washer, and
through just one pinion gear. Fig. l&Tool Set C-758
REAR AXLE--PLYMOUTH 3-1 1
the main screw nut, centralizing washer, compression
sleeve and the front pinion bearing.
COMPRESSION
(TOOL) (2) Install the pinion bearing spacer, the larger
CENTRALIZING bore of spacer next to the rear bearing.
(3) Position sleeve (SP-1730) in the front bearing,
making sure the sleeve is flush with the rear of the
bearing.
(4) Position the original shims, previously removed
I
FRONT BEARING
from the drive pinion shaft, over the sleeve and slide
NUT
(TOOL) the sleeve bearing and shims over the tool main screw
57x12 until the shims rest against the spacer, as shown in
Figure 17.
Fig. 15--Corn~pressionSleeve and Centralizing
Washer (5) Install the tool compression sleeve (SP-535)
(square end out), centralizing washer (SP-534) and
the rear pinion bearing cone over the main screw main screw nut (SP-533).Turn the carrier in the stand
of the tool and inserting it into the carrier from the to bring the nut on top, as shown in Figure 18.
gear side, as shown in Figure 15. (6) Tighten the tool nut to 240 foot-pounds torque,
(2) Place the front pinion bearing over the main and using holding Tool (2-3281 on the compression
screw followed by compression sleeve SP-535, cen- sleeve, to hold the assembly in several positions, to
tralizing washer SP-534, and main screw nut SP-533. make a complete revolution while tightening. Remove
Hold the compression sleeve with companion flange the holding tool and rotate the assembly several turns
holding Tool C-3281 and tighten the nut, as shown in in both directions to align the bearing rollers. Re-
Figure 16; allowing the tool to rotate as the nut is check torque to 240 foot-pounds (torque may have
being tightened in order not to damage the bearings
or cups. Do not remove the tool after installing the
cups. SP-561 PINION LOCATING WASHER OR SHIM
Two types of drive pinions are used. The method
of determining pinion depth of mesh and bearing pre-
load are the same for both pinions, however the
sequence of making the two adjustments changes.
Pinions without a bearing spacer require the depth
of mesh adjustment first, while pinions with a sep-
arate bearing spacer require bearing pre-load adjust-
ment first.
3
7. DIFFERENTIAL BEARING PRELOAD--- SP-3639 u SP-lj30
62 x 246
P I N I O N WITH BEARING SPACER
Pinion Preload (81Y4” Ring Gear)
Bearing Pre-Loud
(1) With the Tool installed in the carrier, remove A
/ 11 PINION LOCATING WASHER OR SHIM
‘\LII1 1
d/
,--+------
SP-1730 57x152
57xl3A
Fig. 116-Seating Bearing Cups in Carrier Fig. 17-Pinion Preload with Spacer (8%” Ring Gear)
3-12 REAR AXLE-PLYMOUTH
Fig. 20-Installing Arbor
drive gear (depth of mesh) is determined by the lo-

cation of the bearing cup shoulders in the carrier and
Fig. 18-Checking Preload Torque (inch-pounds) by the portion of the pinion back of the rear bearing.
The thickness of a pinion spacer washer suitable for
diminished as bearing rollers were aligned by ro- the carrier can be determined by using Tool C-758.
tating). (1) Reverse the carrier in the stand and install
(7) Correct bearing preload readings can only be gauge block SP-528 on the end of the tool, as shown
obtained with the nose of the carrier up. Using an inch in Figure 19, securing it to the tool with the allen
pound torque wrench Tool C-685, with the handle of screw. The flat portion of the spacer should be facing
the wrench floating, read the torque when the wrench the differential bearing pedestals and the offset of
is moving through at least one full rotation. The cor- the spacer (or the large portion) toward the center of
rect reading is 20 to 30 inch-pounds for a new bear- the carrier. Tighten the screw with an allen wrench.
ing and zero to 15-inch-pounds for the original bear- (2) Position the arbor SP-561 (part of Tool C-758)
ing and should be uniform during the full rotations. in the differential bearing pedestals of carrier (Fig.
If bearing preload is more than 30 inch-pounds, a 20). Center the arbor so that an approximate equal
thicker shim should be used under front bearing. If distance is maintained at both ends. Position the dif-
bearing preload is less than 20 inch-pounds, a thinner ferential bearing caps and attaching bolts on the
shim should be used. Shims are available in thick- carrier pedestals. Between the arbor and each cap
nesses of .010, .012, .014, .016, and .018 inch. insert a piece of .002 inch feeler stock and tighten
After correct pinion bearing preload is established, cap bolts securely.
do not remove the tool.
(3) Select a washer that will fit between the tool
Depth of Mesh gauge block and arbor (Fig. 21). This fit must be snug
The position of the drive pinion with respect to the
1s
Fig. 19-Installing Gauge Block Fig. 21-Determining Spacer Washer Thickness

REAR AXLWLYMOUTH 3-1 3
but not too tight (similar to the pull of a feeler
gauge). This washer is then used in determining the
correct thickness washer for installation.
(4) To select a washer for installation, read the
marking on the end of the pinion (-0, -1, -2, + 1,
+2, etc.). When the marking is -, add that amount to
the thickness of the washer selected in Step 3. Ex-
ample: With a washer .086 inch thick and a pinion
marked -2, install a washer .088 inch thick (.086 +
.002 = .088 inch). Example: With a washer ,086
inch thick and a pinion marked +2, install a washer
.084 inch thick, (.086 - .002 = .084 inch) or when a
washer, .086 inch thick is too loose and .088 inch too
tight, use .088 inch.
(5) Remove the tool arbor from the carrier.
(6) Remove the tool and bearings from the carrier.
Fig. 22-Pinion Oil Seal Installation
(7) Remove the shims, spacer, tool sleeve, and rear
bearing cone from the tool main screw. torque to 240 foot-pounds (torque may have dimin-
(8) With the shaft end of pinion facing up, install ished as bearing rollers were aligned by rotating).
the correct pinion spacer washer on the pinion gear
shaft. These washers have a chamfer on one side. The Differential Bearing Preload-Without
chamfer must face the pinion head. Using TOO/ C-758
Depth of Mesh
(9) Position the rear bearing cone on the pinion
(1) If the old and new pinions have the same mark-
shaft (small side away from pinion head). Make cer-
tain that the contacting surfaces of the correct ing, use the spacing washer of the same thickness as
washer, pinion head, and rear bearing cone are per- that of the old washer.
fectly clean and free of any foreign particles. (2) If, for example, the pinion being replaced is
(10) Install the rear bearing cone onto the pinion
marked zero (0), and the new pinion is marked plus
two (+2), try a .002 inch thinner washer, and if
shaft with Tool DD-996. An arbor press may be used
marked minus two (-2) try a .002 inch thicker
in conjunction with the tool.
washer. Due to the fact that these washers are
(11) Install the bearing tabular spacer on the pin- selected more or less by guess, it may be necessary
ion shaft (large bore facing rear bearing). to change the washer several times in order to
(12) 1nstall.the selected shim pack. obtain the correct tooth contact pattern (See Para-
(13) Lubricate the front and rear pinion shaft bear- graph 8).
ing cones with heavy d. Pinion Bearing Preload
(14) Install the front bearing in its cup in the (1) With the spacer and the rear bearing installed
carrier. on the pinion, place the tubular spacer and shims on
(15) Install the oil seal in the carrier with driver the pinion and hold the assembly in the carrier.
Tool (2-3656 (lip of seal must face front bearing). (2) Install the front bearing and companion flange
The seal must be driven into the carrier until tool (without oil seal), using Tool C-496 or DD-999.
bottoms, as shown in Figure 22. (3) Install the washer and nut and tighten to 240
(16) Insert the pinion shaft up through the carrier. foot-pounds while permitting the assembly to rotate
While supporting the pinion in the carrier, install the and to prevent damaging the bearings.
companion flange with installing Tool C-496 or DD-
(4) Measure the preload (see Paragraph 7).
999.
(17) Remove the tool and install the plain washer lnstallation in Carrier
(convex side of washer up) and nut. (1) Install the differential bearing cup on its re-
(18) Hold the companion flange with holding Tool spective bearing, and position the assembly in the
C-3281. Tighten the companion flange nut to 240 foot- carrier.
pounds torque. Rotate the assembly several turns in (2) Install the differential bearing caps, making
both directions to align the bearing rollers. Recheck certain that the identification marks on the cap cor-
(6) Secure dial indicator Tool (2-340 or C-3339 to a

carrier flange so the pointer or indicator is squarely
contacting one of the drive gear teeth (drive side)
(Fig. 24.)
BMk-hsh
(1)Measure the back lash between the drive gear
and pinion. After the first reading is taken, move the
dial indicator away from the tooth sufficiently to ro-
tate the drive gear approximately 90 degrees and
again measure the back lash. The back lash should
be measured in four different positions to determine
the least clearance between the drive gear and pin-
ion. After the point of least clearance has been estab-
lished, mark the drive gear. Do not rotate the drive
gear from the point of least clearance until all adjust-
ments have been completed.
57x20 (2) Turn both bearing adjusters equally (in the
same direction) until the back lash between the drive
Fig. 23-Adlusting Differential Bearings
gear and the pinion is .0005 inch to .0015 inch. This
back lash variation is given to permit alignment and
respond with those on the carrier. Install attaching
installation of the bearing adjuster lock, lock washer
bolts and tighten bolts of each cap by hand.
and attaching bolt. The adjuster must only be turned
(3) Note the identification marks on the Merentia1 in a clockwise direetion and under no circumstances
bearing adjusters and reinstall each in its respective should be backed off.
--
side.
(3) Install the adjuster lock on the back-face side
(4) Screw the adjuster in by hand. No attempt of the drive gear.
should be made at this time to apply any excessive
pressure. To square the bearing cups with the bear- Preload
ing, turn the adjusters “in” with spanner wrench (1) Turn the other bearing adjuster (tooth side of
Tool C-406A,as shown in Figure 23, until the cups DRIVE COAST
are properly squared with the bearings and the end CORRECT
play eliminated, with some back lash existing between ADJUSTMENT
c4llk Cnk TW
the drive gear and pinion.
(5) While facing each bearing support cap, tighten
the left hand bolt 85 to 90 foot-pounds torque on PINION SPACER
TOO THICK
each side. m. La nnl. Lar
PINION SPACER
TOO THIN /e=\
I. PINKIN SPACER CHANGES T M COAST SIDE CONT*CT

FASTER THAN THE DRIVE SIDE
2. BACKLASH ADJUSTMENTS ARM THE DRIVE WE CONlAcl
MUCH FASTER THAN THE COAST SIDE
3. ALL BACKLASH MEASUREMENTS SHOULD BE MADE AT THE
POlM OF MINIMUM BACKLASH
Fig. 2+Mearuring Backlash of Drive Gear 4OXlorU
and Pinion Fig. 2 M e a r Tooth Contact Pattern
REAR AXLWLYMOUTH 3-1 5
drive gear) (Fig. 24) in a notch at a time (notch re- sary to insert a thicker washer behind the pinion rear
ferred to is the adjuster lock holes) until the backlash bearing.
between the drive gear and pinion is a minimum of Heavy Heel Contact
.006 inch to .008 inch. This will pre-load the bearings If the tooth pattern is heavy on the heel of the
and establish the correct backlash. teeth, the edges of the teeth may chip resulting in
(2) Tighten the remaining two bearing support cap excessive damage to the entire assembly. This con-
bolts 85 to 90 foot-pounds torque. dition is corrected by moving the drive gear toward
(3) Install the remaining adjuster lock, lockwasher the pinion. This would result in decreasing the back-
and attaching bolt. Tighten the lock retaining cap lash making it again necessary to insert a thinner
screws 15 to 20 foot-pounds torque. washer behind the pinion rear bearing.
8. GEAR TOOTH CONTACT PATTERN 9. WELDING REAR AXLE HOUSING

The gear tooth contact pattern (Fig. 25) will dis- The axle housing should be completely disassem-
close whether the correct washer has been installed bled if it is to be welded with arc welding equipment.
behind the pinion rear bearing, and the drive gear It is also possible to weld the assembled housing with
has been positioned properly. gas welding equipment, if precaution is taken to
Checking Tooth Contact Pattern protect gaskets and heat-treated parts.
Apply red lead to the drive gear teeth and apply
10. CARRIER ASSEMBLY INSTALLATION
a load against the back of the drive gear with a round
(1) Using a new gasket, install the carrier assembly
bar. As this pressure is being applied to the drive
to the axle housing. Tighten mounting nuts to 45 foot-
gear, rotate the pinion. This action will leave a dis- pounds torque
tinct contact pattern on the gear teeth. The series of
(2) Press the bearing on the axle shaft. Lubricate
illustrations show the correct pattern as well as a the bearing rollers, align the axle spline, and insert
series of incorrect patterns. (Fig. 25). the axle shaft in the housing. Install the axle drive
. Heavy Face Contact
shaft outer bearing cup with Tool C-413.
If the tooth pattern is across the length of the tooth (3) Install the shims in the same manner in which
face, narrow and near the top, the teeth will wear they were removed to maintain a central position of
thin and roll over or score, resulting in excessive the axle shaft thrust block. Install a new seal in the
gear lash and noise. This condition is corrected by brake support plates with Tool C-3565 with the lip
installing a thicker washer behind the pinion rear of seal facing toward the center of the vehicle.
bearing. (4) Install the brake support plates and tighten
the nuts 30 to 35 foot-pounds torque.
Heavy Flank Contact
(5) Measure the axle shaft end play, as outlined in
If the tooth pattern is across the length of the tooth, Paragraph 2.
narrow and low on the flank, the pinion teeth will
score and also result in noise. This condition is cor- (6) Install the hub and drum assembly.
rected by installing a thinner washer behind the pin- (7) Tighten the axle shaft nuts to 145 foot-pounds,
ion rear bearing. minimum, and install new cotter keys.
(8) Connect the rear universal joint.
Heavy Toe Contact
If the tooth pattern is heavy on the toe of the tooth, (9) Remove the block from the brake pedal and
the edges of the teeth may chip resulting in excessive bleed the brake lines.
damage to the entire assembly. This condition is cor- (10) Refill the axle housing and carrier assembly
rected by moving the ring gear away from the pinion. with the specified lubricant. Refer to “Lubrication”,
This will increase the backlash making it again neces- Group 0.
3-1 6 SURE-GRIP DIFFERENTIAL
SURE -GRIP DIFFERENTIAL

The sure-grip differential (Figs. 26, 27, 28 and 29) each other and loose fitting at their inter-section.
is Similar to the COnVentiOnal differential except for Both ends of each shaft have two flat surfaces, or
the addition of friction plates and belleville plates ramps, which mate with identical ramps in the dif-
and discs for clutching the differential case to the
differential gears and a means for engaging these ferential case. There is additional clearance in the
plates. It has four pinion gears, positioned in the case case to Permit slight sideplay of the ends of the
by two pinion shafts which are at right angles to pinion shafts within the case.
SERVICE PROCEDURES
11. SURE GRIP DIFFERENTIAL ion shaft (Fig. 27). The spacers may be observed
IDENTI FlCATlON through the axle shaft opening of the axle housing.
This may be done with the aid of a small flashlight.
Identification o f Sure-Grip type differential assem-
If the spacers are out of place it will be necessary to
bly can be made by the letter "S" stamped o n t h e
disassemble the "Sure-Grip" differential to reinstall
identification p a d o n t h e right side o f carrier housing,
them.
or by a metal tag reading. "Use Sure-Grip Lube" at-
tached by means o f the rear axle housing-totarrier 12. LUBRICATION
bolt, below t h e carrier filler plug, If t h e letter "S" Use Multipurpose Gear Lubricant as defined by
o r tag i s n o t apparent, remove f i l l e r plug a n d use a
M I h 2 1 0 5 B or Mopar Hypoid Lubricant, Part No.
flashlight to look up through t h e filler plug hole to
1879414. Refer to Group "0", Lubrication for serv-
i d e n t i f y t h e t y p e o f differential case. T h e sure-grip
icing.
t y p e differential case (two-piece construction) has
attaching bolts. T h e conventional type differential 13. REMOVAL AND INSTALLATION
case (one-piece construction) has a dome-like shape WARNING: Before raising a rear wheel off t h e
with no case cap attaching bolts. ground shut off engine, set p a r k i n g brake tightly:
carefully block f r o n t wheel, (diagonally opposite t h e
Whenever the rear axle shafts have been removed
one to be removed) against both f o r w a r d a n d rearward
from the "Sure-Grip" axle assembly always determine
movement.
that the thrust spacers have not fallen out of the pin-
Follow the same procedure as outlined under the
removal and installation of the conventional rear axle
FFERENTIAL PINION
IFFERENTIPL CASE
differential.
14. DISASSEMBLY
CLUTCH PLATES (1) Remove the axle drive gear. Measure the runout
of the drive gear mounting flange. Replace both case
halves if runout exceeds .003 inch. Before disassem-
bling t h e case halves, place scribe marks o n each
h a l f t o a i d in aligning t h e case when reassembling
(Fig. 30).
(2) Remove the case cap attaching bolts and re-
move the case cap (Fig. 31) and clutch plates (Fig. 32).
THRUST MEMBER
(3) Remove the side gear retainer (Fig. 33), and
IFFERENTIAL PINION
the side gear (Fig. 34).
(4) Remove the pinion shafts with pinion gears
Fig. 26-Sure-Grip Differential (Schematic) (Fig. 35).
SURE-GRIP DIFFERENTIAL 3-1 7
AXL
Fig. 2'1-Sure-Grip Differential (Cross-Secrion)
(5) Remove the remaining side gear (Fig. 36), side (2) Place the side gears in their retainers. Insert
gear retainer (Fig. 37) and clutch plates (Fig. 38). splines of the retainers through splines of the clutch
(6) Remove the axle shaft thrust spacer by pressing disc.
out the lock pin. (3) Place the aligning pin through one axle shaft
thrust spacer. Assemble the pinion shafts on the
15. CLEANING AND INSPECTION aligning pin.
Clean all parts thoroughly. Inspect all the parts for (4) Place the pinion gears on the shafts and install
wear, nicks and burrs. Replace worn or distorted the assembly on the drive gear half of case. Insert
clutch plates. If the case is worn, it will be necessary the thrust spacer in the pinion shaft (Fig. 40).
to replace both halves. (5) Slide the cap half of the case over the edge
of the bench far enough to insert one finger up
16. ASSEMBLY through the assembly to hold it together. Place the
(1)Position the clutch plates and discs in their
assembly on the drive gear half, matching the scribe
proper location, in each half of the case, as shown in marks.
Figure 39. (6) Make sure the markings on each differential
3-1 8 SURE-GRIP DlFfERENTIAL
“V’
-GROOVE
58x718
Fig. 30-Case Halves Scribed for Reassembly
CASE CAP
Fig. 28-Power-Flow-Axle Shafts Turning at

Same Speed
XLE DRIVE PINION
58x719
Fig. 31-Removing or Installing Differential

DIFFERENTIAL CASE Case Cap
BELLEVILLE
SHAFT PLATE
SIDE GEAR
RETAINER
DIFFERENTIAL
NTIAL PINION
58x262
Fig. 29-Power-Flow-Axle Shafts turning at Fig. %Removing or Insblling Clutch Plater
Different Speeds (Cap Side)
SURE-GRIP DIFFERENTIAL 3-19
EAR
GEAR
58x721
Fig. 33-Removing or Installing Side Gear Fig. 36-Removing or Installing Side Gear
Retainer (Cap Side) from Case
-SIDE GEAR
+AFT
SPACER
---.
---.----^--I SX7Z
._ ----I 58x725
Fig. 34-Removing or Installing Side Gear
tCap Side) Pig. 37-Removing or Installing Side Gear
- *-
Retainer
PINlON
7PGEARSr.‘
INION.
sHAnsL EELLMLLE
PLATE
[CLWCH
PLATES_-
AXLE S
THRUST SPACER
- 58x723
Fig. 35-Removing or Installing Pinion Shafts
and Gears Fig. 3LRemoving or Installing Clutch Plates
3-20 SURE-GRIP DIFFERENTIAL
DISHED PLATE FLAT PLATE
FEELER GAUGES
I
I
c
SIDE GEAR RING DISHED DISC FLAT DISC 62x 126
Fig. 3GArrangement of Clutch Plates, Discs Fig. 42-Checking Clearance of Pinion Shaft
and Washers and Cap
case half coincide. Install the differential case bolts

and turn them in a few threads.
(7) Insert the axle shafts from the vehicle to align
the splines. Make sure the axle shafts engage the
side gear splines as well as the clutch ring splines.
(8) With the shafts installed, center the cross shafts
between the two ramp surfaces in the differential
case. Tighten the differential case bolts evenly by
alternately turning the opposite bolts until all are
tightened to 45 foot-pounds torque. After assembly,
slight misalignment of the splines can be corrected
by moving the axle shafts back and forth until free.
Remove the axle shafts.
58x727
(9) With the differential resting on one hub, insert
Fig. 4Y)-lnstalling Axle Shaft Thrust Spacers two feeler blades, one over each end of the pinion
shaft having ramps above it (Fig. 41). The clearance
FEELER GAUGES should not exceed .010inch at each end of the shaft.
(10) Invert the differential to rest on the opposite
hub. Check the opposite pinion shaft in like manner
to the same specifications (Fig.42).
Measurements over .010 inch indicate that the
clutch discs are worn and should be replaced. New
discs and plates may produce a clearance of as little
as .002 inch.
With either new or used discs, the measurement of
the two shafts should be within .005 inch of each
other.
Use driver Tool C-3565 when installing the rear
axle shaft outer oil seal and the seal protector when
Fig. 41-Checking Clearance Between Pinion installing the brake support plate over the rear axle
Shaft and Case shaft.
REAR AXLLVALIANT 3-21
c
X
09
3-22 REAR AXLLVALIANT
REAR AXLE
VALIANT MODELS W-1
The rear axle housing, shown in Figure 43, is a one- Axle shafts and the pinion oil seal can be removed
piece assembly. The drive pinion and the differential without removing the assembly from the vehicle,
case with drive gear are mounted directly to the but the unit should be removed for any additional
center (carrier) section of the housing assembly. operations. Gear ratio identification numbers are
Access to the differential, drive gears and carrier stamped on the- front face of the pad at the bottom of
bearings is obtaiiled by removal of the carrier cover. the carrier.
SERVICE PROCEDURES
17. REAR AX1.E-REMOVAL (2) Disconnect the brake lines at the wheel cyl-
Should it becor..,na naonccmv tn ramnwa tha Fa-*
AI~--.UUUL J I =a&
sola
LV I SAUV IG C I A G aoIG
inders.
for overhaul or repair, refer to Figure 43, then pro- (3) Using the access hole in the axle flange, r e
ceed as follows: move the retainer nuts from the end of the housing.
(1) Raise the rear of the vehicle until the rear (4) Attach the axle shaft puller Tool C-3725 to the
wheels clear the floor. Support the body at the front axle shaft flange and remove the axle shaft and
of the rear springs. brake assembly from the housing. Remove the brake
assembly from the axle shaft with care, to avoid
(2) Block the brake pedal up. damaging the shaft in the seal contact area, as shown
(3) Remove the rear wheels. in Figure 44.
(4) Disconnect the hydraulic flexible line. (5) Remove the axle shaft oil seal from the housing.
(5) Disconnect the parking brake cable support at (6) Place the axle shaft bearing retaining collar on
the transmission. a heavy vise or anvil and using a chisel cut a deep
(6) Disconnect the propeller shaft at the differential groove into the collar at 90 degree intervals (Figure
yoke. 45). This will enlarge the bore of the collar and permit
it to be driven off of the axle shaft. Using a blunt
(7) Remove the rear spring clips (U bolts) and the
chisel or drift drive the bearing off of the axle shaft.
shock absorbers. Care should be taken not to damage the axle shaft.
(8) Remove the axle assembly from the vehicle.
19. DIFFERENTIAL REMOVAL
18. AXLE SHAFT REMOVAL AND DISASSEMBLY
AND DISASSEMBLY
Side play and runout measurements taken during
(1) With the wheel removed, remove the clips
holding the brake drum on the wheel studs and re-
move the drum.
NOTCH. COLLAR
I
60x111
64x159
Fig. 44 -Removing h l e Shaft Fig. 45-Removing Axle Shaft Baring and Collar
REAR AXLbVALIANT 3-23
-d - 60x1038 60x1036
Fig. &-Measuring Drive Gear Runout Fig. 48-Removing Pinion Oil Seal
disassembly will be very useful in reassembly. uring the differential case. The total indicator reading
(1) Drain the lubricant from the housing, and turn should be no more than .005 inch.
the unit to have the cover facing up. If the runout is over .005 inch, the differential
(2) Remove the cover and clean the differential
case may have been sprung. A test of the case will
be described later.
case and drive gear with kerosene, mineral spirits or
other similar cleaning fluid. (6) Remove the pinion nut and yoke with puller
Tool C-452 and holding Tool C-3281, as shown in
(3) Measure for differential side play. There should
Figure 47.
be no side play.
(7) Remove the pinion oil seal with Puller Tool C-
(4) To measure the drive gear runout on the dif-
748. (Fig. 48.) Remove the pinion front bearing and
ferential case, (provided no side play was found)
preload space washer.
mount a dial indicator Tool C-3339 on pilot stud Tool
C-3288, and load the indicator slightly when the (8) Mark the carrier and differential bearing caps
plunger is at right angles to the back face of the drive for location in assembly, as shown in Figure 49.
gear. (Refer to Figure 46.) (9) Remove the bearing caps and locate the
(5) Measure the drive gear runout by reading the spreader Tool C-3721 on the carrier with the tool
dial indicator, while turning the drive gear several dowels seated in the locating holes in the carrier.
complete rotations. Mark the drive gear and the case Turn the tool screw only finger tight at this time.
at the point of maximum runout for use later in meas- (10) Install a pilot stud, Tool C-3288 in one side
of the carrier. Attach a dial indicator and load the
I TOOLS indicator slightly against the opposite side of the
YOKE
60x1037
Fig. 4 7 4 e m o v i n g Pinion Yoke Fig. 49-Bearing Cap Identification

3-24 REAR AXLLVALIANT
-I
C-
STUD
Fig. 50-Spreading Rear Axle Housing Fig. 52-Removing Differential Carrier Bearing
carrier (Fig. 50). (17)If the drive gear runout exceeded .005 inch in
(11)The carrier must be spread sufficiently (.012- step 4, the differential case flange runout should be
.015") to permit removal of the differential, but not measured. Install the differential case and spacer
over .020 inch. washer in the carrier and loosen the spreader tool.
Mount dial indicator in contact with the drive gear
(12)Remove the dial indicator and remove the dif- side of the flange to take a reading as in steps 3, 4
ferential assembly from the carrier. A light prying and 5. Total allowable runout should not exceed .003
action can be used to unseat the differential from the inch. In a case of slight runout, it may be possible
carrier (Fig. 51). Identify the bearing cups and pre- during assembly to locate the high runout section of
load washers for location in reassembly. Do not re- the drive gear, opposite (180")from the runout section
move the spreader tool. of the case to reduce the tolerance of the assembly.
(13) Remove the pinion from the carrier. (18)Drive the differential pinion shaft lock pin out
(14)Remove the pinion bearing caps with a flat of the case from the drive gear end of case.
end brass drift.
(19)Remove the differential shaft with a brass
(15) Moud the differential case assembly in a vise drift*
equipped with soft jaws.
(20)Rotate the axle side gear to remove the pinion
(16)Remove the drive gear bolts. BOLTS ARE gears and washers.
LEFT HAND THREAD. Remove the drive gear.
(21)Remove the axle side gears and washers.
60x1033
Fig. 51--loosening Dlfferential Assembly Fig. SLRemoving Pinion Rear Bearing

REAR AXLLVALIANT 3-25
(22) Remove the differential bearings with puller (8) Inside the differential case, the machined areas
Tool C-293 and No. 39 plates, as shown in Figure 52. should be polished, without surface imperfections.
(23) Remove the pinion rear bearing with puller The pinion shaft bore in the case should be round
Tool (2-293 and No. 40 plates, as shown in Figure 53. and smooth. Both ends of the pinion shaft should also
be round and without excessive wear.
20. CLEANING A N D INSPECTION (9) The drive gear teeth should have a uniform con-
tact pattern and have smooth, unbroken surfaces with-
(1) Clean all parts except the ball bearings with
out excessive wear. The pinion teeth should have a
kerosene, mineral spirits or other similar cleaning similar appearance. The machined surfaces of the
fluids. Clean the housing tubes with a clean cloth pinion shaft and back face of the head should be
by inserting a stiff wire from the ends of tubes into undamaged and without wear. (See Figs. 54 and 55.)
the carrier section, and withdraw the cleaning cloth
from the center outward. Wipe the ball bearings with (10) Use new gaskets and oil seals during assembly.
a damp cloth.
2 1. ASSEMBLING THE DIFFERENTIAL
(2) The two differential bearing cup contact areas
in the carrier should be smooth and flat, without If new differential side gears are to be installed,
raised metal either in the contact areas or the edges
of the machined surfaces. The bearing caps should ._--
also have undamaged machined surfaces and be free -, 1 BACKLASH
from rafsed metal edges along both sides and also PITCH
LINE
around the bolt holes. /
In the drive pinion section of the carrier the bear- CLEARANCE FACE
ing cup bores should be smooth and flat. Raised FLANK

metal on shoulders of the bores incurred in removing I
I
the cups, should be flattened by use of a flat nose ,
punch. I-
(3) The axle drive shaft bearing and oil seal bores OUTWARD MOVEMFYT OF GEAR-’ INWARD MOVEMENT OF GEAR,A2o,
at both ends of the housing should be smooth and
free from rust or damage. Fig. 54-Gear Tooth Contact Pattern
(4) The axle drive shaft splines should be straight DRIVE COAST
and free from excessive wear. The shaft bearing and
retainer area must be smooth and free from all raised
CORRECT
ADJUSTMENT m m Canter Cantor To#
metal. When it is necessary to clean this portion,
remove only the raised metal and use crocus cloth
to polish the area without reducing the diameter of
the shaft.
PINION SPACER
TOO THICK -aloa. Lou H r l . LOW
(5) If the axle shaft bearings were removed from

the shafts, install new bearings and retaining collars PINION SPACER
as these parts are unfit for further use after removal. TOO
.~ THIN
Hooi. High Too. Hlqh’
(6) Taper roller bearing cone assemblies should
have a smooth, unbroken surface on the cone and
both shoulders. The rollers should also have smooth, GEAR TOO CLOSE
TO PINION
q
-
1 A
=\
unbroken surfaces. The roller retainer should be free TO. Sllghtly HlqlUr
from damage and cracks. Bearing cups should have a

smooth unbroken surface. GEAR TOO FAR q
1
-
(7) Differential pinion gears and side gears should FROM PINION
HOOl Slightly Lorn
have smooth teeth with a uniform contact pattern,
without excessive wear or broken surfaces. The hub 1. PINION SPACER CHANGES AFFECT THE COAST SIDE CONTACT
FASTER THAN THE DRIVE SIDE
surfaces of side gears should be smooth and the 2. BACKLASH ADJUSTMENTS AFFECT THE DRIVE SIDE CONTACT
splines should be straight and without excessive wear. MUCH FASTER THAN THE COAST SIDE
3. ALL BACKLASH MEASUREMENTS SHOULD BE MADE AT THE
The outer surface of the pinion gears should be POINT OF MINIMUM BACKLASH
smooth and bright. Thrust washers should be smooth WxlO2U
and unbroken. Fig. 55-Tooth Contact Pattern

3-26 REAR AXLE-VALIANT
(7) Tap the drive gear against the flange. Tighten

the bolts to 55 foot-pounds torque.
(8) Install the bearing cones with driver, Tool C-
3716, as shown in Figure 56.
22. PINION BEARING CUP INSTALLATION

The rear axle gauge Tool C-3715 is used to install
the pinion bearing cups as well as to determine the
pinion depth of mesh. (See Figure 57.)
(1) Start both bearing cups into the carrier.
(2) Place the rear spacer SP-3244 on main tool.
Seat the pinion rear bearing on the spacer and hold
the tool in housing.
(3) Place centralizing sleeve SP-3245 on the tool
Fig. %--Installing Differential Bearing
and place the pinion front bearing cone on the cen-
tralizing sleeve, then the tool compression sleeve,
place a new thrust washer over the hub of each gear centralizing washer and nut.
and install in position in the differential case, then
proceed as follows: (4) Draw the cups tightly against the housing
shoulders by tightening the nut while holding the
Lubricute All Parts When compression sleeve from turning with Tool C-3281.
Assembling and Adjusting Permit the tool to turn to several rotations during
(1) Install the thrust washers on the differential the tightening operation. Leave the tool in the car-
side gears and position the gears in the case. rier for determining depth of mesh.
(2) Place the thrust washers on both pinion gears
and mesh the pinion gears with the side gears, having 23. DRIVE PINION DEPTH OF MESH
the pinion gears exactly 180 degrees apart. (Using Tool C-3715 1
(3) Rotate the gears to align the pinion gears and (1) With the main tool left in the carrier after in-
washers with the shaft holes in the case. stalling the pinion bearing cups, loosen the tool nut
(4) Install the pinion gear shaft with care so as not and retighten to produce 15 to 25 inch-pounds of
to damage the thnist washers and to have the hole turning torque. Attach the gauge block to the main
in the shaft aligned with the lock pin hole in the tool.
case. (2) Place the cross bore arbor in the carrier and
(5) Install the lock pin from the drive gear teeth install the caps. Tighten the cap bolts lightly.
side of the case. (3) Select a bearing spacer washer which will fit
(6) Position the drive gear on the case to separate
the points of maximum runout 180" and start all
bolts through the case into the drive gear, finger tight.
(BOLTS ARE LEFT H A N D THREAD.)
CENTRALIZING
MAIN TOOL
CROSS BORE ARBOR \ WASHER \2,
*ei:- J
COMPRESSION
CENTRALIZING
SLEEVE A 'A
REAR SPACER GAUGE BLOCK
SPACER (SELECTIVE) 60x1027

60x1028 Fig. 5g--Measuring Housing for Pinion
Fig. 57-Pinion Setting Gauge Tool Spacer Thickness
between the arbor and the gauge block when the
washer is flat on the block. The fit should have a
definite drag, similar to the pull of a feeler gauge.
Should a washer have a little drag and the next
thicker washer will not pass through, select the thin-
ner washer, as shown in Figure 58.
The selected washer is the proper one for this
carrier. I t would be the proper one for installation
with a pinion marked -0. If the pinion has a +2,
marking, select a washer that many thousandths thin-
ner for installation. If the pinion has a -2, select a
washer that many thousandths thicker for installation.
Treat other pinion markings in a similar manner.
Spacer washers are available in .001 inch variations
from .084to .lo0inch.
(4)Remove the tool from the carrier.
Fig. 6Glnstalling Pinion Oil Seal
24. PINION INSTALLATION AND
several turns in both directions to align the bearing
BEARING PRELOAD rollers.
Pinion spacer washers are chamfered on one side (4)Use an inch-pound torque wrench Tool C-685
and must be installed with the chamfered side toward to measure the preload. Accurate readings can be
the pinion head. obtained only with the nose of the carrier up. With
the handle of the wrench floating, take reading when
(1) Place the selected spacer (Paragraph 8) and the the wrench is moving through several full turns. Cor-
bearing on the pinion. Use installing Sleeve Tool C- rect preload is 15 to 25 inch-pounds. A reading which
3717, to press bearing on pinion, as shown in Figure varies during rotation indicates a binding condition
59. which should be corrected. Use thinner washer to in-
(2)Hold the pinion in carrier and install the origi- crease preload and thicker washer to decrease pre-
nal preload washer (chamfered side toward shoulder), load. Always perform Steps 3 and 4 in exactly the
front bearing, yoke and nu2 on the pinion. same manner each time to obtain accurate preload
(3)Turn the housing to bring the nose of the car- readings. Preload washers are available in .001 vari-
rier up. Tighten the nut to 240 foot-pounds (mini- ations from .074to .lo6inch.
mum), with torque wrench C-485,using holding Tool (5) When the preload is correct, remove the nut
(2-3281,on the yoke to hold the assembly in several and yoke.
positions to make a complete revolution while tighten- (6)Apply a thin film of sealing compound to the
ing. Remove the holding tool and rotate the assembly inner bore of the carrier in the area of the pinion
seal.
(7) Install the pinion oil seal (lip toward the pinion
TOOL ".J 60x1024

Fig. 594nstalling Pinion Spacer and
Rear Bearing Fig. 61-Installing Pinion Yoke
head) with holding Tool (3-3719 to space the seal between the spacer and the right side of the casting
flange the proper distance from the carrier, as shown above the centerline of the case (Figure 56). Insert
in Figure 60. the same thickness of another set of feeler gauges
(8) Install the yoke, using installing Tool C-3718 between the spacer and casting below the centerline
and Holding Tool C-3281, as shown in Figure 61. of the case. Increase the thickness of the gauges until
a heavy drag is felt.
(9) Remove the tools and install the washer (cupped
side toward pinion head) and nut. Tighten nut to 240 (4) Rotate the differential several times in both
foot-pounds torque. directions to seat the bearings and cups and recheck
the feeler gauge drag.
25. DRIVE GEAR AND PINION BACKLASH (5) Install a spacer totaling the combined thickness
(1) With the pinion installed and the bearing pre- of the spacer and feeler gauge. This will provide zero
load set, install the differential carrier, ring gear, end play.
bearings and cups with a .254” spacer on the ring (6) Measure the drive gear backlash and refer to
gear side, into the differential housing. Do not install the “Differential Preload Spacer Selection Chart” for
the bearing caps. the proper spacers to provide .004” to .007” backlash.
(2) Install a spacer on the right side that will Measure the backlash at 90” intervals.
leave a little end play. (7) Remove the differential from the carrier hous-
(3) Measure the end play by using two sets of ing and install the proper spacers for left and right
feeler gauges. Push the differential to the left side or sides as specified by the “Differential Preload Spacer
ring gear side of the carrier. Insert a feeler gauge Selection Chart”.
DIFFERENTIAL PRELOAD SPACER SELECTION CHART

Backlash Change left Change Right Backlash Change left Change Right
at Zero Spacer Thickness Spacer Thickness at Zero Spacer Thickness Spacer Thickness
End Play by: by: End Play by: by :
.020 +.026 -.016 .010 +.012 - .002
.019 +.024 -.014 .009 +.OlO - .ooo
,018 +.022 -.012 .008 +.008 +.002
.017 +.022 -.012 .007 +.008 +.002
.016 +.020 -.010 .006 +.006 +.004
.015 +.020 -.010 .005 +.004 +.006
.014 +.018 - .008 .004 +.002 +.008
.013 +.016 - .006 .003 +.002 +.008
.012 +.014 - .004 .002 +.ooo +.OlO
.011 +.014 - .004 .oo 1 +.ooo +.012 ,
Should the zero end play backlash measure more than .020 (Maximum chart figure) increase the thickness of the left spacer from
the specified .254“to a thickness great enough to reduce the zero end play backlash within the chart limits; then follow the, rec-
ommended procedure.
( 8 ) Attach the spreader Tool C-3721 but do not (11) Remove the dial indicator.
spread the housing at this time. (12) Hold the bearing cups and the selected spacers
(9) Install the dial indicator Tool C-3339 on one on the bearing cones and carefully install the differ-
side of the housing and as near the centerline as ential assembly into the housing. Be certain the as-
possible. Position the anvil of the dial indicator in sembly is properly seated into the housing.
contact with the opposite side of the housing (Figure (13) Release the spreader tool and remove it.
50). (14) Install the bearing caps and alternate tighten-
(10) Observe the dial indicator while tightening the ing the bolts to 40 foot-pounds.
spreader tool. Spread the housing .010 to .015 inch. (15) Install the dial indicator to the case with the
Never spread the housing more than .020 inch as the indicator parallel with the drive gear rotation and
case may take a permanent set. with the anvil contacting one tooth.
(16)Determine the amount of backlash and mark

the tooth.
(17)To find the position of least backlash, take
readings on three more teeth approximately 90 de-
grees apart.
(18)Using the teeth with the minimum backlash,
the dial indicator should read .004 to .007 inch. If
the reading is not within tolerance it will be necessary
to refer to the “Differential Preload Spacer Selection
Chart” and install different spacers. TOOL
60x1023
(19)Make a gear tooth pattern test using red lead
and refer to the patterns in (Figure 34).
Fig. 6%lnstalling Axle Shaft Oil Seal
(20)Install the differential cover with a new gasket
and tighten the attaching bolts to 20 foot-pounds 27. AXLE ASSEMBLY-INSTALLATION
torque.
(1) With the body supported at the front of the
rear springs, position the rear axle housing spring
26. AXLE SHAFT INSTALLATION
seats over the spring center bolts.
The axle shaft bearing and bearing collar must fit
(2)Install the spring clips (U bolts) and shock
tightly on the axle shaft. Press them into place. absorbers. Tighten the U bolt nuts to 45 foot-pounds
(1)Place the axle shaft retainer plate, gasket, torque.
bearing and bearing collar on the axle shaft. (3) Connect the hand brake cable support at the
(2)Install a foam gasket Part Number 2070933 at transmission.
each end of the shim pack and place the assembly (4)Connect the propeller shaft and tighten the
on the axle housing studs. Place the brake support nuts to 15 foot-pounds torque.
plate on the axle housing studs. (5)Connect the brake lines to the wheel cylinders
(3)Apply grease on the bearing outside diameter and connect the hydraulic flexible lines.
for prevention of rust. (6)Install the brake drums and retainer clips.
(4)Install the new oil seals in the axle shaft (7)Install the wheels and tighten the nuts to 55
housing, using Tool C-3734,as shown in Figure 62. foot-pounds torque.
(5)Carefully slide the axle shaft assembly through (8)Remove the pedal block and bleed the brake
the oil seal and into the side gear splines. system.
(6) Tap the end of the axle shaft lightly to position (9) Remove the vehicle support stands.
the axle shaft bearing into the bearing bore and at- (10)Fill with 2 pints of lubricant: S A E 90 for
tach the retainer plate to the housing. Tighten the temperatures above 10’F: SAE 80 from -1O0F to
nuts to 35 foot-pounds torque. -30°F; S A E 75 below -30°F.
SERVICE DIAGNOSIS
Rear Axle Noise (a) Wheel loose on axle drum. (a) Tighten wheel in sequence
outlined in “Wheels and Tires.”
(b) Worn drum or worn axle shaft (b) Replace drum or axle shaft as
keyways. necessary.
(c) Wheel hub bolts loose. (c) Tighten bolts to correct torque.
(d) Brinelled or scored wheel bearings. (d) Replace wheel bearings.
(e) Insufficient lubrication. (e) Add lubricant as required.
(f) Bent axle shaft or wheel and hub. (f) Replace wheel, hub or drum as
necessary.
(g) Lubricant level low. (g) Add lubricant as required.
(h) End play in drive pinion bearing. (h) Measure and adjust end play.
(i) Excessive gear lash between drive (i) Measure and adjust gear lash.
gear and pinion.
(j) Loose drive pinion companion (j) Tighten flange nut to 240 (min.)
flange nut. foot-pounds.
(k) Damaged gears. (k) Replace gears as required.
Over-Heating of (a) Lubricant level too low. (a) Add lubricant as required.
T h e Axle Unit (b) Bearing adjusted too tightly. (b) Adjust bearings correctly.
(c) Excessive wear in gears. (c) Replace excessively worn gears.
Loss of Lubricant (a) Lubricant level too high. (a) Remove excessive lubricant.
(b) Improper type lubricant. (b) Remove ‘lubricant and replace
with the recommended type.
(c) Clogged breather. (c) Clean breather thoroughly.
(d) Oil seals worn or damaged. (d) Replace seals as required.
BRAKES 5-1
GROUP 5
BRAKES
CONTENTS
Page Page
Specifications. . . . . . . . . . . . . . . . . . . . Brake Support Plate., . .............. 10

Special Tools. . . . . . . . . . . . . . . . . . . . Wheel Stud Tightening. . . . . . . . . . . . . . . . . . . . .
Torque Reference. . . . . . . . . . . . . . . . Parking Brake Adjustment. . . . . . . . . . . . . . . . . .
Service Brake Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 3 Front Parking Brake Cable.. . . . . . . . . . . . . . . . . . .
Testing Automatic Adjuster Operation. . . . . . . . . . Rear Parking Brake Cable.. . . . . . . . . . . . . . . . . . . . . . 12
Brake Drum-Removal ....................... 4 Booster Brake-Removal (Bendix) . . . . . . . . . . . . . . . . . 14
Brake Shoe-Removal . . . . . . . . . . . . . . . . . . . . . Booster Brake-Removal (Midland Ross). . . . . . . . . . . . 17
Inspecting the Brake Shoes. . . . . . . . . . . . . . . . . . Booster Brake-(Bendix) (Valiant) . . . . . . . . . . . . . . . . . 20
Grinding Recommendations. . . . . . . . . . . . . . . . . . . . . . 6 Removing the Booster Brake from the Vehicle
Brake Shoe-Installation . . . . . . . . . . . . . . . . . . . . . . . . 6 Servicing the Booster Brake.. . . . . . . . . . . . . . . . . . . . . 20
Bleeding the Brake System.. . . . . . . . . . . . . . . . . . . . . . 8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test for Fluid Contamination .............. 8 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Master Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing the Booster Brake in the Vehicle.. . . . . . . . . . 23
Wheel Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service Diagnosis, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPECIFICATIONS
PLYMOUTH
Type . . . . . . . . . . . . . . . . . . . . . . . . . . ....................................... Duo-Servo Single Anchor
Drum Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 10 inches
(Police Special) . . . . . . . . . . . . . . .......................... 11 inches
Number of Brake Shoes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 8
Width
........................... ........ 2% inches
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... 2 % inches
(Police Special)
Front. . . . . . . . . . . . . . . . . ................................... 3 inches
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................. 2 % inches
Brake Lining (Type) ..................................... .............. Bonded Moulded Asbestos
Length & Color Code Markings
...................... . . . . . . . . . . . . 8V2” 1 Red and 1 Black mark
........................ 11” 2 Red and 1 Black mark
. . . . . . . . . 8Yz” 1 Red and 1 Black mark
. . . . . 11” 2 Red and 1 Black mark
........................... ............ 9%” 3 Black marks

. . . . . 12%‘’ 2 Black and 1 White mark
. . . . . . . . . . . . . . . . . . 9%” 3 Black marks
. . . . . . . . . 121/s“ 2 Black and 1 White mark
Front Primary. . . . . . . . . . . . . . . . . . . . . . . . . 9%” 1 Black and 2 White marks

Front Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12’/s“ 1 White and 1 Green mark
.......................... . . . . . . . . . 9%” 1 Black and 2 White marks
. . . . . 12%“ 1 White and 1 Green mark
.................. ?46’f
Wheel Cylinder
Front Wheel Cylinder Bore.. . . . . . . . . . . . . .............................. 1YE”
Rear Wheel Cylinder Bore.. . . . . . . . . . . . . . . . . . . . . .................. 1 %6”-1 3/16f’
......... 1 inch
*11 Inch Brake

5-2 BRAKES
SPECIFICATIONS
VALIANT
.............................................................. Duo-Servo Single Anchor

Drum Diameter. . . . . . . . . . . . . . . . ............................. 9 inches
Number of Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front. . . . . . ............................................. 2Y2" wide
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2" wide
Brake Lining (Type). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bonded Moulded Asbestos
Length 8. Color Code Markings
Front Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7%" 1 Red and 1 Yellow mark
Front Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9%" 2 Red marks
Rear Primary.. ........................... 7%" 1 Red and 1 Yellow mark
Rear Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9%" 2 Red marks
Thickness (all). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %b"
Wheel Cylinder
Front Wheel Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1"
Rear Wheel Cylinder Bore. . . . . . . . . . . . . . . . . . . . . .... ' %b"
Master Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1"
SPECIAL TOOLS
C-4 16 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamps-Brake Cylinder Piston

C-650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H o s ~ B r a k eBleeder
C-845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller-Wheel
.\.
C-3080 . . . . . . . . . . . . . . . . . . . . . . . .............................. Hone-Brake Cylinder

C-3496 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank-Brake Bleeder
C-3784. . ............................................................ Adjuster-Brake Shoe
C-3785. . . . . . . . . . . . . . . ........................................ Remover and Installer-Brake Spring
........................................ Fixture-Piston Assembling
TORQUE REFERENCE
Mounting Bracket to Firewall Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in.-lbs.

Master Cylinder to Vacuum Cylinder Nut. ...................................................... 100 i d b s .
Piston Plate Bolts.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 ft.-lbs.
BRAKES 5-3
BRAKES
The 1964 models incorporates the self-adjusting 1 and 2), except police cars and Taxi cabs with heavy
duro-servo two shoe, internal expanding brakes (Figs. duty brakes.
SERVICE PROCEDURES
1 . BRAKE ADJUSTMENT (3) Be sure the parking brake lever is fully re-
Normally self-adjusting brakes will not require a leased, then back off the parking brake cable adjust-
ment so there is slack in the cable.
manual adjustment, but in the event of a brake re-
line it may be advisable to make the initial adjustment (4) Insert the adjusting Tool ‘2-3784, into the
manually to speed up the adjusting time. star wheel of the adjusting screw. Move the handle
of the tool downward until a slight drag is felt when
(1) Raise the vehicle all wheels are free to turn.
SO the road wheel is rotated.
(2) Remove the rear adjusting hole cover from (5) Insert a thin screw driver into the brake
the backing plate on all of the brake supports of the adjusting hole and the push the adjusting lever out of
vehicle. engagement with the star wheel (Fig. 3), while hold-
Fig. 1-Front Brake Assembly (Disassembled)

5-4 BRAKES
ing the adjusting lever out of engagement, back off should be backed off approximately 30 notches. It
the star wheel 10 to 12 notches to insure a free wheel will be necessary to hold the adjuster lever away
with no brake shoe drag. from the star wheel to allow backing off of the ad-
(6) Repeat the above adjustment at each wheel. justment.
The adjustment must be equal at all wheels. Install Spin the wheel and brake drum in the reverse di-
the adjusting hole covers in the brake supports. rection and apply the brakes vigorously. This will
provide the necessary inertia to cause the secondary
(7) Tighten the parking brake cable adjusting nut
brake shoe to leave the anchor. The wrapup effect
until a slight drag is felt at the rear wheels, loosen the
will move the secondary shoe and the cable will pull
cable adjusting nut until both rear wheels can be
rotated freely, then back off the cable adjusting nut the adjuster lever up. Upon release of the brake pedal,
two full turns. the lever should snap downward, turning the star
wheel. Thus, a definite rotation of the adjuster star
wheel can be observed if the automatic adjusters
2. TESTING AUTOMATIC ADJUSTER working properly. If by the described procedure one
OPERATION or more automatic adjusters do not function properly,
Place the vehicle on a hoist, with a helper in the the respective drum must be removed for adjuster
driver’s seat to apply the brakes. Remove the plug servicing.
from the rear adjustment slot in each brake support
plate to observe the adjuster star wheel. Then, to 3. BRAKEDRUM
exclude the possibility of maximum adjustment; that Removal
is, the adjuster refuses to operate because the closest When the brake drums are removed a thorough
possible adjustment has been reached; the star wheel inspection of the brake conditions should be made
BRAKES 5-5
hole and engage the notches of the brake adjusting
screw. Release the brake adjustment by prying up
with the adjusting tool.
(4) Remove the wheel cover, grease cap, cotter
pin, lock, adjusting nut, outer wheel bearing and re-
move the wheel and drum assembly from the spindle.
Rear Drum
(1) With the vehicle on a hoist, jack, or suitable
stands, remove the rear plug from the brake adjust-
ing access hole.
(2) Insert a thin screw driver (Fig. 3) into the
brake adjusting hole and hold the adjusting lever
away from the notches of the adjusting screw.
6 2 X 5w (3) Insert Tool (2-3784 into the brake adjusting
hole and engage the notches of the brake adjusting
Fig. &Releasing Brake Adjustment screw. Release the brake by prying up with the ad-
justing tool.
Linings should be inspected for wear, saturation by
(4) Remove the wheel cover, cotter pin and axle
brake fluid or grease and brake shoe alignment. Make
all corrections as the inspection indicates. nut.
(5) Install rear wheel hub puller Tool C-845, and
Front Drum remove the hub and drum.
To aid in brake drum removal, loosen the brake
adjustment first. 4. BRAKESHOE
(1)With the vehicle on a hoist, jack or suitable
Removal
stands, remove the rear plug from the brake adjust-
CAUTION: Install brake cylinder piston clamps,
ing access hole.
Tool C-416 to prevent fluid leakage or air entering
(2) Insert a thin screw driver (Fig. 3) into the
the hydraulic system during brake shoe removal.
brake adjusting hole and push the adjusting lever
away from the star adjusting wheel. Removing the Front Brake Shoes
NOTE: Care should be taken not to bend the ad- With the vehicle elevated on a hoist, jack or suit-
justing lever. able stands, remove the front wheels and drums.
(3) Insert Tool C-3784 into the brake adjusting (1) Using Tool C-3785 remove the brake shoe re-
turn springs, as shown in Figure 4.
505
Fig. LRemoving Retainer Springs and Cups
'Fig. &Removing Brake Shoe Return Springs (Plymouth)
5-6 BRAKES
(2)Plymouth: Remove the brake shoe retainer, (6) Disengage the parking brake cable from the
spring and rod, as shown in Figure 1. parking brake lever and remove the brake assembly.
Valiant: Insert a small punch into the center of (7) Over lap the anchor ends of the primary
the brake shoe to backing plate retainer spring, and and secondary shoes and remove the adjusting screw,
while holding the backing plate retainer clip, press adjusting lever, adjusting spring, cable and cable
in and disconnect the spring (Fig. 6). guide.
(3) Remove the anchor pin plate. NOTE: Keep the wheel cylinder assembly com-
(4) Remove the primary and secondary shoe assem- pressed with the aid of a brake cylinder clamp until
bly from the backing plate. the brake shoes are installed.
NOTE: Keep the w k l cylinder assembly com- (8) Remove the brake shoes from the support
pressed with the aid of a brake cylinder clamp until
plate.
the brake shoes are installed.
(9) Remove the parking brake lever from the
(5) Overlap the anchor ends of the primary and secondary brake shoe.
secondary brake shoes and remove the adjusting
screw, adjusting lever, adjusting spring, cable and 5. INSPECTING THE BRAKE SHOES
cable guide. Wipe or brush clean (dry) the metal portions of
Removing the Rear Brake Shoes the brake shoes. Examine the lining contact pattern to
(1) Raise the vehicle on a hoist or support on determine if the shoes are bent. The lining should
suitable stands. show contact across the entire width, extending from
Plymouth: Remove the hub and drum with Tool heel to toe. Shoes showing contact only on one edge
c-845. should be discarded. Shoes having sufficient lining
Valiant: Remove the retaining nuts and remove but lack of contact at toe and heel should be tested
the wheel, remove tinnerman nuts and remove the for proper grind.
brake drum. 6. G R I N D I N G RECOMMENDATIONS
(2)Plymouth: Remove the brake shoe retainer, Brake Shoe Lining-New lining should be meas-
spring and rod as shown in Figure 5. ured and ground .060 to .080 inch (maximum)
Valiant: Insert a small punch into the center of under the drum diameter. The equipment manufac-
the brake shoe to backing plate retainer spring, and turer’s instructions should be followed.
while holding the backing plate retainer clip, press Knowing the drum diameter, the proper measure-
in and disconnect the spring (Fig. 6). ment is then placed on the grinder and the lining
(4) Remove the anchor pin plate and tilt the ground to the required clearnaces.
brake shoe assembly out from the backing plate. Drum Refacing-Measure the drum runout with
(5) Spread the anchor ends of the primary and an accurate gauge. Drum runout should not exceed
secondary shoes and remove the parking brake strut .006 inch out of round. If the drum runout is in excess
and spring. of .006 inch, the drum should be refaced. Remove only
RETAINER CLIP 121
as much material as is necessary to clean up the drum.
NOTE: Do not reface more than .060 inch over
the standard drum diameter.
7. BRAKE SHOE INSTALLATION

Front Brake Shoes
NOTE: Inspect the backing plate platform for
burrs. Remove burrs and apply a light coat of Mopar
Sylglyde to the platforms.,
(1) Match a primary and secondary brake shoe
and place them in their relative position on a work
bench.
(2)Lubricate the threads of the adjusting screw
and install it between the primary and secondary
shoes.
Plymouth: The star adjusting wheels are stamped
Fig. +Removing or Installing Shoe Retainer Spring “R’ (right) and “L” (left), and indicate right or
(Valiant) left side location. The star wheel must be installed
BRAKES 5-7
next to the secondary shoe (Figs. 1 and 4). burrs. Remove burrs and apply a light coat of Mopar
Valiant: The star adjusting wheel must be toward Sylglyde to the platforms.
the rear of the vehicle on the right side of the vehicle, (1) Place a secondary and a primary shoe in their
and toward the front on the left side of the vehicle. relative position on a work bench.
(3) Overlap the anchor ends of the primary and (2)Attach the parking brake lever to the back
secondary brake shoes and install the adjusting spring side of the secondary shoe (Figs. 2 and 5).
and lever. (3) Lubricate the threads of the adjusting screw
(4) Spread the anchor ends of the brake shoes to and install it between the primary and secondary
maintain the adjusting lever and spring in position. shoes.
(5) Holding the brake shoes in their relative posi- Plymouth: The star adjusting wheels are stamped
tion, place the brake shoe assembly on the backing “R” (right) and “L” (left), and indicate right or left
plate and over the anchor pin (Fig. 7). side location. The star wheel must be installed next to
(6) Plymouth: Install the brake shoe retainer
the secondary shoe (Fig. 2).
rods, cups, springs and retainers. Valiant: The star adjusting wheel must be toward
Valiant: Install the brake shoe retaining springs the rear of the vehicle on the right side of the vehicle,
and attach to the retainer clips. and toward the front on the left side of the vehicle.
(4) Overlap the anchor ends of the primary and
(7) Install the anchor pin plate. secondary brake shoes and install the adjusting
(8) Install the cable guide in the secondary shoe spring and lever.
and place the “eye” of the adjusting cable over the (5) Hold the brake shoes in their relative position
anchor pin. and engage the parking brake cable into the parking
(9) Lubricate the groove of the cable guide and brake lever. Place the brake shoe assembly on the
place the adjusting cable over the guide and engage backing plate and over the anchor pin (Figs. 7 or 8).
the hook of the cable into the adjusting lever. (6) Plymouth: Install the brake shoe retainer
(10) Install the return spring into the primary shoe rods, cups, springs and retainers.
and using Tool C-3785, position spring end of spring Valiant: Install the brake shoe retaining springs
anchor. and attach to the retainer clips.
(11) Install the secondary return spring in the (7) Install the parking brake strut and spring b e
same manner. tween the parking brake lever and the primary shoe.
(8) Install the anchor pin plate.
(12) Lubricate the wheel bearings and install the
(9) Install the “eye” of the adjusting cable over
brake drum and adjust the wheel bearing. Refer to
the anchor pin and install the small Brake Shoe return
“Wheels, Bearings and Tires,” Group 22.
spring between the primary shoe and the anchor pin
Rear Brake Shoes using Tool C-3785.
NOTE: Inspect the backing plate platform for
Fig. 7-Installing Brake Assembly to Support Plate Fig. 8-Assembling Rear Brake (Valiant)
5-8 BRAKES
(10) Lubricate the groove of the cable guide and brake pedal) remaining in the hydraulic system. Ad-
install it in the secondary shoe, and install the second- just the brakes.
ary return spring with Tool C-3785. 9. TEST FOR FLUID C O N T A M I N A T I O N
(11) Place the adjusting cable in the groove of To determine if contamination exists in the brake
the cable guide and engage the hook of the cable fluid, as indicated by swollen, deteriorated rubber
into the adjusting lever. cups the following tests can be made.
(12) Plymouth: Install the brake drum and (1) Place a small amount of the drained brake
tighten the axle shaft nut to 145 foot-pounds torque. fluid into a small clear glass bottle. Separation of the
(13) Valiant: Install the brake drum and install fluid into distinct layers will indicate mineral oil con-
the tinnerman nuts to hold the drum in place. tent.
(14) Install the wheels and tighten as outlined in (2) Add water to the contents and shake. If the
Paragraph 13. contents become milky, oil is present. If the contents
(15) Test the operation of the automatic adjusters remain clear, it is not contaminated with mineral
and adjust the brakes. oil.
CAUTION: Be safe and discard old brake fluid that
8. BLEEDING THE BRAKE SYSTEM has been bled from the system. Fluid drained from the
Clean all dirt and foreign material from the cover bleeding operation may contain dirt particles or other
of the master cylinder to prevent any dirt from falling contamination and should not be used again.
into the master cylinder reservoir when the cover is 10. MASTER CYLINDER
removed. Removal (Fig. 91
Using automatic refiller Tool C-837B (with adap- (1) Disconnect the push rod.
ter C-3494A) or the one man bleeder tank C-3496 (with (2) Remove the pedal return spring.
adapter C-3494A) provides a convenient means of (3) Disconnect the brake tube at the master cylin-
keeping the master cylinder full while bleeding the der.
hydraulic system. The brakes may also be bled man- (4) Remove the nuts and bolts that attach the mas-
ually by having an assistant slowly operate the brake ter cylinder. Slide the master cylinder straight
pedal while the brakes are being bled. Be certain to out and away from the dash panel or booster.
refill the master cylinder after bleeding each wheel.
Tighten the brakes of each wheel until the brakes Disassembly
are locked. (This reduces the movement of the wheel Clean the outside of the master cylinder thoroughly,
cylinder cups and assists in bleeding.) then remove the cover and drain all brake fluid. Re-
Starting with the right rear wheel clean all dirt fer to Figure 9 and disassemble the master cylinder
from the bleeder valve. Place bleeder hose C-650 for inspection as follows:
on the bleeder valve and insert the other end of the (1) Remove the piston stop flange attaching screws
bleeder hose in to a clean jar half filled with brake and remove the dust boot, push rod and piston assem-
fluid. (This will permit the observation of air bubbles bly. (Do not remove the pushrod from the piston.)
as they are being expelled from the hydraulic system (2) Remove the brass washer between the pis.
and also prevent air from being drawn back into ton and the cup. Remove the master cylinder cup,
the system as the brake pedal is released on manual spring and valve and seal from the master Cylinder.
bleeding.) Follow the manufacturer’s instructions in (3) Wash the master cylinder in a suitable solvent
the use of bleeder Tools C-837B or C-3496. and inspect for a scored or pitted cylinder.
When manually bleeding the hydraulic system, If the master cylinder piston is badly scored or
push the brake pedal down and let it return slowly, to corroded, replace it with a new one. The piston cups
avoid being drawn into the system. Bleed intermit- and valve assembly should be replaced when recon-
tently, opening and closing the valve about every four ditioning the master cylinder.
seconds. This causes a swirling action in the cylinder Master cylinder walls that have light scratches or
and assists in expelling the air. Continue the action show signs of corrosion, can usually be cleaned up
until the brake fluid is expelled in a solid stream, with crocus cloth. However, cylinders that have deep
without any bubbles. scratches or scoring may be honed, providing the
Continue this bleeding operation on the balance of diameter of the cylinder bote is not increased more
the wheels starting with the left rear wheel, then the than .002 inch. A master cylinder bore that does not
right front and finishing with the left front wheel. clean up at .002 inch should be discarded and a new
If necessary, repeat this bleeding operation if cylinder used. (Black stains on the cylinder wall are
there is any indication of air (a low, soft or spongy caused by the piston cups and will do no harm.)
BRAKES 5-9
BOLT
J
BODY
, - NO T S I P
CUP-
WASHER
-7 Q
SEAL
CONNECTOR
SEAT a
II I
SCREW
STOP
I
cup
60x16136
Fig. 9-Master Cylinder Assembly (Disassembled)
NOTE: Use extreme care in cleaning master cyl- 1 1. WHEEL CYLINDER (Fig. 10)
inder after reconditioning. Remove all dust or grit by
(1)With all drums removed inspect the wheel
flushing the cylinder with alcohol; wipe dry with
cylinder boots for evidence of a brake fluid leak. (A
a clean lintless cloth and clean a second time with
slight amount of fluid on the boot may not be a leak
alchohol. Dry the master cylinder with air pressure,
but may be preservative oil used in assembly.)
then flush with clean brake fluid. (Be sure the com-
pensator port in the master cylinder bore is open.) (2) In the event of a leak, remove the brake shoes
(replace if soaked with grease or brake fluid), boots,
Assembly (Fig. 9 ) piston wheel cylinder cups and wheel cylinder cup
Before assembling, the piston, cups and valve assem- extenstion spring.
bly should be dipped in new MoPar brake fluid. (3) Wash the cylinder with alcohol and inspect
(1) Install the check valve and spring in the cylin- the cylinder for scores and pits.
der with the valve toward the outlet of the cylinder. Wheel cylinder pistons that are badly scored or
(2) Install the master cylinder cup in the cylinder corroded should be replaced. The old piston cups
with the open end of the cup over the closed end of should be discarded when reconditioning the hy-
the return spring. draulic system.
(3) Install the secondary cup on the master cyl-
inder piston and install the piston and push rod as- Cylinder walls that have light scratches, or show
sembly in the cylinder with the flat brass washer be- signs of corrosion, can usually be cleaned up with
tween the piston and the cup. crocus cloth, using a circular motion. However, cylin-
(4) Install the dust boot on the push rod and in-
ders that have deep scratches or scoring may be
stall the stop flange screws. Install the return spring. honed, using Tool C-3080,providing the diameter of
the cylinder bore is not increased more than .002
lnstallatlon inch.. A cylinder that does not clean up at .002 inch
(1) Position the master cylinder on the dash panel should be discarded and a new cylinder installed.
and install the attaching screws. (Black stains on the cylinder walls are caused by
(2) Attach the brake line to the master cylinder. the piston cups and will do no harm.)
(3) Fill the master cylinder and bleed the brake Before assembling the piston and new cups in the
system. wheel cylinder, dip them in MoPar brake fluid. If
5-10 BRAKES
PISTON
'O0i SPRING ' O D Y 1
PISTON' I CUP
SCREW 6 O x 1614A
Fig. 10-Wheel Cylinder Assembly (Disassembled)
the boots are deteriorated, or do not fit tightly on (5) Using a suitable tool compress the three flared
the brake shoe pin, as well as the wheel cylinder legs of the cable retainer and pull the brake cable out
casting, new boots should be installed. of the support plate (Fig. 11).
(4) Wash the wheel cylinder with alcohol and air (6) Remove the brake support plate from the rear
dry. axle housing.
(5) Install the expansion spring in the cylinder.
Install the wheel cylinder cups in each end of the lnstallatlon ( f r o n t Support Plate1
cylinder with the open end of the cups facing each (1)With the brake shoes installed on the support
other. plate, apply a small amount of putty type sealing
(6) Install the wheel cylinder pistons in each end material around the back side of all holes and open-
of the cylinder with the recessed end of pistons facing ings of the support plate to prevent water and dirt
the open ends of the cylinder. from entering the brake assembly.
(7) Install the boots over the ends of the cylin- (2) Place the support plate on the spindle support
der. Keep the assembly compressed with the aid of a and install the attaching bolts, nuts and washers.
brake cylinder clamp until the brake shoes are as- Tighten attaching nuts to 35 foot-pounds torque.
sembled.
(3) Attach the brake line to the wheel cylinder
and tighten to 95 inch-pounds torque.
12. BRAKE SUPPORT PLATE
Removal f front Support Plat e I
(1) With the wheel and brake drum removed, re-
move the support plate attaching nuts and washers.
(2) Disconnect the brake line from the brake
hose.
(3) Remove the support plate and brake assembly
from the spindle.
Removal f Rear Support Plate I

(1) With the wheel and brake drum removed, re-
move the backing plate attaching nuts and washers.
(2) Remove the rear axle shaft and retainer.
(3) Disconnect the hydraulic brake line from the
wheel cylinder.
(4) Disengage the brake cable from the parking
brake lever. Fig. 1 1-Removing Brake Cable From Support Plate
BRAKES 5-1 1
\\ r
(4) Install the brake drum and wheel bearings.
Adjust the bearings. Bleed and adjust the brakes.
lnstallation
I Rear Support Plate J
(1) With the brake shoes installed on the support
plate, apply a small amount of putty type sealing
material around the back side of all the holes and
openings of the support plate to prevent water and
dirt from entering the brake assembly.
(2) Install the support plate onto the rear axle
housing.
(3) Insert the rear axle shaft and retainer into
the housing and install the axle retainer nuts and
washers. Tighten the retainer nuts to 35 foot-pounds BLE & EQUALIZER
tor que. ASSY.
(4) Attach the brake line to the wheel cylinder Iy v ,.i
62x503
and tighten to 95 inch-pounds torque.
(5) Insert the parking brake cable into the sup- Fig. 13-Parking Brake Cable Routing (Plymouth)
port plate and attach the cable to the parking brake.
cable. A center steel cable connected to the rear cable
(6) Install the brake drum and wheel. Bleed and
equalizer is also connected to the foot or hand op-
adjust the brakes. erated parking brake lever (Figs. 13 and 14).
13. WHEEL STUD TIGHTENING 14. PARKING BRAKE ADJUSTMENT
The service brakes must be properly adjusted be-
Tightening sequence and torquing of the wheel fore adjusting the parking brake. Refer to Paragraph
stud nuts is of great importance to insure efficient
1.
brake operation. The use of an impact or long han- (2) Release the parking brake lever and loosen the
dled wrench may distort the drum. cable adjusting nut to insure that the cable is slack
A criss-cross tightening sequence should be used,
(Fig. 13 or 14).
(Fig. 12). Tighten all stud nuts to one-half the speci-
fied torque first, (30 ft. lbs.) and then repeat the (2) Tighten the cable adjusting nut until a slight
sequence tightening to the specified 55 foot-pounds drag is felt while rotating the wheel, loosen the cable
torque. adjusting nut until both rear wheels can be rotated
freely, then back off the cable adjusting nut two full
The rear wheel service brakes also act as the park- turns.
ing brakes. The brake shoes are mechanically oper-
FRONT CABLEn
ated by a lever and strut connected to a flexible steel CABLE AND EQUALIZER- *;
@
Fig. 1'2-Wheel
62x510
Stud Nut Tightening Fig. 14-Parking

- Brake Cable Routing (Valiant)
5-1 2 BRAKES ~~
(3)Apply the parking brake several times, then (2) Insert the cable assembly from beneath the floor
release and test to see that the rear wheels rotate free- and press the grommet into place in the floor pan
ly without dragging on the Brake Shoes. (Plymouth only). On Valiant Models insert the cable
through the cowl assembly.
1 5. PARKING BRAKE CABLE (Front 1 (3) Engage the end of the cable into the parking
brake clevis and insert the retaining clip into the
Removal anchoring hole of the pedal assembly. Snap the cable
(1)With the parking brake released, disconnect housing into place.
the front cable from the parking brake equalizer. (4)Insert the cable through the anchoring hole of
(2) Push the foot lever (Plymouth only) to the floor the frame crossmember. Insert the retaining clip into
and with a screw driver pry the housing and retainer the crossmember. Seat the cable housing firmly into
out of the frame crossmember. Withdraw the cable place.
and housing from the crossmember.
(5) Attach the cable to the equalizer and adjust
(3) Using a screw driver, force the cable and re- the cable. Apply the brakes firmly several times to
tainer out of the pedal assembly (Plymouth only) and seat the housing into the retainer clips. Adjust the
work the cable up out of the clevis. On Valiant models brake cable.
remove the clevis pin attaching the cable assembly
to the parking brake. (Fig. 15 or 16).
16. PARKING BRAKE CABLE (Rear 1
(4)Holding the front edge of the floor mat back,
force the parking brake cable and housing down and Removal
at the same time force the rubber grommet down The independent brake cables are attached to an
through the floor pan. Withdraw the assembly from equalizing cable by “C” type brackets, as shown in
beneath the vehicle (Plymouth only). On Valiant Figures 13 and 14. The cable is adjusted at the
Models remove the cable assembly by pulling the spreader clamp at the center of the equalizing cable.
cable out of the cowl assembly from the engine Should it become necessary to remove the parking
compartment side. brake cable (rear), for installation of a new cable,
lnsf allaf ion refer to Figures 13 and 14.
(1) Dip the rubber grommet in mineral spirits (1)With the vehicle jacked up or on a suitable
and install it on the upper portion of the brake cable hoist, remove the rear wheels.
housing. (2) Remove the brake drum from the rear axle.
SPRING
INSTRUMENT PANEL\ \, COWL slPE PANEL
. CLIP
I
\ CONNECTOR
SCREW A N D WASHER
Fig. 15-Parking Brake Pedal (Plymouth)

BRAKES 5-13
CLIP -9
INSTRUMENT PANEL
SCREW A N D WASHER
64 x 310
Fig. 16-Parking Brake lever (Valiant)
(3) Remove the brake shoe return springs. (1) Insert the brake cable and housing into the
(4) Remove the brake shoe retaining springs. cable bracket and install the retaining clip.
( 5 ) Remove the brake shoe strut and spring from (2) Insert the rear end of the brake cable and
the brake back plate and disconnect the brake cable housing into the brake backing plate making certain
from the operating arm. the housing retainers lock the housing firmly into
(6) Compress the retainers on the end of the brake place.
cable housing (Fig. 11) and remove the cable from (3) Insert the end of the brake cable into the
the brake plate. brake shoe operating lever and install the brake shoes
(7) Remove the retaining bolt and nut from the onto the backing plate.
brake cable bracket and remove the cable assembly.
(4) Install the brake shoe retaining springs, re-
(8) Disconnect the brake cable from the “C” clamp. turn springs and brake drum. Engage the end of the
installation brake cable into the “C” clamp. Install the brake
When installing a new brake cable, lubricate the drum and wheel.
cable with short fibre grease at the points of contact. (5) Adjust the brakes and cable.
5-14 BOOSTER BRAKE (BENDIX)
BENDIX SINGLE DIAPHRAGM BOOSTER BRAKE

The Bendix single diaphragm booster brake (Fig. (2) A control valve built intergral with the power
17) is of the vacuum suspended type and does not diaphragm and connected through a valve rod to the
require a reserve vacuum tank. This booster utilizes brake pedal and controls the degree of brake applica-
engine manif old vacuum and atmospheric pressure tion or release in accordance with the pressure ap-
for its power. It is composed of three basic elements plied to the brake pedal.
to compose a single power unit. The three units are: (3) A master cylinder attached to the vacuum
(1) A vacuum power section which is composed of power section contains all the conventional elements
a front and rear housing, a power diaphragm, a re- except the push rod which is a part of the booster
turn spring and a push rod. brake.
SERVICE PROCEDURES
17. BOOSTER BRAKE CAUTION: The diaphragm is spring loaded and

care should be taken to prevent the front and rear
Removal shells from flying apart.
(1) From within the engine compartment discon-
nect the brake line from the master cylinder.
\(G RING
(2) Remove the vacuum hose from the booster.
(3) From under the instrument panel remove the
brake pedal and push rod attaching bolt and nut.
(4) Remove the four booster-to-dash attaching nuts **
" i
and remove the booster assembly from the vehicle.
Disassembly
(1)Remove the four master cylinder attaching nuts
and remove the master cylinder from the booster.
(2) Remove the dust boot from the back of the
63x586
booster and remove the air filter and silencers (Fig. SILENCERS
18).
Fig. 18-Air Filters and Silencers
(3) Pry off the retaining ring m the back of the
booster and remove the air filter and silencers (Fig.
18).
(4) Place the booster assembly in a vise, scribe the
front and rear shells for indexing location, then re-
move the eight front to rear housing screws.
BRAKE BOOSTER
CHECK VALVE 1 f i
PISTON RETAINER
PUSH ROD'
ADJUSTMENT
63x585
Fig. 17-Power Brake and Master Cylinder Fig. 19-Removing Push Rod Retainer
(BENDIX) BOOSTER BRAKE 5-1 5
)
I
63x588
-.
Fig. 20-Removing Rubber Diaphragm
Fig. 22-Removing or Installing Rod and Valve
-
(5) Holding the two shells together, remove the REACTION DISC
booster from the vise and carefully separate the two
shells.
(6) Remove the return spring.
(7) Remove the master cylinder push rod retainer
(Fig. 19).
(8) Remove the diaphragm and valve assembly
from the rear shell.
(9)Place the diaphragm and valve assembly face
down and stretch the rubber diaphragm out and over
the hub of the valve body (Fig. 20).
(10)Holding the valve housing in a vertical posi-
tion, press in on the push rod and permit the lock
to disengage from the push rod and valve assembly
(Fig. 21).
(11)Holding the diaphragm housing, remove the Fig. 23-Removing or Installing Reaction Disc
rod and valve assembly (Fig. 22). Remove the rubber
valve poppet from the rod.
; ] VALVE BODY
PUSH ROD
I
Fig. 21-Removing Push Rod Lo& Fig. 2rlRemoving Rear Seal

5-16 BOOSTER BRAKE (BENDIX)
(5)With the valve housing supported on a flat
horizontal surface, press down on the plunger rod and
T insert the lock into the housing and valve assembly.
M
(6) Dip the diaphragm in mineral spirits and in-
stall on the plate and valve body.
(7) Install the diaphragm and valve body into the
rear housing.
(8) Install the master cylinder push rod and re-
tainer.
(9) Supporting the rear housing on blocks or a
vise, install the return spring with the small end
toward the front of the booster assembly.
(10)Place the front housing on the return spring
and compress the spring, (guiding the master cyl-
7 63x583 inder push rod through the front seal).
Fig. 25--Removing Front Seal and Retainer (11)Align the scribe marks and install the hous-
ing attaching screws finger tight and then progres-
(12) Press out the reaction disc (Fig. 23) from the sively tighten.
diaphragm plate. (12)Install the air filter, silencer and retaining
(13) Support the rear shell on two wooden blocks ring.
and drive out the rear seal (Fig. 24). (13) Install the master cylinder on the brake
(14)Using a thin screw driver, pry out the front booster assembly.
seal retainer and remove the front seal (Fig. 25).
lnst allat ion
(15) Thoroughly clean with mineral spirits or al-
cohol, all parts; recondition or replace as necessary. (1)Insert the booster push rod through the mount-
ing hole of the dash panel and attach the booster
Inspect ion assembly.
Inspect all parts for excessive wear. Replace any (2)Install the dust boot over the plunger and in-
damaged, worn or chipped parts. Inspect master cyl- sert the spacing washer between the plunger and
inder bore for scoring, rust, pitting or etching. Re- the brake pedal.
condition or replace as necessary. (3)Install the plunger and pedal attaching bolt
Assembly and nut.
(1) Press a new seal into the rear housing until the (4)Install the vacuum hose to the booster assembly.
seal is flush with the housing. (5) Fill and bleed the master cylinder. Attach the
(2) Install the front seal and retainer. brake line to the master cylinder.
(3) Install the reaction disc into the diaphragm (6) Fill the master cylinder and bleed the hydraulic
plate. system.
(4)Install the valve poppet and the rod and valve (7) Start the engine and test the booster for oper-
assembly. ation.
(MIDLAND ROSS) BOOSTER BRAKE 5-17
M I D L A N D ROSS POWER BOOSTER BRAKE

The Midland Ross power booster brake (Fig. 26) derives its power from intake manifold vacuum and
is located on the engine Side of the dash Panel. The atmospheric pressure. It does not require a vacuum
forward portion of the vacuum cylinder is die-cast reservoir.
and supports the master cylinder. The power booster
SERVICE PROCEDURES
18. BOOSTER BRAKE (5) Remove the filter cover and filter.
(6) Working from the front of the unit, push the
Removal outer lip of the bellows assembly into the vacuum
(1) With the engine turned off,apply the brakes chamber (Fig. 27).
several times to balance the internal pressure of the (7) Remove the clamp band securing the front
booster brake. to the front to the rear housing.
(2) Disconnect the hydraulic brake line from the
master cylinder. - L
Tows
(3) Disconnect the vacuum hose from the vacuum FRONT
booster. /COVER
(4) From under the instrument panel, remove the

nut and attaching bolt from the plunger and brake
pedal linkage.
(5) Remove the four booster attaching nuts and
washers.
(6) Remove the booster and master cylinder from
II
the vehicle and place on a service bench for further
disassembly.
Disassembly
(1) Remove the four master cylinder attaching nuts
and remove the master cylinder.
(2) Scribe an aligning mark across the joint of the 64x288
front and rear portions of the booster assembly. This
will insure alignment on reassembly. Fig. 27-Unseating the Bellows Seal
(3) Remove the dust boot from the operating rod.
TRUARC RING
(4) Remove the two filter cover retaining screws. - /
CLAMP BAND VALVE AND VACUUM
HOSE CONNECTOR
REAR COVER.
REAR SEAL
RETAINER
-
-cP
DUST BO6
BRAKE BOOSTER
/ --F
MASTER CYLINDER
64x287
d 4
Fig. 26-Power Brake and Master Cylinder Fig. 28-Rear Seal Retainer
5-1a BOOSTER BRAKE (MIDLAND ROSS)
RETA~NER
\ VLLVE
63x348 LEVERS (12) BODY
63x347 Fig. 31-Valve Body and Reaction Leven

Fig. 29-Removing Bellows Retainer
(8) Using a plastic or rubber hammer tap the out-

side edge of the rear vacuum housing and separate
the housings.
RINGS
(9) Remove the large snap ring from the rear seal
retainer (Fig. 28), and remove the diaphragm, valve
housing assembly and rear seal from the rear hous-
ing.
(10)Using a screw driver pry out the large retain-
ing snap ring that retains the bellows to the dia-
phragm (Fig. 29).
(11)Pull the bellows out of the retainer and re-
move the retaining ring from the bellows.
(12)Slide the master cylinder plunger off. (Fig. 30).
(13)Remove the reaction lever and retainer as-
sembly from the valve body and remove the levers Fig. 32-Removing Valve Retainer
from the retainer (Fig. 31).
(14)Remove the two plastic rings from the plunger (16)Remove the plunger (Fig. 34) from the valve
shaft. body.
(15)Remove the retaining clip (Fig. 32) from the (17)Remove the rear seal retainer from the
plunger shaft, remove the load ring and valve return Dluneer.
spring. Remove the valve (Fig. 33).
CUSHlqN RING
PUW. ROD I
RETAINING
RING
SCREW
REACTION CONE
63x2
Fig. 30-Master Cylinder Push Rod Fig. 33-Removing or Installing Valve

(MIDLAND ROSS) BOOSTER BRAKE 5-19
LIP SEAL O-RINGS with the lip of the seal toward the small end of the
retainer.
(5)Install the “0”ring on the outside diameter
of the rear seal retainer.
(6)Insert the rear seal retainer assembly into the
hub of the rear cover.
(7)Holding the seal retainer in place, invert the
cover over a wrench socket of sufficient size to sup-
port and hold the seal retainer in place.
(8)Apply downward pressure on the rear cover
I PLUNGER
and install the retainer snap ring.
PUSH ROD ASSEMBLY 64x289 (9)Install the plunger assembly into the valve
Fig. 3 L V a l v e Plunger Assembly body.
(10)Install the valve into the valve body with the
(18)Using a small screw driver remove the rear rubber insert contacting the valve seat. Install the
seal (Fig. 35)from the rear seal retainer. Remove the valve return spring over the valve.
“0”ring from the outer diameter of the seal retainer. (11)Install the load ring onto the plunger with
(19)Remove the two “0”rings, seal and cushion the concave face out.
ring from the plunger (Fig. 34). (12)Press downward on the valve body and insert
the spring clip into the groove of the plunger.
(20)Remove the “0”ring from the outside diam- (13)Install the levers and fulcrum ring into the
eter of the valve body. rubber retainer.
NOTE: The plunger assembly will be serviced as a (14)Align the indexing tab with the notch in the
unit and need not be dismantled further. valve body and insert the assembly into the valve
body with fulcrum ring on the underside.
Assembly
(15)Install the two plastic rings onto the plunger
Wash all rubber seals in mineral spirits and air dry, shaft.
relubricate with silicone grease. (16)Install the master cylinder push rod onto the
(1)Install the “0”ring on the outside diameter of plunger assembly.
the valve body. (17)Install the bellows into the bellows retainer
(2)Install the two “0” rings, and seal on the and install the retaining ring onto the bellows.
plunger assembly. (18)Place the valve body assembly into the de-
(3)Install the cushion ring on the plunger assem- tents of the diaphragm and install the bellows and
bly. retainer assembly.
(19)Install the bellows retainer snap ring.
(4)Install the rear seal into the rear seal retainer
(20) Install the diaphragm and valve assembly into
the rear cover.
REAR COVER (21)Align the scribe marks and place the front
cover over the bellows and master cylinder push rod.
(22)Align and squeeze the two housings togeth-
er, install the clamp band and tighten the clamp bolt.
(23)Pull the lip of the bellows up through the
front housing.
(24)Clean the filter and plastic breather.
(25)Install the retaining plate and attaching screws.
(26)Make sure the master cylinder piston stop
and screw are installed in the upper hole on the
master cylinder mounting face. Install the master
cylinder on the booster, install the four nuts and
tighten to 100 inch-pounds torque.
REAR
RETAI (27)Install the booster assembly into the dash
and tighten attaching nuts.
63x349 (28) Connect brake line and vacuum hose.
Fig. 35-Rear Seal Assembly (29)Refill the master cylinder and bleed the brakes.
5-20 BOOSTER BRAKE (BENDIX) (VALIANT)
BENDIX BOOSTER BRAKE-VALIANT (DEALER INSTALLED)

The Bendix vacuum cylinder is combined with a plane as the accelerator pedal, reducing the drivers’
conventional master cylinder and reduces pedal ef- foot movement.
The master and vacuum cylinder assembly is
fort and as ‘Ompared to a non-booster brake mounted directly to the engine side of the firewall.
system. The reduced pedal travel permits the brake The vacuum piston is hooked directly to the sus-
pedal to be positioned in approximately the same pended brake pedal by a valve operating rod.
SERVICE PROCEDURES
19. R E M O V I N G THE BOOSTER BRAKE from brake pedal linkage.
F R O M VEHICLE (5) Remove four attaching nuts from brake unit
(1) Disconnect vacuum line from vacuum cylin- mounting bracket and remove unit from car.
der.
20. BOOSTER BRAKE
(2) Disconnect hydraulic brake line frorn master To disassemble the booster brake unit for repair
cylinder. or overhaul, refer to Figure 36.
(3) Disconnect wires from stop light switch. (1) Clean all dirt from the master cylinder cover
(4) Under instrument panel, disconnect push rod and remove the cover.
6 o x 1 373
Fig. 36-Brake Booster Unit (Disassembled)
(BENDIX) (VALIANT) BOOSTER BRAKE 5-21
(2) Apply pressure to the power lever and insert a
?A wire or rod in the large hole in the brake reservoir,
retaining the master cylinder piston in the cylinder.
(3) Remove the master cylinder from the front
end of the vacuum assembly and remove the hy- REACTION DISC
draulic push rod from the booster brake unit.
(4) Remove the cotter pin and clevis pin from
the upper end of the power lever (Fig. 36).
(5) Remove the rubber dust cover from the valve
rod.
(6) Scribe alignment mark across the end plate FRONT
PLATE
PISTON’ @-POPPET SPRING
and the vacuum cylinder to assure the proper reas-
sembly.
VALVE RETURN-
(7) Remove 6 of the 8 end plate attaching SPRING POPPET SPRING
screws leaving the 2 remaining screws opposite each --RETAINER
other.
(8) Place the vacuum unit on the bench with the -POPPET DIAPHRAGM
VALVE PLUNGER
end plate up. Apply light hand pressure to the end
plate to hold the piston and return spring in place,
then remove the 2 remainihg end plate attaching SUPPORT PLAT
screws.
(10) Relax the retaining pressure on the end plate
and expose the vacuum piston.
(11) Scribe alignment mark on the face of the
piston to coincide with the cover and the cylinder
scribe mark, to insure the alignment on the reas-
sembly.
(12) Remove the vacuum hose from the end plate
and the vacuum piston.
(13) Remove the end plate, piston and piston re-
turn spring.
(14) Remove the air cleaner attaching screws, the
air cleaner assembly and the filter from the end plate. WOOD BLOCKS(2)
(15) Remove the piston felt and expander ring from 60x1374
the piston assembly.
(16) Remove the seal and bumper from the front of Fig. 37-Brake Booster Piston Unit (Disassembled)
the piston plate.
(17) Place the inverted piston assembly on two 21. C L E A N I N G
wooden blocks and remove the 6 pistons plate bolts Clean all metal parts in a suitable solvent then blow
(Fig. 37). Hold the piston plates together by hand dry with compressed air (including recesses and inter-
so the poppet spring and valve return spring do nal passages). Wash rubber parts in clean alcohol.
not become dislodged from their relative positions. After parts are cleaned, place on clean paper or cloth
(18) Carefully separate the piston plates and re- and inspect as follows:
move the leather piston ring.
(19) Remove the poppet spring (outer), valve re- 22. I N S P E C T I O N
turn spring (inner), the poppet spring retainer, pop- Inspect all parts for wear or damage. Replace worn or
et diaphragm and the poppet. damaged parts with new parts. Inspect the inside of
(20) Using a blunt wood rod, push out the rub- the vacuum cylinder. If the cylinder is rusted or cor-
ber reaction disc from the front piston plate. Do not roded, polish with fine steel wool or crocus cloth. If
separate the valve operating rod and valve plunger, inspection reveals nicks or scratches on the piston rod,
as this i s serviced as a unit. valve seat (on end of valve rod) or valve seat (at
5-22 BOOSTER BRAKE (BENDIX) (VALIANT)
(12) Align the front and rear piston plates and

install 6 attaching screws finger tight. Progressively
tighten every other screw lightly until all are tight-
- EXPANDER ened to 55 inch-pounds torque.
(13) Assemble the air cleaner filter over the vac-
uum tube of the air cleaner assembly and attach the
assembly to the end plate and tighten the attaching
: LEATHER screws (Fig. 36).
& PISTON RING' (14) Install the rubber' vacuum hose to the inlet
tube of the power piston and align the hose to lay flat
against the piston.
(15) Remove the vacuum piston assembly from the
PISTON PLATE assembly ring, and coat the inside of the vacuum cyl-
inder and leather packer ring of piston with a thin
60x1364
coating of vacuum cylinder oil.
~
Fig. 38-Assembling Piston Ring, Felt and Expander (16) Install the end plate over the valve push
rod of the piston assembly and attach the vacuum
center of piston plate) install new parts at assem- hose to the inlet tube of the air cleaner assembly.
bly as required. Inspect the leather packing and pis- (17) Center the large end of the piston return
ton rod leather seal. If worn excessively, install new spring in the vacuum cylinder.
parts as required. (18) Align scribe marks of the end plate, piston
assembly and cylinder, then install the piston and
Assembling the Booster Brake end plate, centering the small end of the return spring
(1) Using vacuum cylinder oil, saturate piston felt on the piston assembly.
and permit excess oil to drip off. (19) Compress the spring and install two attach-
(2) Place the assembly fixture Tool (2-3816 on ing screws in the end plate opposite each other.
two wooden blocks and insert the leather piston ring (20) Install the balance of attaching screws and
in the fixture with the lip side up (Fig. 38). tighten uniformly.
(3) Assemble the felt ring into the expander and (21) Install the dust cover over the valve rod and
install the expander and the felt in the groove of the flange of the end plate.
rear piston plate. (22) Install the spring washer between the valve
(4) Hold the felt and the expander compressed push rod and power lever linkage, then install clevis
in the piston plate and install the rear piston plate pin and qotter pin.
into the leather piston ring. (23) With a rotating motion install large end of
(5) Holding the rear piston plate, felt and leather hydraulic push rod into the hub of the front piston
piston ring into the assembly fixture, invert the as- plate.
sembly and place on 2 wooden blocks.
(24) Press and rotate the push rod firmly against
(6) Apply a light coating of lubricant to the valve the rubber reaction disc to insure the expulsion of
plunger and both faces of the reaction disc. any air pocket between the push rod and disc.
(7) Install the reaction disc in the hub of the front
piston (Fig. 37). Push Rod Adjustment
Unless the hydraulic push rod has been replaced,
(8) Insert the eye end of the valve rod through no adjustment of the push rod should be needed.
the hole of the rear piston plate. The self locking screw on the end of the push rod is
(9) Install the diaphragm support in the hub of the set to the correct height on original assembly. If the
rear piston plate. push rod has been replaced or the adjustment altered,
(10) Place flat side of poppet diapnragm over the adjust as follows:
flange of the poppet and install the poppet assembly (1) With the piston assembly free in the cylinder
in the recess of the rear piston plate. and firmly seated in a released position, hold the push
(11) Install the poppet spring retainer over the end rod seated against the reaction disc and centered in
of the poppet and install the valve return spring and the spring of the cylinder.
the poppet return spring. (2) Adjust the self-locking screw so that the head
BRAKLDIAGNOSIS 5-23
(3) Proceed with master cylinder reconditioning
as recommended in Paragraph 10 if necessary.
(4) After reconditioning, reinstall wire in the in-
let port for assembly to brake booster.
(5) Lightly apply pedal and remove the wire from
the inlet port and fill master cylinder.
(6) Install the cover and bleed the hydraulic sys-
SCREW tem.
60xl372A
Fig. 3-Adjusting Master Cylinder Push Rod 23. INSTALLING THE BOOSTER BRAKE
IN VEHICLE
of the screw is 0.938 to 0.943 inch from the face of (1) Holding the master cylinder piston into the
the vacuum cylinder (Fig. 39). Fabricate a gauge if cylinder as recommended, place the master cylinder
necessary to obtain the correct adjustment. on the attaching studs of the brake booster. Tighten
Servicing the Master Cylinder nuts to 100 inch pounds torque.
The service procedures covering the booster brake (2) Place the brake booster unit on mounting
master cylinder are the same as on the conventional studs of firewall and install four attaching nuts. Tight-
master cylinder. Refer to Paragraph 10. en to 100 inch-pounds torque.
The master cylinder push rod is a part of the (3) Connect the push rod to the brake pedal link-
vacuum brake and is not retained in the master
age.
. cylinder piston. On removing the master cylinder from
the brake booster the piston and cups may drop out (4) Attach the wires to the stop light switch.
of the cylinder. (5) Attach the brake line to the master cylinder.
To prevent this from happening;
(6) Attach the vacuum hose to the brake booster.
(1) Clean all the dirt from the master cylinder
cover and remove the cover. (7) Remove the retaining wire from port of the
(2) Lightly depress the brake pedal and insert %” master cylinder reservoir.
wire to drill through the large hole in the brake reser- (8) Fill the master cylinder and bleed the brake
voir to retain the piston in the master cylinder. system as recommended in Paragraph 8.
SERVICE DIAGNOSIS
P A R K I N G BRAKE
Condition Possible Cause Cordon
Dragging Brakes (a) Improper cable or brake adjustment. Properly adjust the service brakes
then adjust the parking brake
cable.
Broken brake shoe return spring. Replace a broken return spring.
Broken brake shoe retainer spring. Replace a broken retainer spring.
Grease or brake fluid soaked lining. Replace the grease seal or
recondition the wheel cylinders
and replaee both brake shoes.
Sticking or frozen brake cable, Clean and lubricate the cables.
Broken rear spring. Replace a broken rear spring.
Bent or rusted cable equalizer. Straighten or replace and
lubricate the equalizer.
Brake Will Not Hold (a) Broken or rusted brake cable. Replace or clean and lubricate the
brake cable.
Improperly adjusted brake or cable. Adjust the brakes and adjust the
parking brake.
Soaked brake lining. Replace the grease seal or
recondition the wheel cylinders.
5-24 BRAKLDIAGNOSIS
SERVICE BRAKE
Ratchet of pedal mechanism worn. Replace ratchet mechanism and

adjust service brakes and parking
brake cable.
Pedal Goes t o Fluid low in master cylinder. Fill the master cylinder and bleed
t h e Floor the brakes.
Excessively worn brake lining. Reline and adjust the brakes.
Improperly adjusted brake shoes. Adjust the brakes and fill the
master cylinder.
Leaking wheel .cylinders. Recondition or replace the wheel
cylinder and replace both brake
shoes.
Loose or broken brake lines. Tighten all brake fittings or replace
the brake line.
Air in hydraulic brake system. Fill the master cylinder and bleed
the hydraulic brake system.
Leaking or worn master cylinder. Recondition or replace the master
cylinder and bleed hydraulic
system.
Spongy Brake Pedal (a> Air in hydraulic system. Fill the master cylinder and bleed
the hydraulic system.
Improper brake fluid (low boiling Drain, flush and refill with the
point). recommended brake fluid.
Excessively worn or cracked brake Replace faulty brake drums.
drums.
Brakes Pulling Uneven tire pressure. Inflate all tires evenly.
Incorrect brake adjustment. Adjust brakes and fill the master
cylinder.
Brake drums out of round. Grind or replace the brake drums.
Brake shoes distorted. Replace the faulty brake shoes.
Grease or brake fluid soaked lining. Replace grease seals or recondition
the wheel cylinders and replace all
contaminated brake lining.
Unmatched brake lining. Install matched shoes and lining.
Restricted brake hose or line. Replace a plugged hose or brake
line.
Front end out of alignment. Align the front end.
Broken rear spring. Replace the broken spring.
Sq uea Iing Brakes Incorrect brake lining. Install matched brake lining.
Dust in brakes or scored brake drums. Blow out brake assembly with
compressed air and grind the
brake drums.
Distorted brake shoes. Replace the brake shoes.
Bent support plate. Replace the support plate.
Broken or weak brake shoe return Replace the return spring.
spring.
Weak or broken brake shoe retaining Replace the retaining spring.
spring.
Glazed brake lining. Cam grind or replace the brake
lining.
Saturated brake lining. Replace grease seals or recondition
the wheel cylinders and replace the
shoes and lining as necessary.
____________ ~
BRAKE-DIAGNOSIS 5-25
SERVICE DIAGNOSIS
SERVICE BRAKES- (Continued 1
Dragging Brakes (a) Incorrect brake adjustment. (a) Adjust the brakes and refill
master cylinder.
(b) Parking brakes engaged. (b) Adjust the parking brakes.
(c) Wheel cylinder sticking. (c) Recondition the wheel cylinder.
(d) Weak or broken brake shoe return (d) Replace the brake shoe return
spring. spring.
(e) Brake pedal binding. (e) Free up and lubricate the brake
pedal and linkage.
(f) Master cylinder cup sticking. (f) Recondition the master cylinder.
(g) Incorrect master cylinder push rod (g) Properly adjust the master
adjustment. cylinder push rod.
(h) Obstructed master cylinder relief port. (h) Use compressed air, blow out
relief port.
(i) Saturated brake lining. (i) Replace grease seals or recondition
the wheel cylinders and replace
brake shoes and lining as necessary.
(j) Bent or out of round brake drum. (j) Grind or replace the faulty brake
drum.
Hard Pedal (a) Incorrect brake lining. (a) Install matched brake shoes and
lining.
(b) Incorrect brake adjustment. (b) Adjust the brakes and refill the
master cylinder.
(c) Frozen brake pedal linkage. (c) Free up and lubricate the brake
linkage.
(d) Restricted brake line or hose. (d) Replace the brake line or hose.
(e) Brake booster inoperative. (e) Recondition or replace the brake
booster.
BOOSTER BRAKES
To determine whether the power unit is function- If no vacuum assist is felt, inspect the vacuum
ing, shut off the engine and apply the brakes several line for kinks or disconnection. A method of testing
times to exhaust the vacuum from the system. Then for an internal leak in the power unit is to apply
lightly apply the brakes and start the engine. If the brakes then hold the brakes on and stop the
the power unit is operating, the brake pedal will engine. After approximately one minute there should
move forward slightly and less pedal pressure will be enough vacuum left to give power assist for several
be needed to apply the brakes. applications.
Wheel Locks (a) Loose or torn brake lining. (a) Replace grease seals or recondition
brake shoes and lining.
(b) Incorrect wheel bearing adjustment. (b) Clean, pack and adjust the wheel
bearings.
(c) Wheel cylinder cups sticking. (c) Recondition or replace the wheel
cylinder.
(d) Saturated brake lining. (d) Replace grease seals or recondition
brake shoes and lining as
necessary.
Brakes Fade (a) Improper brake adjustment. (a) Adjust the brakes and refill
(High Speed) master cylinder.
(b) Distorted or out of round brake drums. (b) Grind or replace the drums.
(c) Overheated brake drums. (c) Inspect for dragging brakes.
5-26 BRAKWI A G N O S I S
SERVICE DIAGNOSIS
BOOSTER B R A K E 6 ( Continued 1
Incorrect brake fluid (low boiling Drain, flush and refill and bleed
temperature). the hydraulic brake system.
necessary.
Pedal Pulsates Bent or out of round brake drum. Grind or replace the brake drums.
Brake Chatter Rough or scored brake drum. Grind or replace the brake drum.
Loose support plate. Tighten the support plate bolts to
the proper torque.
Bent support plate. Replace the support plate.
Distorted brake shoes. Replace the brake shoes.
Machine grooves in the contact face of Grind or replace the brake drum.
the brake drum.
necessary.
Dragging Brakes Brake shoes improperly adjusted. Adjust the brakes.
(All Wheels) Brake pedal linkage binding. Free up the linkage.
Excessive hydraulic seal friction. Lubricate the seal.
Compensator port plugged. Clean out the master cylinder.
Sticking valve plunger. Free up and lubricate the valve
plunger.
Improper booster push rod length Adjust the push rod.
adjustment .
Fluid cannot return to master cylinder. Inspect the pedal return and push
rod adjustment.
Grabbing Brakes (a) Grease or brake fluid on linings. Inspect for a leak and replace
lining as required.
(b) Sticking actuating valve. Free up the valve.
Pedal Goes to Floor (a) Self-adjusters not operating. Inspect the self-adjuster
(Or Almost to Floor) operations.
rb) Air in hydraulic system. Fill the master cylinder, bleed the
hydraulic brake system.
Hydraulic leak. Locate and correct the leak.
Fluid low in master cylinder. Add brake fluid and bleed the
brakes as necessary.
Shoe hanging up on rough platform. Smooth and lubricate the
platforms.
Faulty vacuum check valve. Replace the check valve.
Collapsed or leaking vacuum hose. Replace the hose.
Plugged vacuum fittings. Clean out the fittings.
Leaking vacuum chamber. Locate and correct the leak.
Diaphragm assembly out of place in Position the diaphragm.
housing.
Vacuum leak in forward vacuum housing. Locate and correct the leak.
Broken plunger stem. Replace the plunger stem.
~
BRAKE-D IAGNOSlS 5-27
SERVICE D I A G N O S I S
BOOSTER BRAKES- (Continued 1
Self-Appl ication (a) Leak in rear housing. (a1 Locate and correct the leak.
of Brakes When (b) Diaphragm out of location in housings (b) Position the diaphragm.
Engine Starts and allowing atmospheric pressure into
rear chamber.
Sticking or unseated actuating valve (c) Free up the valve and seat the
assembly. valve properly.
Grunting Noise in (a) Air in hydraulic system. (a) Fill the master cylinder and
Booster on Application bleed the hydraulic brake system.
(b) Lacksf valve plunger lubrication. (b) Lubricate the plunger.
(c) Fluid low in master cylinder. (c) Add brake fluid and bleed the
brakes as necessary.
CLUTCH 6-1
GROUP 6
CLUTCH
CONTENTS
Page Page
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Clutch Fork, Removal and Installation. . . . . . . . . . . . . . 1 1
Special Tools.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Release Bearing, Removal and Installation. . . . . . . . . . 1 1
Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque Shaft Pivot Bushing . . . . . . . . . . . . . . . . . . . . . . 12
Clutch, Removal and Installation. . . . . . . . . . . . . . . . . . 3 Clutch Pedal Free Movement.. . . . . . . . . . . . . . . . . . . . 12
Clutch Cover (Borg and Beck). . . . . . . . . . . . . . . . . . . . 5 Clutch Housing Alignment. . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Cover (Auburn). . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steam Cleaning Precautions,. . . . . . . . . . . . . . . . . . . . . 13
Clutch Shaft Pilot Bushing.. . . . . . . . . . . . . . . . . . . . . . . 10 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
(Special (Special
CLUTCH Equipment) Equipment)
Make . . . . . . . . . . . . . . . . . . . . . . Barg & Beck Borg & Beck Borg 8, Beck Borg & Beck
Model. . . . . . . . . . . . . . . . . . . . . 1505 1506 1570 1594
Type. . . . . . . . . . . . . . . . . . . . . . Single Dry Disc Single Dry Disc Single Dry Disc Single Dry Disc
Vehicle Model Application. . . . . . . . . All VP-2 Plymouth Models
Engine Size. . . . . . . . . . . . . . . . . . . . . 3 18 cu. in. 318 & 361 cu. in. 383 cu. in. 383 & 426 cu. in.
Transmission Type . . . . . . . . . . . . . . . . Standard 3-Speed or 4 Forward Speed Manual Transmission
CLUTCH DISC
Facing Type.. . . . . . . . . . . . . . . . Moulded Woven Moulded Woven Moulded Woven Moulded Woven
Asbestos Asbestos Asbestos Asbestos
Outside Diameter. . . . . . . . . . . . 10“ 10 Y2” 10 Y2” 1O f i ”
Thickness . . . . . . . . . . . . . . . . . . . .125” .125” .125” .135”
Disc Springs (number). . . . . . . . . 10 10 10 10
Disc Spring Color 5 Black 5 Red 5 Green 5 Tan 5 Green 5 Tan 5 Green 5 Tan
CLUTCH COVER
Pressure Springs (number). . . . . . 9 9 12 12
Spring Color. . . . . . . . . . . . . . . . No Color 6 No Color 3 White 6 Orange 6 No Color 6 Tan 6 White
Spring Pressure (Ibs. @ 1 Y2“).. . 185 ea. 185 ea. 233 ea. 162 ea. 185 ea. 160 ea. 233 ea.
Total Spring Pressure (Ibs.). . . . . 1770 1920 2205 251 1
Number of Levers. . . . . . . . . . . . 3 3 3 3
Height from Face of Flywheel. . 2” 2” 2“ 2”
Lever Setting Gauge Number. . . 20 20 20 20
Pedal Free Play (at clutch fork). %2“ Yu” 5/32” 5/32”
SPECIAL TOOLS
DD-286. . . . . . . . . . . . . . . . Clutch Pilot Bushing and Installer C-585A. . . . . . . . . . . . . . . .Compressing Fixture
C-3005. . . . . . . . . . . . . . . .Torque Wrench C-585-32. . . . . . . . . . . . ..Steel Block
C-3181 . . . . . . . . . . . . . . . . Installing and Burnishing Tool C-585-33. . . . . . . . . . . . . .Support Plate
C-3 1 85. . . . . . . . . . . . . . . .Pilot Bushing Remover C-647. . . . . . . . . . . . . . . . .Spring Testing Fixture
C-360. . . . . . . . . . . . . . . ..Clutch Disc Aligning Tool C-730. . . . . . . . . . . . . . . ..Pilot Stud
C-4 1 . . . . . . . . . . . . . . . . . . Pilot Bushing Remover C-771 . . . . . . . . . . . . . . . ..Flywheel Turning Tool
C-435. . . . . . . . . . . . . . . . .Dial Indicator C-870. . . . . . . . . . . . . . . . .Checking Bar
TORQUE REFERENCE Foot-Pounds

Clutch housing to engine bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Clutch cover to flywheel bolts (%6”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clutch cover to flywheel bolts ( W ).. .............. ............ 30
Clutch pan bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Clutch fork pivot bolts. . . . . . . . . . . . . . . . . . . . . .................................................. 15
Flywheel bolt nut. . . . . . . . . . . . . . . . . . . . . . . . . .......... ... 60
Transmission to clutch housing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Torque shaft pivot bracket bolts (engine side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Torque shaft pivot bracket bolts (frame side). . ................................... 15
6-2 CLUTCH
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CLUTCH 6-3
CLUTCH
The clutch (if so equipped) is of the single dry disc models, has lighter pressure springs, so that the clutch
type, with no adjustment for wear being provided pedal may be depressed more easily. To compensate
in the clutch itself. An individual adjustment is pro- for the loss of torque capacity with the use of lighter
vided for locating each lever in the manufacturing, springs, six cylindrical rollers have been added to the
and should never be disturbed, unless the clutch is clutch. The rollers wedge themselves between the
to be removed from the car for repair or overhauling. pressure plate and the clutch cover with a force which
The 10” Special Equipment Clutch for 6-cylinder increases with engine speed. The wedging action of
models, has special bolts to attach the clutch to the the rollers applies additional force to the pressure
flywheel-no lockwashers are used with this assembly. plate to increase the torque transmitting capacity of
The Semi-centrifugal type clutch, for 8-cylinder the clutch.
SERVICE PROCEDURES
Clutch Adjustment in the Vehicle movement of the clutch fork outer end. (Refer to
The only adjustment required while the clutch is Figures 1 or 2, depending on Model.) This adjust-
in the vehicle is linkage adjustment to obtain the ment, if correctly set, will give the necessary 1 inch
correct amount of clutch pedal free play. Clutch pedal free play at the pedal.
free play is the movement of the pedal required to
close the clearance between the throwout bearing 1. CLUTCH
and the clutch fingers. Linkage adjustment is required Removal
to restore pedal free play when it has been reduced Improper operation or excessive wear may impair
by normal wear of the clutch. the clutch function to the point which may neces-
Shorten or lengthen the clutch release fork rod sitate its removal and overhaul.
by turning the adjusting nut until there is 5/32’’ free The clutch can be removed only after the trans-
r C L U T C H AND BRAKE PEDAL BRACKET
\ G. ENG. 8, H D
R. G. ENG.
’ .+SPRING
\
PEDAL STOP
,
I
I
11--1
n v d
PW
BRAKE PEDAL AND BRACKET
SEAL
$f*
- ‘. ,
/ -
LCLUTCH
TORQUE SHAFT PEDAL ASSY. H.D.
PEDAL ASSY.-STD.
63x368
Fig. 1-Cllrtch Pedal and Linkage (170 Cu. In. Engine)

\ ,~,
CLUTCH HOUSING
BRACKET ASSEMBLY-225 CU.

BRACKET ASSEMBLY-318 CU.
I c -..
TORQUE SHAFT ASSEMBLY4 CYL. : , SCREWA!
TORQUE SHAFT ASSEMBLY4 CYL.
TORQUE SHAFT ASSEMBLY4 CYL. H.D.
f
i
SNAP RING
CLUTCH PEDAL ROD\
SPRING WASHER (2)4\?&
k2 SCREW AND WASHER ASSEMBLY (3) 63 x 427
Fig. 2-Clutch linkage (229 and 318 Cu. In. Engine)
mission has been removed. To remove the clutch, plate thoroughly, with fine sandpaper or crocus cloth
proceed as follows: making certain that all oil or grease has been re-
(1) Remove the transmission. moved.
(2) Remove the clutch housing pan. (3) Hold the clutch disc, pressure plate and cover
in mounting position, with the springs on the disc
(3) Disconnect clutch linkage and retracting spring
damper facing away from the flywheel. Do not touch
at the clutch release fork. disc facing, as clutch chatter may result. Now,insert
(4) Pull out the clutch release bearing and sleeve. clutch disc aligning Tool C-360 through hub of disc
(5) Mark the clutch cover and flywheel to assure and into the pilot bushing, as shown in Figure 4. (If
that cover and flywheel will be correctly matched
in assembly. Now, remove the bolts that hold the
clutch cover to the flywheel, loosening each bolt a
few turns (in succession) until cover is free. (See
Figure 3.) .
(6) The clutch disc and pressure plate assembly
5 PUNCH MARKS
can then be removed from the clutch housing. For

further disassembly of the clutch pressure plate, refer
to Paragraph 2 of this Section. FLYWHEEL
lnst allat ion /'

When installing the clutch, observe the following
precautions:
(1) Coat the clutch shaft pilot bushing (in end of
crankshaft) with medium short fibre wheel bearing
grease (about a half teaspoon). Place grease in radius dSPI0&6
at back of bushing.
(2) Clean the surface of the flywheel and pressure Fig. 3-Punch Marks on Clutdh Cover and Flywheel
CLUTCH 6-5
(6) Check the clutch release bearing. If noisy,
rough or dry, press off the old bearing and install
a new one. Pack the recess in the sleeve (directly
behind bearing) with short fibre wheel grease. Coat
the fork contact surface on the sleeve and the pivot
ball with short fibre wheel grease. Slide the bearing
and sleeve up into position, engaging the springs on
the sleeve with the fork. BE SURE THE SPRINGS
HAVE LATERAL FREEDOM. When installing the
transmission, DO NOT LUBRICATE the pilot shaft or
the clutch splines. This area must be kept DRY.
(7) Install the transmission by guiding into position
with pilot studs Tool C-730. Care should be taken in
order not to bend the clutch disc by allowing the
transmission to hang. Support the transmission with
a suitable jack, then slide into place and secure with
Fig. 4-Clutch Disc Aligning Arbor (Tool C-380) bolts.
(8) Adjust clutch linkage (refer to General Infor-
Tool C-360 is not available, use a spare transmission
drive pinion clutch shaft.) mation).
(4) Insert the clutch cover attaching bolts (after
aligning balance punch marks) but do not draw down. 2. SERVICING THE CLUTCH COVER
(5) To avoid distortion of the clutch cover, the (All Borg and Beck)
bolts should be tightened a few turns at a time
(alternately) until they are all tight. Tighten the bolts. With the clutch cover and pressure plate removed
(Refer to Specifications.) Remove Tool C-360 or from the car, refer to Figures 5 or 7, then proceed
pinion shaft (if used). as follows:
SPRING
COVER EYE BOLT ASSEMBLY
PLATE
NUT 62x 62
Fig. 5-Typical Clutch Assembly-Borg and Beck (Disassembled View)

64 CLUTCH
b 55P1152
Fig. &Typical Clutch Assembly-Auburn (Disassembled View)
60 x 70
Fig. 7-Semi-centrifugal Clutch (8-Cylinder)

CLUTCH 6-7
by unscrewing the compression nut slowly in order
to prevent the springs from flying out.
(6) The cover can now be lifted off exposing all
parts for cleaning and inspection. It is important that
a notation i s made of the location of parts, including
the arrangement of the springs. (Refer to Figure 10.)
(7) Remove rollers from slots in pressure plate.
( 8 ) Grasp the lever and eyebolt between the thumb
and fingers, as shown in Figure 9, so that inner end
of lever and the upper end of eyebolt are close to-
gether (keep the eyebolt pin seated in its socket in
the lever).
45x452 (9) Lift strut over ridge on end of lever and then
remove lever and eyebolt from the pressure plate.
Fig. 8-Clutch Cover and Pressure Plate in Fixture lnspection

(1001C-585A) Clean all parts thoroughly using a suitable solvent,
then inspect carefully for excessive wear or distortion.
(1) Mark the cover and pressure plate with a prick Pressure Plate
punch, as shown in Figure 8, so that they may be
If the pressure plate shows signs of scoring, exces-
assembled in their original position to maintain
sive wear, heat checking or, if warped more than
balance.
.005 inch a new pressure plate should be installed.
(2) Mount the clutch assembly on compressing
fixture Tool C-585A,as shown in Figure 8. Testing Pressure Springs
(3) Install the three-legged spider over the center It is advisable to test pressure springs when the
screw, so that it rests directly on top of the clutch clutch is dismantled after considerable service or if
cover. there has been a great amount of slippage creating
(4) Install the thrust washer and compression nut, excessive heat, which may have caused the springs
then compress assembly by tightening the compres- to lose their initial load. To test a spring, first de-
sion nut. termine the length at which the spring is to be tested.
As an example, the compressed length of the spring
(5)With the assembly under pressure, remove the to be tested is 1Y2 inch. Turn the table of Tool (2-647
clutch release lever eyebolt nuts. Release the pressure until surface is in line with the 1% inch mark on the
threaded stud and the zero mark to the front. Place
spring over stud on table and lift compressing lever
to set tone device. Pull on torque wrench tool C-3005
52x540
Fig. 9-Removing or Installing Clutch Release lever Fig. 10-Pressure Spring Replacement
6-8 CLUTCH
With the other hand, grasp strut between thumb
and first finger, then insert in slot of pressure plate
lug. Drop strut slightly until it touches the vertical
milled surface of lug. Insert the lower end of eye-
bolt into hole in pressure plate, which will bring the
short end of lever under the hood of lug and near
the strut. Slide the strut upward in slot and lift over
ridge and into groove on short end of lever.
Assemble the remaining release levers in the same
manner. Continue to assemble, observing the follow-
ing precautions:
(1)Place the pressure springs on the small bosses
on the pressure plate and in the same order of
sequence as whence removed. (See Figure 10.) It is
very important that the springs be arranged in like
sequmce in each group in order to retain original
balance.
(2) Install rollers in slots provided in pressure plate.
(8 Cylinder Engine Clutches Only).
(3) Match up the prick punch marks made when
Pig. 1I-Testing Clut4i Pressure Springs disassembling, so that the cover and pressure plate
will be assembled with the same relation to each
as shown in Figure 11, until ping is heard. Take other.
reading on wrench at this instant. Multiply reading
(4) The assembly may then be slowly compressed
by .two. This will give the spring load to the test
length. Fractional measurements are indicated on
table for finer adjustments. (Refer to Specifications
and select model of clutch for spring pressure.) Dis-
card springs that do not meet minimum requirement.
Cover Plarte
Check the cover plate for distortion by laying plate
on a smooth surface. If the cover shows signs of
distortion, install a new cover.
Release Levers
Replace release levers that are badly worn on the
tips (this is an indication of a sticking release bear-
ing) or an indication of insutncient clutch pedal free
play or a damaged release bearing; worn or damaged
threads on eyebolts or adjusting nuts or where bind-
ing appears to be present which retards free back
and forth movement. Check the struts for wear on
the contact edges. Install new parts as required.
Assembllng the Clutch
To reassemble the clutch, coat the driving lug sides,
eyebolt tail and strut (Figure 12) with a thin coat of
lubriplate, No. 220, then, assemble the release levers
as follows:
Assemble the lever pin and eyebolt to the release
lever. Holding the threaded end of eyebolt between Fig. 12-Adjusting Clutch Release levers
the thumb and index finger, allow the end of lever to 1 - Feeler Blades 3-Spacers (Part of Tool C J 8 5 A )
rest on second finger. Keep end of lever and eyebolt (Part of Tool C-585A) 4-Clutch Release Lever Eye Bolt
2 - Compression Plate 5 -Clutch Release lever Eye Bolt Nut
as close together as possible. (Part of Tool C-585A) 6 -Stake Here to lock
CLUTCH 6-9
(as outlined for disassembly), making sure that the WASHER COMPRESSION NUT
eyebolts are guided through the holes in the cover.
(5) Screw the adjusting nuts on the protruding
eyebolts, until the nuts are flush with the top of the
SELF ALIGNING
WASHER \ \ 11 /, COMPRESSION
WASHER
eyebolts. Slowly release pressure by unscrewing the

compression nut on the tool. Depress release levers
several times to properly seat parts, using Tool
C-585A.
Adjusting-the Release Levers
Mount the clutch assembly on the fixture (Tool C-
585A) with the release levers over the feeler gauges
in the base of the fixture, then proceed as follows:
(1) Install the bolts that hold the cover to the Fig. 14-Adjusting Clutch Release Levers (Auburn)
fixture and tighten securely.
(2) Place the proper spacers on the center screw sure each one is adjusted properly. Stake the nuts
of the fixture. (Refer to specifications for model and to hold them in position.
spacer usage.) (8) Check clearance between lugs and cover holes.
(3) Install the compression plate on the center (9) Remove clutch from fixture and install in car,
screw. Make sure it rests directly against the clutch as described in Paragraph 1of this Group.
release levers.
(4) Install the self-aligning washer, flatwasher and 3. SERVICING THE CLUTCH COVER
compression nut. (All Auburn)
(5) Tighten the compression nut until the com- To overhaul the clutch, refer to Figure 6, then
pression plate comes into contact with the spacers proceed as follows:
for setting lever height. (1) Mark the cover and pressure plate with a prick
(6) Adjust the clutch release lever until the feeler punch, as shown in Figure 14, so that they may be
gauges have the same slight drag or feel while being assembled in their original position to maintain bal-
pushed in or pulled out. Tighten the nuts to decrease ance.
drag and loosen to increase drag, as shown in Figure (2) Place cover suppsrt plate (Tool C-585-33) over
13. the center screw of fixture C-585A and install clutch
(7) Recheck the release lever adjustment to make cover assembly on fixture as shown in Figure 14.
(3) Install the cover support plate compression
washer over the center screw, so that it rests directly
on top of the clutch release levers.
(4) Install the compression nut and then compress
the levers by tightening the compression nut.
(5) With the levers under pressure, remove the
adjusting screw, washer and plate return spring.
Place a Y2 inch steel block (C-585-32),under the outer
end of each lever. (Refer to Figure 14.)
(6) Back off the compression nut slowly until the
release levers rise and contact the steel blocks. Re-
move the nut and compression washer and lift off
cover.
(7) Remove the pressure springs by forcing each
release lever downward by hand, lift out the steel
block and allow the lever to return slowly. Lift out
A5 x 8?
the pressure spring.
Fig. 13-Disassembling Auburn Clutch in Fixture (8) Grind off one end of the lever pin, then drive
(C-585A) the pin out of the lever and cover.
6-10 CLUTCH
For cleaning and inspection, refer to Paragraph plain washer and the compression nut. Tighten the
2 of this Section. This is a standard procedure for all compression nut until compression plate comes into
clutches. snug contact with spacer (or spacers).
(3) Adjust the clutch release levers, as shown in
Assembling the Clutch
Figure 15, until each of the three feeler gauges have
To assemble the clutch, refer to Figure 6,then pro- the same slight drag or feel, when being pushed in
ceed as follows: or pulled out. Tighten the release lever screws to
(1) Assemble the release levers to the cover. Install decrease the drag or loosen them to increase the
new pins and peen over. drag.
(2) Install the pressure springs between the levers (4) Recheck the adjustment of each lever to make
and cover. Make sure the springs rest on the bosses certain the adjustment is correct.
of the cover and are seated in the embossed seats of
(5) Tighten the locknuts and remove the clutch
the levers.
assembly from the fixture. When removing the clutch
(3) Press down each lever in turn by hand, and assembly, loosen the housing clamps first, and then
insert the steel blocks under the outer ends of levers. remove the compression nut. This procedure will
(4) Install the cover support plate on the fixture avoid imposing unequal strain on the release levers.
and lower the cover over the pressure plate, with (6) Install in car as described in Paragraph 1 of
the punch marks aligned. this Group.
(5) Install the compression plate, self-aligning
washer, thrust washer and compression nut. 4. SERVICING THE CLUTCH SHAFT
(6)Tighten the compression nut and remove steel PILOT BUSHING
blocks. Install the washers and adjusting screws in
the pressure plate. To remove pilot bushing, screw the tapered pilot of
(7) Unscrew the compression nut slowly, then in- Tool C-41 into the bushing, allowing pilot to cut its
stall the pressure plate return springs. Do not lubri- own threads until a solid grip is obtained. Insert
cate any parts of the cover or pressure plate with puller screw and turn, forcing bushing out of crank-
oil or grease. Use only Iubriplate No. 220 applied in shaft. Tool C-3185 may be used if Tool C-41 is not
a very thin coat. available. Follow manufacturer's instructions for use.
To replace pilot bushing, slide new bushing over
Adjusting the Releuse Levers the pilot of tool DD-286 and drive into place with a
(1) Install the clutch assembly on fixture, Tool soft hammer. This causes bushing to tighten up on
C-585A,making certain that the housing clamps line pilot. Inktall cup and puller nut and tighten, removing
up with holes. tool from bushing. This action burnishes the bushing
(2) Slide proper spacer (or spacers-consult 'speci- to the exact size and leaves a smooth and lasting
fications) over the center screw of the fixture. Install finish. Tool C-3181 may be used if Tool DD-286 is not
the compression washer, the self-aligning washer,
NEW BEARING
Fig. 15-lubricating Pilot Bushing Fig. 16-lnstalling Clutch Release Bearing

CLUTCH 6-11
available. Follow manufacturer’s instructions for use. is an ‘L’ shaped bracket bolted inside the clutch
Lubricate the bushing with about half a teaspoon housing.
of short fibre grease. Insert grease in radius at back (2) Lubricate contact areas of end of clutch fork.
of bushing (not on clutch shaft) as shown in Figure (3) Install clutch fork in housing being careful to
16. engage flat retaining spring in the hole of the pivot.
5. CLUTCH FORK (4) Rotate retaining springs of bearing sleeve over
ends of clutch fork. (Refer to Figures 1 or 2.)
Removal ( 5 ) Install the dust seal boot over release fork and
Should it become necessary to replace, remove or engage the groove of the boot into the clutch housing.
install the clutch fork, proceed as follows:
(6) Attach clutch rod and rehook retracting spring.
(1) Disconnect the clutch fork retracing spring
(7) Adjust clutch as described under General In-
(Refer to Figures 1or 2).
formation.
(2) Disconnect clutch rod from clutch fork.
(3) Pry dust seal boot out of clutch housing and 6. RELEASE BEARING (Clutch Removed1
remove from clutch fork.
Removal
(4) Rotate retaining spring clips of the throw out
bearing sleeve off of the ends of clutch fork. (1) Support the release bearing in a vise or press
and carefully press out the release bearing sleeve.
(5) Grasp the outer end of clutch fork and pull
clutch fork out and off of knife edge pivot. The clutch (2) Position new bearing on end of sleeve and using
fork has a riveted flat retaining spring that i s engaged old bearing against the face of the new bearing,
in a hole of the pivot bracket. carefully press on bearing. Make certain bearing is
(6) Remove clutch fork from clutch housing.
seated on flange of release bearing sleeve.
Exercise care when installing a new clutch release
Insfallation bearing to avoid damaging the bearing race. Never
(1) Apply short fiber grease to the pivot edge and drive the bearing on the sleeve with a hammer.
hole of pivot bracket. The clutch release fork pivot Then place the bearings and sleeve in a vise and
SPRING 6 CYL.
SPRING 8 C Y L . 4 CYL.-H.D.
ING-(2)-(8 CYL. & 6 CYL. H D J
NUT & L.W. ASSY. (2)
SPRING WASHER
H PEDAL ASSY. (6 O L . 1
(8 CYL. & 6 CYL. H.D.)
62 x 45A
Fig. 17-Clutch Pedal linkage (Disassembled View)

6-12 CLUTCH
press the new bearing on the sleeve. See Figure 17.
Turn the bearings as they are pressed together. The
new bearing must be flush with the shoulder of the
release bearing sleeve.
(3) Fill the cavity of bearing sleeve with short fiber
grease prior to installation in car.
lnstallatton
(1) Slide release bearing as far forward as it will
go. Slide clutch fork into housing and engage with
springs on thrsw-out bearing, allowing retaining
spring to pass around pivot stud. Before installing
clutch fork, be sure the fork fingers are lubricated
with short fiber grease and the pivot indent is Iubri- &7 61x131
cated with lubriplate No. 220.
Fig. 184hecking Clutch Housing Bore
(2)Slide dust boot over outer end of clutch fork
and down against clutch housing. Insert boot in ings (8 cylinder) require no periodic lubrication.
housing until groove in boot fits around edge of
(2) Set the release bearing free play by adjusting
housing opening.
the self locking nut on the fork rod to provide %2
(3) Engage rear end of clutch fork rod with fork inch of free movement at the fork-to-push rod con-
aligq holes. Install clevis pin and flatwasher. Secure necting pin. This will result in free play at the pedal
with spring retainer. of about 1to 1%inch.
(4) Rehook the release fork pull back spring.
9. CLUTCH HOUSING ALIGNMENT
7. REMOVING OR INSTALLING THE When performing adjustments or repairs that in-
TORQUE SHAFT PIVOT BUSHING volve removing the clutch housing, it will be neces-
sary to align the face of the housing parallel with
To replace the torque pivot bushing, refer to Figure that of the block when assembling.
2 and proceed as follows:
Bore Runout
(1)Unhook the clutch release fork return spring
from the bracket and fork. To eorrectly align the clutch housing, proceed as
follows:
(2) Disconnect the clutch release fork and rod from
the torque shaft. (1) Mount Tool C-870 with dial indicator C-435 on
flywheel, as shown in Figure 19.
(3) Remove the clutch release rod spring clip from
the release rod and disconnect rod from torque shaft. (2)With flywheel turning Tool C-771,crank engine
while noting dial indicator needle deflection. Out-of-
(4) Remove the torque tube bracket screws from
the side shield and the pivot bolt/or bolts from the
engine block and remove torque tube assembly.
(5) Remove spring retainer from end of torque
tube and pull out the two pivot bushings. Repeat
procedure at other end of tube.
(6) Clean all old grease from within the tube and
reassemble. Lubricate and reassemble on car.
8. ADJUSTING THE CLUTCH PEDAL

FREE MOVEMENT (Fig. 18 1
(1) Inspect the linkage for damaged rubber clutch

stop pad. Replace if necessary. The upper end of REAR FACE OF ENGINE BLOCK 6oxl6ol
the clutch pedal pivots in the pedal mounting bracket.
The nylon pedal bushing (6 cylinder) and needle bear- Fig. 19-Offset Dowel Diagram (6 Cy!.)
CLUTCH 6-13
round of bore must not exceed .008inch (maximum)
total indicator reading.
If bore runout is in excess of .008 inch total in-
dicator reading proceed with correction as follows:
To illustrate the recommended correction proce-
dure, assume that the total indicator reading is .020
inch, in a direction which approximates 2 o’clock on
engine block, (refer to Figures 20 or 21 depending on
Model).
In this case, the housing is off crankshaft center-
line .010 inch (one-half total indicator reading) which
is .066 inch greater than the allowable limit of .004
(one-half total indicator reading).
In the case under consideration, use of the .007
61x130
inch offset dowels (pair) will bring the runout well
within the allowable limits of .008inch or .008 inch
minus .007 inch (offset dowels) equals .001 inch run- Fig. 21-Checking Clutch Housing Alignment
out. Dowels must be used in pairs (same part number).
(3) To install the dowel pins (pair), remove clutch centricity.) Both dowels must be inserted into engine
housing (after disconnecting and removing starting block, up to off-set shoulder.
motor). Remove dowel pins from engine block. Select (5) Install and tighten clutch housing bolts to 50
eccentric dowels (pair) which are available with the foot-pounds (7/1 6’’). Remount dial indicator and re-
following amount of offset: .007” (No. 1736347), .014” check bore runout. Small corrections can be made by
(No. 1736348), .021” (No. 1736353). removing clutch housing (if necessary) and turning
The amount of eccentricity of the dowel will pro- dowels with a screw driver to shift the housing and
duce a total indicator reading change of double the bring bore within limits. (Refer to Figure 19.)
dowel eccentricity, therefore, a pair of dowels with
the nearest to Y2 of the total indicator runout of Face Runout
the bore. For runout (total indicator reading) of (1) Relocate dial indicator, as shown in Figure 21.
.012” through .020”, use a .007” dowel (P/N1736347), Rotate flywheel, using Tool C-771. If the total in-
.022” through .034”, use .014” dowel (P/N 1736348), dicator reading is greater than..006” note the amount
and .036” through .052”, use .021” dowel (P/N 1736- of the total indicator reading and the location of the
353). lowest indicator reading (i.e., the point where the
(4) Install both dowels with the slots parallel and indicator arm or follower is extended the furthest).
aligned in the direction to correct the bore runout. (2) To correct excessive runout, place proper thick-
(Slot indicates the direction of maximum dowel ec- ness of shim stock between the clutch housing and
engine block or between transmission and clutch hous-
ing. After re-checking face runout, tighten housing
12
bolts to 50 foot-pounds. Install transmission.
- 1
10. STEAM CLEANING PRECAUTIONS
The clutch housing, being ventilated, steam vapor
condenses and moisture settles on the intkrnal +ov-
ing parts of clutch mechanism. The facings of the
disc will absorb moisture and under the force exerted
by the pressure plate, will bond the facings to fly-
wheel and/or, the pressure plate, if the car is allowed
REAR FACE OF
ENGINE BLOCK to stand for some time before use. If this condition
occurs, it will necessitate complete replacement of
disc, pressure plate, flywheel and/or, driving plate.
Immediately after the cleaning operation, start en-
gine and “slip the clutch” in order to dry off the disc
Fig. 20-Offset Dowel Diagram (8 Cyl.) assembly, pressure plate, and/or flywheel.
6-14 CLUTCH
SERVICE DIAGNOSIS
Clutch Chatter (a) Worn or damaged disc assembly. (a) Replace the disc assembly.
(b) Grease or oil on disc facings. (b) Replace the disc facing or disc
assembly.
(c) Improperly adjusted cover assembly. (c) Remove and recondition.
Clutch Slipping (a) Burned, worn, or oil soaked facings. (a) Replace the facings or disc
assembly.
(b) Insufficient pedal free play. (b) Adjust the release fork rod.
(c) Weak or broken pressure springs. (c) Recondition the cover assembly.
Dlfflcult Gear Shifting (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 assembly. (c) Remove and recondition.
(d) Clutch disc splines sticking. (d) Remove the disc assembly and free
up splines or replace the disc.
Clutch Noisy (a) Dry clutch linkage. (a) Lubricate where necessary.
(b) Worn release bearing. (b) Replace the release bearing.
(c) Worn disc assembly. (c) Replace the facings or disc
assembly.
(d) Worn release levers. (d) Recondition the cover assembly.
(e) Worn or dry pilot bushing. (e) Lubricate or replace bushing.
(f) Dry contact-pressure plate lugs in (f) Lubricate very lightly.
cover.
COOLING SYSTEM 7-1
GROUP 7
COOLING SYSTEM
CONTENTS
Page Page
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Radiator Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Radiator Pressure Cap. . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pressure Testing the Cooling System. . . . . . . . . . . . . . . 10
Fluid Fan Drive.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Water Temperature Gauge.. . . . . . . . . . . . . . . 10
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Proper Belt Tension.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Belt Deflection Method.. ........................ 11
Transmission Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . 8 Torque Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Flushing the Cooling System.. . . . . . . . . . . . . . 8 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS
Valiant W-1 Plymouth VP-2, VP-1

170 225 225 318 361 -383 426
Engine Type Cu. In. Cu. In. Cu. In. Cu. In. Cu. In. Cu. In.
Capacity (Quarts)
With Heater. . . . . . . . . . . . . . . . . . 12 13 13 21 17 17
Without Heater. . . . . . . . . . . . . . . . 11 12 12 20 16 16
Radiator Type.. ............... Tube & Spacer Tube & Spacer
Fin & Tube
Transmission Oil Cooler
Type . . . . . . . . . . . . . . . . . . . . . . . Concentric Tube
location. . . . . . . . . . . . . . . . . . . . . Radiator Bottom Tank
Radiator Pressure Cap
Type. . . . . . . . . . . . . . . . . . . . . . . . . Pressure Vent
Pressure Setting. . . . . . . . . . . . . . . . 12-15 psi Std.
15-16 psi A/C
Fan
Diameter-No Blades. . . . . . . . . . 16"-4 Std. 17"-4 Std. 18"-4 Std. 18"-7 Std.
17"-6 A/C 18"-4 A/C 18"-7 A/C
Fan Spacer
Thickness. .................... .90" Std. 1.40" Std. 2.20" Std. 1.40" Std. None
.90" A/C 1.24" A/C 2.00" A/C
Fan Drive
Silicone Fluid Filled-
Thermal Control. . . . . . . . . . . . . A/C Only Jtd.
Thermostat
Type . . . . . . . . . . . . . . . . . . . . . . . . Pellet
Setting . . . . . . . . . . . . . . . . . . . . . . . 177O-184"F
Fan to Radiator Clearance. . . . . . . . . . . 54"-1 l/qn Std. and A/C
Radiator Fan Shroud.. . . . . . . . . . . . . . Full Ring Full Ring Box Box None
A/C-Air Conditioning
7-2 COOLING SYSTEM
ACCESSORY BELT DRIVES

BELT TENSION SPECIFICATIONS
Belt D e f l e c t i o n Method
D e f l e c t i o n (Inches 1 To B e Applied at Midpoint of

B e l t S e g m e n t Under a 5 Lb. Load-See F i g u r e 12
ACCESSORY USED BELT NEW BELT

361 -383 361-383
170 225 318 426 170 225 318 426
Cu. In. Cu. In. Cu. In. Cu. In. Cu. In. Cu. In. Cu. In. Cu. In.
Power Steering. . . . . . . . . . . . !h !h %6 M6 M6 1% vi
Fan Belt Idler.. ............ - - - !h - - - 1
h
Alternator
Without A/C. ......... '/4 % '/4 '/4 E
42 !h vi '/i
With A/C. . . . . . . . . . . . - !4 '/4 % !h vi vi ?A
BELT TENSION SPECIFICATIONS 170-225 CU. IN. ENGINES
TORQUE METHOD
T o r q u e ( Ft-Lbs. 1 to be applied to c o m p o n e n t s
ACCESSORY NEW BELT USED BELT*
Power Steering Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 45

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
A/C Idler Bracket.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 25
BELT TENSION SPECIFICATIONS--318 CU. IN. ENGINE

TORQUE M€THOD
T o r q u e (Ft-Lbs.1 to be applied to c o m p o n e n t s
Power Steering Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 50
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 30
A/C Idler Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 55

COOLING SYSTEM 7-3
BELT TENSION SPECIFICATIONS---361 ,383,426

CU. IN. ENGINES
TORQUE METHOD
Torque ( Ft-Lbs. 1 to be applied to components
Power Steering Bracket. .................................................... 90 55
Alternator
With Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 40
Without Air Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 40
Fanldler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 35
*Any belt that has operated for a minimum of a half-hour i s considered to be used.
SPECIAL TOOLS
C-412 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller-Fan Hub

C-3250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pliers-Hose Clamp
C-3468. ...................................................................... Installer-Pump Bearing and Shaft
C-3476. ............... .............................................. Pu ler-Pump Impeller Insert
C-3499. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge-Pressure Testing

C-3514.. .. ....... .................................................. Flushing Gun
c-3753 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover-Pump Soal
C-384 1 . . . . . . . . . . . . . . . . . .............................. .Belt Adjustlng Tool
TORQUE REFERENCE
Water Pump Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fan Attaching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
Thermostat Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
74 COOLING SYSTEM
All engines are equipped with a 180" thermostat and water or antifreeze and water depending on the
as standard equipment. With this thermostat, ethyl- season. The quantity of antifreeze to be added
ene glycol base permanent type antifreeze must be should be sufficient to protect for the lowest anti-
used. If an alcohol type antifreeze is desired, a 160" cipated temperature.
thermostat must be installed. Vehicles with factory equipped air conditioning
When draining the cooling system, the cylinder must use at least 20% glycol (+ 15" protection) at all
block drain plugs should be removed and the radia- times, both winter and summer, to prevent heater
tor drain cock opened. Refill with either rust resistor core freezing.
SERVICE PROCEDURES
1. FAN The main features of the thermal drive is to run the
fan slow in cold weather and faster in hot weather.
There are no repairs to be made on the fan. If the
fan is bent or damaged it should be replaced. If a cooling malfunction is encountered and the
fluid fan drive unit is suspected, install a unit
Removal known to be operating properly and test by oper-
Remove the upper half of the shroud (if so equip- ating the vehicle under the same conditions. Replace
ped). Loosen the fan belt and remove the four bolts the drive unit assembly if the trouble was corrected
attaching the fan to its pulley. On models so equip with the test unit.
ped, the fluid fan drive unit must be removed with
the fan. 3. WATER PUMP
Removal from the Vehicle
installation (1) Drain the cooling system and remove the fan
shroud (air conditioning equipped vehicles). Loosen
Use the correct spacer, if required, so that clear- the fan drive belt by loosening the alternator mount-
ance between the fan blades and the radiator is ing bracket and swing the alternator in towards the
from s/s inch to 1% inches. The fan should be in- water pump (on vehicles equipped with air condition-
stalled so that the portion of each blade nearest the ing, loosen the idler pulley).
radiator is almost parallel to the radiator core. In-
stalling the fan backwards (with the forward portion (2) Remove the fan, spacer and pulley.
of the fan blade sharply angled away from the (3) Remove the water pump to housing retaining
radiator core), will cause low air flow. Install the
upper half of the shroud on vehicles so equipped.
Tighten the fan belt as outlined in "Accessory Belt
Drives". PULLEY
7
18
2. FLUID FAN DRIVE
The fan drive unit is a silicone fluid filled coupling
connecting the fan to the fan drive pulley. (Fig. 1.)
The unit is designed to provide the following:
SPRjNG
(1) Maintain satisfactory engine cooling in hot
weather.
(2) Eliminate fan noise at all speeds in cold
weather.
(3) Reduce fan noise in hot weather at high vehicle
speed. FLUID FA1 60x748
The speed of the drive is controlled by the thermal
coil or spring mounted in front of the drive unit. Fig. 1-Fluid Fan Drive
COOLING SYSTEM 7-5
PUMP BODY WITH
SHAFT AND BEARING IMPELLER
through the front of the pump. If an attempt is
SERVICED AS AN AS mads to remove the shaft in the opposite direction
damage to the pump body may result.
(8) Use a wire brush to remove all rust from
the separator plate. Clean all parts with a suitable
solvent and dry with compressed air. Bearing as-
semblies removed from water pumps should not be
SCREW AND reused, as damage to the bearing will usually result
during removal.
W a f e r Pump Assembly (6-Cylinder1

SEAL ,++" Inspect seal surface of the impeller hub to be sure
it i s free of nicks, burrs, scratches and rust. If
GASKETS~ 60x242 A necessary remove these blemishes using crocus cloth
Fig. 2-Six Cylinder Water Pump on a flat plate.
bolts and washers and remove the water pump from (1) Apply a thin coat of Mopar Perfect Seal Seal-
the vehicle. Discard the gasket. ing Compound, Part Number 1057794 to the seal
pocket in the pump body.
W a t e r Pump Disassembly (6-Cylinder 1 (2) With the pump housing supported at the hub
(Fig. 21
end, use a 1% inch (12 point) socket to apply
pressure against the outer lip of the seal retainer
(1) Break the plastic impeller and remove it from and press the seal assembly into the body until the
the metal insert. If the impeller is made from cast retainer lip is against the pump body.
iron remove it with a suitable puller.
(3) With the thrower ring in position on the long
(2) Remove the separator plate and gasket. end of the pump shaft (approximately Ys inch from
(3) Split the sintered metal insert of the plastic the bearing assembly) start the shaft and bearing
impeller with a chisel and hammer. assembly into the fan end of the pump body bore.
(4) Remove the rubber portion of the shaft seal (4) Use a 1% inch (12 point) socket and support
and the spring. the pump body at the seal end, and with Tool C-3468,
(5) Using puller Tool C-3753 (Fig. 3) remove the positioned against the outer bearing race only, press
retainer portion of the seal. the shaft and bearing into the pump body so the end
(6) Remove the fan hub using puller Tool C-412.
of the bearing is flush with the body hub end.
(5) While supporting the pump, on the impeller
(7) Support the pump body on the front face (fan
hub end) and apply pressure to the rear end of the end of the shaft, press the fan hub onto the shaft
shaft to press the shaft and bearing assembly out (flat surface out) so the shaft extends inch
beyond the fan hub.
(6) Position new gaskets on each side of the sep-
arator plate and install the plate on the pump body.
(7) Clean the seal face and impeller hub seal
surf ace.
(8) Support the pump on the fan hub end of the
shaft and position the new impeller on the pump
shaft (blade portion down). Using a tool that will
press against the impeller insert only, press the im-
peller onto the shaft until it is flush with the end of
the shaft.
W a t e r Pump Disassembly t 8-Cylinder 1

( 3 1 8 Cubic lnch Engine) (Fig. 4 )
6Ox 1 346 (1) Break the plastic impeller and remove it from
the metal insert. If the impeller is made of cast iron
Fig. 3-Removing Seal Retainer remove it with a suitable puller.
COOLING SYSTEM 7-7
(5)Using Tool C-3753,remove the seal retainer NOTE: Inspect the seal surface of the impeller
from the housing. hub to be sure it is free of nicks, burrs, scratches
(6)Support the body on the front face (fan hub and rust. If necessary remove these blemishes using
end) and apply pressure to the rear end of the shaft crocus cloth on a flat plate.
to press out the shaft and bearing assembly through (1)Apply a thin coat of Mopar Perfect Seal
the front of the pump. If an attempt is made to Sealing Compound, Part Number 1057794 to the seal
remove the shaft in the opposite direction, damage pocket in the pump body.
to the water pump body will result. (2)With the pump housing supported at the hub
end, use a 1% inch (12 point) socket to apply
Water Pump Assembly f 8-Cylinder I pressure against the outer lip of the seal retainer
and press the seal assembly into the body until the
(318 Cubic lnch Engine) retainer lip is against the pump body.
NOTE: Inspect the seal surface of the impeller (3)With the thrower ring in position on the long
hub to be sure it is free of nicks, burrs, scratches end of the pump shaft (approximately 4/8 inch
and rust. If necessary remove these blemishes using from the bearing assembly) start the shaft and
crocus cloth on a flat plate. bearing assembly into the fan hub end of the pump
(1) Apply a thin coat of Mopar Perfect Seal Seal- body bore.
ing Compound, Part Number 1057794 to the seal (4)Use a 1% inch (12 point) socket and support
pocket in the pump body. the pump body at the seal end. With Tool C-3468
(2) With the pump housing supported at the hub positioned against the outer bearing race, press the
end, use a 1% inch (12 point) socket to apply pres- shaft and bearing into the pump body so the end of
sure against the outer lip of the seal retainer and bearing is exactly flush with the end of the pump
press the seal assembly into the body until the body.
retainer lip is against the pump body. (5)While supporting the pump on the impeller
(3)With the thrower ring in position on the long end of the shaft, press the fan hub onto the shaft
end of the pump shaft (approximately Ya inch from (flat surface out) so the shaft extends inch
the bearing assembly) start the shaft and bearing as- through the fan hub.
sembly into the fan hub end of the pump body bore. (6)Support the pump on the fan hub end of the
(4)Use a 1% inch (12 point) socket and support shaft and position the new impeller on the pump
the pump body at the seal end, and with Tool (2-3468, shaft (blade portion up). Using a tool that will press
positioned against the outer bearing race only, press against the impeller insert only, press the impeller
the shaft and bearing into the pump body so the end onto the shaft until it is flush with the end of the
bearing is flush with the housing. shaft.
(5) While supporting the pump on the impeller lnstallation
end of the shaft, press the fan hub onto the shaft so (1)Use a new gasket and install the water pump.
the shaft extends inch through the fan hub. Tighten the bolts to 30 foot-pounds.
(6)Support the pump on the fan hub end of the (2)Install the pulley spacer, fan and shroud
shaft and position the new impeller on the pump (when so equipped). Fill the cooling system and
shaft (blade portion down). Using a tool that will test for leaks. Test the belt tension as outlined in
press against the impeller insert only, press the “Accessory Belt Drives”.
impeller onto the shaft until it is flush with the end
of the shaft, 4. RADIATOR
Removal
W a t e r Pump Assembly (1)Drain the cooling system.
f 36 1-383-426 Cubic lnch Engines) (2) On vehicles with automatic transmission, dis-
connect the oil cooler lines at the radiator bottom
Before assembling, clean all parts thoroughly in a tank.
suitable solvent and dry with compressed air.
(3)Remove the radiator hoses (using pliers, Tool
CAUTION; Bearing assemblies removed from C-3250),lower half of fan shroud, (if so equipped)
water pumps, for any reason should not be reused and radiator attaching bolts.
as damage to bearings will usually result during (4)Raise the radiator straight up and out of the
removal. engine compartment.
7-8 COOLING SYSTEM
lnstallatlon (3) Melt the soft solder holding the cooler to the
tank.
(1) Slide the radiator down into position behind
the radiator support and install the attaching bolts. (4) Remove the stamped retainer nuts holding the
(2) Install the fan shroud (if so equipped), con-

cooler fittings to the bottom tank and remove the
cooler.
nect the hoses, and connect the transmission oil
cooler lines (if so equipped). (5) Install a new cooler or repair the old cooler
(3) Fill the cooling system to 1% inches below with silver solder and reinstall as follows:
the filler neck with water and rust resistor or water (6) Position the oil cooler in the bottom tank and
and antifreeze. install the stamped retainer nuts on the oil cooler
(4) Measure the transmission oil level (after warm- fitting.
up) and add oil as required. (7)Use soft solder to secure the cooler in the
tank.
Cleaning (8) Attach the bottom tank to the radiator using
(1) Drain the cooling system and refill with clean soft solder.
SOFT water and add the contents of one can (No. 1 (9) Install the radiator as described in Paragraph
top-compartment) of MoPar Cooling System Cleaner. 4.
(2) Operate the engine at a fast idle for Y2 to (10) Fill the cooling system and test for leaks.
?4 hour.
If the transmission operates properly after re-
(3) Drain the cooling system and refill with clean pairing the leak, drain the transmission and torque
water. converter while hot, remove the transmission oil
(4) Pour the conditioner (No. 2 bottom-compart- pan and inspect for sludge, rust, dirty or plugged
ment) into the radiator and run engine for ten inlet filter. If none of these conditions are found,
minutes. reconditioning may not be necessary. Reassemble,
(5) Flush the entire cooling system until water using Transmission Fluid Type “A”, Suffix “A”.
runs clean. .
(6) Refill the radiator with clean SOFT water. 6. PRESSURE FLUSHING THE C O O L I N G
(7) Use MoPar Radiator Rust Inhibitor during the SYSTEM
summer months.
(1) Clean the system using the recommended
Cooling System Cleaner according to the directions
5. TRANSMISSION OIL COOLER on the label.
Automatic transmission equipped vehicles use a (2) Drain the radiator and engine block and re-
transmission oil cooler in the radiator bottom tank. move both radiator hoses.
A leaking oil cooler may permit entrance of trans-
(3) Remove the thermostat and reinstall the
mission oil into the cooling system and engine
housing.
coolant into the transmission.
(4) Connect a flushing gun, Tool C-3514, to the
Testing Oil Coolers for Leaks engine thermostat housing, using a length of rubber
(1) Disconnect both oil lines at the radiator. hose.
(2) Attach a pressure gauge to one radiator (5) Install a drain hose on the water pump inlet.
fitting and an air line equipped with a shut-off valve (6) Connect a flushing gun to sources of water
to the other fitting. and air pressure.
(3) Coat all fitting joints with oil. (7) Fill the cylinder block with water by restrict-
(4) Apply air pressure (up to 100 psi). Oil bubbles ing the drain hose. Leave the water valve open.
will identify any fitting joint leaks which should be (8) Open and close the air valve to agitate and
corrected before proceeding with the test. force away any foreign material. Continue the opera-
(5) Close the valve and note pressure gauge read- tion until the water runs clear.
ing. If pressure drops off, the oil cooler leaks. (9) For the final block flushing, fill the block with
water and remove the drain plugs. Use air pressure
Repairing the Oil Cooler until the water from the block drains runs clear.
(1) Remove the radiator. (10) To reverse flush the radiator, disconnect
(2) Remove the radiator bottom tank. the two hoses from the engine and attach them to the
COOLING SYSTEM 7-9
radiator. Attach the flushing gun hose to the lower thermostat housing using pliers Tool C-3250.
radiator tank and the drain hose to the top tank. (3)Remove the thermostat housing bolts and re-
(11)Fill the radiator with water, leave the water move the thermostat and housing.
valve open, and open and close the air valve. Con-
tinue the operation of the air valve until the water Testing the Thermostat
runs clear. (1) Visually inspect the thermostat to make sure
(12)For the final radiator flushing, attach a flush- the valve closes tightly. If the valve does not close
ing gun to the top hose and repeat the flushing completely due to dirt, sand or other foreign
operation. material, carefully clean the sealing edge making
sure the sealing edge is not damaged. If the valve
(13)Test the thermostat as described in paragraph
does not close tightly when clean, install a new
7. If satisfactory, install with the pellet towards the
thermostat.
engine, using a new gasket.
(2)Immerse the thermostat in a container of
(14)Install the hoses and fill the cooling system
warm water so that the pellet of the thermostat is
to 1% inches below the filler neck, using water and
completely covered. The pellet must not touch the
rust resistor or water and antifreeze, depending on
bottom or sides of the container.
the season.
(3)Heat the water and stir it continuously (to
(15) Operate the engine until the temperature
insure uniform temperature) and test the water
gauge indicates normal operating temperature and temperature with a thermometer at the point when
continue an additional five minutes to release any
a .003" feeler gauge can be inserted into the valve
air trapped in the system. Inspect the coolant level
opening. The feeler gauge should pass freely into
and if necessary, add additional water.
the valve opening at a water temperature of 175'
7. THERMOSTAT to 185°F. If outside of this range, replace the ther-
The thermostat is actuated by a pellet containing mostat.
a copper-impregnaled wax (Fig. 8). As the temper- (4)Continue heating the water to approximately
ature of the pellet increases, the wax expands and 200°F. The thermostat valve should be fully open at
opens the valve. A 180" thermostat is standard this temperature. If it does not, replace the ther-
equipment. mostat.
If the thermostat does not close completely when
cold, the engine will warm up slowly or not at all, installation
and heater performance will also be impaired. Poor (1)Using a new gasket, position the thermostat
heater performance may also be due to the valve so the pellet end is toward the engine and attach
opening at too low a temperature. Too high a valve with bolts through the thermostat housing.
opening temperature or a valve that will not open (2)If removed, reinstall or replace the upper hose
can cause overheating. using Tool C-3250.
Removal (3)Fill the cooling system to 1% inches below
(1)Drain the cooling system down to the ther- the filler neck with water and rust resistor or water
mostat level or below. and antifreeze.
(2)Remove the upper radiator hose from the
8. R A D I A T O R HOSES
The hoses are removed and installed using hose
clamp pliers Tool C-3250.
A hardened, cracked, swollen or restricted hose
should be replaced.
The reinforcement spring inside the lower hose
is necessary to prevent collapsing of the hose due to
suction at medium or high engine speeds. If this
spring is weak or broken, it should be replaced.
9. R A D I A T O R PRESSURE C A P
\PELLET/ 64 x 187 A 14 psi pressure-vent type radiator cap (Fig. 9) is
used as standard equipment (16 psi for air con-
Fig. 8-Thermostats ditioned vehicles).
7-10 COOLING SYSTEM
(2) Wipe the filler neck sealing surface clean.
(3) Attach a tester Tool C-3499 to the filler neck
and apply 15 psi pressure (Fig. 11).
(4) If the pressure gauge reading holds steady,
the system is satisfactory. If the pressure drops,
continue the test as follows:
GASKET
(5) Test all points for external leaks. If no ex-
VENT VALVE
64x186 ternal leaks are found after the gauge dial showed
a drop in pressure, continue the test.
Fig. 9-Radiator Pressure Cap (6) Remove the tester and run the engine until
normal operating temperature is reached.
When removing the pressure cap, turn the cap
counter-clockwise to the stop permitting any pres- (7) Re-attach the tester, apply 7 psi pressure and
sure to be released through the overflow tube. This increase engine speed to half throttle.
will prevent hot water from spraying out of the (8) If the needle on the dial fluctuates, it in-
radiator filler opening after pausing at the stop, dicates a combustion leak, generally at the head
continue turning counter-clockwise until the cap is
released. gasket. On V-8 engines, detach spark plug leads
from one bank and operate the engine on the op-
The brass vent valve at the bottom of the cap
should hang freely. If the rubber gasket has swollen posite bank. If the needle continues to fluctuate, the
and prevents the vent valve from hanging loosely, bank in operation leaks. If the needle stops fluc-
the cap should be replaced. tuating, the bank not in operation leaks.
(9) If the needle on the dial did not fluctuate in
Pressure Testing the Radiator Cap (Fig. 10) step 7, sharply accelerate the engine several times.
(1)Attach the neoprene seal and adapter to tester, If an abnormal amount of water emits from the tail
To01 C-3499. pipe, it indicates a head gasket leak, cracked block,
(2) Dip the pressure cap in water and install the or cracked head.
cap on the tester adapter.
(3) Apply pressure to the cap. If the pressure cap 1 1. ENGINE WATER TEMPERATURE GAUGE
fails to hold pressure within a range of 12 to 15 psi,
replace with a new tested cap. (Air conditioned For Removal, Installation and Testing procedures
vehicles caps should test between 15 and 16 psi.) of the water temperature sending and receiving
units, refer to Group 8, Electrical system, “Gauges”.
10. PRESSURE TESTING THE C O O L I N G
SYSTEM
(1) For testing purposes only, fill the radiator to
within 342 inch of the filler neck.
7PRESSURE CAP k
Fig. 10-Testing the Prerwre Cap Fig. 1 1-Pressure Testing the Cooling System
COOLING SYSTEM 7-11
ACCESSORY BELT DRIVES

12. PROPER BELT TENSION (2) Retighten all belts at the 2 month service
inspection.
The satisfactory performance of the belt driven
accessories depends on the maintenance of the (3) Measure all belts by the deflection method at
proper belt tension. If the specified tensions are not servicing and retighten if needed.
maintained, belt slippage may cause engine over- (4) The new belt tension specifications should be
heating, lack of power steering assist, loss in air used on all belt replacements, and the above pro-
conditioning capacity, reduced alternator charging cedure followed thereafter.
rates, and greatly reduced belt life. To avoid any There are two methods by which belt tensions
such adverse effects, the following service procedure can be properly established.
should be followed:
(1) Retighten all belts to the specified used belt 13. BELT DEFLECTION METHOD
tension at the new vehicle preparation. The belts may be tensioned by measuring the
60x2346
Fig. 12-Belt Deflection Locations

7-12 COOLING SYSTEM
deflection of the belt at the mid-point between two 14. TORQUE METHOD
pulleys under a five-pound push or pull. A small The alternator and power steering pump belts
spring scale can be used to establish the five-pound may be tightened to the specified tension, by the use
load. See Figure 12 for correct locations at which of a torque wrench. (Refer to Belt Tension Speci-
to measure deflection. fications.) The alternator belts are adjusted by using
This method should be used only when it is not Tool C-3841along with a torque wrench.
possible to use the torque method, as it is a less The power steering belts are adjusted by inserting
accurate substitute. To tension the belts by the the square shank of the torque wrench into the
deflection method, loosen all the mounting bolts hole provided in the pump bracket.
and use a bar to apply tension to the belts being To tighten the belts by the torque method, loosen
careful not to damage the accessory. Tighten the all the mounting bolts, then apply the specified
mounting bolts and measure the deflection. (See torque to the accessory, as shown in the Specifica-
Belt Tension Specifications.) It may be necessary to tions. Tighten all the mounting bolts while the torque
repeat this procedure several times to establish the is applied to the accessory.
correct tension. Other belts may also be tightened by this method
if the adjusting bracket has a square hole. If it is not
Any belt that has operated for a minimum of a possible to use the torque wrench, because of clear-
half-hour is considered to be “used”. ance, use an extension.
SERVICE DIAGNOSIS
~
Loose hose clamp. (a) Replace the hose clamp.

Hose leaking. (b) Replace the hose.
Leaking radiator. (c) Repair or replace the radiator as
necessary.
Worn or damaged water pump (d) Replace the water pump seal.
seal.
Loose core hole plug. (e) Install new core hole plug.
Damaged gasket, or dry gasket, (f) Replace gaskets as necessary.
if engine has been stored.
Cylinder head bolts loose, or (8) Replace the cylinder head gasket and
tightened unevenly. torque head in correct sequence.
Leak a t heater connection. (h) Clean the heater connections and replace
the hoses and clamps if necessary.
Leak a t water temperature (i) Tighten the water temperature sending
sending unit. unit.
Leak at water pump attaching (j) Tighten the water pump attaching bolts
bo1t. 30 foot-pounds torque.
Leak at exhaust manifold stud. (k) Seal and re-drive the stud.
Cracked thermostat housing. (1) Replace the thermostat housing.
Dented radiator inlet or outlet (m) Straighten the radiator inlet or outlet
tube. tube as necessary.
Leaking heater core. (n) Repair or replace the heater core.
Cracked or porous water pump ( 0 ) Replace the water pump assembly.
housing.
Warped or cracked cylinder (p) Replace the cylinder head.
head.
Cracked cylinder block. (q) Replace the cylinder block.
Sand holes or porous condition (r) Replace the cylinder block or cylinder
in block or head. head as necessary.
Faulty pressure cap. (9) Replace pressure cap.
Loose or stripped oil cooler (t) Tighten or replace as necessary.
fittings.
COOLING SYSTEM 7-13
SERVICE DIAGNOSIS- ( Continued 1
Condition Possible Cause Comction
Internal Leakage (4 Faulty head gasket. (a) Install a new head gasket.
(b) Refer to causes (f), (g), (P), (s), (b) Refer to corrections (f), (g), (p), (q), (r)
(r) and (t)listed under External and (t) listed under External Leakage.
Leakage.
Crack in head into valve (c) Pressure test cooling system, replace the
compartment . cylinder head.
Cracked valve port. (d) Pressure test cooling system, replace the
cylinder head.
Crack in block into push rod (e) Pressure test cooling system, replace the
compartment. cylinder block.
Cracked cylinder wall. (f) Pressure test cooling system, replace the
cylinder block.
Leaking oil cooler. (g) Repair or replace the oil cooler.
Low coolant level. (a) Fill radiator to correct level.

Collapsed radiator hose. (A (b) Replace the hose and spring.
bottom hose with faulty spring
may collapse only at medium or
high engine speeds.)
Fan belt glazed, oil soaked, or (c) Tighten or replace the fan belt as
loose. necessary.
Air leak through bottom hose. (d) Reposition hose clamps or replace
the hose.
Faulty thermostat. (e) Replace the thermostat.
Water pump impeller broken (f) Replace the water pump impeller
or loose on shaft. assembly.
Restricted radiator core water (8) Flush the radiator thoroughly.
passages.
Restricted engine water jacket. (h) Flush the engine cooling system
thoroughly.
Overheating orApparent(a) Low coolant level. (a) Fill radiator to proper level.
Overheating (refer t o
Causes listed under (b) Blocked radiator air passages. (b) Blow out the radiator air passages.
“Poor Circulation”)
(c) Incorrect ignition timing. (c) Time the engine ignition system.
(d) Low engine oil level. (d) Add engine oil to the correct level.
(e) Incorrect valve timing. (e) Correct the engine valve timing.
(f) Inaccurate temperature gauge. (f) Replace the temperature gauge.
(g) Restricted overflow tube. (g) Remove restriction from the overflow
tube.
Faulty radiator pressure cap or (h) Replace the radiator cap.
seat.
Frozen heat control valve. (i) Free up the manifold heat control valve.
Dragging brakes. (j) Adjust the brakes.
Excessive engine idling. (k) Stop engine.
Frozen coolant. (1) Thaw out cooling system, add antifreeze
as required.
(m) Faulty fan drive unit. (m) Replace the fan drive unit.
(n) Faulty temperature sendingunit. (n) Replace the sending unit.
7-14 COOLING SYSTEM
SERVICE DIAGNOSIS
Overflow Loss Refer to causes listed under (a) Refer to corrections under “Poor
“Poor Circulation and Circulation and Overheating”.
Overheating”.
Overfilling. (b) Adjust coolant to the correct level.
Coolant foaming due to (c) Flush the radiator and add MoPar
insufficient corrosion inhibitor. antifreeze or rust inhibitor as required.
Air leak at bottom radiator hose. (d) Reposition hose clampsor replace the hose.
Blown head gasket. (e) Replace the head gasket.
Corrosion Use of water containing large (a) Use only clean soft water.
concentration of lime and
minerals.
Low coolant level. (b) Fill the cooling system to the correct level.
Insufficient corrosion inhibitor. (c) Use MoPar antifreeze or rust inhibitor
as required.
Use of antifreeze for extended (d) Drain cooling system and replace with
length of time. new antifreeze.
Failure to use corrosion inhibitor (e) Flush radiator and refill with clean soft
in summer. water and rust inhibitor.
Air leak at bottom radiator hose. (f) Reposition hose clamps or replace the hose.
Temperature Too Faulty thermostat. (a) Replace the thermostat.
Low-Slow Engine
Warm Up Inaccurate temperature gauge. (b) Replace the temperature gauge.
Faulty temperature sendingunit. (c) Replace the sending unit.
Water P u m p Noisy Seal noisy. (a) Add 202 MoPar Water Pump Lube.
Bearing corroded. (b) Replace bearing seal and impeller.
ACCESSORY DRIVE BELTS

Insufficient Accessory Belt too loose. (a) Adjust belt tension.
O u t p u t Due t o Belt
Slippage Belt excessively glazed or worn. (b) Replace and tighten as specified.
Belt Squeal When Belts too loose. (a) Adjust belt tensions.
Accelerating Engine
Belts glazed. (b) Replace belts.
Belt Squeak a t Idle Belt too loose. (a) Adjust belt tension.
Dirt and paint imbedded in belt. (b) Replace belt.
Non-uniform belt. (c) Replace belt.
Misaligned pulleys. (d) Align accessories (file brackets or use
spacers as required).
Non-uniform groove or eccentric (e) Replace pulley.
pulley.
Belt Rolled Over in Broken cord in belt. (a) Replace belt.

Groove
Belts not matched (A/C). (b) Install matched belts.
Belt J u h p s Off Belt too loose. (a) Adjust belt tension.

Belts not matched (A/C). (b) Install matched belts.
Misaligned pulleys. (c) Align accessories.
ELECTRICAL SYSTEM 8- 1
GROUP 8
CONTENTS
PART 1-BATTERY
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 High Rate Discharge Test of Battery Capacity . . . . . . . 12
Specific Gravity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Battery Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . 11 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PART 2-STARTING MOTOR-DIRECT DRIVE
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replacing the Field Coils . . . . . . . . . . . . . . . . . . . . . . . . 20

Starting Motor Circuit Tests . . . . . . . . . . . . . . . . . . . . . . 16 Servicing the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starting Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . 16 Servicing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . 20
Testing the Starting Motor . . . . . . . . . . . . . . . . . . . . . . . 17 Starter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Adjusting Starter Drive Gear Clearance . . . . . . . . . . . . 21
Brushes and Springs Replacement . . . . . . . . . . . . . . . . . 18 Starter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Testing the Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Testing Field Coils for Ground . . . . . . . . . . . . . . . . . . . . 19
STARTING MOTOR-REDUCTION GEAR TYPE
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Testing the Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Testing Starter Resistance and Current Draw . . . . . . . . 21 Replacing the Field Coils . . . . . . . . . . . . . . . . . . . . . . . . 27
Starter Ground Circuit Test . . . . . . . . . . . . . . . . . . . . . . 23 Servicing the Bushings ........................... 27
Starting Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 23 Servicing the Starter Clutch Unit . . . . . . . . . . . . . . . . . . . 29
Testing the Starting Motor (Bench Test) . . . . . . . . . . . . . 23 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Replacement of Brushes and Springs . . . . . . . . . . . . . . . 27
PART 3-ALTERNATOR A N D VOLTAGE REGULATOR

Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Construction and Operation . . . . . . . . . . . . . . . . . . . . . . 34 Testing the Rectifiers with Tool C-3829 . . . . . . . . . . . . . 42
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Testing the Rectifiers without Tool C-3829 . . . . . . . . . . 43
Testing the Alternator System . . . . . . . . . . . . . . . . . . . . . 35 Replacing the Slip Rings......................... 44
Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-2 ELECTRICAL SYSTEM
ELECTRICAL CONT€NTS--. ( Continued 1
PART E l G N l T l O N SYSTEM
6 CYLINDER
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Distributor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Testing the Secondary Circuit., . . . . . . . . . . . . . . . . . . . 50 Testing Breaker Arm Spring Tension . . . . . . . . . . . . . . . . 56
Distributor Resistance Test ........................ 50 Distributor Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Idle R.P.M. Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Testing Distributor Advance ...................... 56
Distributor Point Dwell .......................... 51 Installing the Distributor ......................... 57
Dwell Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Distributor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Shaft and Bushing Wear Test ..................... 52
8 CYLINDER
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dwell Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Secondary Circuit Inspection. . . . . . . . . . . . . . . . . . . . . . 58 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Distributor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . 59 Distributor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Idle R.P.M. Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Distributor Point Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Dual Breaker Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PART 5-LIGHTING SYSTEM

Page Page
Aiming the Headlamps. . . . . . . . . . . . . . . . . . . . . . . . . . 69 Adjusting the Headlamps . . . . . . . . . . . . . . . . . . . . . . . . 71

Aimer Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Headlamp Sealed-Beam Replacement . . . . . . . . . . . . . 71
Compensating and Mounting the Aimers . . . . . . . . . . . . 70 Visual Headlamp Adjustment
Mounting and Adjusting the Aimers . . . . . . . . . . . . . . . . 70 (Without Aimers) Single Beam-Valiant . . . . . . . . 71
Measuring Headlamp Aim . . . . . . . . . . . . . . . . . . . . . . . 70 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
PART 6--lNSTRUMENTS--INDlCATORS
INSTRUMENTS
Page Page
Voltage Limiter . . . . . . ................... 74 Instrument Cluster-Valiant . . . . . . . . . . . . . . . . . . . . . . . 78
Fuel Level Indicating System . . . . . . . .......... 74 Printed Circuit Board Testing . . . . . . . . . .
Temperature Indicating System . . . . Cluster Components. . . . . . :. .................. '78
Oil Pressure Warning Lamp . . . . . . . . . . . . . . . . . . . . . . 77 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Instrument Cluster Bulb Replacement. . . . . . . . . . . . . . . 77 Circuit Breakers. .......................... 79
Instrument Cluster-Plymouth . . . . . . . ....... 77 . . . . . . . . . . . . . . . . . . 79
DIRECTIONAL INDICATORS
Page Page
Directional Indicator Switch-Plymouth . . . . . . . . . . . . . 80 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Directional Indicator Switch-Valiant . . . . . . . . . . . . . . . 82 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ELECTRICAL SYSTEM 8-3
ELECTRICAL CONTENTS ( Continued 1
PART 7-WINDSHIELD WIPERLHORNS

WINDSHIELD WIPERS
Page Page
Wiper Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Inspecting Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 88
Wiper Motor Park Switch Timing . . . . . . . . . . . . . . . . . . 86 Wiper Switch (Instrument Panel Mounted). . . . . . . . . . . 88
Wiper Parking Operation Test-Variable Speed . . . . . 86 End Play Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Parking Spring Lubrication-Variable Speed . . . . . . . . 86 Wiper Mcter Bench Testing . . . . . . . . . . . . . . . . . . . . . . 88
Wiper Motor-Plymouth . . . . . . . . . . . . . . . . . . . . . . . . . 87 Assembling Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . 89
Wiper Motor-Valiant . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Wiper Link Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Disassembly of Wiper Links . . . . . . . . . . . . . . . . . . . . . . 87 Replacing Wiper Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Wiper Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . 87 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
HORNS
Page Page
Testing Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Adjusting Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
PART 8-POWER EQUIPMENT

ELECTRIC WINDOW LIFTS---PLYMOUTH
Page Page
Wiring Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Quarter Glass Regulator (2 Door Hardtop) . . . . . . . . . 94

Motor (Except 2 Door Hardtop Quarter Window) . . . . 93 Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Window l i f t (Except 2 Door Hardtop Quarter
Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
POWER SEATS
Page Page
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Drive Unit and Solenoid Assembly . . . . . . . . . . . . . . . . . 98
Front Seat Assembly and Adjuster . . . . . . . . . . . . . . . . . 96 Slave Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Flexible Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Power Seat Wiring ............................. 99
Seat Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Service Diagnosis .............................. 99
PART 9-WIRING DIAGRAMS
Page Page
Engine Compartment Wiring-Valiant . . . . . . . . . . . . . . 102 Body Wiring (Except Station Wagon)-Plymouth . . . . . 108
Instrument Panel Wiring-Valiant . . . . . . . . . . . . . . . . . 103 Body Wiring (Station Wagon) Plymouth. . . . . . . . . . . . 109
Body Wiring (Except Station Wagon) Valiant . . . . . . . 104 Tail Gate Window l i f t Wiring-Plymouth, Valiant .... 109
Body Wiring (Stafion Wagon) .................... 104 Top Lift Switch Wiring-Plymouth, Valiant .......... 109
Engine Compartment Wiring-Plymouth . . . . . . . . . . . . 105 Electric Window l i f t Wiring-Plymouth ............. 110
Instrument Panel Wiring-Plymouth . . . . . . . . . . . . . . . . 106
SPECIFICATIONS
BATTERY
Model Usage w-1 w-1 VPI -VP2 VP-2 VP-2

Standard Standard Standard Standard Standard
With 170 With 225 With 225 With 361 With 383
Cu. In. Cu. In. Cu. In. Cu. In. Cu. In.
Engines Engines Engines Engines Engines
Capacity (Ampere Hours), . . . . . . . . . . . . . 38 48 48 59 70

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 12 12 12
Number of Plates Per Cell. . . . . . . . . . . . . 7 9 9 11 13
Ground Terminal. .................... Negative Negative Negative Negative Negative
Model Identification Number. . . . . . . . . . . M9HS-38 MB-24-48 MB-24-48 MB-24-59 MB-27-70
STARTING M O T O R
All Plymouth Models (Wl, with 170 Cu. In.)

*VP-l with 8 Cylinder Engines.
Starting Motor Type. . . . . . . . . . . . . . . . . . Direct Drive (Gear Reduction) (Gear Reduction)

Identification Number. . . . . . . . . . . . . . . . . 2095753 20951 50 2098500
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrysler Built Chrysler Built Chrysler Built
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 12
No. of Fields.. ...................... 4 (&Series) 4 (3 Series, 1 Shunt) 4 (4 Series)
No. of Poles.. ....................... 4 4 4
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4
Spring Tension. ...................... 32 to 48 Ounces 32 to 48 Ounces 32 to 48 Ounces
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overrunning Clutch Overrunning Clutch Overrunning Clutdr
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . .005" Minimum .010"-.035" .010"-.035"
Free-Running Test
Voltage . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11
Amperage. ..................... 78 90 90
Speed RPM . . . . . . . . . . . . . . . . . . . . . 3800 1925 to 2400 2950
lock-Resistance Test
Voltage ........................ 4 4 4
Amperage Draw. . . . . . . . . . . . . . . . . 350 400 to 450 340 to 420
Solenoid Switch
Pull-In Coil.. .................... 20.0 to 22.2 Amps. 14.4 to 16.0 Amps. 14.4 to 16.0 Amps.
@ 6.0 Volts @ 6.0 Volts @ 6.0 Volts
Hold-In Coil.. ................... 11.2 to 12.4 Amps. 11.5 to 12.6 Amps. 11.5 to 12.6 Amps.
@ 6.0 Volts @ 6.0 Volts @ 6.0 Volts
"Taxi and Police Use.

SPECIFICATIONS .
ALTERNATOR A N D VOLTAGE REGULATOR
ALTERNATOR
ALTERNATORS
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise at Drive End
Voltage. ................................................................... 12 Volt System
Current Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Controlled
Voltage Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limited by Voltage Regulator

Brushes (Field). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Condenser Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S O Microfarad plus or minus 20%

Field Current Draw-
Rotating Rotor by Hand @ 12 Volts. ........................................ 2.38 to 2.75 Maximum amperes
Current Output-
Valiant.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 plus or minus 3 amperes
Standard (Except Valiant). ................................................ 34.5 plus or minus 3 amperes
Special Equip., Heavy Duty and/or Air Conditioning

(Both Single and Double Pulleys). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 plus or minus 3 amperes
NOTE: Plus or minus three ampere tolerance i s provided to allow for temperature variation. Current output i s measured at1 250
engine RPM. and 15 volts. Voltage i s controlled by variable load across the battery such as a carbon pile.
ALTERNATOR VOLTAGE REGULATOR

Alternator Voltage
Regulator Identification Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2098300
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ground Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
Point Gap. ............................................................. .014 inch plus or minus .002 inch

Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .048 to .O52 inch nominal setting
Measure gap with gauge back of stop. Contacts close with .052 inch gauge installed. Contacts open with .048 inch gauge installed.
Temperature in Degrees 47°F. 70°F. 93°F. 117°F. 140°F. 163°F.
Minimum Setting. . . . . . . . . . . . . . . . . . . 13.8 to 13.7 to 13.6 to 13.5 to 13.4 to 13.3 to

Maximum Setting. . . . . . . . . . . . . . . . . . . 14.4 14.3 14.2 14.1 14.0 13.9
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SPECIFICATION& (Continued 1
IGNITION SYSTEM
Vehicle Model.. ........................................... VP-2 with 2 bbl. Carb. VP-2 with 2 bbl. Carb.
& Automatic Trans. & Manual Trans.
Engine Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 18 Cubic Inch 318 Cubic Inch

Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrysler Built Chrysler Built
Identification No.. ...................................... 2444259 2444258
Advance-Automatic (Distributor Degrees at

Distributor RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0"@ 330 to 570 O o @ 320 to 480
0 to 2"@ 570 0 to 2"@ 480
2 to 4"@ 800 4.5 to 6.5"@ 850
8 to 10" @ 2300 10.5 to 12.5" @ 2300
Advance-Vacuum (Distributor Degrees at

Inches of Mercury). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O o @ 8 to 10" O o @ 8 to 10"
5 to So@ 13" 5 to 8"@ 13"
9 to 12'@ 16" 9 to 12"@ 16"
Breaker Point Gap .................................. .o 14" to .o 19" .014" to .019"
Dwell Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28" to 33" 28" to 33"
Breaker Arm Spring Tension.. ............................ 17 to 20 oz. 17 to 20 oz.

Condenser Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 to .285 mfd. .25 to .285 mfd.
Shaft Side Play (New or Rebuilt). . . . . . . . . . . . . . . . . . . . . . . . . . .OOO to .003"* .OOO to .003"*

Shaft End Play (After Assembly). . . . . . . . . . . . . . . . . . . . . . . . . . .003 to .017" .003 to .017"
Rotation. . . . .................................. Clockwise Clockwise
Spark Plug Type. .................................. J-12Y Champion J-12Y Champion
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 MM-% Reach 14 MM-% Reach
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .O35" .O35"

Firing Order. . ....................................... 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2
Ignition Timing. . . . . . . . . . . .............................. 10" BTC 10" BTC

........................... ............... Chrysler Prestolite Chrysler Essex
Identification No.. . . . ............................. 2444242 200759 244424 1 67- 160-4
Primary Resistance @ 70-80" F.. ...... ............... 1.65 to 1.79 ohms 1.41 to 1.55 ohms
Secondary Resistance @ 70-80" F.. . . . . . . . . . . . . . . . . . . . . . . . 9400 to 11700 ohms 9200 to 10600 ohms
Ballast Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2095501
Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 0.6 ohms
Current Draw (Coil and Ballast Resistor in the Circuit)

Engine Stopped. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 amperes
Engine Idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 amperes
*Service wear tolerance should not exceed .006 inch.

8-8 ELECTRlCAL SYSTEM
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SPECIFICATIONS--- ( Continued 1
BULB CHART
BULB VALIANT PLYMOUTH
Sealed Beam-Lo-Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002

Sealed Beam-Hi-Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 400 1
Single Beam 2 filament.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 6012
Tail, Stop & Turn Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034 1034
Park & Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1034 1034
Back-up lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1073 1073
license Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 67
Trunk and/or Under Hood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004 1004
Glove Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1891 1891
Radio.. ............................................................. 53 x 1892-AM
57-FM
Transmission Control Push Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 x (a)
Handbrake Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 57
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004 1004
Map Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 90
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... (a)
Heater and/or A.C. Control P/B. . ....................................... - (a)
Turn Signal Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............. 57 57
High Beamlndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 57
Oil Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 57
nstrument Cluster Illumination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 57
(a) Included in instrument cluster lighting.
FUSE CHART
Circuit Fuse Type Ampere Rating
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 7.5 AMP

Heater or Air Conditioning.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 20 AMP
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 15 AMP
Cigar Lighter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 20 AMP
Toil,Stop,Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 20 AMP
Instrument Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AG/AGC 2 AMP
CIRCUIT BREAKER CHART
Circuit Breaker Circuit Breaker Location Ampere Rating
Windshield Wiper (Variable Speed) Back of Wiper Switch. . . . . . . . . . . . . . . . . . . . . . . . 6 AM?

Windshield Wiper (Single Speed) Integral with Wiper Switch. . . . . . . . . . . . . . . . . . . . 5 AMP
Lighting System Integral with Headlamp Switch. . . . . . . . . . . . . . . . . 15 AMP
Elec. Window Lifts, Power Seats, Top Lift* Behind left front kick panel. . . . . . . . . . . . . . . . . . . . 30 AMP
~~
*Electric Window Lifts and Power Seats-Plymouth only.

SPECIAL TOOLS
ELECTRICAL
C-707. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Point Gap Indicating Tool
C-744. ........................................... .Test Lamp
C-770. ............................................ Commutator Undercutter
C-828. ........................................... .Tool Kit-Generator Regulator
C-3379. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Belt Gauge Tool
C-3296. .......................................... .High Voltage Tester
C-3769. ........................................... Installer-Drive End Housing Bearing
C-3770-A. ........................................ Remover-Rectifier End Housing Bearing
C-3744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller-Distributor Shaft Bushings
C-3829. ........................................... Tester-Alternator-Diode
C-3855. .......................................... .Holders Armature Brush Set
C-3900. .......................................... .Slip Ring Installer
C-392 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer and Locator-Alternator Bearing Grease Retainer
C-3925 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support Alternator Rectifier End Shield Supporting-

End Shield Bearing Removing and Installing
C-3928 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remover and Installer-Alternator Rectifier Diodes
c-3934. . . . . . . . . . . . . . . . . . . . . . .Pulley Removing Tool (Power Steering Pump Pulley Removing Tool)
C-3944 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover and Installer-Starter Housing Bushings
SP-3375. ....................................... Ada pters-Bea ring Remover
SP-338 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer-Rectifier End Housing Bearing
MT-379 . . . . . . . . . . . . . . . . . . . . . . . .
MTU-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Scale
MT-3 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Circuit Voltage Tester
MX-75.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Terminal Cleaner Tool
C-304 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Drive Shaft Bushing-Remover and Installer
C-3428. .......................................... .Steering Wheel Puller
C-3674. .......................................... .Headlamp Aimer Kit
C-3826. .......................................... .Gauge Tester

BATTERY 8-11
PART 1
BATTERY
1. BATTERY VISUAL INSPECTION securely. Coat all connections with light mineral
(11 Protect the fender r>aint finish with fender
grease or petrolatum.
\ I
covers. (9) If the electrolyte level is low, fill to recommend-

ed level with mineral-free water.
(2) Inspect the battery carrier and fender side panel
for damage caused by loss of acid from the battery.
2. SPECIF,C TEST
(3) Remove the battery hold-down clamp and clean A hydrometer is used to measure the specific grav-
the top of the battery with a solution of clean warm ity of the electrolyte in the battery cells. This gives an
water and baking soda. Scrub areas with a stiff bristle indication of how much unused sulphuric acid re-
brush being careful not to scatter corrosion residue mains in the solution. Hydrometer floats are cali-
with the bristles. Finally wipe off with a cloth moist- brated to indicate correctly only at one fixed tem-
ened with ammonia or a baking soda and water peratu re.
solution.
The specific gravity of the battery electrolyte varies
CAUTION: Keep cleaning solution out of bat- not only with the quantity of acid in solution but also
tery cells to eliminate weakening the electrolyte. with temperature. Draw electrolyte in and out of the
(4) Inspect the cable. Replace damaged or frayed hydrometer barrel several times to bring the tem-
cables. perature of the hydrometer float to that of the acid
in the cell and then measure the electrolyte tempera-
(5) Inspect the terminal posts to see that they are ture in the cell. The temperature correction amounts
not deformed nor broken. Clean the tapered battery to .004 specific gravity points for each 10 degrees
terminals and the inside surfaces of the clamp ter- Fahrenheit change in temperature.
minals with the terminal cleaning tool, as shown in
Figures 1and 2. The liquid level of the battery cell should be at
normal height and the electrolyte should be thor-
(6) Examine the battery case for cracks and top of oughly mixed with any battery water which may
battery, and raised cells. Inspect sealing compound have just been added by charging the battery before
for leaks. Reseal as necessary. taking any hydrometer readings. See “Adjustment
(7) Tighten the battery hold-down screw nuts to of Acid Gravity”.
3 foot-pounds torque. A fully charged battery has a specific gravity read-
(8) Observe the polarity of the terminals of bat- ing of 1.255 to 1.275 (all batteries for use in temper-
tery to be sure the battery is not reversed and con-
ate climates).
nect the cable clamps to the battery posts and tighten If the battery specific gravity is below 1.220, re-
Fig. 1-Cleaning the Inside of Cable Clamp Fig. 2-Cleaning the Outside of Battery Post
8-1 2 BATTERY
off and wait several minutes before t a k i n g another

reading.
To make a battery test, contact the meter prods
(Tool MT-379) to the proper cell 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 with buried link for each cell reading.
The individual cell readings should not vary more
than .05 volt between any two cells. A battery vary-
ing more than .05 volt between any two cells should
be recharged and “high rate discharge tester” should
be used to test the battery before discarding the bat-
tery as unsuitable for use.
NOTE: T h e cell connectors are not exposed,
therefore it will be necessary t o pierce t h e cell covers
t o contact t h e connector strips to obtain individual
60x837 cell voltages. A f t e r making tests, the cell covers
Fig. L H i g h Rate Discharge Test should be sealed.
CAUTION: Do not use an open flame near t h e

charge the battery to a full charge, then proceed with battery.
the battery “Voltage Tests” and “Battery Capacity
Tests”.
4. HIGH RATE DISCHARGE TEST OF
3. VOLTAGE TESTS (Open Circuit 1 BATTERY CAPACITY
NOTE: Freshly charged batteries may have a Satisfactory capacity tests can be made only when
“surface charge” which causes high and inaccurate battery equals or exceeds 1.220 specific gravity at
readings unless properly dissipated. If battery is in 80 degrees Fahrenheit. If reading is below 1.220,
t h e vehicle, turn t h e headlights o n f o r one t o three the battery should be slow charged until fully charged
minutes to remove surface charge. Then turn lights in order to secure proper test results.
60x8 38
Fig. A T h r e e Minute Charge Test
BATTERY 8-13
(1) Turn the control knob of the battery starter

tester to the OFF position.
(2) Turn the voltmeter selector switch to the 16
volt position (test units so equipped).
(3) Connect the test ammeter and voltmeter posi-
tive leads to the battery positive terminal and am-
meter and voltmeter negative leads to the battery
negative terminal (Fig. 3).
NOTE: The voltmeter clips must contact the bat-
tery posts or cable clamps and not the ammeter clips.
(4) Turn the control knob clockwise until ammeter
reading is equal to three times the ampere hour rat-
ing of the battery. 60x839
(5) Maintain the load for 15 seconds, voltmeter Fig. 5-Fast Charging the Battery
should read 9.5 volts or more, which will indicate
that the battery has good output capacity. and slow-charged until specific gravity reaches 1.260
(6) Turn the control knob to the OFF position. (See “Slowing Charging”).
If the specific gravity remains constant after test-
5. C H A R G I N G THE BATTERY ing the battery at one hour intervals for three hours,
the battery is at its highest state of charge.
If the voltage in “The High Rate Discharge Test”
was under 9.5 volt, the battery should be test charged (7) Make another capacity test. If the capacity
to determine whether the battery can be satisfac- test does not meet specifications, replace the battery.
torily charged. NOTE: A slow charge is preferable to bring the
battery up to a full charge.
Three Minute Charge Test (Fig. 41 Safe slow charging rates are determined by allow-
NOTE: This test should not be used if battery ing one ampere per positive plate per cell. The proper
temperature is below 60 degrees F. slow charging rate would be 3 amperes for a 38 am-
(1) Connect the positive ( + ) charger lead to the pere hour battery, 4 amperes for a 48 ampere hour,
battery positive terminal and the negative (-) charg- 5 amperes for a 59 ampere hour battery and 6 am-
er lead to the battery negative terminal. peres for a 70 ampere hour battery.
IMPORTANT: Be sure of correct battery polar-
Fust Charging the Buttery (Fig. 51
ity when charging the batteries.
If adequate time for a slow charge is not available,
(2) Trip the charger power switch to the ON a high rate (FAST) charge is permissible and will
position. Turn the charger timer switch past “three give a sufficient charge in one hour, enabling the
minutes” then back to “three minutes”. battery and alternator to continue to carry the elec-
(3) Adjust the charge switch to the highest pos- trical load.
sible rate not exceeding 40 amperes. Connect the positive ( + ) battery charger lead to
(4) When the timer switch cuts off at end of 3 the battery positive terminal and the negative (-)
minutes, turn the timer switch back to fast charge. battery charger lead to the battery negative terminal.
(5) Use the 4 volt scale of the battery starter CAUTION: The battery can be damaged beyond
tester voltmeter (test units so equipped) and quickly repair unless the following precautions are taken:
measure the voltage across each cell while the battery
(1) The battery electrolyte temperature must
is being fast charged. A faulty cell or cells will be
NEVER exceed 125 degrees Fahrenheit.
detected by a cell voltage variation of more than .1
volt. If this temperature is reached, the battery should
(6) If the cell voltages are even within .1 volt, use
be cooled by reducing the charging rate or remove
the battery from the circuit.
16 volt scale of the battery starter tester (test units
so equipped) and measure the total voltage of the (2) As the batteries approach full charge the elec-
battery posts while the battery is being fast charged. trolyte in each cell will begin to gas or bubble. Ex-
If the total voltage during the charge exceeds 15.5 cessive gassing must not be allowed.
volts, the battery is sulphated and should be cycled (3) Do not fast charge longer than one hour.
8-1 4 BATTERY
Remember to use the temperature correction when of the batteries an charge. A spark w i l l occur when
when checking specific gravity. the live circuit i s broken. Keep a l l opon flames away
If the battery does not show a significant change f r o m the battery.
in the specific gravity after one hour of “FAST” Slow Charging Batteries to Remove
charge, the slow charge method should be used. Sulphat ion
NOTE: The manufacturers of high rate charging To condition a battery that is sulphated, charge
equipment generally outline the precautions and the battery for a minimum of 24 hours at a maximum
some models have thermostatic temperature l i m i t i n g charging rate of (4) amperes. As the battery approach-
and time l i m i t i n g controls. es full charge, test the specific gravity at hourly in-
WARNING: When batteries are being charged, tervals. With no rise in specific gravity for three
a n explosive gas mixture forms beneath the cover of successive readings, the battery is charged to its
each cell. Do not break live circuits a t the terminals peak capacity.
SERVICE DIAGNOSIS
BATTERY TESTING CHART
Hydrometer l e s t State of Charge or

(corrected to 80” F.) Battery Condition Correction
Less t h a n 1.220 Battery low. Recharge the battery. Give a high rate discharge test
SP. G R . for capacity. If the cells test O.K., recharge and
adjust the gravity of all cells uniformly. Test the
voltage regulator setting. Thoroughly test the elec-
trical system for short circuits, loose connections,
corroded terminals, etc.
Cells s h o w m o r e Short circuit in low cell. Try to recharge the battery. See “Charging the
t h a n 25 p o i n t s (.025 Loss of electrolyte by Battery”. Test battery for capacity. Install a new
Specific G r a v i t y ) leakage or excessive battery if necessary.
variation. overcharge.
Improper addition of acid.
Natural or premature failure.
Cracked case.
State of Charge or
Open Circuit Voltage l e s t Battery Condition Correction
Cells s h o w i n g m o r e Satisfactory. No correction required if the variation among cells is

t h a n 1.220 specific not over .05 volt. If the variation is more than .05
gravity. volt, recharge. Give high rate discharge capacity
test. If cells test O.K., adjust gravity of all cells
uniformly.
Cells s h o w i n g less Questionable. Recharge the battery. Give high rate discharge test
t h a n 1.220 specific for capacity. If the cells test O.K., recharge. Test
gravity, b u t n o t the voltage regulator setting. Thoroughly test the
m o r e t h a n .05 v o l t electrical system for short circuits, loose connections,
variation. corroded terminals, etc.
Cells s h o w i n g m o r e Short circuit in low cell. Recharge battery. See “Charging the Battery”.
t h a n .05 v o l t Loss of electrolyte by leakage
variation. or excessive overcharge.
Improper addition of acid or
“Dopes”. Cracked Case.
~~~ ~ ~ ~
BATTERY 8-15
SERVICE D I A G N O S I b ( Continued1
~~ ~~ ~ ~ _ _ ~ _ _
Natural or premature failure

Cranking Test Possible Cause Correction
If t h e voltage drop is Poor contact between Locate the high resistance: repair or replace as necessary.
more t h a n 0.3 volts the cable terminal and the
(3/10) between t h e vehicle frame or between the
starting motor cable cable clamp terminal and the
and t h e vehicle frame battery post or the starter
while cranking switch contacts. Frayed,
look for: corroded or broken cable.
While operating t h e Faulty cell or cells. Compare the voltage readings with the hydrometer
starting motor, igni- reading-low voltage is usually accompanied by low
t i o n “OFF” check gravity. Try to recharge the battery. See “Charging
t h e voltage of all the Battery”.
cells. If t h e voltage
varies more t h a n
0.15 volt between
cellsb look for:
ARMATURE
BRUSHSET- -
BEARING -
HEAD -___
WASHER
BRUSH SPRING
FRAME 61 x 18
Fig. 1-Starting Motor (Disassembled View) (Typical)
8-1 6 STARTING MOTOR-DIRECT DRIVE
PART 2
STARTING M O T O R (DIRECT DRIVE)

The Chrysler built starting motor (Fig. 1) is a 12- mounted on the starting motor.
volt, four coil assembly. The starter drive is an over- The brush holders are riveted to a separate brush
running clutch type with a solenoid shift type switch plate and are not serviced individually.
SERVICE PROCEDURES
1. STARTING M O T O R CIRCUIT TESTS that the last part eliminated in the test is at fault.
Insulated Circuit Test
Maximum allowable voltage loss is as follows:
Battery insulated cable .2 volt
(1) Test the battery electrolyte specific gravity. Solenoid Switch .1 volt
The specific gravity should be 1.220 or above. If the Each connection .o volt
battery specific gravity is below 1.220, recharge the Replace the faulty cables. Clean and tighten all
battery to a full charge before proceeding with the connections.
test.
Starter Ground Circuit Test
(2) Turn the voltmeter selector switch to the 4
volt position. (1) Connect the voltmeter positive lead to the
starter housing and the negative voltmeter lead to
(3) Disconnect the ignition coil secondary cable. the battery negative post.
(4) Connect the voltmeter positive lead to the bat- (2) Crank the engine with a remote control start-
tery positive post and the voltmeter negative lead to er switch and observe the voltmeter reading. The
the solenoid connector which connects to the starter voltmeter reading should not exceed .2 volt. A read-
field coils. ing of .2 volt or less indicates voltage loss in the
NOTE: The voltmeter will read off the scale to ground cable and connections are normal. If the volt-
the right until the starter is actuated. meter reading is more than .2 volt, it indicates ex-
cessive voltage loss in the starter ground circuit.
(5) Connect the remote control starter switch to the
Make the following tests to isolate the point of ex-
battery and the solenoid terminal of the starter relay.
cessive voltage loss. Repeat the test at each con-
(6) Crank the engine with the remote control nection.
starter switch and observe the voltmeter reading.
(a) Starter drive housing.
The voltmeter reading should not exceed .3 volt. A
voltmeter reading of .3 volt or less indicates the volt- (b) Cable terminal at the engine.
age drop is normal in the cables, starter relay switch, (c) Cable clamp at the battery.
solenoid switch and connections between the battery A small’change will occur each time a normal por-
and the starting motor are normal. See “Starter tion of the circuit is removed from the test. A defi-
Ground Circuit Test”. nite change in the voltmeter reading indicates that
If the voltmeter reading is more than .3 volt, it the last part eliminated in the test is at fault.
indicates high resistance in the starter insulated cir- Maximum allowable voltage loss is as follows:
cuit. Make the following test to isolate the point of Battery ground cable .2 volt
excessive voltage loss. Engine ground circuit .1 volt
(7) Remove the voltmeter lead from the solenoid Each connection .o volt
connector and connect to the following points, re-
peating the test at each connection. The starter ter- 2. STARTING MOTOR
minal of the solenoid, battery terminal of the sole-
noid, battery cable terminal at the solenoid, starter Removal
relay and the cable clamp at the battery. (1) Disconnect the ground cable at the battery.
(8) A small change will occur each time a normal (2) Remove the starter cable at the starter.
portion of the circuit is removed from the test. A (3) Disconnect the solenoid lead wire from the
definite change in the voltmeter reading indicates solenoid.
STARTING MOTOR-DIRECT DRIVE 8-1 7
(4) Remove the bolts attaching the starting motor

to the flywheel housing and remove the starting mo-
tor.
3. TESTING THE STARTING M O T O R

(Bench Test)
free Running Test
(1) Place the starter in a vise equipped with soft
jaws and connect a fully-charged, 12 volt battery to
the starter.
(2) Connect a test ammeter (100 amperes scale)
and carbon pile rheostat in series with the battery
positive post and the starter terminal.
Fig. 3-Field Coil leads Disconnected from the
(3) Connect the voltmeter (15 volt scale) across the Solenqid Connector
starter.
(4) Rotate the carbon pile to the full-resistance (3) With the applied battery voltage adjusted to
position. 4 volts, the stall torque should be 8.5 foot-pounds
minimum with a current draw of 350 amperes.
(5) Connect the battery cable from the battery neg-
ative post to the starter frame.
4. STARTER DllSASSEMBLY (Fig. 1 1
(6)Adjust the rheostat until the battery voltage (1) Remove the through bolts and tap the com-
shown on the voltmeter reads 11volts. mutator end head from the field frame.
The current draw should be 78 amperes maximum
at 3800 minimum rpm.
Stall Test
(1) Install the starting motor in the test bench.
(2) Follow the instructions of the test equipment
manufacturer and check the stall torque of the starter
against the following specifications.
Fig. &Removing the Starter Solenoid
Fig. 2-Removing the Bkush Ring Fig. 5-Removing the Shifter Fork Pivot Pin
8-1 8 STARTING MOTOR-DIRECT DRIVE
h
the stop retainer toward the clutch pinion gear to
expose the snap ring and remove the snap ring.
(11) Slide the over-running clutch drive from the
/SHIFTER FORK armature shaft.
(12) If it is necessary to replace the field coils, re-
move the ground brushes terminal attaching screw
and raise the brushes with the terminal and shunt
wire up and away from the field frame (Fig. 7). Re-
move the pole shoe screws with a special pole shoe
impact screwdriver, Tool C-3475.
Cleunlng und lnspectlon
\‘ ‘STOP RETAINER
SNAP RING
SPACER WASHER 61 x23
(1) Do not immerse the parts in a cleaning sol-
vent. Immersing the field frame and coil assembly
and/or armature will damage the insulation. Wipe
Fig. -Removing or Installing the Shifter Fork these parts with cloth only.
(2) Do not immerse the drive unit in a cleaning sol-
(2) R move the thrust washers from the armature
shaft. vent. The drive clutch is pre-lubricated at the factory
and solvent will wash lubrication from the clutch.
(3) Lift the brush holder springs and remove the
(3) The drive unit may be cleaned with a brush
brushes from the brush holders.
moistened with cleaning solvent and wiped dry with
(4) Remove the brush plate (Fig. 2). a cloth.
(5) Disconnect the field coil leads at the solenoid
connector (Fig. 3). 5. BRUSHES AND S P R I N G 6
. (6) Remove the solenoid attaching screws and re- REPLACEMENT
move the solenoid and boot assembly (Fig. 4). (1) The brushes that are worn more than ?h the
(7) Drive out the over-running clutch shift fork length of the new brush, or are oil-soaked, should be
pivot pin (Fig. 5). replaced. The brushes and springs can be replaced
(8) Remove the drive end pinion housing and after removing the commutator end head and the
spacer washer. brush plate.
(9) Note the position of the shifting fork on the (2) Lift the brushes; disengage the brushes from
starter and remove the shifter fork (Fig. 6). the brush holders and remove the brush plate.
(10)Slide the over-running clutch pinion gear (3) Disconnect the field lead wires at the solenoid
toward the commutator end of the armature, drive connector (Fig. 3).
(4) Remove the screw attaching the ground brush
/ + d
terminal to the field frame and raise the brushes and
GROUND BRUSHES “h
TERMINAL
terminal up and away from the field frame (Fig. 7).
(5) Remove the field terminal plastic covering and
remove the old brushes. Use side cutters to break the
weld by rolling the brush wire off the terminal.
(6) Drill a .174 to .184 inch hole, 3/ls inch from the
top of the field coil terminal. Use an inch drill.
CAUTION. Do not damage the field coil during
the drilling operation.
(7) Position the new brushes and terminal and in-
stall the brush terminal retaining screw.
(8) The brush springs can be removed by spread-
w ing the retainers and disengaging the springs from
61x24 the retainer legs.
Fig. 7-Removing or Installing the Ground (9) Measure the brush spring tension with a spring
Brushes Terminal scale hooked under the spring near the end. Pull the
STARTING MOTOR-DIRECT DRIVE 8-1 9
scale on a line parallel to the edge of the brush and

take a reading just as the spring end leaves the brush.
The spring tension should be 32 to 48 ounces. Replace
the springs that do not meet specifications.
6. TESTING THE ARMATURE

Testing the Armature for Short Circuit
Place the armature in the growler (Fig. 8) and hold
a thin steel blade parallel to the core and just above
it, while slowly rotating the armature in the growler.
A shorted armature will cause the blade to vibrate
and be attracted to the core. Replace a shorted arma-
ture.
Testing Armature for Ground
Touch the armature shaft and end of a commutator Fig. 9-Testing Armature for Ground
bar with a pair of test lamp test prods (Fig. 9). If the
lamp lights, it indicates a grounded armature. Re- (3) Disconnect the field lead wires at the solenoid
place a grounded armature. connector and separate the field leads to make sure
they do not touch the solenoid connector (Fig. 3).
Testing Commutator Runout,
Refacing and Undercutting (4) Remove the ground brushes attaching screw
and raise the brushes with the terminal and shunt
Place the armature in a pair of “V” blocks and
wire up and away from the field frame (Fig. 7).
measure the runout with a dial indicator. Test both
the shaft and the commutator. A bent shaft requires (5) Touch one probe of the test lamp to the series
replacement of the armature. When the commutator field coil lead and the other probe to the field frame
runout exceeds ,003 inch, the commutator should be (Fig. 10). The lamp should not light.
refaced. Remove only sufficient metal to provide a (6) Touch one probe to the shunt field coil lead
smooth, even surface. and the other probe to the field frame (Fig. 11).
If the lamp lights in either test steps ( 5 ) or (6),
7. TESTING THE FIELD COILS the field coils are grounded. If the field coils are
FOR G R O U N D grounded, test each coil separately after unsoldering
(1) Remove the through bolts and remove the com- the connector wires. Replace the grounded field coils.
mutator end frame. (7) Touch each of the brush holders with one test
(2) Remove the brushes from the brush holders probe, while holding the other test probe against the
and remove the brush ring (Fig.2). brush ring. Two brush holders that are 180 degrees
Fig. 8-Testing A’rmature for Short Fig. 1LTesting the Series Coil for Ground
8-20 STARTING MOTOR-DIRECT DRIVE
9. SERVICING THE BRUSHES

Inspect the armature shaft bearing surfaces and
bushings for wear by placing the armature core in
a vise equipped with soft jaws. Do not squeeze tightly.
Try the commutator end frame, the drive end frame,
and armature support bushings for wear by placing
them on shafts and inspecting for side play. Replace
the commutator end frame and bushing assembly if
the bushing is worn, also, replace the drive end bush-
ing if it is worn. The bushing should be well soaked
in SAE 30W engine oil before it is installed.
10. SERVICING THE DRIVE U N I T

Place the drive unit on the shaft and, while holding
the armature, rotate the drive pinion. The drive
pinion should rotate smoothly in one direction (not
Fig. 1 1-Testing the Shunt Coil for Ground
necessarily easily), but should not rotate in the op-
apart should cause the test lamp to light as they are posite direction. If the drive unit does not function
intentionally grounded. The other two brush holders properly, or the pinion is worn or burred, replace
(Fig. 12) should not cause the lamp to light when the drive unit.
tested, as they are insulated. If the insulated brush
holders cause the lamp to light when tested, it indi- 1 1. STARTER ASSEMBLY (Fig. 1 1
cates that the brush holders on the brush ring are (1) Lubricate the armature shaft and splines with
grounded. Replace the brush ring assembly if the S A E 1OW oil or 30W rust preventive oil.
brush holders are grounded. (2) Install the starter drive, stop collar (retainer),
the lock ring and the spacer washer.
8. REPLACING THE FIELD COILS (3) Install the shifter fork over the starter drive
A pole shoe impact screwdriver Tool C-3475 should spring retainer washer with the narrow leg of fork
be used to remove and install the field coils to pre- toward commutator (Fig. 6). This is important, if the
vent damage to the pole shoe screws and for proper fork is not properly positioned, the starter gear travel
tightening. The pole shoes that are loose and not will be restricted causing a lockup in the clutch
properly seated may cause the armature core to rub mechanism.
the pole shoes. This will decrease the starter effi- (4) Install the drive end (pinion) housing on the
ciency and damage the armature core. armature shaft, indexing the shifting fork with the
slot in the drive end of the housing.
(5) Install the shifter fork pivot pin (Fig. 5).
INSULATED BRUSH (6) Install the armature with the clutch drive,
shifter fork, and pinion housing; slide the armature
into the field frame until the pinion housing indexes
with the slot in the field frame.
(7) Install the solenoid and boot assembly (Fig. 4).
Tighten bolts to 60 to 70 inch-pounds torque.
(8) Install the ground brushes (Fig. 7).
(9) Connect the field coil leads at the solenoid
connector (Fig. 3).
(10)Install the brush holder ring (Fig. 2) indexing
the tang of the ring in the hole of the field frame.
(11) Position the brushes in the brush holders. Be
61x27 sure the field coil lead wires are properly enclosed
Fig. 12-Testing the Insulated Brush Holder for behind the brush holder ring and that they do not
Ground interfere with the brush operation,
STARTING MOTOR-REDUCTION GEAR 8-2 1
NOTE: Place a wedge or screwdriver between
/
the bottom of the solenoid and the starter frame to
eliminate all deflection in the solenoid when making
the pinion clearance check. (Fig. 13).
(2) Push in on the solenoid plunger link (Fig. 13)
(NOT THE FORK LEVER) until the plunger bot-
toms.
(3)Measure the clearance between the end of the
pinion and pin stop with plunger seated and pinion
pushed toward the commutator end. The clearance
should be % inch. Adjust for proper clearance by
loosening the solenoid attaching screws and move the
solenoid fore and aft as required.
61x28 (4) Test the starter operation under a free run-
ning test.
Fig. 13-Measuring the Starter Drive Pinion
Clearance 13. STARTER INSTALLATION
(12) Install the thrust washers on the commutator (1) Before installing the starter, be sure the starter
end of the armature shaft to obtain .010 inch mini- and flywheel housing mounting surfaces are free of
mum end play. dirt and oil. These surfaces must be clean to make
(13) Install the commutator end head. good electrical contact.
(14)Install the through bolts and tighten 40 to 50 (2) Position the starter to the flywheel housing re-
inch-pounds torque. movable seal (units so equipped).
(3)Install the starter from beneath the engine.
12. ADJUSTING STARTER DRIVE GEAR (4) Tighten the attaching bolts securely.
Clearance 1
( Pinion (5) Attach the wires to the solenoid switch and the
(1) Place the starter assembly in a vise equipped starter terminal.
with soft jaws and tighten the vise sufficiently to hold (6) Install the battery ground cable and test oper-
the starter. ation of the starter for proper engine crankink.
STARTING M O T O R - (REDUCTION GEAR TYPE)

The reduction-gear starting motor has an arma- The starting motor utilizes a solenoid shift device.
tUre-tO-en@ne crankshaft ratio Of 45 to 1, a 3.5 to 1 The housing of the solenoid is integral with the start-
reduction gear set is built into the motor assembly, ing motor drive end housing.
which is housed in an aluminum die casting (Fig. 6).
SERVICE PROCEDURES
1. TESTING STARTER RESISTANCE AND (2) Disconnect the positive battery lead from the
CURRENT D R A W battery terminal post. Connect an 0 to 300 scale am-
meter between the disconnected lead and the battery
(1) Test the battery electrolyte specific gravity. terminal post.
Specific gravity should be 1.220 or above. If the bat- (3) Connect a test voltmeter with 10 volt scale di-
tery specific gravity is below 1.220, recharge the bat- visions between the battery positive post and the
tery to full charge before proceeding with the test. starter switch terminal at the starter solenoid.
8-22 STARTING MOTOR-REDUCTION GEAR
.-
C
0
c
U
C
Y 0
u- Y)
I
v,
Q
3
STARTING MOTOR-REDUCTION GEAR 8-23
(4) Crank the engine and observe the readings on (3) Connect a voltmeter (15 volt scale) across the
the voltmeter and ammeter. The voltage should not starter.
exceed .3 volt. A voltage reading that exceeds .3 volt (4) Rotate the carbon pile to a full-resistance po-
indicates there is high resistance caused from loose sition.
circuit connections, a faulty cable, burned starter
(5) Connect the battery cable from the battery
relay or solenoid switch contacts. A high current
reading combined with slow cranking speed, indi- negative post to the starter frame.
cates that the starter should be removed and repaired. (6) Adjust the rheostat until the battery voltage
shown on the voltmeter reads 11volts.
2. STARTER G R O U N D CIRCUIT TEST (7) The current draw should be as shown in “Spec-
(1) Connect the voltmeter positive lead to the start-
ifications”.
er housing and the negative voltmeter lead to the
Locked Resistance Test
battery negative post.
(1) Install the starter in a test bench.
(2) Crank the engine with a remote control starter
switch and observe the voltmeter reading. The volt- (2) Follow the instruction of the test equipment
meter reading should not exceed .3 volt. A reading manufacturer and test the locked resistance of the
of .3 volt or less indicates voltage in the ground cable starter.
and connections is normal. If the voltmeter reading (3) With applied battery voltage adjusted to 4 volts,
is more than .3 volt, it indicates excessive voltage loss the amperage draw should be as shown in “Specifi-
in the starter ground circuit. Make the following tests cations”.
to isolate the point of excessive voltage loss, repeat-
ing the test at each connection. Disassembly (Figure I I
(a) Starter drive housing. (1) Place the gear housing of the starter in a vise
(b) Cable terminal at the engine. equipped with soft jaws. Use the vise as a support
(c) Cable clamp at the battery. fixture only. DO NOT clamp.
A small change will occur each time a normal por- (2) Remove the two through bolts and the starter
tion of the circuit is removed from the test. A definite end head assembly.
change in the voltmeter reading indicates that the
(3) Carefully pull the armature up and out of the
last part eliminated in the test is at fault.
gear housing, and the starter frame and field assem-
Maximum allowable voltage loss is as follows:
bly. Remove the steel and fiber thrust washer.
Battery ground cable .2 volt
Engine ground circuit .1 volt NOTE: On 8 cylinder engines the starting motors
Each connection .o volt have the wire of the shunt field coil soldered to the
brush terminal. The 6 cylinder engines have the 4
3. STARTING M O T O R coils in series and do not have a wire soldered to the
Removal brush terminal. One pair of brushes is connected to
this terminal. The other pair of brushes i s attached to
(1) Disconnect the ground cable at the battery.
the series field coils by means of a terminal screw.
(2) Remove the cable at the starter. Carefully pull the frame and field assembly up just
(3) Disconnect the solenoid lead wire at the sole- enough to expose the terminal screw and the solder
noid terminals. connection of the shunt field at the brush terminal.
(4) Remove the one stud nut and one bolt attach- Place two wood blocks between the starter frame and
ing the starting motor to the flywheel housing and starter gear housing (Fig. 2) to facilitate removal of
remove the starting motor. the terminal screw and the unsoldering of the shunt
field wire at the brush terminal.
4. TESTING THE STARTING M O T O R (4) Support the brush terminal by placing a finger
(Bench Test) behind the terminal and remove the terminal screw
Free Running Test (Fig. 2).
(1) Place the starter in a vise and connect a fully- ( 5 ) On 8 cylinder engine starting motors unsolder
charged, 12 volt battery to the starter as follows: the shunt field coil lead from the starter brush ter-
(2) Connect a test ammeter (100 amperes scale) minal (Fig. 3). The 6 cylinder engine starting motors
and carbon pile rheostat in series with the battery are a 4 series coil type.
positive post and the starter terminal. (6) Remove the brush insulator which prevents
BRUSH HOLDER INSULATOR

PLATE SCREW \
ASSEMBLY
AL
.ENOID
MINAL
62x200
62x198 Fig. &Removing or Installing the brush Holder

Plate Screw
Fig. 2-Removing or Installing the h s h
Terminal Screw
\ SOLENOID WINDING LEAD
contact between the brush terminal and the gear
housing (Fig. 4).
% \ BRUSH TERMINAL POST
NOTE: The brush holder plate with the brush

terminal, contact and brushes is serviced as an asmm-
bly.
(7) Thoroughly remove all old sealer around the
brush holder plate and gear housing.
(8) Remove the screw attaching the brush holder
plate to the starter gear housing (Fig. 4).
(9) On shunt type starters, unsolder the solenoid
winding from the starter brush terminal (Fig. 5). The
4 series coil starters do not have a wire soldered to
the brush terminal.
Fig. 5-Unsoldering the Solenoid lead
Fig. 34nsoldering the Shunt Coil Lead Wire Fig. &Removing the Solenoid Terminal Nut
STARTING MOTOR-REDUCTIO'N GEAR 8-25
SOLENOID W I N D I N G LEAD
SOLENOID RELAY
BRUSt
TAB SOLENOID COIL
RETAINER
63x39
62x206
Fig. 7-Solenoid Assembly Removed

Fig. 9-Identification of the Solenoid Coil Retainer
(10) Remove nut wrench), steel washer and and Retainer Washelr
insulating washer from the solenoid terminal (Fig. 6).
(11)Straighten the solenoid wire and remove the solenoid coil retainer from the solenoid housing
brush holder plate with brushes as an assembly. (Fig. 9).
(12) Remove the ground screw from the gear hous- (20)Remove the dust cover from the gear housing
ing. (Fig. 10).
(13)Remove the solenoid assembly from the gear (21)Release the snap ring that positions the driven
housing well (Fig. 7). gear on the pinion shaft (Fig. 11).
(14) Remove the nut, steel washer and sealing
washer from starter battery terminal.
(15)Remove the starter battery terminal from
holder plate.
(16)Remove the solenoid contact and plunger as-
sembly from the solenoid.
(17)Remove the solenoid coil sleeve (Fig. 8).
(18)Remove the solenoid return spring from the
-vel1of the solenoid housing movable core.
(19)Remove the solenoid coil retainer washer and
Fig. 1LRemoving the Dust Cover

f
i
,Fig. 8-Removing the Solenoid Coil Sleeve Fig. 11-Removing the Driven Gear Snap Ring
A
ASS
PINION SHAFT
Fig. 14--Removing or Installing the Clutch

Assembly
Fig. 12LRemoving or Installing the Pinion

Shaft Retainer Ring
CAUTION: The r i n g i s under tension and a cloth

should be placed over the r i n g to prevent the r i n g
from springing away after removal.
(22) Release the retainer ring at the front of the
pinion shaft (Fig. 12).
NOTE: Do not spread the retainer r i n g any
greater than t h e outside diameter of the pinion shaft
otherwise t h e lock ring can be damaged.
(23) Push the pinion shaft towards the rear of the
housing (Fig. 13) and remove the snap ring and thrust
washers, clutch and pinion assembly, with the two
shifter fork nylon actuators (Fig. 14).
(24) Remove the driven gear and friction washer.
(25) Pull the shifting fork forward and remove Fig. 1 G R e m o v i n g or Installing the Movable Core
the solenoid moving core (Fig. 15).
(26) Remove the shifting fork retainer pin (Fig.
16) and remove the clutch shifting fork assembly. SHIFTING FO I
NOTE: The gear housing is serviced w i t h the PIN
PINION SHAFT
/r,
SHIFTING FORK
'62x21
Fig. 1'6-Removing or Installing the Shifting

Fig. 1L R e m o v i n g the Pinion Shaft Fork Pin
pinion shaft and armature shaft bushings as an Contact the armature shaft and each of the com-
assembly. Bushings can be replaced with Tool C-3944. mutator riser bars with a pair of test lamp test prods.
If the lamp lights, it indicates a grounded armature.
Cleaning and Inspection Replace any grounded armature.
(1) Do not immerse the parts in cleaning solvent.
Immersing the field frame and coil assembly and/or Testing Commutator Runout, Refacing and
Undercutting
armature will damage the insulation. Wipe these
parts with a clean cloth only. Place the armature in pair of “V” blocks and meas-
ure the runout with a dial indicator; measure both
(2) Do not immerse the clutch unit in cleaning the shaft and the commutator. A bent shaft requires
solvent. The clutch is pre-lubricated at the factory replacement of the armature. When the commutator
and solvent will wash the lubrication from the clutch. runout exceeds .003 inch, the commutator should be
(3) The starter clutch outer housing and pinion refaced and undercut using Tool C-770. Remove only
gear may be cleaned with a cloth moistened with sufficient metal to provide a smooth, even surface.
cleaning solvent and wiped dry with a clean dry Testing Field Coils for Ground
cloth.
(1) Remove the field frame assembly from the start-
(4) Unsolder the solenoid lead wires from the sole- er.
noid terminal relay stud.
(2) Carefully drill out the rivet that attaches the
( 5 ) Clean all corrosion from the solenoid assembly series field coil (ground) lead and shunt field coil
(washers, sleeve and retainer and inside of the sole- lead to the field frame.
noid housing). These metal parts are part of the sole-
(3) Insulate the field coil leads from the field frame.
noid hold-in coil ground circuit and they must be
clean. (4) Test for ground using a 110 volt test lamp.
(6) Clean the terminal contacts and contactor with On shunt type starters (3 coils in series, one shunt),
crocus cloth. touch one prod of the test lamp to the series field coil
(7) Thoroughly clean the outside area of the brush lead, other test prod to the starter field frame. The
lamp should not light. Repeat the same procedure for
plate to remove all oil and dirt.
the shunt field coil. On the 4 coils in series starters,
touch one prod of the test lamp to the series field coil
5. REPLACEMENT O F BRUSHES A N D lead, other test prod to the starter field frame.
SPRINGS
If the lamp lights, it indicates that the field coils
(1) Brushes that are worn more than % the length are grounded and require replacement.
of the brushes, or are oil-soaked, should be replaced.
(2) When resoldering the shunt field and solenoid 7. REPLACING THE FIELD COILS
lead, make a strong, low resistance connection using A pole shoe impact screwdriver Tool C-3475 should
a high temperature solder and resin flux. Do not use be used to remove and install the field coils to pre-
acid or acid core solder. Do not break the shunt vent damage to the pole shoe screws and for proper
Add wire when removing and installing the brushes. tightening. The pole shoes that are loose and not
(3) Measure the brush spring tension with a spring properly seated may cause the armature core to rub
scale hooked under the spring near the end. Pull the the pole shoes. This will decrease starter efficiency
scale on a line parallel to the edge of the brush and and damage the armature core.
take a reading just as the spring end leaves the NOTE: Make sure the area between the leads
brush. The spring tension should be 32 to 48 ounces. and the field frame i s clean. Peen a new rivet
Replace the springs that do not meet specifications. securely to insure a good electrical contact.
8. SERVICING THE BUSHINGS

6. TESTING THE ARMATURE
Inspect the armature shaft bearing and pinion shaft
resting the Armature for Short Circuit surfaces and bushings for wear. Try the bushings
Place the armature in the growler and hold a thin for wear by placing them on shafts and testing for
steel blade parallel to the core and just above it, side play. Replace the commutator end head and
while slowly rotating the armature in the growler. A bushing assembly if the bushing is worn. Replace
shorted armature will cause the blade to vibrate and the starter gear housing bushings if they are worn.
be attracted to the core. Replace any armature that Use Tool C-3944 to correctly position the pre-sized
is shorted. bushings.
9. SERVICING THE STARTER CLUTCH

UNIT SHIFTING FORK
TCH ASSEMBLY
Do not immerse the starter clutch unit in a cleaning
solvent. The starter clutch is pre-lubricated at the
factory and the solvent will wash the lubricant from
the clutch.
The starter clutch outer housing and pinion gear
may be cleaned with a cloth moistened with cleaning
solvent and wiped dry with a clean dry cloth.
Rotate the pinion. The pinion gear should rotate
smoothly in one direction, but should not rotate in
the opposite direction. If the starter clutch unit does
not function properly, or the pinion is worn, chipped
or burred, replace the starter clutch unit. SHIFTING FORK
Assembly (Fig. 1 7 ) Fig. 19-Shifter Fork and Clutch Arrangement

NOTE: The shifter fork consists of two spring
she1 plates assembled with two rivets (Fig. 18). NOTE: The friction washer must be positioned
There should be approximately 1/16 inch side on the shoulder of the splines of the pinion shaft
movement, as shown in Figure 18 to insure proper before the driven gear i s positioned.
pinion gear engagement. Lubricate between the plates
sparingly with SAE 10 engine oil.
(6)Install the driven gear snap ring (Fig. 11).
(1)Position the shifter fork in the drive housing (7) Install the pinion shaft retaining ring (Fig. 12).
and install the shifting fork retainer pin (Fig. 16). Make sure the ring fits tightly in the shaft groove.
One tip of pin should be straight, the other tip should (8) Bend the four (4) tangs of the coil retainer “up”
be bent at a 15 degree angle away from the housing. to a measurement of 5/32’’ to X6’’ above the surface
Fork and retainer pin should operate freely after of the retainer (Fig. 20) to insure higher com-
bending the tip of pin. pression and a more positive ground.
(2) Install the solenoid moving core and engage (9) Install the solenoid coil retainer (Fig. 9) (with
the shifting fork (Fig. 15). tangs down).
(3) Enter the pinion shaft into the drive housing, NOTE: Space the retainer in the housing bore
and install the friction washer and driven gear. so that the four tangs rest on the ridge in the housing
bore and not in the recesses.
(4) Install the clutch and pinion assembly (Fig. 14),
thrust washer, retaining ring and the thrust washer. (10) Install the solenoid coil retainer washer.
(5) Complete the installation of the pinion shaft (11) Install the starter solenoid return spring into
engaging the shifting fork with the clutch actuators. the bore of the movable core.
Figure 19 shows the correct relation of the parts at
the assembly.
IEWAYS
IVEMENT
62x214 63x40
Fig. 2LChecking the Height of the Solenoid
Fig. 118-Shifter Fork Assembly Coil Retainer Tangs
BRUSH HOLDER PLATE
62x203
Fig. 21-Assembling the Solenoid to the Brush

Holder Plate
(12) Straighten the solenoid lead wires and install

the solenoid contact seal over the wires, inserting the
double wires of the terminal stud into the large hole 523
(Fig. 7) and the solenoid winding lead wire into the
small hole. Fig. 2C3-lnstalling the Solenoid Coil, Sleeve
and Brush Holder
(13) Insert the ends of the terminal stud wires into
the groove of the terminal stud, crimp wires in (15) Assemble the battery terminal stud in the
place and solder with resin core solder. brush holder placing the sealing washer under the
NOTE: Inspect the condition of the starter plain washer.
solenoid switch contacting washer. If the top of NOTE: Inspect the condition of the contacts in
washer is burned or arcing, disassemble the contact the brush holder plate. If the contacts are badly
switch plunger assembly and reverse t h e washer. burned, replace the brush holder w i t h brushes and
(14)Install the solenoid contact plunger assembly contacts as an assembly.
into the solenoid and reform the double wires to al- (16) Enter the solenoid lead wire through the hole
low for proper entry of the terminal stud into the in brush holder (Fig. 20) and install the solenoid stud,
brush holder with the double wires curved around the insulatihg washer, flat washer and nut.
contactor.
NOTE: Use care when installing the solenoid
CAUTION: The contactor must not touch the contact seal over the tab on the brush plate t o pre-
double wires when the solenoid i s energized after vent tearing the seal.
t h e assembly is completed (Fig. 7). Make sure the
contact spring is positioned on t h e solenoid contact
(17) Solder the solenoid lead wire to the brush
terminal post (Fig. 22). Wrap the wire securely around
assembly.
the terminal, and solder securely with a high tempera-
“Pm ““e I
I.----
- ture solder and resin flux.

(18) Carefully enter the solenoid coil and solenoid
coil sleeve into the bore of the gear housing and posi-
tion the brush assembly into the starter gear housing
(Fig. 23). Align the tongue of the ground terminal
with the notch in the brush holder.
(19) After the brush holder is bottomed in the
housing, install the attaching screw (Fig. 4). Tighten
the screw 10 to 15 inch pounds. Install the flat insul-
ating washer and hold in place with friction tape.
(20) Position the brushes with Tool C-3855, as
PO~ITIVE ‘BRUSHES 62x202 shown in Figure 24.
Fig. 22-Soldering the Soleonid Wind’ing lead (21) Position the field frame to the exact position
\\ TOOL
TO
TERMINAL Fig. 26-Removing the Brush,Positioning Tools
(25) Install the thrust washer (fibre) and washer

62x217 (steel) on the armature shaft.
(26) Position the starter end head assembly and
Fig. 24-Positioning the Brushes with Tool install the starter frame screws and lockwashers.
Set C-38'55 Tighten the screws securely.
(27) Install the gear housing dust cover. Make
and resolder the field coil lead (Fig. 3). sure the dimples on the cover are securely engaged
in the holes provided in the gear housing.
(22) Install the brush terminal screw (Fig. 2).
(28) Install ground screw in gear housing. Tighten
(23) Install the armature thrust washer on the
securely.
brush holder plate (Fig. 1) and enter the armature
into the field frame and gear housing (Fig. 25); care- (29) Clean the area at joint between the brush
fully engaging the splines of the shaft with the reduc- holder plate to field frame and gear housing mating
tion gear. joint. Apply a bead of brush plate sealer MoPar
2421847 around the four sides of the joint (Fig. 27).
(24) Remove the brush positioning Tool C-3855
CAUTION: The sealer must be flowed contin-
(Fig. 26).
uously to avoid gaps. After bead has been flowed on,
use a brush or a small paddle moistened in mineral
spirits to press adhesive into joint. Be sure not to get
the adhesive on the battery and/or solenoid terminals.
MULTI-PURPO
I
SHORT FIBRE
GREASE
\
GROUNC
63x41
Fig. 2Llnstalling the Starter Armature Fig. 27-Sealing the Brush Holder Plate
installation t O n the EngineJ NOTE: When tightening the attaching bolt and
(1) Before installing the starting motor, make sure nut be sure to hold the starting motor pulled away
starter and flywheel housing mounting surfaces are from the engine to insure proper alignment.
free of dirt and oil to insure a good electrical contact. (4) Attach the wire at the solenoid switch terminal
(2) Position the starter to the flywheel housing. and cable to starter terminal.
(3) Install the starting motor, washer and bolt, oil ( 5 ) Connect the battery ground cable and test the
cooler lines bracket (if so equipped) and washer and operation of the starting motor for proper engine
nut. cranking.
SERVICE DIAGNOSIS
STARTING MOTOR
Starter Fails (a) Weak battery or dead cell in Test for specific gravity and test for dead
t o Operate the battery. cell. Replace or recharge the battery as
required.
(b) Ignition switch faulty. Test and replace the switch if necessary.
( c ) Loose or corroded battery Clean terminals and clamps, replace if
cable terminals. necessary. Apply a light film of vasoline
to terminals. Tighten clamps securely.
Open circuit, wire between Inspect and test all the wiring.
the ignition-starter switch and
ignition terminal on the starter
relay.
Inoperative clutch unit. Replace the clutch unit.
Faulty starting motor. Test and repair.
Armature shaft sheared. Test and repair.
Starter Fails Weak battery or dead cell Test the specific gravity and test for
and Lights Dim in the battery. dead cell. Replace or recharge the battery
as required.
Loose or corroded battery Clean the terminals and clamps, replace
cable terminals. if necessary. Apply a light film of vasoline
to the terminals. Tighten the clamps
securely.
Internal ground in wiring. Test and repair the starter.
Grounded starter fields. Test and repair the starter.
Armature rubbing on pole Test and repair the starter.
shoes.
Starter Turns, Starter clutch slipping. Replace the clutch unit.

B u t Pinion Does Broken teeth on flywheel drive Replace the flywheel ring gear.
Not Engage gear. Also examine teeth on the starter
clutch pinion gear.
Pinion shaft rusted, dirty or dry, Clean, test and lubricate.
due to lack of lubrication.
Wrong starter pinion clearance. Repair starter as necessary.
SERVICE DIAGNOSIS--. ( Continued 1
STARTING MOTOR
Starter Relay (a) Battery discharged. (a) Recharge or replace the battery.
Does N o t Close (b) Faulty wiring. (b) Test for open circuit, wire between the
starter relay ground terminal post and
neutral starter switch (automatic trans-
mission only). Also test for open circuit,
wire between ignition-starter switch and
ignition terminal and starter relay.
Neutral starter switch on auto- (c) Test and replace the switch if necessary.
matic transmission faulty.
Starter relay faulty. (d) Test and replace if necessary.
Ignition-starter switch faulty. (e) Test and replace switch if necessary.
Relay Operates Faulty wiring, open circuit wire (a) Test for open circuit wire between the
But Solenoid Does between the starter-relay and starter-relay solenoid terminal and
not solenoid terminal and solenoid solenoid terminal post.
terminal post.
Faulty solenoid switch or (b) Test for loose terminal connections
connections. between solenoid and starter field.
Solenoid switch contacts (c) Test and replace the solenoid if necessary.
corroded.
Broken lead or loose soldered (d) Test and replace the solenoid if necessary.
connection inside solenoid switch
cover (brush holder plate).
Solenoid Plunger (a) Battery low. (a) Test for specific gravity of the battery.
Vibrates Back and Replace or recharge the battery.
Forth When Switch (b) Faulty wiring. (b) Test for loose connections a t relay,
is Engaged ignition-starter switch and solenoid.
Repair as necessary.
Lead or connections broken (c) Test and replace the solenoid if necessary.
inside solenoid switch cover
(brush holder Plate) or open
hold in winding.
Check for corrosion on solenoid (d) Test and clean the contacts.
contacts.
Starter Operates (a) Broken solenoid plunger spring (a) Test and repair.
B u t Will N o t Disengage or spring out of position.
When Ignition Starter (b) Faulty ignition-starter switch. (b) Test and replace the switch if necessary.
is Released (c) Solenoid contact switch plunger (c) Remove the contact switch plunger, wipe
stuck in solenoid. clean of all dirt, place a film of SAE 10
oil on the plunger, wipe off excess.
Insufficient clearance between (d) Test and repair.
winding leads to solenoid
terminal and main contactor
in solenoid.
Faulty relay. (e) Test and replace the relay if necessary.
8-34 ALTERNATOR AND REGULATOR
PART 3
ALTERNATOR AND VOLTAGE REGULATOR

1. CONSTRUCTION AND OPERATION regulator (Fig. 2) is used in the field circuit to limit
The alternator (Fig. 1) is an A.C. current genera- the output voltage.
tor, with six (6) built-in silicon rectifiers, that convert The main components of the alternator are the
the A.C. current into D.C. current. D.C. current is rotor, the stator, the rectifiers, the two end shields
available at the “output” “BAT” terminal. A voltage and the drive pulley (See Fig. 3).
HEAT SINK GROUND BRUSH

OUTPUT TERMINAL
VOLTAGE REGULATOR
\
BEARING 62x101 -- 63x629-
\
.
Fig. 1-Alternator hsembly Fig. %Voltage Regulator Installed
SHIELD -1 INSULATOR
HEAT SINK
INSUL A T 0 R I SHIELD
\ NUT II PULLEY
A
RE~IFIER /
RETAINEh
WASHER /’
/1
I
WASHER
RETAINER- -’
I SCREW
BEAR1NG
HOLDER
NYLON WASHER
1 WASHER
SCREW
BEARING
62 x 2AOA
Fig. ?Alternator (Exploded View)

ALTERNATOR AND REGULATOR 8-35
2. VOLTAGE REGULATOR (2) Set tester control knob to the DIRECT position.
The only function of the regulator is to limit the (3) Set voltage switch to the 2 VOLT position.
output voltage. The voltage regulator accomplishes (4) Set field control to the OPEN position.
this by controlling the flow of current in the rotor
field coil, and in effect controls the strength of the C. T e s t e r L e a d Connections (Fig. 41
rotor magnetic field. (1) Disconnect the positive battery cable from the
battery post and install the BATTERY POST ADAPT-
3. TESTING THE ALTERNATOR SYSTEM ER between the cable and post.
(On the Vehicle using the Sun Volt Ampere
(2) Connect the “BAT” lead of the tester to the
Tester Model VAT-2OC and Sun Battery Post Adap-
stud on the adapter.
ter. (3) Connect the “REG” lead of the tester to the
NOTE: For the sake of uniformity, one type of
binding post on the adapter.
equipment is shown. Follow the instructions of the (4) Connect the “GRD” lead of the tester to a
equipment manufacturers on comparable equipment good ground on the vehicle.
when making the following tests: (5) Connect the negative lead of the voltmeter to
the field terminal of the regulator.
A. Prelirninury Checks
(6) Connect the positive lead of the voltmeter to
(1) TEST BATTERY CONDITION. Perform reliable the battery end of the positive battery cable.
battery tests to determine the condition and state of
NOTE: The Battery Post Adapter BY-PASS
charge of the battery. If the battery is defective or
SWITCH must be open for a l l charging system tests.
not fully charged, install a fully charged battery for
It is closed only for starting the engine.
test purposes.
(2) TEST ALTERNATOR BELT TENSION AND D. F i e l d Circuit Resistance Test ( Fig. 5 J
CONDITION. Replace the alternator drive belt if (1) Disconnect the slip-on connector from either
necessary and make sure that there is adequate ten- end of the ignition ballast resistor.
sion on the belt. (2) Turn the ignition switch on.
(3) INSPECT CONDITION OF WIRES AND THEIR (3) With vehicle doors closed and all accessories
CONNECTIONS. Before performing the test on the turned off, observe the Voltmeter reading. The volt-
system, correct any problem with the wiring, such as age should not exceed .55 volt. A reading in excess
loose connections, corroded connections, burned of .55 volt indicates high resistance in the field
wiring harness, etc. circuit between the battery and the voltage regulator
6. T e s t e r Controls and S w i t c h e s field terminal.
(4) If high resistance is indicated, move the nega-
(1) Set Polarity Switch to the NEGATIVE position.
BY-
sw
- 64 x 472 64 x 473
Fig. 5-Field Circuit Resistance and Field Current

Fig. &Tester lead Connections Drive Test
(8) Close the BY-PASS Switch of the Battery

Post Adapter.
(9) With the tester Field Control in the OPEN
position, start the engine and adjust to 1250 rpm.
(10) Open the BY-PASS Switch of the Battery
Post Adapter.
(11) Rotate the tester Control Knob to the LOAD
position until the Voltmeter reads 6 volts.
(12) Rotate the tester Field Control to the Direct
position and adjust the tester Control Knob until
the Voltmeter reads exactly 15 volts.
(13) Observe the ammeter. The ammeter now in-
dicates maximum output of alternator. The current
output should be within the limits shown in “Spec-
64 x 474
ifications”.
Fig. .(Current Output Test NOTE: The current output should be within 5
amperes of the rated output as there is a total of 5
amperes supplied by the alternator that will not a p
tive voltmeter lead to each connection along the
pear on the test ammeter. This consists of Y2 ampere
circuit towards the battery. A sudden drop in volt-
approximate for the instruments, 1V2 amperes for
age indicates a loose or corroded connection between
the engine ignition system, and 3 amperes for field
that point and the last point tested. To test the
current.
terminals for tightness, attempt to move the terminal
while observing the voltmeter. Any movement of If the output is slightly less (5 to 7 amperes) than
the meter pointer indicates looseness. that specified above, it may be an indication of
possible “open” rectifier or other alternator internal
NOTE: Excessive resistance in the regulator wir- problem. If the output is considerable lower than
ing circuit will cause fluctuation in the ammeter or that specified above, it may be an indication of a
a below normal charge rate. possible “shorted” rectifier or other alternator inter-
E. Field Current Draw Test (Fig. 51 nal problem. In either case the alternator should be
removed and tested on the bench before disassembly.
With tester connections positioned as for the Field
Circuit Resistance Test, observe the test ammeter. (14) Return the tester Field Control to the OPEN
The test ammeter will indicate the field current draw. position.
Refer to ‘Specifications”. (15) Return tester Control Knob to the DIRECT
position.
F. Current Output T e s t (Fig. 6 1
(1) With the ignition switch off, disconnect the
field wire from “FLD” terminal of the alternator and
at the regulator.
(2) Connect a special jumper from the “FLD” ter-
minal of the alternator to one of the test leads of
the tester Field Control.
(3) Connect the other lead of the tester Field
Control to the “BAT” terminal of the alternator.
(4) Set the Tester Voltage Switch to the 16 VOLT BY-
position. sw
(5) Connect the positive lead of the test Voltmeter
to the “BAT” terminal of the alternator.
(6) Connect the negative lead of the Test Volt-
meter to a good ground. 64 x 475
(7) Reconnect the slip-on connector at ignition bal-
last resistor. Fig. 7-Insulated Circuit Resistance Test
0. I n s u l a t e d Circuit Resistance Test

Fig. 7 I
(1) Connect the negative lead of Voltmeter to
battery end of positive battery cable.
(2)Set Voltage Switch to 2 VOLT position.
(3) Adjust Field Control Unit the tester ammeter
reads exactly 10 amperes.
(4) Observe the Voltmeter reading. The voltmeter
now indicates the amount of voltage loss across the
insulated circuit. The voltage loss should not exceed
.3 volt. If a higher voltage loss is indicated, inspect,
clean and tighten all the connections in the charging
circuit. A voltage loss test may be performed at each
connection to locate the connection with excessive
resistance. 64 x 477
H. Ground Circuit Resistance Test (Fig. 8 I Fig. %Voltage Regulator Test

(1) Connect the positive lead of the test Voltmeter
to the negative terminal of battery. the “BAT” terminal of alternator and connect to
(2)Connect the negative lead of the test Volt- the disconnected field wire from regulator.
meter to a good ground on the alternator. (2) Set Voltage Switch to 16 VOLT position.
(3) With the alternator charging 10 amps, observe (3) Connect positive lead of Voltmeter to “BAT”
the Voltmeter reading. The voltmeter now indicates terminal of alternator.
the amount of voltage loss across the ground circuit.
(4) Rotate tester Field Control to DIRECT posi-
The voltage loss should not exceed .3 volt.
tion.
(4) Rotate the tester Field Control to the OPEN
(5)With the engine operating at 1250 rpm, rotate
position.
the tester Control Knob clockwise until the Ammeter
1. Voltage R e g u l a t o r Test (Fig. 91 reads exactly 15 amperes.
NOTE: Regulator temperature should be nor- (6)Rotate the tester Field Control from the
malized by operating with a 10 ampere load for 15 DIRECT position to the OPEN position and then back
minutes just prior to testing. to the DIRECT Position to cycle the system.
Upper Contacts Test (7) Observe the test Voltmeter. The voltmeter now
(1)Remove test lead of tester Field Control from indicates the setting of the voltage regulator upper
contacts. Refer to “Specifications”.
(8) Rotate the tester Control Knob to DIRECT po-
sition. If the regulator operates within specifications,
proceed to the lower contact voltage test. If the
upper contact voltage setting is not within specifi-
cations, remove the regulator cover and adjust the
voltage setting as outlined in “Regulator Adjust-
ments” test number (1).
L o w e r C o n t a c t Test
(1) Increase the engine speed to 2200 rpm.
(2)Rotate the tester Control Knob to the VI OHM
position only if the tester Ammeter reads over 5
amperes.
(3) Rotate tester Field Control from DIRECT posi-
tion to the OPEN position and then back to the
64 x 476
DIRECT position to cycle the system.
Fig. 8-Ground Circuit Resistance Test (4) Observe Voltmeter. The voltmeter now indi-
cates setting of voltage regulator lower contacts. specific gravity in the winter or 1.245 specified
Refer to “Specifications”. gravity in the summer, with a minimum water require-
Voltage should increase not less than .2 volt or ment (not more than an ounce of water per cell per
more than .7 volt above the previous operating volt- one thousand miles).
age setting recorded in the upper contact set. A
voltage reading of less than .2 volt or more than .7 Regulator Mechanical Adjustments
volt is an indication of a possible wrong air gap Step (1)- Adjust the upper contact voltage setting
setting, refer to “Regulator Mechanical Adjustments”. as necessary by bending the regulator lower spring
hanger down to increase voltage setting, up to de-
(5) Rotate tester Field Control to OPEN position
crease voltage setting. Use an insulated tool to bend
and Control Knob to DIRECT position.
the spring hanger (Fig. 10). The regulator must be
Upon completion of the test, reduce engine speed
installed, correctly connected, and retested after
to idle, stop engine, and disconnect all test leads
and adaptors. Be sure that all vehicle’s cables and each adjustment of the lower spring hanger.
wiring connections are secure before restarting en- NOTE: If repeated readjustment i s required, it
gine. i s permissible to use a jumper w i r e to ground the
regulator base t o t h e fender splash shield f o r testing,
CAUTION: Be sure t h e negative post o f the bat-
in lieu of reinstalling t h e regulator each time. How=
t e r y i s always connected t o ground. Incorrect battery
ever, it i s important t h a t t h e regulator cover be r e
p o l a r i t y may result in wiring harness damage and
installed, t h e regulator connections correctly con-
m a y damage t h e alternator rectifiers. Do not ground
nected, and t h e regulator satisfactorily insulated by
t h e alternator field circuit, as this may damage the
t h e fender cover t o prevent grounding t h e regulator
regulator.
terminals or resistances. When testing, the regulator
Adjusting the Voltage Setting to Driving must be a t t h e same attitude (or angle) as when
Conditions installed on t h e vehicle. If step (1) under ”Mechanical
The specifications called for in the voltage regu- Adjustments” does n o t bring t h e voltage regulator
lator chart indicate a tolerance of .6 volt from the within spedfications, proceed t o Step (2) following:
low setting to the high setting at the temperatures Step (2) - Measure the lower contact point gap.
indicated. The lower contact gap should be .014 inch plus or
To maintain the battery in a full state of charge, minus .002 inch. Adjust the lower contact gap as
the voltage regulator should be adjusted to provide necessary by bending the lower stationary contact
the proper voltage limiting setting according to the bracket making sure contacts are in alignment.
customer’s driving and load requirement habits as If the lower contact gap is correct and the voltage
follows: regulator setting is still outside the .2 to .7 volt
(1) Test the entire charging system and battery increase, adjust the air gap as follows:
as outlined in this Service Manual. (a) Connect a small dry cell test lamp in series
(2) If there are no defects in the charging system with the “IGN” and “FLD” terminal of the voltage
or in the battery and the battery was found to be regulator.
in a low state of charge, increase the setting by .3
volt (do not exceed specified voltage limits) and re-
test for an improved battery condition after a reason-
able service period (week or two). If the battery state
of charge has increased to a satisfactory level, do
not change the voltage setting. If the battery shows
evidence of over-charge - (low electrolyte level,
high water consumption, excessive dampness on top
of battery), decrease the setting by .3 volt and retest
for an improved battery condition after a reasonable
service period (week or two).
CAUTION: Always adjust t h e settings in steps
not to exceed .3 v o l t a t a t i m e (Do not exceed speci-
fied voltage limits.)
(3) The proper setting of the voltage regulator
is attained when the battery remains at least 1.225 Fig. 19-Adjusting Spring Tension
CAUTION: If an attempt is made to unrolder

the old fuse, the very small wire from the voltage coil
may be damaged.
(2) Tin the end of the fuse wire part number
2275242. Use resin core solder only.
(3) Holding the tinned end of the new fuse wire
into the recessed rivet at the base of the regulator
and against the old piece of fuse wire that remains,
cause a drop of solder from a soldering iron to fall
on these parts. Allow the solder to cool sufficiently
for fuse wires to make a good solder joint.
I \ (4) Pull the new fuse wire up enough to remove
the slack and wrap it around the bracket. Solder the
coiled wire to the bracket and cut off surplus fuse
Fig. 11-Checking Air Gap wire.
NOTE: The original fuse wire is machine
(b) Insert an .048 inch wire gauge between the wound on the upper bracket. The replacement fuse
regulator armature and the core of the voltage coil should be soldered to the bracket to ensure a good
next to the stop pin on the armature (Fig. 11). electrical contact.
(c) Press down on the armature (not on the con- (5) Install the regulator cover. Install the regula-
tact reed) until the armature contacts the wire gauge. tor. The electrical adjustment must be performed
The upper contacts should just open and the test on the vehicle after installation of the regulator.
lamp should be dim.
(d) Insert an .052 inch wire gauge between the 4. ALTERNATOR
armature and the voltage coil core next to the stop Removal
pin on the armature. If the alternator performance does not meet cur-
(e) Press down on the armature until it contacts rent output specification limits, it will have to be re-
the wire gauge. The upper contacts should remain moved and disassembled for fuyther test and serv-
closed and test lamp should remain bright. icing.
If an adjustment is required to obtain the dif- (1) Disconnect the battery ground cable.
ference between the upper contact voltage and the
lower contact voltage of .2 volt to .7 volt; adjust (2) Disconnect the alternator output “BATT” and
the air gap by loosening the stationary contact field “FLD” leads and disconnect the ground wire.
bracket screw and moving the bracket up or down as (3) Remove the alternator from the vehicle.
necessary to obtain the proper air gap setting as
follows: 5. BENCH TESTS
If the difference is above .7 volt, reduce the air Field Coil Draw
gap to a minimum of .045 inch with the contacts
open and the test lamp dim. At .048inch the contacts If the alternator field coil draw has not been tested
should close and the test lamp should be bright. on the vehicle, it may be tested on the test bench as
If the difference is below .2 volt, increase the follows :
air gap to a maximum of .055 inch with the contacts (1) Connect the test ammeter positive lead to the
closed and test lamp bright. At .052 inch contacts battery positive terminal of a fully charged battery.
should be open and test lamp should be dim. Connect the test ammeter negative lead to the field
NOTE: Make sure the air gap is tested with the terminal of the alternator. Connect a jumper wire to
stationary contact bracket attaching screw fully tight- the negative terminal of the battery, and ground it to
ened. the alternator end shield.
(2) Slowly rotate the alternator rotor by hand.
Voltage Regulator Fusible W i r e Observe the ammeter reading. The field coil draw
Replacement should be 2.3 amperes to 2.7 amperes at 12 volts.
(1) Cut the fuse wire above the solder connection NOTE: A low rotor coil draw is an indication
at the base and unwind the wire at the top bracket. of high resistance in the field coil circuit (brushes, slip
rings, or rotor coil). A higher rotor coil draw indicabs G R O U N D B R U S H ASSEMBLY / ‘
a possible shorted rotor coil or a grounded rotor.
Testing Alternator Internal Field Circuit

for Ground
(1)To test the internal field circuit for a ground,
remove the ground brush. Touch one test prod from
a 110 volt test lamp to the alternator insulated brush
terminal and the remaining test prod to the end
shield. If the rotor assembly or insulated brush is
not grounded, the lamp will not light.
(2)If the lamp lights, remove the insulated brush
assembly (noting how the parts are assembled) and
separate the end shields by removing the three
through bolts.
(3)Again test by placing one of the test prods Fig. 1WRemoving or Installing the Ground Brush
to a slip ring and the remaining test prod to the
end shield. If the lamp lights, the rotor assembly (1)Remove the retaining screw lockwasher, in-
is grounded and requires replacement. If the lamp sulated washer, and field terminal, and carefully lift
does not light after removing the insulated brush the plastic holder containing the spring and brush
and separating the end shields, the insulated brush assembly from the end housing (Fig. 12).
is grounded. (2) The ground brush is positioned horizontally
(4)Examine the plastic insulator and the screw. against the remaining slip ring and is retained in a
The screw is a special size and must not be subrti- holder that is integral with the end shield. Remove
tuted by another size. the retaining screw and lift the clip, spring and
(5) Install the insulated brush holder, terminal, brush assembly from the end shield (Fig. 13).
insulated washer, shake proof washer and screw. If CAUTION: The stator is laminated, do not burr
the parts were not assembled in this order or if the the stator or the end shield.
wrong screw was used this could be the cause of the (3)Remove the through bolts and pry between the
ground condition.
stator and drive end shield with the blade of a screw-
Disassembly driver (Fig. 14). Carefully separate the drive end
To prevent possible damage to the brush assem- shield, pulley and rotor assembly away from the
blies, they should be removed before proceeding with stator and the rectifier shield assembly.
the disassembly of the alternator. The insulated (4)The pulley is an interference fit on the rotor
brush is mounted in a plastic holder that positions shaft. Remove the pulley with puller Tool C-3615
the brush vertically against one of the slip rings. or C-3934 and special adaptor SP-3002 (Fig. 15).
h INSULATED
/ KtCTlFlER E N D
62 x 106
Fig. 12-Removing or Installing
I.
the Insulated
.rc::b,., ,a-
Fig. l+Separating the Drive E n d Shield from
hush , ’ ‘th8Stator . ’
TOOL
TOOL
RETAINER
2 x 110 6 2 x 112
Fig. 1'5-Removing the Alternator Pulley Fig. 17-Removing the Bearing from the Rotor
Shaft
(5) Pry the drive end bearing spring retainer from
CAUTION: The tool sleeve must bottom on the
the end shield with a screwdriver (Fig. 16).
bearing, otherwise, the adapters may be damaged.
(6)Support the end shield and tap the rotor shaft
with a plastic hammer to separate the rotor from the (d) Turning the center screw while holding the
end shield. outer body of tool (Fig. 17) will withdraw the bearing
from the rotor shaft.
NOTE: The new bearing i s lubricated with a pre-
determined amount of special lubricant and does not
(8) Remove the D.C.output terminal nuts and
require additional lubrication.
washers and remove the terminal screw and inside
capacitor.
(7)The drive end ball bearing is an interference
NOTE: The heat sink is also held in place by the
fit with the rotor shaft. Remove the bearing with
terminal screw.
puller Tool C-3615 or (2-3934and adapter as follows:
(a) Position the center screw of Tool C-3615 or (9) Remove the insulator (Fig. 18).
(2-3934on the rotor shaft. (10)The needle roller bearing in the rectifier end
(b) Place the thin lower end of the adapters shield is a press fit. If it is necessary to remove the
SP-3375 under the bearing equally spaced and the rectifier end frame needle bearing, protect the end
upper end of the adapters around the center screw. shield by supporting the shield with Tool SP-3383
when pressing the bearing out with Tool C-3770A
(c) Hold the adapters and center screw in posi- (Fig. 19).
tion with the tool sleeve.
NOTE: The new bearing is prelubricated and no
62x111
Fig. 1LDisengaging the Bearing Retainer from Fig. 1,LRemoving or Installing the Heat Sink
the End Shield Insulator
%k5 C-3770 NEGATIVE CASE

RECTIFIERS
END HOUSING
I
61x362 C3829
63x65 Fig. 21-Testing the Negative Rectifiers (Typical)
Fig. 19-Removing the Rectifier End Shield Rearing

CAUTION: Do not break t h e sealing around t h e
additional lubricant should be added, as an excessive rectifier lead wire. T h e sealing material i s f o r protec-
amount of lubricant will contaminate t h e slip rings t i o n against corrosion. Always touch the test prod
a n d cause premature brush and r o t o r failures. to t h e exposed metal connection nearest t h e rectifier.
The reading for satisfactory rectifiers will be 1%
6. TESTING THE RECTIFIERS WITH amperes or more. The reading should be approxi-
TOOL C - 3 8 2 9 mately the same for the three rectifiers.
When two rectifiers are good and one is shorted,
Rectifier Tester Tool C-3829 provides a quick,
the reading taken at the good rectifiers will be low,
simple and accurate method to test the alternator
and the reading at the shorted rectifiers will be zero.
rectifiers without the necessity of disconnecting the
Disconnect the lead to the rectifier reading zero and
soldered rectifier leads. With the alternator rectifier
retest. The reading of the good rectifiers will now
and end shield separated from the drive end housing
be within the satisfactory range.
proceed with rectifier tests as follows:
Negative Case Rectifier Test (Fig. 2 I 1
Positive Case Rectifier Test (Fig. 201
(a) Connect the test lead clip to the rectifier end
(a) Place the alternator on an insulated surface.
housing.
Connect the test lead clip to the alternator (“BAT”)
output terminal. @) Touch the exposed connection of each of the
negative case rectifiers with the test prod.
(b) Plug in the Tool C-3829 power source lead
into a 110 volt A.C. power supply. Touch the ex-
The test specifications are the same, and the test
results will be approximately the same as for the
posed metal connections of each of the positive case
rectifiers with the test prod.
61x361 C-3829
‘u ‘ Y
POSITIVE CASE
RECTIFIERS
Fig. 20-Testing the Positive Rectifiers (Typical) Fig. 22-Separating the Three Stator leads (Typical)
positive case rectifiers, except the meter will read
on the opposite side of the scale.
7. TESTING THE RECTIFIERS AND STATOR

(Without Tool C-3829 1
(a) Separate the three (3) stator leads at the “Y” 110-VOLT BULB
connection (See Fig. 22).
NOTE: Cut the stator connections as close to the
connector as possible because they will have to be
soldered together again. If they are cut too short it
-T\ ii
may be difficult to get them together again for sol-
dering.
(b) Test’the rectifiers with a 12 volt battery and
I 61 x251
a test lamp equipped with a number 67 bulb (4
candle power) by connecting one side of test lamp to Fig. 24-Testing the Stator for Grounds (Typical)
the positive battery post and the other side of the
test lamp to a test probe. Connect another test probe capacitor capacity-.50 microfarad plus or minus
connected to the negative battery post. 20%.
(c) Contact the outer case of the rectifier with (e) Unsolder the rectifiers from the stator leads.
one probe and the other probe to the wire in the (f) Test the stator for grounds using a 110 volt
center of the rectifier (See Fig. 23). test lamp (Fig. 24). Use wood slats to insulate the
(d) Reverse the probes, moving one probe from stator from the rectifier shield. Contact one prod
the rectifier outer case to the rectifier wire, and of the test lamp to the stator pole frame, and con-
the other probe from the rectifier wire to the rectifier tact the other prod to each of the three stator leads.
outer case. The test lamp should “not light”. If the test lamp
If the test lamp “lights” in one direction but does lights, the stator windings are “grounded”.
“not light” in the other direction, the rectifier is (g) Test the stator winding for continuity by con-
satisfactory. If lamp lights in “both directions”, the tacting one prod of the test lamp to all three stator
rectifier is “shorted”. If the test lamp does “not leads at the “Y” connection. Contact each of the three
light” in either direction, the rectifier is “open”. stator leads (disconnected from the rectifiers). The
NOTE: Possible cause of an open or a blown test lamp should “light” when the prod contacts each
rectifier is a faulty capacitor or a battery that has been of the three leads. If the test lamp does not light the
installed on reverse polarity. If the battery is in- stator winding is “open” (See Fig. 25).
stalled properly and the rectifiers are open, test the (h) Install a new stator if the one tested is
TEST LAMP
fi TEST LAMP
A
y 61x244
Fig. 2LTesting the Rectifiers with Test Lamp Fig. 25-Testing the Stator Windings for
(Typical) Continuity (Typical)
SOLDER LUG A ”“A”‘,

SOLDER LUG
63x42
Fig. 26-Removing a Rectifier
“grounded” or “open”. If the rectifiers must be re-

V m
6 2 X 529
placed unsolder the rectifier wire at the soldered Fig. 27-Solder Points-Slip Ring Installed
joint.
NOTE: Three rectifiers are pressed into the heat (5) Clean away dirt and particles of the old slip
sink and three in the end shield. When removing the ring from the rotor.
rectifiers, it i s necessary to support the end shield (6) Scrape the ends of the field coil lead wires
and/or heat sink to prevent damage to these cast- clean for good electrical contact.
ings. (7)Scrape one end (about 3/ls inch) of a piece of
(i) Place the rectifier support adapter in the plat- bare wire (approx. 18 gauge) three inches long (to
form of Tool C-3928 and the remover adapter into be used as a guide wire).
the end of the tool pressure screw. (8)Tin the scraped area of the guide wire with
(j) Place the clamp tool in a vise and support the resin core solder. Lap the tinned end of the wire
end shield on the support adapter under the recti- over the field coil lead to the insulated ring and
fier to be removed (Fig. 26). solder the two together.
NOTE: The support tool adapter i s cutaway and
slotted to fit over the wires and around the bosses in
the end shield. Make sure that the bore of the tool
completely surrounds the rectifier.
Or) Carefully apply pressure with the tool pressure
screw, until the support tool rectifier end shield and
remover pin are in alignment, then press the rectifier
out of the end shield. ’
/- ,
/ .
\ -
OLD SLIP RING
8. REPLACING THE SLIP RINGS ‘91
Slip rings that are damaged can be replaced as
follows:
(1) Cut through the rotor grease retainer with a
chisel and remove the retainer and insulator.
(2) Unsolder the field coil leads at the solder lugs
CUT WITH
(Fig. 27). CHISEL
(3) Cut through the copper of both slip rings at

opposite points (180O apart) with a chisel (Fig. 28).
(4)Break the insulator and remove the old ring. Fig. 2 L C u t t i n g the Old Slip Rings
(11)Position the rotor, slip ring and tool assem-

bly in an arbor press (Fig. 30). Pull upon the guide
GUIDE WIRE wire being careful to guide the insulated field lead
into the slip ring groove. While guiding the insulated
field lead through the groove, press the slip ring
GUIDE WIRE i-
on the shaft. When the slip ring is bottomed on the
SOLDERED TO
rotor fan the end of the field lead should be visible
at the solder lug (Fig. 27).
(12)Unsolder the guide wire from the insulated
b brush slip ring lead. Press the field lead into the sol-
der lug and solder to lug with resin core solder.
CAUTION: Be sure the solder bead does not
protrude beyond the surface of the plastic material.
Do not use acid core solder. A short may result and
corrosion will definitely occur.
(13) Coil the ground brush field lead around the
X527 solder lug and solder with resin core solder.
(14)Test the slip rings for ground with a 110 volt
Fig. 29-Aligning the Slip Ring with the Field test lamp by touching one test lead prod to the rotor
Wire and Guide Wire pole shoe and the remaining prod to the slip rings.
The test lamp should not light. If the lamp lights,
(9) Position the new slip ring carefully over the the slip rings are shorted to ground, possibly due to
guide wire and the rotor shaft so the wire will lay grounding the insulated field lead when installing
in the slip ring groove (Fig. 29). The groove in the the slip ring.
slip ring must be in line with the insulated brush If the rotor is not grounded, lightly clean the slip
field lead to provide room for the lead without dam- ring surfaces with -00-sand paper and assemble the
aging it. alternator.
(10) Place installing Tool C-3900 over the rotor (15)Position the grease retainer gasket and grease
shaft with the guide wire protruding from the slot retainer on the rotor shaft and press the retainer on
in the tool. the rotor shaft with Installer Tool C-3921. Fig. 31.
Retainer is properly positioned when inner bore of
installer tool bottoms on rotor shaft.
Assembly
(1)Test the rectifier identification to make sure
63x43
Fig. 3Llnstalling the Slip Ring Fig. 31-Installing the Bearing Grease Retainer
846 ALTERNATOR AND REGULATOR
HAMMER OR SHOCK the rectifkr In any manner
FIXTURE
as this will fracture the thin riliecm wafw in the
rectifier causing complete rectifier failure.
(3) Clean the leads and mate the stator lead with
the rectifier wire loop and bend tho loop snugly
around the stator lead to provide a good electrical
and mechanical connection. Solder the wires with
resin core solder. Hold the rectifier lead wire with
pliers just below the joint while soldering (Fig. 33).
The pliers will absorb the heat from soldering and
protect the rectifier.
NOTE: After soldering, quickly c o d the soldered
connection with a dampened cloth. This will aid in
forming a solid joint.
Fig. 32-Installing a Rectifier

(4) After soldering, the stator leads must be pushed
down into the slots that are cast into the end shield
and cemented with MoPar Cement Part Number
the correct rectifier is being installed. Refer to MoPar 2299314 to protect the leads against possible inter-
Parts List for rectifier identification. ference with the rotor fans. Test each replacement
(2) Support the heat sink or rectifier end shield rectifier to make certain the rectifier was not dam-
on the installer adapter SP-3820 of Tool C-3928. With aged by the soldering or pressing operations.
the installing adapter positioned on the rectifier, care- (5) Support the end shield on Tool C-3925 so that
fully apply pressure with the tool pressure screw the notches in the support tool will clear the raised
until the installer tool, rectifier, rectifier end shield section of the heat sink and press the bearing into
or heat sink are in alignment and after determining position with Tool SP-3381(Fig. 34).
that the rectifier is started squarely in the casting,
NOTE: New bearings are pre-lubricated and ad-
slowly apply pressure with the tool pressure screw
ditional lubrication is net required.
until you feel the collar of the rectifier bottom
against the casting (Fig. 32). (6) Insert the drive end bearing in the drive end
shield and install the bearing retainer plate to hold
NOTE: Make sure that the installer support adapt- the bearing in place.
er fits squarely around the rectifier inner boss and
(7) Position the bearing and drive end shield on
that pressure is applied on the outer rim of the
rectifier.
the rotor shaft and, while supporting the base of the
rotor shaft, press the bearing and shield into position
CAUTION: DO NOT USE a hammer to start the on the rotor shaft with arbor press and Tool C-3769
rectifier into its bore in the end shield. DO NOT (Fig. 35).
RECTIFIER LEAD 62x114 63x728
Fig. 33-Solder the Rectifier and Stator Leads Fig. 3le-lnstalling the Rectifier End Skiold During
PRESSING TOOL
BEARING
\
IVE END SHIELD
ROTOR
62x116
Fig. 35-Installing the Drive End Shield and Bearing Fig. 36-Installing the Alternator Pulley
CAUTION: Make sure that the bearing i s in- bolt holes in the stator, rectifier end shield and drive
stalled squarely at installation; otherwise, damage to end shield.
the bearing will result. Press the bearing on the rotor (15) Compress the stator and both end shields by
shaft until the bearing contacts the shoulder on the hand and install the through bolts, washers and nuts.
rotor shaft.
(16) Install the insulated brush in the rectifier
(8) Install the pulley on the rotor shaft. The shaft end. Place the bronze terminal on the plastic holder
of the rotor must be supported in a manner so that with the tab of the terminal in the recess in the
all pressing force is on the pulley hub and rotor shaft plastic holder.
(Fig. 36).
(17) Place the nylon washer on the bronze termi-
NOTE: Do not exceed 6800 pounds pressure.
nal and install the lockwasher and attaching screws.
Press the puller on the rotor shaft until the pulley
contacts the inner race of the drive end bearing. (18) Install the ground brush and attaching screw.
(9) The alternators have the capacitor mounted in- (19) Rotate the pulley slowly by hand to be sure
ternally. Make sure the heat sink insulator is in place that the rotor fans do not hit the rectifiers, capaci-
(Fig. 18). tor lead, and stator connections.
(10) Install the capacitor stud through the heat sink (20) Install the alternator and adjust the drive
and end shield. belt.
(11) Install the insulating washers, lockwashers (21) Connect the output “BAT” and the field
and lock nuts. “FLD” leads and connect the ground wire.
(12) Make sure the heat sink and insulator are (22) Connect the battery ground cable.
in position and tighten the lock nut. (23) Start and operate the engine, and observe the
(13) Position the stator on the rectifier end shield. alternator operation.
(14) Position the rotor end shield assembly on the (24) Test the current output and regulator volt-
stator and rectifier end shield. Align the through age setting, if necessary.
848 ALTERNATOR AND REGULATOR
SERVICE DIAGNOSIS
ALTERNATOR
Alternator Fails t o (a) Blown fusible wire in voltage (a) Locate and correct the cause of the fuse
Charge (No O u t p u t ) regulator. blowing. Install a new fuse wire. Solder
both ends of a new fusible wire securely.
(b) Alternator drive belt loose. (b) Adjust the drive belt according to
Specifications under “Cooling System”,
Group 7.
Worn brushes and/or slip rings. (c) Install new brushes and/or slip rings.
Sticking brushes. (d) Clean the slip rings and brush holders.
Install new brushes.
Open field circuit. (e) Test all the field circuit connections, and
correct as required.
Open charging circuit. (f) Inspect all connections in the charging
circuit, and correct as required.
Open circuit in stator windings. (g) Remove the alternator and disassemble.
Test the stator windings. Install a new
stator if necessary.
Open rectifiers. (h) Remove the alternator and disassemble.
Test the rectifiers. Install new rectifiers
if necessary.
Low, Unsteady Alternator drive belt loose. (a) Adjust the alternator drive belt. See
Charging Rate “Cooling System”, Group 7.
High resistance at battery (b) Clean and tighten the battery terminals.
terminals.
High resistance in the charging (c) Test the charging circuit resistance.
circuit. Correct as required.
High resistance in the body to (d) Tighten the ground lead connections.
engine ground lead. Install a new ground lead if necessary.
Open stator winding. (e) Remove and disassemble the alternator.
Low O u t p u t and a (a> High resistance in the charging (a) Test the charging circuit resistance and
Low Battery circuit . correct as required.
(b) Low regulator setting. (b) Adjust the voltage regulator.
(c> Shorted rectifier. (c) Perform the current output test. Remove
Open rectifier. and disassemble the alternator. Test the
rectifiers. Install new rectifiers as required.
Grounded Stator windings. (d) Remove and disassemble the alternator.
Excessive Charging (a> Regulator set too high. (a) Reset the voltage regulator according to
Rate t o a Fully Specifications.
Charged Battery (b) Regulator contacts stuck. (b) Install a new voltage regulator.
(c) Regulator voltage winding open. (c) Install a new voltage regulator.
(4 Regulator base improperly (d) Connect the regulator base to the ground
grounded. connection.
ALTERNATOR
-
Regulator Contacts High regulator setting. (a) Reset the voltage regulator according to
Ox id ized specifications.
Regulator air gap improperly (b) Reset the voltage regulator air gap and
set. lower the contact gap.
Shorted rotor field coil ( c ) Test the rotor field coil current draw.
windings. If excessive, install a new rotor.
Regulator Contacts High regulator setting. (a) Reset the voltage regulator according to
Burned specifications.
Shorted rotor field coil (b) Test the rotor field coil current draw.
windings. If excessive, install a new rotor.
Regulator Voltage High regulator setting. (a) Install a new voltage regulator. Test the
Coi I Windings regulator voltage setting and reset if
Burned necessary.
Regulator Contacts Poor ground connection between (a) Correct the ground connection. Install
Points Stuck the alternator and the regulator. regulator voltage setting and reset if
necessary.
Noisy Alternator Alternator mounting loose. (a) Properly install and tighten the alternator
mounting.
Worn or frayed drive belt. (b) Install a new drive belt and adjust. See
“Cooling System”, Group 7.
Worn bearings. ( c ) Remove and disassemble the alternator.
Install new bearing as required.
Interference between the rotor (d) Remove and disassemble the alternator.
fan and stator leads or rectifiers. Correct the interference as required.
Rotor or rotor fan damaged. (e) Remove and disassemble the alternator.
Install a new rotor.
Open or shorted rectifiers. (f) Remove and disassemble the alternator.
Test the rectifiers. Install new rectifiers
as required.
Open or shorted winding in (g) Remove and disassemble the alternator.
the stator. Test the stator windings. Install a new
8-50 IGNITION SYSTEM‘.-CYLINDER
PART 4
IGNITION SYSTEM CYUNDER)

The ignition system consists of two separate circuit. The secondary high voltage circuit includes the
cuits. The battery, ammeter, ignition switch, ballast coil secondary winding, the distributor cap and rotor,
resistor, primary winding of the ignition coil, distribu- the high tension wiring, the spark plug and the ve-
tor contacts and condenser, vehicle frame, and the hicle frame.
primary wiring make up the low voltage primary cir-
SERVICE PROCEDURES
1. TESTING THE SECONDARY CIRCUIT ary resistance. To remove the wire, grasp the boot at
the end of the wire and rotate the boot slightly to
The coil to distributor cap wire and the spark plug
break the adhesion between it and the spark plug
wires should make good, clean contact in the ignition
insulator. Then use a straight pull to remove from
coil, the distributor cap towers and on the spark
the spark plug.
plugs. Wires that are loose or that are not inserted
The rotor and distributor cap electrodes should be
all the way into the towers or on the plugs will
inspected for burning. Replace the rotor if the elec-
corrode and increase resistance as well as cause
trode is burned on the top or if electrode is worn too
carbon tracking of the coil or cap towers.
short.
Make sure the cap nipples and spark plug covers
are in good condition and pushed down securely on
the cap towers and around the spark plug insulators. 2. DISTRIBUTOR RESISTANCE TEST
Push the plug covers tight against the cylinder head. This test indicates the resistance of the ignition
The ignition coil tower, if oily or dirty, should be primary circuit from the distributor side of the coil,
wiped clean and inspected for cracks, carbon track- through the points and the distributor ground. Ex-
ing oil leaks. Replace the coil if defective. cessive resistance in this portion of the ignition sys-
Inspect the distributor cap for oil film, dirt or tem will prevent the coil from producing sufficient
metal particles on the inside surface. Any contamina- output for good over-all ignition. To perform test,
tion, however slight, can become conductive and proceed as follows:
cause hard starting in wet weather. Thoroughly wash (1) Turn the Selector Switch of a tach-dwell unit
the cap in a weak solution of liquid soap or deter- to the CALIBRATE position and adjust the Dwell
gent in warm water. Do not use a concentrated solu- Calibrator until the Dwell Meter reads on the set
tion or soak the cap in the solution. Scrub the inner line (test leads separated).
surfaces with a stiff bristle nylon brush to clean be-
(2) Leave Selector Switch in the CALIBRATE posi-
tween the ribs and the crevices. Rinse well in hot
tion, connect the tach-dwell red lead to the distributor
water, shake out excess water and dry thoroughly.
terminal of coil and the black lead to a good ground.
Do not use compressed air to dry or blow out the
water. Carefully inspect for cracks or carbon tracking (3) Turn ignition switch “ON”. Observe dwell
on the inner and outer surfaces. Replace the cap if meter reading. Meter pointer should be well within
defective. the black bar marked “DISTRIBUTOR RESISTANCE.”
Old, cracked, or damaged wires should be replaced. If reading is zero or outside of black bar, crank
The secondary cables, cap and rotor should be tested, engine with starter until the meter pointer moves as
using Tool C-3296. This tester provides high voltage far to right as possible (This will indicate that breaker
which is sufficient for testing secondary insulation. points are closed). A reading now within the black
Test the resistance type wire for an open circuit, indicates a normal distributor primary circuit.
loose terminals or high resistance. Replace the cable If reading is outside the black bar, high resistance
if resistance is more than 30,000 ohms, or if the is present in the distributor primary circuit.
terminal has pulled off the cable. (4) Remove test lead from the distributor terminal
NOTE: Jerking the wires to disconnect them of coil and connect to the following points:
from the plugs can stretch them and increase second- (a) Distributor primary terminal (outside)
IGNITION SYSTEM4-CYLINDER 8-5 1
(b) Distributor primary terminal (inside) (3) Start the engine and operate at idle speed.
(c) Breaker point terminal bracket (insulated brack- (4) Observe the dwell meter reading. If the dwell
et) reading is within “Specifications”, the point gap, cam
(d) Ground side of contact points rubbing block and breaker arm are all in satisfactory
condition.
(e) Distributor housing
If the dwell reading is not within specifications,
(5) Repeat tort at each connection until a notice-
incorrect point gap, defective cam, worn rubbing
able change occurs in the meter reading. If a bad
block or distorted breaker arm is indicated.
connection or faulty lead is indicated, clean, tighten
or replace 118 necessary and repeat test (3).
If bad point8 are indicated, remove distributor for
5. DWELL VARIATION
complete inspection, service, testing and calibration. This test indicates the mechanical condition of the
distributor. Excessive wear in distributor mechanical
3. IDLE RPM TEST parts causes dwell variation which will affect ignition
timing. Test procedures are as follows:
The engine Idle rpm setting should be tested and
recorded RS it 18 when the vehicle is first brought into (1) With engine at idle speed, vacuum hose dis-
the shop for testing. This will assist in diagnosing connected, and with the test leads connected as in the
complaints of engine stalling or complaints of creep- Point Dwell Test, Paragraph 4, turn the Tachometer
ing and hard shifting on vehicles equipped with auto- rpm Switch to the 5000 rpm position.
matic tranamimions. Test procedures are as follows: (2) Slowly increase the engine speed to 1500 rpm,
(1) Turh the Selector Switch to the CALIBRATE then slowly reduce to idle speed while observing the
position and adjust Dwell Calibrator until the Dwell dwell meter reading.
Meter reada on the SET line (test leads separated). If the dwell reading varies more than 3 degrees
(2) Connect the red lead of the test unit to the from initial reading between idle speed and 1500
distributor primary terminal at coil and the black rpm, probable wear in the distributor shaft, bushings
lead to a good ground. or breaker plate is indicated. Remove distributor
for complete inspection and testing on a distributor
(3) Turn the Selector Switch to the 6 LOBE posi- tester.
tion.
(4) Turn the tachometer rpm switch to the 1000 NOTE: Dwell variation a t speeds above 1500
rpm position. rpm does not necessarily indicate distributor wear.
Dwell and gap of the points must both be within
(5) With engine at normal operating temperature their specified limits at the same time. If this cannot
(off faat idle), momentarily open the throttle and be accomplished, it is probable that wrong points
release to make sure there is no bind in the linkage are installed or the rubbing block or cam lobes are
and that the idle speed screw is against its stop. badly worn or contact arm i s distorted.
(6) Note englne rpm on 1000 rpm scale and adjust
carburetor idle speed screw to “Specifications”. See 6. IGNITION TIMING
“Fuel System” Specifications Group 14.
To obtain maximum engine performance, the dis-
4. DISTRIBUTOR POINT DWELL tributor must be correctly positioned on the engine
to give proper ignition timing. The ignition timing
The degrees of dwell of the distributor breaker test will indicate the timing of the spark at No. 1
points are the degrees of rotation through which the cylinder at idle (only). Test procedures are as fol-
breaker polnts remain closed. This is also commonly lows:
referred to aa “dwell angle” or “cam angle.” Correct
distributor point dwell is essential for good ignition (1) Disconnect the vacuum hose at distributor.
performance and point life. Test procedures are as (2) Connect the secondary lead of Power Timing
follows: Light to No. 1 spark plug, red primary lead to posi-
(1) Connect the Tach-Dwell red lead to the dis- tive terminal of battery and black primary lead to
tributor terminal of coil and black lead to a good the negative battery terminal.
ground. NOTE: Do not puncture the wires, boots or
(2) Turn the Selector Switch to the 6 LOBE posi- nipples with test probes. Always use adapters. Punc-
tion. turing spark plug wires with a probe will damage
8-52 IGNITION SYSTEML-CYLINDER
the wires. The probe can separate the conductor and (6) Carefully lift the distributor from the engine.
cause high resistance. In addition breaking the rubber
insulation may permit secondary voltage to arc to 8. SHAFT AND BUSHING W E A R TEST
ground. (1)Remove the distributor rotor.
(2) Disconnect the primary lead wire at the dis-
(3) Start the engine and set at idle. (transmission
in neutral). tributor terminal. Do not looren the movable contact
arm spring retaining unit.
(4) Use a timing light to observe the position of
(3) Clamp the distributor hold-down arm in a vise
the timing mark on crankshaft damper and check
against specifications. equipped with soft jaws and apply only enough pres-
sure to restrict any movement of the distributor
(5) Loosen the distributor hold-down arm screw during this test.
and rotate the distributor housing so that crankshaft (4) Attach a dial indicator to the distributor hous-
damper mark aligns with the specified BTC mark on ing so that the indicator plunger arm rests against
timing plate. Refer to “Specifications.” (Moving dis-
the movable breaker arm at the rubbing block and
tributor housing counter-clockwise advances the igni- with the rubbing block of the breaker arm on the
tion timing and clockwise retards the timing.) highest point of a cam lobe (Fig. 1).
(6) Tighten the distributor hold-down arm screw (5) Place one end of a wire loop around the top of
after timing has been set and recheck timing adjust- the distributor shaft. Hook a spring scale in the other
ment with a Power Timing Light. end of the wire loop and pull on a line with the
(7) When the spark timing is correct, reconnect plunger of the indicator gauge. The wire loop must be
vacuum hose to distributor. down on the distributor shaft to insure a straight
pull also be sure that the wire’loop does not interfere
7. DISTRIBUTOR REMOVAL with the indicator or indicator holding bracket. Apply
(1) Disconnect the vacuum hose at distributor. a five pound pull and read the movement of the
plunger on the indicator dial (Be sure the rubbing
(2) Disconnect the primary lead wire at coil.
block of breaker arm is on the highest point of the
(3) Unfasten the distributor cap retaining clips and cam lobe during this test). If the plunger movement
lift off the distributor cap. exceeds .006 inch, replace the bushings and/or dis-
(4) Rotate the engine crankshaft until the distribu- tributor shaft, see “Distributor Disassembly.”
tor rotor is pointing toward the cylinder block. Scribe
a mark on the block at this point to indicate the posi- 9. DISTRIBUTOR
tion of rotor as reference when reinstalling the dis- Disassembly I Fig. 2 1
tributor. (1) Remove distributor rotor.
(5) Remove the distributor hold-down arm screw. NOTE: The distributor cap clamp springs are
Fig. 1-Checking Distributor Shaft Side Play

IGNITION SYSTEMhCYLlNDER 8-53
-CAP
ROTOR
SCREW,
CONTACT SET
BREAKER PLATE
FELT
SNAP RING
Fig. 3-Removing or Installing the Distributor

Cam Felt
Bushing Wear Test,” Paragraph 8, replace bushings

GOVERNOR WEIGHT and/or shaft as follows:
(a) Remove the distributor drive gear retaining
SHAFT pin and slide the gear off the end of the shaft.
CAUTION: Support the hub of gear in a manner
that the pin can be driven out of the gear and shaft
without damaging the gear teeth.
BASE
S- SCREW (b) Use a fine file to clean the burrs from around
., ., the pin hole in the shaft and remove the lower thrust
0 RING-
c, SPRING washer.
.
,
01L,2ER- lr+
-WASHER
B E AR ING (c) Push shaft up and remove through top of dis-
tributor body. Remove the upper thrust washer.
(d) Remove the shaft oiler and lift out the oiler
PLATE wick.
CAUTION: Do not drive the bushings out of the
housing.
Fig. 2-Six Cylinder Distributor (Erploded View) (e) Remove the upper bushdng with Tool (2-3744
(Fig. 5) by threading the tap securely into the bush-
held in place by peening the metal around the
ing. Place the spacer over the tap. Install tool nut
openings and should not be removed.
(2) Remove the two screws and lockwashers at- SPRING CLIP IGHT SPRING
taching the vacuum control unit. HEAVY SPRIN
(3) Remove the primary lead terminal at terminal

screw and slide the primary lead off the breaker
plate terminal. Remove wire and grommet as an
assembly. (Push grommet toward the inside of dis-
tributor to remove. Do not pull the wire).
(4) Remove the two screws and lockwashers at-
taching the breaker plate to housing and lift out the CAM
breaker plate, points and condenser as an assembly.
(5) Remove the oil felt wick from the distributor
cam (Fig. 3). Remove the wire clip from the oil well
in cam (Fig. 4), them remove the cam and yoke as-
sembly, and the spacer. 60x695
(6) If side play exceeds .006 inch in the “Shaft and Fig. 4-Distributor Cam Installed
8-54 IGNITION SYSTEM4-CYLNDER
Is
TOOL
(DRIVER) TOOL (ADAPTER)
Fig. 5-Removing the Distributor Housing Fig. 7-Installing the Distributor Housing Upper
Upper Bushing Bushing
and while holding the tool tap, tighten tool nut to

remove the bushing. Invert housing and remove the
lower bushing in the same manner (Fig. 6).
(f) Soak new bushings in light engine oil for ap-
proximately 15 minutes before installation.
(g) Position the new upper bushing with hole in
bushing up and in line with oil hole in housing, then
press bushing into housing with Tool (2-3041 and
adapter (flat face of adapter contacting bushing)
(Fig. 7) so that upper end of bushing is above the
top of the housing bore. The upper end of bushing
should be 1.613 inch from the top of distributor
housing measured from bottom face of straightedge
to top of bushing. Invert housing and install lower
bushing flush with face of distributor base (Fig. 8).
(h) Insert a 3/32 inch rod through housing oiler
hole to see if hole in bushing indexes with oiler hole
in the housing. If the rod cannot be inserted through
the housing and bushing, drill a VS inch hole through Fig, &Installing the Distributor Housing lower
Bushing
the upper bushing by drilling through the oil wick
hole. Remove burrs caused by the drilling operation,
and blow the chips out of the oil hole.
Fig. &Removing the Distributor Housing lower

Bushing Fig. 9-Burnishing the Distributor Housing Bushing
IGNITION SYSTEM4-CYLINDER 8-55
OILING FELT CENTER LINE+

OF ROTOR ELECTRODE
,L jlnMANDYOKE
60x702A
Fig. 16Distributor Shaft Disassembled
(i) Install the burnishing tool part of Tool Set C-

3041 and press the burnisher through both bushings
(Fig. 9). I 63x761
Assembly Fig. 11-Scribe line on the Distributor Shaft

(1) Test the operation of centrifugal weight and
check weight springs for distortion. the centerline of the next pair of gear teeth, aligning
(2) Lubricate the governor weights. again with the scribe mark on the cnd of the shaft.
(3) Inspect all bearing surfaces and pivot pins for (e) Before drilling through the shaft and gear place
roughness, binding or excessive looseness. a .007inch feeler gauge between the gear and thrust
washer and after again observing that the centerline
(4) Install the cam spacer, chamfered end down,
between two of the gear teeth is in line, with the
on distributor shaft.
centerline at the rotor electrode (Fig. 12) drill a .124-
(5) Slide the cam and yoke assembly on the dis- .129 inch hole and install the roll pin.
tributor shaft and engage the weight lugs with the CAUTION: Support the hub of gear when in-
slots in the yoke (Fig. 10).
stalling the roll pin so that the gear teeth will not be
(6) Install the cam retaining spring clip (Fig. 4). damaged.
(7) Lubricate and install the upper thrust washer
(or washers) on the shaft and slide the shaft into CENTER LINE OF ROTOR ELECTRODE
the distributor body (Fig. 10). I
(8) If the gear is worn or damaged, replace as
follows:
(a) Install the lower thrust washer and old gear
on the lower end of the shaft and temporarily install
the roll pin.
(b) Scribe a line on the end of the shaft from the
center to edge, so that the line is centered between
two gear teeth as shown in Figure 11. Do not Scribe
completely across the shaft.
(c) Remove the roll pin and gear. Use a fine file
to clean the burrs from around the pin hole.
(d) Install the new gear with thrust washer in place MARK O N GEAR
and with hole in gear rotated approximately 90 de- ROTATED APPROX.
Og DEGREES
grees from the old hole in the shaft and with the
scribed line centered between two gear teeth as CENTER LINEOF SPACE
shown. BETWEEN TWO TEETH 63x762
NOTE: If it appears that the new pin hole may
interfere with the shaft oil groove, rotate the gear to Fig. 12-Drive Gear Alignment at Assembly
8-56 IGNITION SYSTEM4-CYLINDER
(10) Install the breaker plate assembly, align con- E CONTACT ARM
denser lead, breaker point spring, primary lead, and
install attaching screws.
(11) Install the felt wick in top of distributor cam
(Fig. 3).
(12) Install the vacuum unit attaching washers and
screws.
(13) Test the breaker arm spring tension (Para-
graph that follows).
(14) Adjust the contact gap.
(15) Lubricate the felt pad in top of distributor
cam with 3 to 5 drops of light engine oil and install
rotor. \ A
60x1122 A
resting Breaker Arm Spring Tension Fig. 1GChecking Point Clearance with Indicator
(1) Hook a spring scale MTU-36 on the breaker
arm and pull in a straight line at a right angle to the sulator also retains the terminal screw head.
point surfaces (Fig. 13). Take a reading as the points
start to separate under the slow and steady pull of (4) Connect the condenser and primary leads.
the scale. Spring tension should be 17 to 20 ounces. (5) Align the contacts, if necessary, to provide
If not, loosen the screw which holds the end of the center contact by bending the stationary contact
point spring and slide the end of the spring in or out bracket only. Never bend movable arm to obtain
as necessary. alignment.
(2) Retighten the screw and retest the spring (6) After aligning the contacts, adjust point clear-
tension. ance to “Specifications,” using dial indicator (Fig.
14). Retest breaker arm spring tension.
NOTE: Spring tension that is too great, will
dause excessive wear on the distributor cam and on Distributor Lubrication
the nylon block of the movable breaker arm. Spring (1) Add 3 drops of SAE 1OW oil to the oiler on
tension that is too weak, is unable to keep the points the outside of distributor base.
in contact with-each other when they close. This is (2) Lubricate felt wick under rotor in top of dis-
particularly true as engine speed is increased, causing
tributor cam with 3 to 5 drops of SAE 1OW oil.
high-speed misfiring.
(3) Wipe all old grease from surface of the breaker
installing and Aligning Contact cam. Apply a light film of new distributor cam grease
Points MoPar Part Number 1473595.
(1) Loosen the terminal screw nut, and remove NOTE: Do not over-lubricate. Excess gream will
the primary lead, condenser lead and terminal screw. be thrown from the distributor cam when the engine
(2) Remove the stationary contact lock screw and is running. If this grease strikes the contact points,
remove the old contact set. arcing and burning of the points will result.
(3) Install a new contact set; the sleeve at one Testing Distributor Advance
end of the adjustable bracket fits over and pivots on Automatic Advance Curve f Centrifugal)
the upper breaker plate mounting pin, the contact in-
Mount the distributor assembly (less cap and rotor)
in a reliable stroboscope-type distributor tester and
KER ARM AND SPRING proceed with tests as follows:
(1) Turn the Tach-Dwell switch to the 6 LOBE
position and Motor Switch to the clockwise rotation.
Refer to “Distributor Advance Specifications” at the
front of this group.
60x703 (2) Turn battery switch “ON.”
(3) Adjust the tester speed control to operate dis-
Fig. 13-Testing Breaker Arm Spring Tension tributor at 100 distributor rpm.
IGNITION SYSTEM4-CYLINDER 8-57
(4) Hold the distributor breaker plate in the full Distributor Installation On the Engine 1
retard position and align the “0”of distributor tester (1) Position the distributor on engine. Make cer-
degree ring with any of the arrow flashes. tain rubber seal is in groove of distributor shank.
(5) Adjust the tester speed control to operate the
(2) Carefully engage the distributor drive gear
distributor at speeds called for under “Specifications”
with the camshaft drive gear so that when the dis-
and observe arrow flashes opposite tester degree ring
tributor is installed properly, the rotor will be in line
to determine degrees of advance.
with the scribed line on the cylinder block.
(6) If the advance is not according to specifications,
corrections can be made by bending either the light NOTE: If the engine has been cranked while
or heavy governor weight spring tabs to increase or distributor is removed, it will be necessary to establish
decrease spring tension. Adjust the light spring ten- the proper relationship between the distributor shaft
sion to obtain the first two positions shown in the and the Number 1 piston position as follows:
specifications; adjust the heavy spring tension to ob- (a) Rotate the crankshaft until number one piston
tain the last two positions. The governor spring tabs is at the top of the compression stroke. (Mark on in-
can be reached through the access hole at the breaker ner edge of crankshaft pulley should be in line with
plate. Rotate the shaft until the proper spring and the “0” VDC) mark on timing chain case cover.
tab lines up with access hole. Insert a screwdriver (b) Rotate the rotor to a position just ahead of
blade through the access hole and bend the spring the number one distributor cap terminal.
tab toward the distributor cam to decrease spring
tension and advance the spark, or away from the (c) Lower distributor into opening, engaging the
distributor cam to increase spring tension and re- distributor gear with the drive gear on the camshaft.
tard the spark. With the distributor fully seated on the engine, the
rotor should be directly under the cam Number 1
Vacuum Diaphragm Leak Test tower with ignition points just separating.
With the distributor mounted in Distributor Tester (3) Install the distributor cap (make sure all high
and with vacuum unit attached to the distributor, tension wires “snap” firmly in the cap towers).
proceed as follows:
(4) Install the hold-down lock plate screw and
(1) Place thumb over end of vacuum pump hose tighten finger tight.
and adjust the regulator control knob to give a read-
ing of 20 ihches of vacuum with hose closed off to ( 5 ) Attach the primary lead to coil.
. -
insure tester hose does not leak. NOTE: Do not connect the distributor vacuum
(2) Attach vacuum pump hose to the tube on the hose at this time.
vacuum unit. Vacuum gauges should hold on maxi- (6) Connect the secondary lead of a Power Timing
mum vacuum obtainable if no leaks exist. Light to the Number 1spark plug and the red primary
(3) Observe the breaker plate while performing lead to the positive terminal of the battery and the
leak test to check response of breaker plate to black primary lead to the negative battery terminal.
vacuum advance. There should be instant response to
the pull of the diaphragm, moving the plate without NOTE: Do Not puncture the cable cap nipples or
a drag, bind or jerk in either direction. spark plug covers with a sharp tool to make con-
tact. Use the proper adapters.
(4) If leakage is indicated, replace the vacuum
unit assembly. (7)Start the engine and run at slow idle.
Vacuum Advance Curve ( 8 ) Rotate the distributor housing so that the
If only the vacuum advance curve is to be checked, timing mark on the crankshaft damper is aligned
connect tester vacuum pump hose to distributor vac- with the “BTC” mark on the chain case cover. Refer
uum advance unit and perform operations 1 through to “Specifications.” (Moving distributor housing coun-
4 under “Automatic Advance Curve.” Then proceed ter-clockwise advances the timing and clockwise re-
as follows: tards the timing.)
(1) Turn tester vacuum pump “ON.” Adust vacuum (9) Tighten distributor hold-down arm screw after
pump regulator to vacuum test specifications. See timing has been set and recheck timing adjustment
“Specifications” and observe arrow flashes on tester with Power Timing Light.
degree ring to determine degrees of advance. (10) If timing is correct, connect vacuum hose to
(2) If the vacuum advance is below or above speci- distributor.
fications, replace the vacuum advance unit. (11) Remove timing light from engine.
8-58 IGNlTfON SYSTEM--&CYLINDER ~ ~~
10. SPARK PLUGS external ballast resistor.

The ballast resistor is a fixed resistance in the
Remove the spark plugs. Examine the firing ends of
ignition primary circuit. During low speed operation,
the plugs for evidence of oil fouling, gas fouling,
when the primary circuit current flow is high, the
burned or overheatiflg conditions.
ballast resistor temperature rises, increasing the re-
Cleaning und Regupping sistance. This reduces the current flow, thereby
Carefully clean the spark plugs in an abrasive type prolonging ignition point life. At high speed opera-
cleaner. Use a pin type feeler gauge to check spark tion, when the primary current flow is low, the
plug gap. Reset gaps to .035 inch. ballast resistance cools off allowing more current
flow, which is required for high speed operation.
NOTE: Before setting the spark plug gap, file the During starter operation, the ballast resistor is by-
center electrode flat. Make adjustment by bending passed, allowing full battery voltage to the ignition
the ground side electrode; never bend the center primary circuit.
electrode. When testing the coil for output, include the resis-
Inspect the spark plug cables, coil secondary cable, tor in tests. Inspect the coil for external leaks and
nipples and covers for cracks, wear and fraying. Test arcing.
for loose terminals. When installing spark plugs, Test the coil according to the coil tester Manufac-
tighten to 30 foot pounds. turer’s instructions. Test the coil primary resistance.
Test the ballast resistor resistance. Test the coil
11 I G N I T I O N COIL secondary resistance. Replace any coil and ballast
The ignition coil is designed to operate with an resistor that does not meet specifications.
I G N I T I O N SYSTEM (8 CYLINDER)
The ignition system consists of two separate cir- circuit. The secondary high voltage circuit includes
cuits. The battery, ammeter, ignition switch, ballast the coil secondary winding, the distributor cap and
resistor, primary winding of the ignition coil, dis- rotor, the spark plug cables, the spark plugs and the
tributor contacts and condenser, vehicle frame, and vehicle frame.
the primary wiring make up the low voltage primary
SERVICE PROCEDURES
12; SECONDARY CIRCUIT INSPECTION hard starting in wet weather. Thoroughly wash the
cap in a weak solution of liquid soap or detergent in
The coil to distributor cap wire and the spark plug
warm water. Do not use a concentrated solution or
wires should make good, clean contact in the ignition
soak the cap in the solution. Scrub the inner surfaces
coil, the distributor cap towers and on the spark
with a stiff bristle nylon brush to clean between the
plugs. Wires that are loose or that are not inserted
ribs and the crevices. Rinse well in hot water, shake
all the way into the towers or on the plugs will cor-
rode and increase the resistance as well as cause car- out excess of water and dry thoroughly. Do not use
compressed air to dry or blow out the water. Care-
bon tracking of the coil or cap towers. Make sure the
fully inspect for cracks or carbon tracking on the in-
cap nipples on spark plug covers are in good con-
ner and outer surfaces. Replace the cap if faulty.
dition and that they are tight on the cap towers and
The secondary cables, cap and rotor should be
around the plug insulators.
tested, using Tool (2-3296.This tester provides high
The ignition coil tower, if oily or dirty, should be
wiped clean and inspected for cracks, carbon track- voltage which is sufficient for testing secondary in-
sulation. Test the resistance of the spark plug cables.
ing or oil leaks. Replace the coil if faulty.
Replace the cable if resistance is more than 30,000
Inspect the distributor cap for oil film, dirt or metal
ohms, or if the terminal has pulled off the cable.
particles on the inside surface. Any contamination,
however slight, can become conductive and cause NOTE: Pulling the wires to disconnect them
IGNITION SYSTEM-8-CYLINDER 8-59
from the plugs can stretch them and increase sec- 14. IDLE RPM TEST
ondary resistance. To remove the wire, grasp the boot
The engine idle rpm setting should be tested and
at the end of the wire and rotate the boot slightly
to break the adhesion between it and the spark plug
recorded as it is when the vehicle is first brought into
the shop for testing. This will assist in diagnosing
insulator. Then use a straight pull to remove the
complaints of engine stalling, creeping and hard shift-
spark plug.
ing on vehicles equipped with automatic transmis-
The rotor and distributor cap electrodes should be sions.
inspected for burning. Replace the rotor if the elec- Test procedures are as follows:
trode is burned on the top or if the electrode is worn
(1) Turn the Selector Switch to the CALIBRATE
too short.
position and adjust the Dwell Calibrator until the
Dwell Meter reads on the SET line (test leads sepa-
13. DISTRIBUTOR RESISTANCE TEST rated).
This test indicates the resistance of the ignition (2) Connect the red lead of the test unit to the
primary circuit from the distributor side of the coil, distributor primary terminal at the coil and the black
through the points and the distributor ground. Ex- lead to a good ground.
cessive resistance in this portion of the ignition sys- (3) Turn the Selector Switch to the 8 LOBE posi-
tem will prevent the coil from producing sufficient tion.
output for good over-all ignition. To perform test,
proceed as follows: (4) Turn the tachometer rpm switch to the 1000
rpm position.
(1) Turn the Selector Switch of a tach-dwell unit
to the CALIBRATE position and adjust the Dwell (5) With the engine at normal operating tempera-
Calibrator until the Dwell Meter reads on the set ture (off fast idle), momentarily open the throttle
line (test leads separated). and release to make sure there is no bind in the link-
age and that the idle speed screw is against its stop.
(2) Leave selector Switch in the CALIBRATE posi-
tion, connect the tach-dwell red lead to the distributor (6) Note engine rpm on 1000 rpm scale and adjust
terminal of coil and the black lead to a good ground. carburetor idle speed to specifications. See “Fuel
System” specifications.
(3) Turn ignition switch “ON”. Observe dwell me-
ter reading. Meter points should be well within the 15. DISTRIBUTOR POINT DWELL
black bar marked “DISTRIBUTOR RESISTANCE”. If
reading is zero or outside of black bar, crank the The degrees of distributor dwell are the degrees of
engine with the starter until the meter pointer moves rotation through which the breaker contact points re-
as far to right as possible. (This will indicate that main closed, This is also commonly referred to as
breaker points are closed.) A reading now within the “dwell angle” or “cam angle”.
black indicates a normal distributor primary circuit. The correct distributor point dwell is essential for
If the reading is outside the black bar, high re- good ignition performance and contact point life.
sistance is present in the distributor primary circuit. Test procedures are as follows:
(4) Remove the test lead from the distributor (1) Connect the Tach-Dwell red lead to the dis-
terminal of coil and connect to the following points: tributor terminal of coil and black lead to a good
ground.
(a) Distributor primary terminal (outside)
(2) Turn the Selector Switch to the 8 LOBE posi-
(b) Distributor primary terminal (inside)
tion.
(c) Breaker point terminal bracket (insulated
(3) Start the engine and operate at idle speed.
bracket)
(4) Observe the dwell meter reading. If the dwell
(d) Ground side of contact points reading is within “Specifications” the point gap, cam
(e) Distributor housing rubbing block and breaker arm are all in satisfactory
(5) Repeat test at each connection until a notice- condition.
able change occurs in the meter reading. If a poor If the dwell reading is not within specifications, in-
connection or faulty lead is indicated, clean, tighten correct point gap, worn cam, worn rubbing block or
or replace as necessary and repeat test (3). distorted breaker arm may be indicated.
If faulty contact points are indicated, remove dis-
tributor for complete inspection, service, testing and 16. DUAL BREAKER P O I N T S
calibration. Block one set of contacts with a clean insulator and
8-60 IGNITION SYSTEM-8-CY LINDER
adjust the opposite set of contacts to specifications (2) Connect the secondary lead of the Power Tim-
using the dwell meter. ing Light to the No. 1 spark plug, red primary lead to
NOTE: Loosen the stationary contact lock screw the positive terminal of the battery and the black
just enough, so that the stationary contact can be primary lead to the negative battery terminal.
moved with a slight drag; otherwise it will be difficult NOTE: Do not puncture the wires, boots or
to set the contacts accurately. nipples with test probes. Always use adapters. Punc-
When the one set of contacts has been adjusted turing spark plug wires with a probe will damage the
for the correct clearance, tighten the stationary con- wires. The probe can separate the conductor and
tact lock screw. cause high resistance. In addition, breaking the rubber
Block the adjusted set of contacts with an insulator insulation may permit secondary current to arc to
and adjust the remaining set of contacts in the same ground.
manner as the first set. Remove insulator and re- (3) Start the engine and set the idle to specifica-
check tightness of the stationary contact lock screw. tions, engine at normal operating temperature (trans-
If the contacts have been properly adjusted, the mission in neutral).
dwell should be as specified for two contact sets.
(4) Using a timing light, observe the positions of
timing mark on the crankshaft damper and check
17. DWELL V A R I A T I O N
against the specifications.
This test indicates the mechanical condition of the (5) Loosen the distributor hold down clamp screw
distributor. Excessive wear in distributor mechanical and rotate the distributor housing so that the speci-
parts cause dwell variations which will affect igni- fied timing mark on damper aligns with the specified
tion timing. “BTC” mark on the timing plate. Moving the distribu-
Test procedures are as follows: tor “clockwise” advances the timing and “counter-
(1) With the engine at idle speed, the vacuum clockwise” retards the timing.
hose disconnected, and with the test leads connected (6) Tighten the distributor hold down clamp screw
as in Paragraph, “Point Dwell Test”, turn the Ta- after the timing has been set and recheck the timing
chometer rpm Switch to the 5,000 rpm position. adjustment with a Power Timing Light.
(2) Slowly increase the engine speed to 1500 rpm, (7) When the ignition timing is correct, connect
then slowly reduce to idle speed while observing the the vacuum hose to the distributor.
dwell meter reading.
If the dwell reading varies more than 2 degrees NOTE: As the engine speed is increased, the
from initial reading between idle speed and 1500 timing mark should move down on the vibration
rpm, probable wear in the distributor shaft, bushings dampener below the pointer if advance units are
or breaker plate bearing and pivot pin is indicated. functioning.
Remove distributor for complete inspection and test-
ing on a distributor tester. 19. DISTRIBUTOR
NOTE: Dwell variation at speeds above 1500 Removal
rpm does not necessarily indicate distributor wear.
(1) Disconnect the vacuum hose at the distributor.
Dwell and gap of the points must both be within their
specified limits at the same time. If this cannot be (2) Disconnect the primary lead wire at the coil.
accomplished, it i s probable that wrong points are (3) Unfasten the distributor cap retaining clips and
installed or the rubbing block or cam lobes are badly lift off the distributor cap.
worn or movable contact i s distorted. (4) Scribe a mark on the edge of the distributor
housing to indicate the position of the rotor as refer-
18. I G N I T I O N T I M I N G ence when reinstalling the distributor.
To obtain maximum engine performance, the dis- (5) Remove the distributor hold-down clamp screw
tributor must be correctly positioned on the engine and the clamp.
to give the proper ignition timing. (6) Carefully lift the distributor from the engine.
The ignition timing test will indicate the timing
of the spark at No. 1cylinder at idle (only). Shaft and Bushing Wear Test
Test procedures are as follows: (1) Remove the distributor rotor.
(1) Disconnect the vacuum hose at the distribu- (2) Clamp the ribbed section of the distributor
tor. housing lightly in a vise equipped with soft jaws
and attach the dial indicator to the body of the dis- (4) Remove the primary lead wire and rubber
tributor with the indicator plunger arm resting grommet as an assembly. Push the grommet towards
against the moveable breaker arm with the rubbing the inside of distributor to remove. Do not pull the
block of the breaker arm on the highest point of the wire.
cam lobe (Fig. 15). (5) Remove the two screws and lockwashers at-
(3) Place one end of a wire loop around the top taching the breaker plate to the housing and lift out
of the distributor shaft. Hook a spring scale in the the breaker plate, points and condenser as an assem-
other end of the wire loop and pull on a line with bly.
the plunger of the indicator gauge. Be sure the wire (6) Remove the oil wick from the distributor cam
loop on the shaft end is down on the shaft to insure (Fig. 18). Remove the spring clip from the oil well
a straight pull and also that the wire loop does not in the cam and remove the cam and yoke assembly
interfere with the indicator or holding bracket. Ap- and spacer.
ply a five pound pull and read the movement of the
If the side play exceeds .006 inch in the “Shaft
plunger on the indicator dial (Be sure the rubbing
and Bushing Wear Test”, replace the bushings and/or
block of breaker arm is on the highest point of the
distributor shaft as follows:
cam lobe during this test). If the plunger movement
exceeds .006 inch, replace the bushing and/or dis- (a) Remove the distributor drive collar retain-
tributor shaft, see “Distributor Disassembly”. ing pin and slide the collar off the end of the shaft.
(b) Use a fine file to clean the burrs from around
Disassembly (Figs. 16 and 1 7 )
the pin hole in the shaft and remove the lower thrust
(1) Remove the distributor rotor. washer.
NOTE: The distributor cap clamp springs on (c) Push the shaft up and remove it through the
Chrysler built distributors are held in place by top of the distributor body. Remove the upper thrust
peened metal around the openings and should not washer.
be removed.
(d) Remove the shaft oiler and lift out the oiler
(2) Remove the retainer attaching the vacuum wick.
advance unit to the breaker plate advance arm.
CAUTION: On Chrysler Built distributors, do
(3) Remove the two screws and lockwashers at-
not drive the bushings out of the housing.
taching the vacuum advance unit to the distributor
housing and remove the unit. (e) Remove the upper bushing with Tool C-3744
62x326
Fig. 15-Shaft and Bushing Wear Test

842 IGNITION SYSTEM-8-CYLINDER
/CAP
.EAD
CAM‘ / F >
SPACER WEIGHT
BEARING\ 1
,E SPRING
SCREW
,---BASE
\
SCREY
VACUUM
SPRING -
61x109 B
.~
PIN
-1 61xl096
Fig. 1&Distributor (Disassembled View) Chryrler Built
L IGNITION SYSTEM4-CLY INDER 8-63
-- - CAP
-4. -- - ZPRING
LEAD _- ROTOR
*, , , CONDENSER
SCREW
WASHER
SCREW
BREAKER PLATE
.
I'
%
< =-___
/-----
WASHER
SCREW
FELT - +eb
BEARING -- ---*?
u 1
,
d,,,,:~
'
CLAMP
LOCKWASHER
SCREW
VACUUM CHAMBER
e---
@ PIN - SPRING
.
)
WASHER
Fig. 17-Distributor (Disassembled View) (Prestolite) (High Performance and Police Engines Only)
8-64 IGNITION SYSTEM-8-CYLINDER
.ex * ’ ’
TOOL (DRIVER)
TOOL (ADAPTER)
56 A 61x151
Fig. 20-Installing the Distributor Housing Upper
Fig. 18-Removing the Distributor Cam Felt Wick
Bushing
(Fig. 19) by threading the tap securely into the bush-
ing. Place the spacer over the tap. Install the tool then press the bushing into the distributor until top
nut and, while holding the tap, tighten the tool nut of bushing is 1.1613 inches from the top of the ma-
chined face of distributor housing. Place a straight-
to remove the bushing. Invert the housing and re-
edge on machined surface of housing and measure
move the lower bushing in the same manner.
from the bottom face of the straightedge to the top
On Prestolite built distributors, place the housing
of the bushing. Invert the housing and install the oth-
in an arbor press and press out the upper and lower
er bushing (Fig. 21) flush with the face of the distrib-
bushings from the bottom of the housing using driver
utor base.
To01 (2-3041.
(h) Insert a 3/32 inch rod through the housing
(f) Soak the new bushing in light engine oil for oiler hole to see if the hole in the bushing indexes
approximately 15 minutes.
with the oiler hole in the housing. If the rod cannot
(g) Position the new upper bushing with the be inserted through the housing and the bushing,
hole in the bushing up and in line with the oil hole drill a %” hole through the upper bushing by drilling
in the housing, then press the bushing into the dis- through the oil wick hole. Remove burrs caused by
tributor housing wit4 Tool (2-3041and adapter (Fig. the drilling operation.
20). The bushing will measure .094 inch below the
(i) Install the burnishing tool part of Tool set
top of the housing bore for Prestolite distributors.
C-3041 and force the burnisher through both the
For the Chrysler built distributors use Tool (2-3041
bushings (Fig. 22). The correct bushing inside the
with the flat face of adapter contacting the bushing
diameter is .4994to .5000 inch.
PRESS RAM
TOOL (DRIVER)
61x150
Fig. 1GRemoving the Distributor Housing Upper Fig. 214nstalling the Distributor Housing Lowor
Bushing bushing
BREAKER ARM
AND SPRING
TOOL
(BURNISHER)L!
UPPER BUSHING
61x154 A
Fig. 23LTesting the Breaker Arm Spring Tension
61x149 Testing Breaker Arm Spring Tension

(1) Hook a spring scale Tool MTU-36 on the break-
Fig. 2Q-Burnishing the Distributor Housing Bushings
er arm and pull in a straight line at right angles
to the point surfaces (Fig. 23). Take a reading as the
Distributor Assern bly points start to separate under the slow and steady
pull of the scale. The spring tension should be as
(1) Test the operation of the centrifugal weight
shown in specifications. If the reading is outside these
and inspect the weight springs for distortion. Lubri-
limits, loosen the screw which holds the end of the
cate the governor weights.
breaker arm spring, and slide the end of the spring in
(2) Inspect all the bearing surfaces and pivot pins or out, as necessary.
for roughness, binding or excessive looseness.
(2) Tighten the screw and measure the spring ten-
(3) Install the cam spacer, chamfered end down sion.
on the distributor shaft.
NOTE: Spring tension that i s too great, will
(4) Slide the cam and yoke on the distributor
cause excessive wear on the distributor cam and on
shaft, engage the weight lugs with the slots in the
the nylon block of the movable breaker arm. Spring
yoke. Install the cam retaining spring clip. Be sure
tension that is too weak, is unable to keep the points
it is properly seated in the groove of the distributor
in contact with each other when they close. This is
shaft.
particularly true as engine speed is increased, caus-
(5) Lubricate and install the two concave upper ing high-speed misfiring.
thrust washers for Prestolite distributors or a single
flat thrust washer for Chrysler-built distributors. installing and Aligning Contact Points
Position the washers on the distributor shaft and (1) Remove the old contact points and install a
slide the shaft into the distributor body. Position the new set.
lower thrust washer and drive the collar on the lower
end of the shaft. Install the retainer pin.
(6) Install the oiler wick and oiler.
(7) Install the breaker plate assembly. Align the
condenser lead, breaker point spring, primary lead
and install the attaching screws.
(8) Install the felt wick in the top of the distributor
cam.
(9) Attach the vacuum advance unit arm to the
breaker plate and install the retainer. Install the
vacuum unit attaching screws and washers.
(10) Test the breaker arm spring tension, and
adjust the contact gap.
(11) Lubricate the felt pad in the top of the dis-
tributor cam with 3 to 5 drops of light engine oil and
install the rotor. Fig. 2LAdjusting the Contact Point Cleutance
8-66 IGNITION SYSTEM-8-CYLINDER
NOTE: Touching the contact points faces with tester degree ring with any one of the arrow flashes.
fingers during installation will cause burning of (5) Regulate the tester speed control to operate
points during operation. the distributor at speeds called for under “Specifi-
(2) Align the contacts to obtain contact in the ten- cations” and observe arrow flashes opposite tester
ter of the points by bending the stationary contact degree ring to determine degrees of advance.
bracket only. Never bend the movable arm to obtain (6) If the advance is not according to specifica-
alignment. tions, corrections can be made by bending the pri-
(3) After aligning the contact points, readjust the mary and secondary spring tabs to increase or de-
point clearance to specifications using a dial indicator crease the spring tension. The governor spring tabs
(Fig. 24). can be reached through the access hole at the breaker
(4) Test the dwell angle to show proper degree of plate. Rotate the shaft until the proper spring and
closure. See Paragraph, “Distributor Point Dwell”. tab lines up with the access holes. Insert a screw-
The lock screw should be loosened just enough so driver blade through the access hole and bend the
that the stationary bracket can be moved with a spring tab toward the distributor cam to decrease
slight drag; otherwise, it will be difficult to set the spring tension and advance the spark, or away from
points accurately. After setting the points to correct the distributor cam to increase the spring tension and
the gap, tighten the lock screw. retard the spark.
NOTE: The light tension spring controls the
Dist ributor Lubrication
lower end of the advance curve, and the heavier
(1) Add 3 to 5 drops of SAE 1OW oil to the oiler spring controls the upper end of the advance curve.
on the outside of distributor base.
(2) Lubricate the felt pad under the rotor in the Vacuum Diaphragm Leak Test
top of the distributor cam with 3 to 5 drops of SAE With the distributor mounted in the distributor
1OW oil. tester and with the vacuum unit attached to the dis-
(3) Wipe all old grease from surface of the breaker tributor, proceed as follows:
cam. Apply a light film of new distributor cam lubri- (1) Place the thumb over the end of the vacuum
cant MoPar Part Number 1473595. Do not over-lu- pump hose and adjust the regulator control knob to
bricate. Excess grease will be thrown from the d i e give a reading 20 inches with hose closed off to be
tributor cam when the engine is running. If this sure tester hose does not leak.
grease strikes the breaker points, arcing and burning
(2) Attach the vacuum pump hose to the tube on
of the points will result.
the vacuum unit. The vacuum gauge should hold on
Testing Distributor Advance maximum vacuum obtainable if no leaks exist.
Centrlf ugal Advance Curve 1 (3) Observe the breaker plate while performing
Note the model number of the distributor and refer the leak test to test response of the breaker plate.
to the specifications before making this test. There should be instant response to the pull of the
Mount the distributor assembly (less cap and ro- diaphragm, moving the plate without a drag or bind.
tor) in a reliable stroboscope-type distributor tester (4) If leakage is indicated, replace the vacuum
and proceed with tests as follows: unit assembly.
NOTE: Clamp around the rib section of the dis-
Vacuum Advance Curve
tributor housing. The bottom section of the distrib
utor housing is not a machined surface and concen- Connect the tester vacuum pump hose to the dis-
tricity would be affected, causing a wobble. tributor vacuum advance unit and perform operations
1 through 5 under “Centrifugal Advance Curve”
(1) Turn the Tach-Dwell switch to the 8 “LOBE” Then proceed as follows:
position and the motor switch to the correct direc-
(1) Turn the tester vacuum pump “ON”. Adjust
tion of rotation. Refer to “Distributor Advance
Specifications”. the vacuum pump regulator to vacuum test specifica-
tions. See “Specifications” and observe the arrow
(2) Turn the battery switch “ON”. flashes on the tester degree ring to determine the
(3) Regulate the tester speed control to operate degrees of advance.
the distributor at 200 distributor rpm. (2) If the vacuum advance is above or below
(4) Hold the distributor breaker plate in the full specifications, replace the vacuum advance unit. re-
retard position and align the “0” of the distributor test the vacuum advance curve.
lnstallat ion 20. SPARK PLUGS

(1) Position the distributor on the engine. Align Cleaning and lnspection
the rotor with marks previously scribed on the dis-
tributor housing. Remove the spark plugs. Examine the firing ends of
the plugs for evidence of oil fouling, gas fouling,
(2) Engage the tongue of the distributor shaft burned or overheating conditions.
with the slot in the distributor and oil pump drive
gear. Cleaning and Regapping
NOTE: If the engine has been cranked while the Carefully clean the spark plugs in an abrasive type
distributor is removed, it will be necessary to ertab cleaner. Use a pin type feeler gauge to check spark
lish the proper relationship between the distributor plug gap. Reset the gaps to .035inch.
shaft and the Ne. 1 pisten position as follows: NOTE: Before setting the spark plug gap, file cen-
(a) Rotate the crankshaft until the number one ter electrode flat. Make adiustment by bending the
piston is at top of the compression stroke. ground side electrode; never bend the center elec-
(b) Rotate the rotor to the position of the number trode.
one distributor cap terminal. Inspect the spark plug cables, coil secondary cable,
(c) Lower the distributor into the opening, con- nipples and covers for cracks, wear and fraying. Test
nect the primary lead and install the distributor cap. for loose terminals. When installing spark plugs,
Make sure all high tension wires “snap” firmly in tighten to 30 foot pounds.
the cap towers. Install the distributor hold-down
clamp screw. Tighten the screw finger tight. 21. IGNITION COIL
NOTE: DO NOT puncture cable cap nipples or The ignition coil is designed to operate with an
spark plug covers with a sharp tool to make con- external ballast resistor.
tact. Use the proper adapters. The ballast resistor is a fixed resistance in the
(3) Connect the secondary lead of a Power Tim- ignition primary circuit. During low speed operation,
ing Light to the No. 1 spark plug (using proper adapt- when the primary circuit current flow is high, the
er). Connect the red primary lead to the positive ballast resistor temperature rises, increasing the re-
terminal of the battery and the black primary lead sistance. This reduces the current flow, thereby pro-
to the negative battery terminal. longing ignition point life. At high speed operation,
when the primary current flow is low, the ballast re-
(4) With distributor vacumn hose disconnected
sistance cools off allowing more current flow, which
start and operate the engine at idle speed. Rotate
is required for high speed operation. During starter
the distributor housing so that the specified timing
operation, the ballast resistor is bypassed, allowing
mark and the pointer are in alignment. (Moving the
full battery voltage to the ignition primary circuit.
distributor housing “clockwise” advances the timing
When testing the coil for output, include the re-
and “counterclockwise” retards the timing.
sistor in tests. Inspect the coil for external leaks and
(5)Tighten the distributor clamp screw after the arcing.
timing has been set and recheck the timing adjust- Test the coil according to the coil tester Manufac-
ment with a power timing light. turer’s instructions. Test the coil primary resistance.
(6) If the timing is correct, connect the vacuum Test the ballast resistor resistance. Test the coil sec-
hose to the distributor and remove the timing light ondary resistance. Replace any coil and ballast resist-
from the engine. or that does not meet specifications.
8-68 IGNITION SYSTEM-8-CY LINDER
SERVICE DIAGNOSIS
IGNITION SYSTEM
Burned or Pitted (a) Dirt or oil on points. (a) Replace points and adjust if the oil is on
Distributor Points contact face, determine the cause and cor-
rect the condition.
(b) Alternator voltage regulator (b) Test the alternator voltage regulator
setting too high. setting, adjust as necessary. Replace and
adjust the distributor contact points.
Points misaligned or gap too ( c ) Align and adjust points.
small.
Faulty coil. (d) Test and replace coil if necessary. Replace
and adjust contact points.
Ballast resistor not in circuit. (e) Inspect conditions, and correctly connect
the coil.
Wrong condenser or faulty (f) Test the condenser and replace if
condenser. necessary. Replace and adjust points.
Faulty ignition switch. (8) Replace the ignition switch.
Bushings or distributor shaft (h) Recondition the distributor.
worn.
Touching of points with hands (i) Replace and adjust the contacts.
during installation.
Ignition Coil Alternator voltage regulator (a) Test the alternator voltage regulator
Failure setting too high. setting and adjust as necessary. Inspect
the condition of the distributor contact
points.
Coil damaged by excessive heat (b) Replace coil. Inspect the condition of the
from engine. distributor contact points.
Coil case or tower cracked. (c) Replace the coil.
Oil leak at tower. (d) Replace the coil.
Coil tower carbon-tracked. (e) Wipe the tower clean. Test the coil, replace
if necessary.
Condenser Failure (a) Normal fatigue. (a) Test and replace the condenser. Inspect
distributor contact points for pitting.
(b) Damaged by excessive engine (b) Test and replace the condenser. Inspect
heat or moisture. distributor contact points for pitting.
Fouled Spark Plugs (a) Carburetor mixture over-rich. (a) Adjust the carburetor. Refer to Group 14
“Fuel System”.
Improper gap adjustment. (b) Set the spark plug gap to .035 inch.
Improper plug heat range. ( c ) Install the correct plugs.
Burned Spark Plugs (a) Plugs loose or too tight (a) Replace the spark plugs: Install new
in the cylinder head. gaskets. Tighten spark plugs to 30
foot-pounds torque.
Carburetor mixture too lean. (b) Adjust the carburetor. Refer to Group 14
“Fuel System”.
Improper plug heat range. (c) Install the correct plugs.
Improper ignition timing. (d) Adjust the ignition timing.
LIGHTING SYSTEM 8-69
PART 5
LIGHTING SYSTEM
Plymouth
The dual headlamp system on Plymouth models
consists of four sealed beam headlamps.
The two outboard lamps are of the two filament
type for low and high beam and are marked by a
numeral 2 molded in the lamp lens.
The lamps cannot be installed wrong as the mount-
ing lugs for the number one (1) and number two (2)
lamps are offset at different angles.
The number 1 lamp provides the high intensity
“reach” down the highway and the off focus filament
in the number 2 lamp provides the “body” light which
illuminates the side of the road, ditches, etc.
Valiant
The single beam system on Valiant models consists Fig. 1-Testing Aimer for Calibration
of two sealed beam headlamps.
The lamps are the two filament type for low and
(10) Remove the headlamp front trim panel. Do
high beam and are marked by a number 2 molded
not remove the seal beam retainer rims.
in the lamp lens.
The low beam provides the “body” light which il- (11) Thoroughly clean the headlamp lenses.
luminates the side of the road, ditches, etc.
The high beam provides the high intensity “reach” 2. AIMER CALIBRATION
down the highway. Testing and Adjusting (Fig. I J
(1) Using a carpenter or a stone mason level of
1. AIMING THE HEADLAMPS known accuracy, locate a true vertical plate glass
Pre -Aiming lnst ructions window or smooth surface.
(1) Test the dimmer switch operation. (2) Set the DOWN-UP pointer on DOWN 2.
(2) Test the high beam indicator-indicates the (3) Set the RIGHT-LEFT pointer and the floor level
high beam is in operation when lighted. compensator at “0”.
(3) Inspect for badly rusted or faulty headlamp as- (4) Secure the aimers to the glass or smooth sur-
semblies. These must be corrected before a satisfac- face three to five feet apart so split image targets can
tory adjustment can be made. be located in the viewing ports.
(4) Place the vehicle on a level floor.
(5) Adjust the front suspension height as neces-
sary.
(6) Inspect tire inflation.
(7) Rock the vehicle sideways to allow the vehicle \
to assume its normal position. .. .

(8) If the gasoline tank is not full, place a weight
\
.....
in the trunk of vehicle to simulate the weight of a full
tank (6% pounds per gallon). . \
..‘
(9) There should be no other load in the vehicle
TRANSIT
other than the driver or a substituted weight of ap- 59x431.1
R A N G E SCR
proximately 150 pounds placed in the driver’s posi-
tion. Fig. %Determining Slope of Floor
8-70 LIGHTING SYSTEM
(5) If the bubble is centered in the glass dial, verti- 4. MOUNTING AND ADJUSTING THE
cal calibration is correct. If the bubble is not centered, AIMERS
make the DOWN-UP adjustment by rotating the level
(1) While holding an aimer in alignment with the
adjusting screw until the bubble is centered in the
lens of one outboard headlamp, bring aimer up to
spirit level.
and against headlamp lens.
(6) The horizontal aim is correct if the targets on
opposite aimers are aligned in the viewing ports. If NOTE: Make certain that the headlamp lens pads
the targets are not aligned in the viewing ports, ro- are making full contact with the aimer mounting
tate the mirror adjusting screw until the target split flange and that the aimer target is facing inboard.
image becomes aligned. (2) Push the release lever forward (to expel
air from suction cup) and while holding the aimer
3. COMPENSATING AND MOUNTING THE firmly against the headlamp aiming pads, slowly pull
AIMERS the release lever back until the spring lock engages
Determining the Slope of Floor in the slot, as shown in Figure 4.
(1) Place the transit on the floor in line with the (3) Mount the second aimer on the other outboard
vertical centerline of the right front wheel (Fig. 2). headlamp, in the same manner.
Place the split image target in like position at the
(4) On each aimer, set the pointer to numeral 2 the
right rear wheel.
DOWN side of the DOWN-UP scale.
(2)Adjust the range screw on the transit until the
(5) On each aimer position the pointer, of the
target split image coincides or merges into one un-
RIGHT-LEFT scale, at 2-RIGHT.
broken line.
NOTE: Make sure that the line of sight is per-
5. MEASURING HEADLAMP A I M
pendicular from the eye to the viewing port of the
transit and that the target image is centered in view- Horizontal Test
ing port of transit. Turn the RIGHT-LEFT scale knob until the split
(3) Turn the dial on the side of the transit until image is in alignment. If the RIGHT or LEFT POR-
the bubble in the spirit level is centered. TION of scale exceeds the following values, the
lamps should be aimed.
(4) When the bubble is centered, note “plus” or
“minus” reading on the compensator scale. This fig- Values given represent inches at 25 feet.
ure indicates the degree of slope of the floor and Right left
must be transferred to each aimer. No. 1 Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4
(5) With a screw driver, turn the adjusting slot of No. 2 Unit.. .......................... 4 4
the floor level compensator in each aimer, until the Vertical Test
correct plus or minus figure (or fractional part) ap- Turn DOWN-UP scale knob until the spirit level is
pears in the proper window, as shown in Figure 3. centered. If Down or Up portion of the scale exceeds
the following values, the lamps should be aimed.
Down UP
No. 1 Unit. .................... to 3 %
’/2 0
No. 2 Unit.. . . . . . . . . . . . . . . . . . . . % to 3% 0
4 I
Fig. 3-Acrjurting Floor level Compensator in

the Alimers Fig. ~ M o u R and
~ ~Adjusting
A ~ Aimers
Vertical Adjustment
(1) Turn the vertical adjusting screw on the head-
lamp in a counterclockwise direction to bring the
bubble of the spirit level on the aimer to the vehicle
side of center. Use care to avoid disturbing the in-
stalled position of the aimers. Then turn the screw
clockwise until the bubble is centered for correct aim
and elimination of backlash.
(2) Make the vertical adjustment on the other out-
board unit in the same manner.
(3) Inspect the target alignment on each side and
readjust the horizontal aim, if necessary.
Proceed to adjust the inboard units by following
the instruction as outlined for the outboard head-
Fig. &Headlamp Adjustment Points (Plymouth)
lamps Paragraph 4. Install headlamp trim panels.
NOTE: Remove the aimers by releasing the spring
lock at the rear (bottom) of the aimer and pushing
6. ADJUSTING THE HEADLAMPS the release lever forward. Do not attempt to remove
Horizontal Adjustment the aimers by pulling them away from the head=
(1) With the pointer of RIGHT-LEFT scale still set lamp lens-slide the suction cup downward and away
at 2-RIGHT, sight through the aimer viewing port. from the lens.
NOTE: Make sure that the line of sight is per- 7. HEADLAMP SEALED-BEAM
pendicular from the eye to the viewing port of the REPLACEMENT ( All Models 1
aimer and that the target image is centered in the
viewing port of the aimer. Lens, filament and reflector are sealed into one
unit which can be removed as follows:
(2) While sighting through the viewing port of the
aimer, turn the horizontal adjusting screw on the (1) Remove the screws from the headlamp panel
headlamp until the split target image line merges into and remove the panel.
one unbroken line. To remove backlash, be sure to (2) Remove screws from interior retaining ring,
make a final adjustment by turning headlamp horizon- and remove the ring. Do not disturb the headlamp
tal adjusting screw in a clockwise direction, as shown aimer screws.
in Figures 5 or 6. (3) Pull out the sealed-beam unit and unplug the
(3) Make the horizontal adjustment on the other connector, pulling it straight off.
outboard headlamp in the same manner. (a, Install a new sealed-beam unit.
( 5 ) Install the unit retaining ring and headlamp
panel.
(6) Aim ,the headlamp.
8. VISUAL HEADLAMP ADJUSTMENT

(Without Aimers 1
SINGLE BEAM-VALIANT
Place the vehicle on a known level floor 25 feet
from the aiming screen or light colored wall.
Four lines are required on the screen or wall: (See
Fig. 7)
(a) A horizontal line at the level of the centers of
the lamplamps.
(b) A center vertical line which must be lined up
with the center of the hood.
63x624A (c) A vertical line on the left of the screen or wall
Fig. 6-Headlamp Adjustment Points (Valiant) in line with the center line of the left headlamp.
8-72 LIGHTING SYSTEM
Remove the headlamp door. Adjust the top adjust-

ing screw for vertical adjustment, adjust the side
screw for horizontal adjustment. (See Fig. 6).
Refer to Figure 7 and adjust the headlamp as fol-
lows:
1. Lower beam pattern of the right headlamp.
2. Lower beam pattern of both headlamps.
3. Horizontal line at the level of the headlamp
centers.
4. Vertical line in line with the center of the left
Fig. 7-Single Beam Adjustment Pattern headlamp.
(d) A vertical line on the right of the screen or 5. Vertical line in line with the center of the hood.
wall in line with the center line of the right head- 6. Vertical line in line with the center of the right
lamp. headlamp.
HEADLAMPS
Headlamps Dim (engine (a) Partly discharged battery. (a) Charge the battery.
idling or shut off) (b) Faulty cells in battery. (b) Replace the battery.
(c) High resistance in headlamp (c) Test the headlamp circuit including
circuit. ground connection. Make necessary
repairs.
Faulty sealed beam units. (d) Replace sealed beam units.
Headlamps Dim (engine (a) High resistance in headlamp (a) Test the headlamp circuit including
running above idle) circuit . ground connection. Make necessary
repairs.
Faulty sealed beam units. (b) Replace sealed beam units.
Faulty voltage regulator. (c) Test the voltage regulator and alternator.
Make necessary repairs.
Lamps Flicker Loose connections or (a) Tighten the connections and inspect for
damaged wires in headlamp damaged wiring.
circuit .
Headlamp wiring insulation (b) Test headlamp wiring and replace or
damaged producing tape damaged wires.
momentary.
~~ ~
SERVICE D I A G N O S I L (Continued1
HEADLAMPS
Lamps Burn O u t (a) High voltage regulator (a) Adjust the voltage regulator.
Freque n t I y setting.
(b) Loose connections in (b) Inspect the circuit for loose connections.
headlamp circuit.
Lamps Will Not Light (a) Discharged battery. (a) Recharge the battery and correct cause.
(b) Loose connections in (b) Tighten the connections.
headlamp circuit.
(c) Burned out lamps. (c) Replace the bulbs or sealed beam unit.
(d) Open or corroded contacts (d) Replace the headlamp switch.
in headlamp switch.
(e) Open or corroded contact ( e ) Replace the dimmer switch.
in dimmer switch.
8-74 INSTRUMENT CLUSTER
PART 6
INSTRUMENTS
INSTRUMENTS - INDICATORS
to the cluster base serve as a ground for the instru-
ment lamps and the voltage limiter.
The instrument cluster assembly is attached to the With the exception of the leads to the alternator
instrument panel by four cross-recessed screws. The (ammeter) and clock, all wiring to the cluster is con-
cluster contains the speedometer, fuel gauge, tem- nected through a plug type multi-connector to the
perature gauge, alternator (ammeter), oil pressure male connector pins on the printed circuit board
warning light and clock (if so equipped). The instru- which is mounted to the back of the instrument
ments and lamps are attached to a printed circuit cluster assembly. The female multi-connector is a
board in which are imbedded the electrical circuits push type with a master locator pin.
(conductors) in the form of die cut, copper foil strips. The fuel and temperature gauges are the thermal
The printed circuit completes the circuit to the fuel type. The gauges operate on a principle of a constant
gauge, temperature gauge, voltage limiter and instru- voltage being applied and are sensitive to changes in
ment lamps. The screws attaching the printed circuit fuel level or temperature.
SERVICE PROCEDURES
1. VOLTAGE LIMITER battery negative post. Touch the positive lead of the
voltmeter to the input terminal of the voltage limiter.
Plymouth A reading of 12 volts should be shown on the volt-
Constant voltage is provided to the gauges through meter.
the use of a voltage limiter mounted on the back of Touch the positive lead of the voltmeter to the out-
the instrument cluster printed circuit board and is put terminal of the voltage limiter. A fluctuating
connected in parallel to the gauges and provides the reading between 0 and 7 volts should be shown on the
same regulated voltage to the gauges. voltmeter. Any other reading indicates the voltage
Valiant limiter is not functioning properly and should be re-
Constant voltage is provided through a voltage pleaced
limiter contained inside the fuel gauge. The voltage Valianf
limiter is connected in parallel to the gauges and Connect a jumper wire from the positive post of
provides the same regulated voltage to the gauges. a 12 volt test battery to the "I" terminal of the
Testing the Voltage Limiter-in the fuel gauge. Connect another jumper wire from the
Vehicle battery negative post to the fuel gauge case (ground).
A quick test to determine if the voltage limiter is Connect the negative lead of a voltmeter to the
operating is to connect one lead of a voltmeter or battery negative post. Touch the positive lead of the
test lamp to the temperature sending unit and the voltmeter to the "I" terminal of the fuel gauge. A
other lead to 9 good ground; leave the sending unit reading of 12 volts should be shown on the voltmeter.
lead wire attached to the sending unit. Touch the positive lead of the voltmeter to the "A"
Turn the ignition switch to the "on" position. A terminal of the fuel gauge. A fluctuating reading be-
fluctuating voltmeter or a flashing lamp indicates the tween 0 and 7 volts should be shown on the volt-
voltage limiter is operating. meter. The same fluctuating reading should be shown
at the "S" terminal of the fuel gauge. Any other
readings indicate the voltage limiter is not function-
Testing the Voltage Limiter-Instrument
ing properly and the fuel gauge should be replaced.
Cluster Removed
Plymouth 2. FUEL LEVEL I N D I C A T I N G SYSTEM
Connect a jumper wire from the positive post of a (Figs. 1 and 2 )
12 volt test battery to the voltage limiter input term- Turning the ignition key on, connects the system
inal. Connect another jumper wire from the battery to the battery or charging system voltage. The func-
negative post to the voltage limiter case (ground). tion of the voltage limiter is to regulate this input
Connect the negative lead of a voltmeter to the voltage from the battery or charging system to a con-
INSTRUMENT CLUSTER 8-75
TO BATTERY POSITIVE TO BATTERY NEGATIVE
VOLTAGE LIMITER
( O N INSTRUMENT CLUSTER) (+) POST- (-) POST
FUEL TANK FUEL GAUGE
I
I
I
I
/FUEL TANK SENDING UNIT
FROM SENDING UNIT

64x
\
STER BASE (GROUND)
( O N DASH PANEL) Fig. 3-Testing Fuel Gauge (Tool C-3826) (Plymouth)

64 x 418
from the tank unit. Attach one lead of the Gauge
Fig. 1’-Fuel level Indicating System (Plymouth) Tester (C-3826) to the disconnected terminal. Connect
the other lead of the tester to a good ground.
stant voltage of approximately 5 volts D.C. With the ignition switch turned on and gauge tester
The effect of this constant voltage supply is to in the “L” position, the fuel gauge should show
cause the balance of the system to be sensitive to “E” or minus 3/32 inch.
changes in the value of resistance at the tank unit NOTE: This tolerance permits a small reserve
only. of fuel at the “E” position.
A float arm is hinged to allow the float to raise or
With the gauge tester in the “M” position, the fuel
lower dependent on the fuel level. The float connects
gauge should slowly advance to the Y2 position, plus
to a variable resistance that provides a change in the
or minus l/la inch. With the gauge tester in the
resistance with any up or down movement of the float
“H” position the fuel gauge should advance to ‘IF”,
through a wiping contact in the gauge body.
plus or minus % 2 inch.
When the fuel level is low or if the fuel tank is
Should the gauge fail to respond to the above tests,
empty, the resistance is increased which decreases the
indications are of possible loose connections, broken
current flow and consequently positions the instru- wire, faulty printed circuit or a defective fuel gauge.
ment panel gauge pointer to low or empty. The instrument cluster should be removed for further
When the tank is full, the float level is at the top, tests. See “Instrument Cluster”, Paragraphs 6 and 7.
the minimum resistance is in the circuit and the flow
of current in the circuit is high. The instrument panel Testing Fuel Gauge-lnstrument Cluster
gauge pointer will be moved across the dial to indi- Removed (Figs. 3 and 41
cate a full tank. Place the instrument cluster on a padded service
Testing Fuel lndicating System In the BATTERY TO BAllERY
Vehicle NEGATIVE POST
Raise the vehicle on a lift. Disconnect the terminal FUEL
12 VOLT INPUT I \\ 1 TO GROUND
I 01
FROM SENDING UNIT TO IGNITION

INPUT TERMINAL
\BULKHEAD CONNECTOR
( O N DASH PANEL)
64 x 417 TO “S” TERMINAL
Fig. 2-Fuel level Indicating System (Valiant) Fig. 4-Testing Fuel Gauge (Tool C-3826) (Valiant)
bench to protect the cluster finish. n

The gauges in the instrument cluster can be tested
with a fully charged 12 volt battery and Gauge Tester
vo=--t-o
(FROM VOLTAGE LIMITER
OR FUEL GAUGE)
A I
To01 C-3826.
To prevent a possible error that might result in
burning out the gauges the following test procedures ,TEMPERATURE SENDING
UNIT ( O N ENGINE)
should be closely followed.
I I TEMPERATURE GAUGE
CAUTION: A direct connection from a 12 volt
battery to the gauges will burn them out. A short
circuit to the printed circuitry will burn it out.
(1) On Plymouth models insulate the pins at both
sides of the ignition input pin of the printed circuit. 64 x 419
Connect a jumper wire to the voltage limiter input Fig. 5-Temperature lndicating System
terminal on Plymouth models or to the ignition in-
put terminal of the fuel gauge on Valiant models.
Connect the other end of the jumper wire to the Testing the Temperature lndicating System
positive post ( + ) of a 12 volt test battery. in the Vehicle
(2) Connect a jumper wire from the negative (-) Disconnect the terminal from the temperature
post of the battery to the instrument cluster base sending unit on the engine. Connect one test lead of
(ground). tester C-3826 to the terminal and the other test lead
(3) Connect one lead from Tester Tool C-3826 to to a good ground. Place the pointer of the gauge
the fuel gauge “S” terminal. tester on the “L” position and turn the ignition
switch to ”on”. The temperature gauge should show
With the gauge tester in the “L” position, the fuel “C” plus or minus Y’ inch.
gauge should show “E” or minus 3/32 inch.
NOTE: Thermal gauges are slow in operation. Al-
NOTE: The minus tolerance provides a small fuel
low time for gauge to heat up.
reserve when the gauge is on ”E” position.
Place the pointer on the tester on the “M” position
With the gauge tester on “M”, the fuel gauge should and the temperature gauge should advance to the
slowly advance to the Y2 position. With the gauge driving range or Y8 position of the dial. Place the
tester on “H” the fuel gauge should show “F” plus or pointer of the tester in the “H” position and the
minus 3/32 inch. If the gauge does not perform as gauge should advance to the “H” position of the dial.
above test for an open printed circuit or replace the Should the gauge respond to the above tests but not
fuel gauge. operate when the terminal is attached to the send-
3. TEMPERATURE INDICATING SYSTEM
(Fig. 5 )
The operation of the temperature indicating sys- TO BATTERY POSITIVE EMPERATURE GAUGE
“S’ TERMINAL
tem is identical in operation with the fuel system
with the exception of the method of varying the re-
sistance of the sending unit. In this system the resist-
ance varies in direct relation to the temperature of
the coolant.
Any change in the coolant temperature causes a
like change in the resistor incorporated in the engine
sending unit.
When the engine is cold the resistance of the disc
in the temperature sending unit is high and a low
temperature will be indicated.
As the engine temperature increases, the resistance
of the temperature sending unit disc starts to de-
crease. A resultant increase in the current flow will
occur causing the gauge pointer to indicate the in- Fig. &Testing Temperature Gauge (Tool C-3826)
crease in engine temperature. (Plymouth).
TO BATTERY
(+)POSITIVE
p (-1
TO BATTERY
NJGATIVE POST
spond to the above tests, indications are of possible
loose connections, broken wire, or a burned out lamp.
f TEMPERATURE
GAUGE
\L 1 TO GROUND 5. INSTRUMENT CLUSTER BULB
REPLACEMENT
All bulbs in the instrument cluster are retained
by sockets which plug-in into the printed circuit.
The bulbs can be reached from under the instrument
panel. To remove the socket turn it v4 turn counter-
clockwise and pull out. For replacement bulb number
see the “Bulb Chart” specifications.
2
6. INSTRUMENT CLUSTER-PLYMOUTH
NOTE: Disconnect the battery negative cable be-
TO IGNITION INPUT
TERMINAL 64 x 185 fore servicing the cluster.
Fig. 7-Testing Temperature Gauge (Tool C-3826) Removal

(Valiant) (1) Disconnect the speedometer cable from the
speedometer.
ing unit, indications are of a defective sending unit (2) Remove the four mounting screws from the
and it should be replaced. steering column opening cover in the instrument
Should the gauge fail to respond to the above tests, panel.
indications are of possible loose connections, broken (3) Remove the mounting screw on steering column
wire printed circuit, or defective gauge. The instru-
strap and the two screws on the steering column
ment cluster should be removed for further inspec-
brace to allow steering column to drop.
tion. See “Instrument Cluster”. Paragraphs 6 and 7.
(4) Remove the transmission control sprag arm
Testing Temperature Gauge-Instrument knob.
Cluster Removed (Figs. 6 and 71 ( 5 ) Remove the three screws from the transmis-
The temperature gauge is tested in the same man- sion control bezel and remove the bezel.
ner as the fuel gauge with the exception that Tester (6) Remove the heater temperature control knob.
C-3826 is connected to the temperature gauge “S” (7) Remove the two screws from the heater con-
terminal. trol bezel and remove the bezel.
With the gauge tester on “L” position, the temper-
ature gauge should show “C” or cold. With the gauge (8) Remove the four instrument cluster mounting
tester on “M”position, the temperature gauge should screws.
show Y2 of the operating scale of the dial. With the (9) Roll the cluster out to allow removal of the
gauge tester on the “H” position, the temperature wires and cables to the cluster.
gauge tester should show “H”. If the gauge does not (10) Disconnect the bowden cable from the heater
respond to the above tests, test for an open printed control.
circuit or replace the temperature gauge. (11) Remove the two printed circuit plugs and the
alternator gauge wires.
4. OIL PRESSURE W A R N I N G L A M P (12) Disconnect the heater switch vacuum hoses
To test the oil pressure warning lamp, remove the and the two wires from the heater control.
terminal from the oil pressure sending unit. Con- (13) Remove the instrument cluster.
nect one lead of the gauge tester to the terminal and
the other test lead to a good ground. Installation
With the ignition switch in the “on” position and (1) Position the instrument cluster in front of the
the gauge tester in the “L” position, the warning cluster opening in the instrument panel and connect
lamp should not light. With the gauge tester in the the two printed circuit plugs, alternator gauge wires,
“M” position, the warning lamp should show a dull heater switch vacuum hoses, heater bowden cable,
glow. With the gauge tester in the “H” position, the and the two wires to the heater control switch.
lamp should show full brilliance. (2) Roll the cluster into the instrument panel open-
Should the oil pressure warning lamp fail to re- ing and install the four mounting screws.
(3) Install the transmission and heater control push (7) Test the cluster instrument operation.
button control bezels.
(4) Install the transmission control sprag and tem- 8. PRINTED CIRCUIT BOARD TESTING
perature control lever knobs. ( Instrument Cluster R e m o v e d 1
(5) Position the steering column to the steering The printed circuit board should be visually in-
column brace and install the column brace strap. spected first to determine if a conductor is open. If
(6)Install steering column opening cover on the there is no visual break, ground the instrument
instrument panel. cluster with a jumper wire from the cluster base to
(7) Connect the speedometer cable to the speed-
a good ground.
ometer. (1) Test the individual printed circuit plug con-
(8) Connect the battery negative cable. nector with a test lamp to determine if voltage is
available at that point.
7. INSTRUMENT CLUSTER-VALIANT (2) If voltage is available, substitute a good lamp
Removal or gauge in the inoperative circuit.
NOTE: The instruments and printed circuit can (3) Connect the plug connector to the printed cir-
be serviced after the cluster i s removed from the in- cuit board and connect a test lamp prod to the input
strument panel. side of the lamp opening or gauge.
CAUTION: Remove the battery cable at the bat- (4) If voltage is available at the input side of the
tery negative terminal before removing the cluster. gauge or lamp, test for continuity at the ground
(1) Cover the steering column jacket tube area be- terminal. If an open circuit is detected in the con-
tween the steering wheel and the instrument panel ductor, the printed circuit board must be replaced.
with masking tape to avoid scratching the paint finish.
9. CLUSTER COMPONENTS
(2) Loosen the steering column clamp screws sev-
eral turns to lower the steering column slightly. Disassern bly
(3) Reach up under the instrument panel and dis- (1) Remove the clock reset knob (if so equipped).
connect the speedometer cable at the speedometer. (2) Place the cluster assembly on a padded surface
(4) Remove the four screws visible on the face of with the bezel face down.
the cluster. Tilt the cluster downward and to the (3) Remove the screws attaching the bezel assembly
right and disconnect the lead wires to the ammeter, to the cluster base and remove the bezel.
the ignition switch multi-connector and the printed
(4) Remove the attaching nuts or screws for re-
circuit multi-connector. Remove the cluster to the
moval of the desired gauge or speedometer.
work bench for testing or replacing the instruments
or printed circuit.
fnstallation
CAUTION: The battery cable to the battery nega-
tive terminal must be disconnected before installation
of cluster.
(1) Rest the cluster bezel face on the protected
area of the steering column jacket between the steer-
ing wheel and the instrument panel.
(2) Connect the lead wires to the ignition switch,
printed circuit, and ammeter. Tighten all connections
securely to insure proper electrical contact.
(3) Roll the cluster into position in the instrument
panel and install the four cluster attaching screws.
(4) Reach under the instrument panel and connect
the speedometer cable to the speedometer.
(5) Tighten the steering column clamp screws.
(6) Connect the battery cable to the battery nega-
tive terminal. Fig. 8-Fuse Block
Assembly by a self tapping screw.

When installing the instruments into the printed In the fuse block are mounted the radio, cigar
circuit, take special note of alignment. lighter, air-conditioner or heater, tail-stop-dome light
Position the printed circuit on the cluster base and and accessory fuses. The fuse capacity is printed on
install the attaching screws. the fuse block as an aid to replacement requirements.
Install gauges and speedometer.
Position the cluster base on the cluster bezel and 1 1. CIRCUIT BREAKERS
install the attaching screws. As a safety precaution, circuit breakers are used
for the headlamps and wiper circuits. They insure
10. FUSE BLOCK (Fig. 8 ) that these essential services will continue to function
The fuse block is located at approximately the cen- if an intermittent short circuit occurs. Use only
ter, forward edge of the instrument panel and is re- identical type and amperage value circuit breakers as
tained to the instrument panel lower reinforcement replacements for service.
INSTRUMENTS
A l l Gauges Read H i g h (a) Faulty constant voltage (a) Test the voltage limiter.
(“against t h e peg”) limiter (stuck points or an
After I g n i t i o n Switch open heater coil).
is Turned “ON” (b) Cluster not properly (b) Tighten cluster mounting screws.
grounded to panel.
Gauge Pointers Do (a) Faulty constant voltage (a) Test voltage limiter. Test wiring, repair
N o t Move When limiter or an open circuit or replace as necessary.
I g n i t i o n Switch on battery side (input of
is Turned “ON” limiter).
T e m perature Gauge (a) Fuel tank sending unit or (a) Test sending unit and gauge.
Indicates Normal instrument panel fuel gauge
Operation. But t h e is faulty.
Fuel Gauge Indicates (b) Fuel tank is improperly (b) Test fuel tank for a good ground.
a Higher o r Lower Fuel grounded. NOTE: Testing t h e system w i t h t h e
Level t h a n Actually Exists t a n k sending unit positioned f o r b o t h
“empty” and “full” is usually
sufficient t o determine t h e calibra-
t i o n in t h e range between these
positions.
Fuel Gauge Indicates (a) Faulty instrument panel (a) Test wiring, repair or replace as
Correctly But Tempera- temperature gauge, wiring necessary. Test gauge and sending unit.
t u r e Gauge Indicates or faulty temperature
Higher or Lower Tempera- sending unit in engine.
t u r e t h a n Actual Engine
Tempera tu re
8-80 DIRECTIONAL INDICATOR
SERVICE DIAGNOSIS--. (Continued 1

INSTRUMENTS
Erratic Temperature (a) Loose or dirty electrical (a) Clean and tighten all electrical connec-
Gauge Operation connections. tions and test the gauge operation.
Erratic Operation (a) Loose or dirty electrical (a) Test the fuel gauge sending unit, and
of Fuel Gauge connections or faulty fuel proceed as follows:
tank sending unit. (1) Clean and tighten all electrical
connections.
(2) Make sure that the fuel tank
sending unit is grounded to the tank
and that the tank is grounded to the
frame.
DIRECTIONAL INDICATOR SYSTEM

SERVICE PROCEDURES
1. DIRECTIONAL INDICATOR SWITCH moved leave the string or wire in the steering column
( Plymouth1 jacket tube as an aid to replacement of the wiring.
Removal (8) Remove the screws attaching the directional

(1) Disconnect the battery cable at the battery neg- switch to the steering column and remove the switch
ative terminal. from the top of the steering column.
(2) Compress and turn the horn button ?A turn l n s tallation
counterclockwise to release the button from the re- (1) Attach the string or wire, (that was left in the
tainer. On models equipped with a horn blowing ring steering column jacket tube during removal), to the
remove the 2 attaching screws from the underside of directional switch wiring and carefully pull the string
the steering wheel. or wire down through the column jacket tube until
(3) Disconnect the horn wire at the horn blowing the directional switch is positioned in the steer-
switch. ing column jacket tube. Install the attaching screws
(4) Remove the three (3) screws and insulators at- and connect all wire connections.
taching the horn ring and horn blowing switch to the (2) Install the directional switch lever.
steering column. Remove the horn ring and switch. (3) Install the steering wheel and the steering wheel
(5) Loosen the steering wheel nut several turns nut. Tighten to 24 foot-pounds torque. Test the op-
and install the Steering Wheel Puller Tool C-3428 and eration of the cancelling lever.
remove the steering wheel nut and steering wheel. (4) Install the horn blowing switch, horn ring, in-
(6) Remove the screw attaching the directional sulators and attaching screws. Connect the horn
swi.tch lever to the directional switch and remove the wire at the horn blowing switch.
lever. (5)Install the horn button by compressing and
(7) Disconnect the directional switch wiring at turning ?4 turn clockwise to lock the horn button on
the steering column jacket tube below the instru- the retainer. On models equipped with a horn blowing
ment panel. ring install the 2 attaching screws from the underside
NOTE: Attach a piece of string or fine wire to the of the steering wheel.
directional switch wiring before removing the switch (6) Connect the battery cable at the battery nega-
from the steering column. When the switch is re- tive terminal.
DIRECTIONAL INDICATOR 8-8 1
LEFT TURN
LEFT PARK
AND TURN AND STOP
1-
RIGHT TURN
RIGHT PARK AND STOP
TURN AND
--
SIGNAL
FLASHER
BULKHEAD
INDICATOR
SWITCH
STOP
LAMP
FUSE BLOCK SWITCH
AMMETER
TAIL-STOP-DOME
20 AMP. FUSE
BATTERY
i
IGNITION SWITCH 64 x 420
Fig. 1-Directional Indicator Wiring Diagram (Plymouth)
LEFT TURN
LEFT PARK AND STOP
AND TURN
RIGHT TURN
RIGHT PARK PANEL INDICATOR AND STOP
AND TURN
7 +=il
I INDK A T 0R
- SWITCH
-
FUSE BLOCK
AMMETER
TAIL-STOP-DOME
I 20 AMP. FUSE
64 x 421
Fig. 2-Directional Indicator Wiring Diagram (Valiant)

a-a2 DIRECTIONAL INDICATOR
2. DIRECTIONAL INDICATOR SWITCH (8) Remove the screws attaching the directional
( Valiant 1 switch to the steering column and remove the switch
Removal from the top of the steering column.
(1) Disconnect the battery cable at the battery
negative terminal. Installation
(2) Pry the cap off of the horn button with a (1) Attach the string or wire (that was left in the
screwdriver using care to avoid damage to the cap. steering column jacket tube during removal), to the
(3) Disconnect the horn wire at the horn blowing directional switch wiring and carefully pull the string
switch. or wire down through the column jacket tube until
(4) Remove the three (3) screws and insulators the directional switch is positioned in the steering
attaching the horn ring and horn blowing switch to column jacket tube. Install the attaching screws and
the steering column. Remove the horn ring and connect all wire connections.
switch. (2) Install the directional switch lever.
(5) Loosen the steering wheel nut several turns (3) Install the steering wheel and the steering
and install the steering wheel puller Tool C-3428 and wheel nut, tighten to 24 foot-pounds torque. Test the
remove the steering wheel nut and steering wheel. operation of the cancelling lever.
(6) Remove the screw attaching the directional (4) Install the horn blowing switch, horn ring, in-
switch lever to the directional switch and remove sulators and attaching screws. Connect the horn wire
the lever. at the horn blowing switch.
(7) Disconnect the directional switch wiring at ( 5 ) Press the cap onto the horn blowing button.
the steering column jacket tube below the instrument
panel. (6) Connect the battery cable at the battery nega-
tive terminal.
NOTE: Attach a piece of string or fine wire to
the directional switch wiring before removing the
switch from the steering column. When the switch is
3. W I R I N G D I A G R A M S
removed leave the string or wire in the steering For the wiring diagrams of the directional indicator
column jacket tube as an aid to replacement of the systems refer to Figure 1 for Plymouth models and
wiring, Figure 2 for Valiant models.
External Lamps Operate (a) Faulty pilot bulb in (a) Replace bulb.
Normally, N o Indication instrument cluster.
o n Instrument Cluster
System Does N o t Flash (a) Faulty flasher unit. (a) Replace flasher.
(b) Faulty external bulb. (b) Replace faulty bulb.
(c) Faulty contact in switch. ( c ) Replace switch.
System Does N o t Cancel (a) Broken or loose cancelling (a) Replace cancelling finger.
After Completion of Turn finger.
(b) Improperly aligned can- (b) Align cancelling finger properly.
celling finger.
Broken or faulty switch. ( c ) Replace switch.
DIRECTIONAL INDICATOR 8-83
SERVICE D I A G N O S I L (Continued 1
Entire System Does (a) Open circuit in feed wire (a) Test wiring circuits. Refer to “Wiring
Not Operate to switch. Diagrams”.
(b) Faulty fuse. (b) Replace fuse.
Pilot Lamp Illuminates (a) Loose or corroded external (a) Clean and tighten ground connection.
Brightly, External Lamps lamp ground connection.
Glows D i m l y w i t h No
Flash
8-84 WINDSHIELD WIPERS
PART 7
WINDSHIELD WIPERS- HORNS

The single speed wiper motor shown in Figures 1 circuit breaker which is attached to the “B” terminal
and 2, is connected to the wiper switch and from the of the switch.
wiper switch “B” terminal to the “ACC’ accessory The variable speed system has a depressed parking
terminal of the ignition-starter switch so that the feature (against windshield mouldings) which is ac-
wiper motor is actuated only when the ignition switch complished by reversing the motor and using parking
key is turned to the right or left position. The cams at the pivot pins of the intermediate crank arm.
variable speed wiper motor is connected from the When the switch is turned to the “off” position, the
wiper motor to the wiper switch and then through a motor reverses direction and at the same time the
circuit breaker to the ignition switch. Refer to the parking cams rotate 180 degrees, lengthening the
“Wiring Diagrams”. The single speed wiper motor linkage slightly to park the blades against the wind-
is protected by a circuit breaker built into the wiper shield moulding. The linkage shortens when the motor
switch. The variable speed motor is protected by a runs in the wiping direction (Figs. 1and 3).
LEVER
RETAINER WASHER \ /LINK
ARM A N D PARTIAL BLADE
\A i
KNOB W/SCREW
ARM\
Fig. 1-Windshield Wiper Variable and Single Speed (Plymouth)

WINDSHIELD WIPERS 8-85
RETAINER
63x809
Fig. 2-Windshield Wiper Single Speed (Disassembled) (Valiant)
63x810
Fig. 3-Windshield Wiper Variable Speed (Disassembledl (Valiant)

SERVICE PROCEDURES
1. WIPER ARM ADJUSTMENT 2. WIPER MOTOR PARK SWITCH TIMING
NOTE: The wiper arm is equipped with a three- The timing of the wiper motor park switch must be:
jaw clutch which provides infinitely fine adjustment (a) late enough that the wiper arms come to rest
of the wiper arm position. The serrations which key at the extreme lower limit of travel on dry glass.
the clutch jaws to the tapered portion of the wiper (b) early enough that the wiper arms do not raise
pivot shaft do not restrict or control angular posi- appreciably beyond the lower limit of travel on fully
tioning of the wiper arm. This system differs from wet glass.
the other types of arms which provide stepped Adjust the timing of the park switch on the wiper
positioning by means of the attaching serrations. motor to provide “shut off” at the lowest point of
Variable Speed wiper blade travel under both wet and dry glass con-
ditions.
Plymouth When adjusting the timing of the variable speed
To determine if an adjustment is required apply an park switch, note that the variable speed motor ro-
upward force, parallel to the windshield glass, at the tates in reverse at the time the park switch opens.
end of the wiper arm (where the wiper blade is “Early” and “Late” directions are therefore opposite
attached to the arm). Measure the force necessary to single speed motors.
to pull the tip of the wiper blade out of contact with
the windshield moulding. If this separation force is 3. WIPER PARKING OPERATION TEST-
not between 10 and 40 ounces loosen the wiper arm VARIABLE SPEED
nut and change the arm position to bring the separa-
tion force into the 10 to 40 ounce range for both (1) Turn the instrument panel wiper switch to ON
wiper arms. and allow the wiper system to run through several
cycles of operation.
Valiant
(2)Very slightly, after the wiper blades reach
Same procedures as outlined for Plymouth Var- the top of the wipe pattern, turn the wiper switch
iable Speed, except the separation force should be to OFF to cause the blades to park in a one-half
3 to 15 ounces for the right wiper arm and 5 to 25 (Y2)cycle of wiper motor operation.
ounces for the left arm. If the blades do not park in the desired Y2 cycle
Single Speed but require 1% cycles to park, the procedure of
going through the switching operation must be re-
Plymouth peated as follows:
To determine if an adjustment is required apply a a. Turn the switch to the “ON” position and allow
constant downward force of 24 ounces, parallel to the wiper system to operate for a few cycles.
the windshield glass, at the end of the wiper arm b. Turn the switch to the “OFF” position, only
(where the wiper blade is attached to the arm). With this time allow the timing of operating the switch
the 24 ounces force applied pull the wiper blade to occur at a position in respect to wiper blade
away from the windshield glass once or twice to travel that is slightly later than the first operation.
prevent glass friction from affecting downward Again, note cycle requirement to reach park.
movement of the wiper arm and blade. With this Having parked the wiper system in Y2 cycle of
force applied the clearance between the tip of the motor operation note whether the wiper blades have
wiper blade and the windshield moulding should be traveled well below the normal wipe pattern. If they
between Vi and 1 inch. If the clearance is not in the have not, replacement of the parking cam, spring and
specified range loosen the wiper arm nut and change spring trip is indicated. If they have, but have not
the arm position to bring the clearance into the reached the windshield moulding, wiper arm adjust-
correct position for both wiper blades. ment is required. See Paragraph 1.
Valiant
4. PARKING SPRING LUBRICATION-
Use the same procedures as outlined for Plymouth,
Single Speed except use a constant force of 20 VARIABLE SPEED
ounces. The clearance should be between ?4 and To insure satisfactory life of the parking mech-
1Y2 inches for the left blade and between 1% and anism use only Lead-Plate, MoPar Part #2275437 to
2Y2 inches for the right blade. lubricate the parking spring during service. It is
essential to thoroughly coat all rubbing surfaces of 6. WIPER MOTOR-VALIANT

the spring and pin area. Use of any other lubricant
than Led-Plate (such as lubriplate, etc.) will result in Removal
noisy operation, rapid wear of components and pre- (1) Disconnect the wiper link at the wiper motor.
mature failure of the parking mechanism. For variable speed motors note position of follower
cam.
5. WIPER MOTOR-PLYMOUTH (2) Disconnect the wiper motor lead wires at the
wiper motor.
Removal
(3) Remove the three nuts attaching the wiper
NOTE: On models equipped with air-condition- motor and wiper motor bracket assembly to the cowl
ing the wiper motor must be serviced through the panel and pull the motor and bracket assembly down
glove box opening in the instrument panel. from the bracket mounting studs and out from under-
(1) From under the instrument panel remove the neath the instrument panel.
clips that retain the wiper drive links to the left
lnstallation
and right windshield wiper pivots. Lift the drive links
off of the pivot pins. (1) Enter the wiper motor and mounting bracket
from underneath the instrument panel and position
(2) Disconnect the wiring terminals at the wind-
the mounting bracket and install the three mounting
shield wiper motor.
nuts. Tighten the mounting nuts securely.
(3) Remove the support brace from the wiper
(2) Connect the lead wires to the wiper motor at
motor mounting bracket to the instrument panel
the wiper motor.
lower reinforcement.
(3) Connect the wiper link at the wiper motor and
(4) Remove the four nuts that attach the wiper
install the retaining clip. For variable speed motors
motor mounting bracket to the mounting studs on
the cowl panel. position the follower cam as outlined in Paragraph
14.
(5) Remove the wiper motor, wiper motor mount-
ing bracket, and the wiper drive links as an assembly 7. DISASSEMBLY OF WIPER LINKS
from under the instrument panel by carefully pull-
ing the assembly down and to the right and out (1) Remove the clip holding the link to the crank
through the right door opening. arm.
(2) Remove bevel washers and link.
lnstallation (3) Remove the parking cam and spring release
NOTE: On models equipped with air-condition- (Variable Speed).
ing the wiper motor must be serviced through the (4) Remove coil spring by spreading the ends
glove box opening in the instrument panel. (Variable Speed).
(1) Working through the right door opening install (5) On Plymouth disassemble the right-hand link
the wiper motor, wiper motor mounting bracket, and in same manner after removing crank arm to lever
wiper drive links as an assembly under the instrument nut and the spacing washers between the link crank
panel. arm and lever.
(2) From under the instrument panel position the
windshield wiper assembly on to the four mounting 8. WIPER M O T O R DISASSEMBLY
studs on the cowl panel. Variable Speed
(3) Install the four nuts that attach the wiper (1) Remove the switch plate and the cover plate.
motor mounting bracket to the cowl studs. Tighten (2) Remove the crank arm nut, washers, crank arm,
the nuts securely. and gear in that order.
(4) Install the support brace from the wiper motor (3) Remove the end head through bolts and pull
mounting bracket to the instrument panel lower out the end head using care so as not to break the
reinforcement . lead wire to the brush holder and remove the ar-
(5) Connect the wiring terminals at the windshield mature.
wiper motor.
Position the wiper drive links on to the right and Single Speed
left pivot pins. Install the retaining clips. (1) Remove the switch plate.
(2) Remove the motor crank nut, washers and

motor crank arm, noting sequence of washers and
the position of park switch components. END PLAY I
ADJUSTMENT SCREW
(3) Lift out the nylon gear. Note position of the \
gear.
(4) Remove the end head through bolts and care-
fully pull off the head and remove the armature. \
9. INSPECTING WIPER MOTOR
(1) Thoroughly inspect the motor parts for wear,
corrosion or damage.
(2) Clean the armature commutator with 00 or \
000 sandpaper or if necessary due to excessive wear
replace the windshield wiper motor. j- .. \
62 x 307 s;, \
(3) Replace worn or oil soaked brushes.
Fig. +End Play Adjustment
(4) Test the armature and crankshaft in their re-
spective bushings and replace worn parts if any the “P” terminal of the post. Lamp should remain
looseness is detected. lighted in either “ON” or “OFF” position. Failure
(5) Inspect the gears for worn or broken teeth and to light indicates a faulty circuit breaker.
replace gears showing damage or excessive wear.
11. END PLAY ADJUSTMENT
10. WIPER SWITCH (Instrument Panel To adjust the armature shaft end play turn adjust-
Mounted 1 ment screw in until it bottoms and back-off v4 turn,
Variable Speed as shown in Figure 4.
The switch contains a bar resistance plate which
12. WIPER MOTOR BENCH TESTING
provides a Iiieans of controlling the amount of current
flow to the motor. The switch is designed to provide Variable Speed
a circuit to the motor to reverse the direction of the (1) Connect a jumper wire between the wiper motor
current to the field winding thus providing a means of yellow wire and the wiper motor ground strap. Con-
reversing the armature. A separate circuit breaker is nect another jumper wire between the battery nega-
attached to the “B” terminal of the switch to protect tive terminal and the wiper motor ground strap.
the motor. Connect another jumper wire between the wiper
To test the switch, refer to the proper wiring &a- motor blue and yellow wires and the battery positive
gram, disconnect the lead wires and remove the terminal. The wiper motor should run continuously
switch. Connect a jumper wire from the battery in the wipe direction.
positive terminal to the case of the switch and another (2) Connect a jumper wire between the wiper
wire from the battery positive terminal to the “FI” motor blue and yellow wires and the battery positive
terminal of the switch. Connect a test lamp between terminal. Connect another jumper wire between the
the battery negative terminal and the “B” terminal wiper motor red wire and the wiper motor ground
of the switch. Lamp should light when switch is strap. Connect another jumper wire between the bat-
turned on and gradually dim as switch is rotated tery negative terminal and the wiper motor ground
clockwise. Lamp should go out when switch is turned strap. The wiper motor should run in reverse and
“off”. The switch is serviced only as an assembly, stop at the park position.
Single Speed Single Speed
The switch contains a built-in circuit breaker to (1) Connect a jumper wire between the battery
protect the motor and is serviced only as an assembly. negative terminal and the wiper motor ground strap.
To test the switch, refer to the proper wiring diagram, Connect another jumper wire between the black and
disconnect the lead wires and remove the switch blue wires of the wiper motor and the battery posi-
from the instrument panel. Connect a test lamp be- tive terminal. The motor should run continuously.
tween “B” terminal of the switch and negative bat- (2) With the jumper wires connected, as in Step
tery post. Connect the positive battery terminal to 1, disconnect the black wire from the jumper wire
leaving the blue wire connected to the battery posi- INTERMEDIATE

tive terminal. The wiper motor should park. CRANK ARM
13. ASSEMBLING WIPER M O T O R

Make sure the wiper motor gear teeth are ade-
\ RIGHT LINK
I
quately covered with long fibre grease.
Correct indexing of the contact plate (single speed
motor) or the contact follower (variable speed motor)
on the nylon gear is important. On Plymouth models
after the armature, nylon gear, and crank arm are
installed, index the contact plate (constant speed PARKING
CAM
motor) on the nylon gear with the slot pointing in (ECCENTRIC)
55P1071
the same direction as the motor crank arm, Install
Fig. &Link Arm Installed (Variable Speed) Plymouth
the contact follower (variable speed motor) with open
end pointing in same direction as motor crank arm.
Assemble the left link and cam assembly in the
14. WIPER LINK ASSEMBLY same manner locking in place with a clip.
Variable Speed-Plymouth Variable Speed-Valiant
Install spring washer, concave surface toward crank Install the flat washer on the motor crank arm
arm. Install the crank pivot coil spring on the pivot. pin. Assemble the release, parking cam, and parking
Install the spring release. spring, as shown in Figure 7, and install on the
Install the parking cam to index with spring release motor crank arm pin.
and engage spring ends, between the release and
MOTOR TABS ON SPRING
parking cam in openings at point of index, as shown CRANK ARM MUST BE IN THIS
in Figure 5. POSITION WHEN
When assembling to the left link the “L” on the ASSEMBLED
FLAT WASHER
left crank and on the parking cam should be seen.
>&
The cam marked “R’is installed in the same manner.
If the intermediate crank is held so that the letter PARKING SPRING
“L” can be seen from this position, the opposite side
will show three letters “R”. LUBRICATE WITH
Install the link arm with the stop projection on LED-PLATE ONLY
the link arm toward the cam assembly. Install the
spring washer, convex surface toward the cam as- RELEASE
sembly.
Install the retaining bolt and nut, as shown in
Figurr: 6.
LINK SPRING
.
TRIP INTERMEDIATE
IDENTIFICATION-
LETTER “P”
c PARKING CAM
DRIVE LINK
LINK SPRING 55P1070 RETAINER 64x25
Fig. &link Spring Trip Installed (Variable Speed) Fig. 7-Variable Speed Parking Mechanism-
Plymouth Va liont
Install the drive link on the motor crank arm pin Single Speed-Vdunt
making sure the parking cam is seated correctly in (1) Place the nylon insert in the end of the wiper
the opening in the drive link. Install the convex drive link with the metal ear into the keying slot.
washer and the concave spring washer as shown in
(2) Install the link and bushing.
Figure 7.
Install the retainer on the end of the motor crank (3) Install the cone washer and the retaining clip.
arm pin.
15. REPLACING WIPER PIVOT
Single Speed-f lymouth (1) Remove the wiper arm.
(1) Install a felt washer over the intermediate crank (2 Disconnect the link from the pivot.
arm stud; follow with the right hand link and another (3) Remove the pivot and gasket.
felt washer. Install the intermediate crank stud (with
(4) Install a new gasket and pivot.
link installed) on the wiper motor crank and install
the attaching nut. (5) Tighten the retaining stud nuts 75 inch-pounds
torque.
(2) Install a felt washer, the left hand link, another
felt washer and shim washer over the remaining pin (6 Reconnect link to pivot crank pin and install
of the intermediate crank and retain with the retain- washer and retainer clip.
ing clip. (7) Install the wiper arm.
SERVICE DIAGNOSIS
WINDSHIELD WIPERS
Wiper Fails to Operate (a) Binding linkage. (a) Relieve the binding condition.
(b) Faulty instrument panel (b) Test Switch. See “Wiper Switch
switch. (Instrument Panel Mounted).”
(c) Faulty Motor. (c) Test motor. See “Wiper Motor Bench
Testing.”
(d) Open or Grounded wiring. (d) Test wiring for continuity. Repair as
necessary.
Wiper Blades Not (a) Arm set a t incorrect (a) Adjust arm. See “Wiper Arm
Parking Properly position. Adjustment.”
(b) Motor park switch timing (b) Time park switch. See “Wiper Motor
incorrect. Park Switch Timing.”
(c) Broken link spring. (c) Replace Spring. See “Wiper Link
(Variable Speed) Assembly”.
(d) Link spring trip not en- (d) Inspect “Wiper Link Assembly.”
gaging stop on linkage.
(Variable Speed)
Blades Slap Windshield (a) Improperly adjusted wiper (a) See “Wiper Arm Adjustment”.
MouId ings arm.
(b) Looseness of the motor (b) Replace the defective part.
crank or other drive parts.
HORNS 8-91
SERVICE D I A G N O S I h (Continued 1
WINDSHIELD WIPERS
Blades Chatter (a) Twisted arm holds blade a t Replace wiper arm. Do not a t t e m p t to
wrong angle to glass. straighten bent or twisted arm.
Wrong type blades used. Install correct wiper blades.
Foreign substances such as Clean the glass.
body polish on glass.
Motor will not Stop (a> Motor park switch failure Repair or replace motor park switch.
when Instrument Panel in the “closed” position;
Switch is Turned “OFF”
Motor Stops in any (a) Motor park switch failure Repair or replace motor park switch.
Position when Instrument in the “Open” position.
Panel Switch is
Turned “OFF”
HORNS
1. TESTING HORNS 2. ADJUSTING HORNS
Touch a jumper wire from relay “S” terminal to Aufolite Horn
ground. If horn blows, difficulty is in the horn button (1) Disconnect connections at each horn to de-
contact ring, the grounding of the steering column, termine which horn is not operating.
or in wire from “S” terminal to horn button. If horn
fails to blow, connect a jumper wire from “B” ter- (2) Remove horn and bracket assembly. Do not
minal to “H” terminal. If horns operate, relay is remove horn from bracket. (The bracket is retained
defective. If horns fail to operate, difficulty is in wire to the horn by a self-threading screw.)
to the horns, in the horns, the wire to horn relay (3) Pry the cover off (Fig. 1).
“B” terminal or in the grounding of the steering (4) Turn the adjusting nut counter-clockwise un-
column. til there is no vibration (sound), see Figure 2.
(5) Turn the adjusting nut clockwise, approxi-
\ mately 1/4 turn at a time until the tone has a clear
\
mellow sound. Do not turn nut while horn is blowing.
i
NOTE: Adjustment will only clear up sound and
cannot change horn tone frequency.
RESIS{O R .,,/ADJUSTMENT STUD NUT
62x437
Fig. 1-Removing the Cover (Auto-Lite Horn) Fig. 2-Cover Removed (Auto-Lite Horn)
8-92 HORNS
post of a 12 volt battery and horn terminal post.
Connect a jumper lead from the negative battery
post to the horn base. Clean the paint from the horn
bracket where the connection is made. Turn the ad-
justing nut to obtain a reading of eight amperes
minimum to ten amperes maximum at 12.5 volts.
NOTE: Must not exceed ten amperes maximum.
Sparton Horn
(1) Disconnect connections at each horn to deter-
mine which horn is not operating.
(2) Remove horn and bracket assembly.
(3) With a suitable spanner wrench (Fig. 3,) turn
the tone adjuster counter-clockwise until there is no
vibration (sound).
(4) Turn the tone adjuster clockwise, approximate-
ly 34 turn at a time until the tone has a clear mellow
sound. Do not turn tone adjuster while horn is blow-
ing.
Fig. 3-Adjusting Sparton Horn
NOTE: Adjustment will only clear up sound and
(6) Check horn solenoid coil leads, make sure they cannot change horn tone frequency.
are securely wrapped on horn coil terminals. If lead (5) Connect a test ammeter between the positive
wires are loose, solder them securely to the coil ter- post of a 12 volt battery and horn terminal post. Con-
minals. Use resin core solder. nect a jumper lead from the negative battery post
(7) Check horn contacts. If contacts are badly to the horn base. Clean the paint from the horn
burned, check resistor for continuity. If contacts are bracket where the connection is made. Turn the tone
separated, when adjusting nut is removed from the adjuster to obtain a reading of six amperes minimum
adjusting stud; contacts have taken a permanent set to eight amperes maximum at 12.5 volts.
and horn should be replaced. NOTE: Must not exceed eight amperer max-
(8) Connect a test ammeter between the positive mum.
SERVICE DIAGNOSIS
HORNS
Horns Will N o t Blow (a) Improper adjustment. (a) See “Adjusting Horns”.
(b) Broken or faulty wiring. (b) See “Testing Horns”.
(c) Faulty horn. (c) See “Testing Horns”. Replace horn if
necessary.
(d) Faulty relay. (d) See “Testing Horns”. Replace relay if
necessary.
Horns Blow Continuously (a) Shorted wiring. (a) See “Testing Horns”.
(b) Horn button sticking. (b) Disconnect battery ground cable.
Release horn button. After correction,
reconnect battery ground cable.
(c) Relay sticking. (c) Replace relay.
ELECTRIC WINDOW LIFTS 8-93
PART 8
ates all the windows and the individual switches are

ELECTRIC WINDOW LIFTS-PLYMOUTH located on their respective doors. The circuit breaker
A master switch group, on the left front door, oper- is above the left front cowl panel.
SERVICE PROCEDURES
1. WIRING TEST 3. WINDOW LIFT (Except 2 Door Hardtop

Disconnect the cable at the battery negative post Quarter Window 1
and remove the two window lift feed wires from the Removal
circuit breaker. Do not remove the battery feed wire. (1) Disconnect the battery cable at the battery
Reconnect the battery negative cable at the battery negative terminal.
and replace the feed wires one at a time as follows: (2) Remove the garnish moulding, the door trim
(1) One feed wire feeds the left front door. panel and disconnect the wires from the switch.
(2) The other feed wire feeds the right front door (3) Remove the clips from the regulator pins hold-
and both rear doors. ing the lower glass channel.
(3) Test the wiring to the doors one at a time to (4)Raise the glass manually and prop in the up
locate the short. position.
NOTE: When testing for faulty wiring, inspect ( 5 ) Remove the regulator attaching screws, pivot
the wiring harness control wires for a break behind arm from the guide on the inner panel and remove
the plate and sector or the regulator in each door. the motor and regulator through the opening in the
door.
2. MOTOR (Except 2 Door Hardtop (6) If it is necessary to replace the gear box, re-
Quarter Window 1 move the regulator counter-balance spring.
Removal NOTE: Be sure to remove the counter-balance
(1) Remove the garnish moulding and trim panel. spring before disassembling the gear box.
(2) Remove the two nuts that attach the motor to The gear box is replaced as an assembly only and
the gearbox assembly. is lubricated at assembly. No further lubrication is
(3) Drop the motor down off the gearbox assem- required.
bly. lnstallation
(4) Ground the motor through bolt to the body (1) Place the motor and regulator through the door
inner panel. opening and insert the pivot arm into the guide on
(5) Test the operation of the motor using the the inner panel.
window lift switch. If the motor is defective replace (2) Install the regulator screws finger tight. DO
the motor. Do not attempt any internal service on the NOT tighten at this time.
motor. (3) Remove the window prop and lower the glass.
(6) Disconnect the lead wires to the motor and (4)Insert the control arms into the glass channel,
remove the motor. using a leather washer on each side of the channel
Installation and secure with a clip.
(I) Position the motor on the gearbox assembly and (5) Connect the wires to the motor and connect' the
install the two mounting nuts. battery.
(2) Connect the wiring to the motor. (6) Operate the window several times and stop the
(3) Test operation of the motor using the window glass halfway.
lift switch. (7)Tighten the regulator screws.
(4)Install the trim panel and garnish moulding. (8) Inspect the glass alignment.
8-94 ELECTRIC WINDOW LIFTS
(9) Connect a test ammeter into the electrical cir- (7) Remove the roller track assembly mounting
cuit and operate the window. The ammeter reading bracket.
should be constant without fluctuation at approx- (8) Disconnect the wires to the motor.
imately 14 amperes.
(9) Unhook the lower glass frame from the regula-
If the ammeter reading fluctuates, there is a bind tor arm.
in the glass or in the linkage. The down stop should
be adjusted so that the window is flush with the (10) Remove the regulator mounting screws.
garnish moulding. (11) Remove the regulator assembly out through
(10) Install the trim panel, switch and garnish the access opening in the inner panel.
moulding. lnstallation
4. QUARTER GLASS REGULATOR ( 2 Door (1) Install the regulator assembly in through the
Hardtop 1 access opening in the inner panel and install the
mounting screws.
NOTE: If the window regulator is jammed in
either the extreme ”UP” or ”DOWN” position it is (2) Hook the lower glass frame to the regulator
necessary to remove the ”UP” or ”DOWN” regulator arm.
stop to allow removal of the window glass. (3) Install the roller track assembly mounting
bracket.
Removal
(4) Install the roller track assembly.
(1) Remove the rear seat.
( 5 ) Install the regulator adjusting lock nut.
(2) Remove the trim panel and garnish moulding.
(6) Install the window glass in through the top
(3) Run the window down (using the window lift
of the inner panel.
switch) until the glass to window frame mounting
screws are opposite the access holes in the inner (7) Position the window glass to the lower glass
panel. frame and install the window glass mounting screws.
(4) Remove the window glass mounting screws and (8) Connect the wires to the motor.
lift the glass up out of the inner panel. (9) Test the operation of the window lift.
( 5 ) Remove the regulator adjusting lock nut. (10) Install the trim panel and garnish moulding.
(6) Remove the roller track assembly. (11) Install the rear seat.
ELECTRIC WINDOW LIFTS
A Window Will N o t (a) Faulty switch in the (a) Replace master switch.
Operate f r o m t h e master switch group.
Master Switch, B u t (b) Break in the wire a t the (b) Test for continuity, see “Wiring
C a n be Operated f r o m door opening, or at the Diagrams”. Repair wiring. Avoid
t h e Individual Door door holding the master making a splice in the flexing sections
Switch switch group. of the wiring harness.
None of t h e Windows (a) Faulty circuit breaker- (a) Replace circuit breaker and test the
W i l l Operate f r o m located above left cowl new circuit breaker to determine if
t h e Master Switch or panel. voltage is present a t the terminal
f r o m t h e Individual opposite the battery feed.
Door Switch (b) Open in the battery feed (b) Test for continuity and repair as
wire from the circuit necessary.
breaker to the alternator
(ammeter).
POWER SEATS 8-95
SERVICE DIAGNOSIS--- ( Continued1

ELECTRIC WINDOW LIFTS
A Window Cannot (a) Test for faulty circuit Replace circuit breaker.
be Operated f r o m breaker located above
Either t h e Master left cowl panel.
Switch or t h e Individual (b) Master switch and door Test the master switch and door switch
Door Switch switch inoperative. for continuity.
( c ) Open in wire between Test for continuity between the motor
motor and switch. and the switch. Repair wiring as
necessary.
Jammed gear box. Test and repair. Inspect motor to gear
box alignment.
Coupling broken between Replace coupling and test motor and
the motor and the gear box. gear box alignment.
Lift motor burned out. Repair or replace lift motor. Test for
sticking door switch as possible cause of
motor failure.
Short in the wiring circuit. Inspect and test wiring. See “Wiring
Diagrams”.
A Window W i l l Operate (a) Faulty circuit between Test the master switch and door switch
In One Direction Only master switch and door for continuity. Check for continuity
When Controlled by switch. between the motor leads and the switch.
Either t h e Master (b) If the window can be Remove the window lift motor and
Switch or by t h e moved by rotating the test on bench with battery voltage.
Individual Door Switch coupling between the motor See “Wiring Diagrams”.
and the gear box.
Lift motor burned out. Test for sticking switch.
Short in wiring circuit. Inspect and test all wiring. See “Wiring
Diagrams”.
Circu it Breaker C I icks (a) Short in the feed wire that Test the wiring, repair or replace as
rrOn” and rrOff” Contin- feeds the right front and necessary.
uously and Window Does rear doors.
n o t Operate (b) A faulty switch. Replace the switch if necessary.
The power seat can be moved six ways-forward, front and two inches at rear. The available tilt is 8
back, up, down and tilt. The horizontal travel is five degrees forward and 7% degrees rearward from
inches and horizontal plane of seat track is inclined neutral.
eleven degrees. ‘i’he vertical travel is one inch at
SERVICE PROCEDURES
1. OPERATION (Fig. 1 ) plies power to the slave units, located in the seat
tracks, through flexible cables. The control switch
The motor operates a gear drive train which sup- is on the left side of front seat and is wired through
8-96 POWER SEATS
RIGHT SEAT TRACK ASSEMBLY (3) Disconnect the switch control wires.
(4)Remove the front seat and cushion assembly.
(5) Disconnect the seat adjuster red feed wire.
(6) Remove the seat guide attaching stud nuts and
remove the adjuster.
MOTOR AND DRIVE UNIT ASSEM lnstallatton
LEFT SEAT TRACK ASSEMB (1) Install the adjuster and seat guide stud nuts.
(2) Reconnect the seat adjuster red feed wire.
63x632 SIX-WAY CONTROL&ITCH
(3) Install the front seat assembly.
Fig. 1-Power Seat Arrangement
(4)Reconnect the control wires to the switch and
tighten the mounting stud nuts securely.
a relay to a 30 ampere circuit breaker, located above (5) Reconnect the battery ground cable.
the left cowl panel.
The wire from the bulkhead disconnect supplies 3. FLEXIBLE CABLES
power to the circuit breaker.
Power is supplied to the relay from the circuit Removal
breaker. (1) Remove the front seat assembly.
Six wires go to the switch. One used for power, (2) Disconnect the red feed wire.
two for motor field current, which also actuates the
(3) Remove the retainer plate that holds the right
relay for motor armature current and three wires
side tubes to the drive assembly.
attach to solenoids controlling the movement of the
front riser, rear riser and horizontal movement. (4)Remove the left seat guide attaching stud nuts
The right and left tracks are each replaced as an and remove the guide and the drive assembly (Fig. 2).
assembly only. They cannot be adjusted and are not NOTE: Be careful not to bend or damage right
interchangeable. side tubes when sliding tubes out of drive assembly.
(5) Pull the flexible cables from the right side
2. FRONT SEAT ASSEMBLY AND ADJUSTER tubes (Fig. 3).
Removal (6) Remove the bolts that hold the motor and
(1) Disconnect the battery ground cable. drive assembly to the left guide bracket.
(2) Remove the four mounting stud nuts which (7) Remove the drive assembly with tubes from
hold the front seat to the adjuster and tilt the com- the left slave unit (Fig. 4).
plete seat back assembly forward. (8) Remove the flexible cables from the tubes.
LEFT SEAT
TRACK ASSEMBLY.
BLE MOUNTING BRACKET

- 9 B R A C K E T MOUNTING
SCREWS
FLEXIBLE CABLES AND
TUBES ASSEMBLY 63x633
Fig. 2-Removing Cables from Drive Assembly Fig. 3-Removing Cables from Right Slave Unit
POWER SEATS 8-97
SLAVE UNIT
Fig. 5-Installing left Cable Tubes in Slave Unit

63x630A
Fig. &Removing Drive A’ssembly from left (2) With the shortest tube on the inside and long-
Slave Unit est on the outside, install the flexible cables in the
tubes. Make sure the cables seat in the slave unit.
lnstallation (3) Position the drive unit on the left side tubes.
CAUTION: Seat guides should be in the up and Make sure the flexible cables seat in the slot in the
forward position when installing cables. Make sure drive unit.
both guides are a t the same position (in alignment.) (4) Bolt the drive unit to the guide bracket.
(1) Place the three left cable tubes into the left (5) Place the right side flexible cables in the right
slave unit (Fig. 5). side tubes.
COIL COVER
RUBBER COUPLING
I
-,COL
I
SOLENOID CdlL SPRINGS RELAY
COIL GROUND WIRE

COIL PLATE
INSULATING
WASHER
58x749 B
Fig. &Solenoid and Coil (Disassembled View)

8-98 ’ POWER SEATS
(6) Position the left guide and drive assembly on ground wire at the cover tab and remove the coil
the right side tubes. Make sure the cables seat in the cover from the coil.
drive assembly. (5) Remove the screws holding the cover on the
(7) Install the rjight side tubes retainer plate. drive unit.
(8) Bolt the left guide assembly to the floor. (6) Remove the cover and lift out the clutch lever
(9) Install the s(eat and cushion assembly. and shaft.
(10) Reconnect the red feed wire and test the Assembly
operation of the s(sat. (1) Install the clutch lever and shaft. Make sure
the lever is properly seated on the c(illar.
4. SEATMOTOIR (Fig. 6 ) (2) Install the cover and screws.
Removal - .. .. . .. ..
(SI install tne coil in tne coil cover with the coil
I#.\ 1 I.
(1) Remove the two mounting stud attaching nuts ground wire next to one of the cover tabs.
that hold the left side of the front seat to the sent ‘4) Position the cover tabs in the slots on the coil
adjuster. te.
(2) Prop-up the lef t side of the seat cushior 5) Bend over the tabs and resolder the coil ground
proximately six incheIS. ‘eto the tab and plate.
. - .. -
(3) Disconnect the control switch wires from 6) Install the three solenoid spring and position
relay on the motor. solenoids over the springs.
(4) Remove the two nuts that attach the motor (7) Fasten the solenoids to the drive unit.
to the drive unit. (8) Install the drive unit. Refer t;o “Installation of
(5) Remove the! motor and rubber coupling from Flexible Cables”, steps 1through 4.
the drive unit.
(6) Disconnect the motor wires from the relay. 6. SLAVE UNIT
(7) Remove the relay from the motor. Removal
lnstullution the cables. Refer
teps 1 through 4.
(1) Position the and forward posi-
attaching screw.
(2) Connect the motor wires TO me relay. (2) Remove the long clevis pin from the front of
(3) Install the motor and rubber coupling to the the guide (Fig. 7).
drive unit. Install the two attaching nuts. (3) Remove the front rack clevis pin.
(4) Connect the control switch wires to the relay
on the motor.
(5) Remove the prop from the left side of the
seat cushion. Position the seat on the seat adjuster
and install the two mounting stud attaching nuts.
5. DRIVE UNIT A N D SOLENOID ASSEMBLY

Disassembly
(1) Remove the drive unit from the seat assembly.
Refer to “Removal of Flexible Cables” steps 1through
4.
(2) Remove the two screws holding the plate and
solenoids to the drive unit (Fig. 6).
4 p ’
SLAVE UNIT SLAVE UNIT
CAP
@’ i ,
I
(3) Remove the plate and solenoid assembly. Be
careful not to lose the three springs under the sole-
noid.
(4) To remove the solenoid coils, bend back on
SEAT GUIDE CLEVIS PIN -_
~ 8 ~ 7 4 8FRONT RACK CLEVIS PIN-L
11
O!
--
--
the tabs of the solenoid cover. Unsolder the coil Fig. 7-Removing the left Slave Unit
POWER SEATS a-99
(4)To facilitate the removal of the slave unit,
remove the slave unit cap.
CLUTCH SOLENOIDS
NOTE: Be careful not to lose the springs under
the cap. The springs are between the racks and the
slave cap.
(5) Remove the nuts holding the slave unit to the
guide. F
(6) Remove the slave unit.
lnst allat ton
(1) Position the slave unit over the studs on the I ‘I- --. .., 1
guide base.
(2) Position the racks in the slave unit so they
will be in the up and forward position.
(3) Fasten the racks to the guide assembly.
(4)Position the springs on the racks and install
the slave unit cap.
( 5 ) Install the slave unit mounting nuts.
NO. COLOR CIRCUIT
(6)Install the front guide clevis pin. F-5 RED FEED
(7) Install the cables in their slots and try operation F-6 BROWN FRONT ELEVATOR
of guide. F-7 DARK GREEN HORIZONTAL
Install drive unit and cables. Refer to “Installation F-8 YELLOW REAR ELEVATOR
of Flexible Cables”, steps 6 through 9. F-9 WHITE DOWN AND REARWARD
F-10 DARK BLUE UP AND FORWARD 54 x 416
7. POWER SEAT WIRING
Refer to Figure 8 for wiring of the power seat
assembly. Fig. 8-Six-Way Power Seat Wiring
SERVICE DIAGNOSIS
POWER SEATS
-
Entire Unit Inoperative (a) Broken wire or loose (a) Test electrical continuity of the system.
connections in any part of Repair as necessary.
motor control circuit.
Motor Inoperative (a) Short or open circuit (a) Test the red wire at relay with a test
between power source, light. If the test light does not light,
faulty relay, switch or motor. check for continuity in the red feed wire,
a faulty circuit breaker or a poor
connection between the circuit breaker
and alternator (ammeter). If the test
light lights, connect the red feed wire
with the red and black or red and green
wires from the motor. If motor runs,
relay is faulty.
(b) Faulty Motor. (b) Repair or replace motor.
8-100 POWER SEATS
SERVICE DIAGNOSIS- (Continued 1
POWER S E A T C (Continued 1
Seat Inoperative (a) Short or open circuit Jump the wire from the red feed wire
(Motor Runs) between the switch and to each solenoid terminal on the clutch
affected solenoid. assembly. Each solenoid should “Click”
as the jumper is connected. If solenoid
does not click:
Test the wire in the harness for an open
circuit. Repair. Test for a possible
seized solenoid armature in the coil.
Replace the coil. Test for a possible
burned-out solenoid. Replace the solenoid.
Seat Inoperative (Motor (a) Possible stripped or broken Inspect and replace the drive unit if
Runs and Solenoid Click) gear in the drive unit. necessary.
Slave Unit Inoperative (a) Possible broken drive cable. Inspect and replace the parts as necessary.
(Motor, Solenoids and
Drive Unit O.K.)
Excessive Free Play in t h e (a) Possibly due to the roller Repair as follows:
Unit (Seat has a Rocking Fig. 9, being out of position. (1) Remove the power seat from
Motion, Excessive Move- the vehicle.
m e n t between t h e Slide (2) Remove the seat drive tubes
and t h e Base of t h e from the slave unit.
Track assembly) CAUTION : Do n o t run t h e seat m o t o r
w i t h t h e drive cables and tubes dis-
assembled or t h e unit w i l l be placed
o u t of synchronization.
(3) Remove the seat support (B)
and the rear clevis pin. Refer to “Slave
Unit Removal” steps 5 and 6.
(4) Remove the seat slave unit from
the seat track slide (C). Refer to “Slave
Unit Removal” steps 5 and 6.
(5) Remove the horizontal stops
located on the slide at (D).
(6) Separate the seat slide (C) from
the base (N) by pressing the slide
rearward which will allow the rollers
(A) to jump the retaining rivets (E, F,
G, H), thereby separating the slide
from the base.
(7) Remove the rivet (F) and
replace with 5/16-18 x %’’ bolt (I) as
shown to retain the rollers in the proper
position. To reassemble, reverse the
above sequence.
In reassembly, frayed drive cable
m a y occur. Such a cable m a y be
repaired by applying a l i g h t coating
of solder and t h e n grinding t o
cable size.
POWER SEATS 8-101
SERVICE DIAGNOSIS- ( Continued 1
POWER S E A T 6 (Continued1
Seat Track Excessively (a) Loose rivet joints. (a) Disassemble the upper track seat support
Loose (A loose Rivet (B) by removing the cotter keys and
Joint) pins. Remove the seat support and
tighten all the riveted joints (J) by
peening with a ball peen hammer. (Fig. 9).
Loose Front Levers (a) Movement between the two (a) Arc weld the front levers (K) to prevent
sections comprising the movement between the two sections.
front lever assembly (Fig. 9).
Seat Chuck Fore and A f t (a) Loose horizontal rack support (a) Repair as follows:
arm to lower track base. (1) Remove the seat track from the
vehicle and arc weld as shown (at “L”
Fig. 9).
(2) Tighten the rack attaching pins
(M) by arc welding (Fig. 9).
Loose horizontal rack in (b) Test and replace slave unit if necessary,
slave unit gear train.
Fig. 9-Seat Guide (Disassembled View)

8-102 WIRING DIAGRAMS
I I 2
I
L
WIRING DIAGRAMS 8-103
4
4
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
\.
\
TO M-2 CIRCUIT IN
INSTRUMENT PANEL WIRING MOTOR ON SHELF PANEL
RIGHT TAIL STOP AND

( O N INSTRUMENT PANEL)
TRUNK LAMP
(MOPAR ONLY ITEM)
LICENSE LAMP
PANEL WIRING SPLICE INTO

L-7 CIRCUIT
I\ D-8
INSTRUMENT PANEL WIRING

LEGEND
AUTOMATIC SWITCH MOPAR ONLY ITEM

b LEFT REAR DOOR
6.2 -0- B-ZA

LEFT BACK-UP LAMP
TO FUEL GAUGE
RIGHT BACK-
UP LAMP
64 x 40
1
CIRCUITS
CIRCUITJGAI
COLOR
1181 WHITE 1
Fig. 3-Body Wiring (Except Station Wagon) Valiant
TO FUE GAUGE TAIL GATE WINDOW LIFT MOTOR

UP I D O W N
w - e - 1
4
W-25D
18 WHITE TAIL GATE I RIGHT TAILASTOPAND TUR
WINDOW LIFT SIGNAL LAMP
18 BROWN
L-7A 18 BLACK
I
M-2
TO SIDE COWL ClRCUll
BREAKER SEE INSTRUMEN]
PANEL WIRING DIAGRAM
FOR' CIRCUIT BREAKER
c
LIMIT
6 I W-15D
W-15C
TAIL SWITCH
GATE
W-156
1
W-25C
W-25B
I
RIGHT BACK-UP
LAMP
FEED
L-7B
W-5B 112) RED W-25A L-7A-L-7c@++ LICENSE LAMP
r
w.5r I121 RED
W-15A 12 WHITE
l W-15 I I
G
.ROMMET,
rW-15B I12 I BROWN I

L&!N&Gfi :f SWITCH
WINDOW LIFT I
I-~A LEFT BACK-UP
WIRING(ON INSTRUMENT PA i L) I I AMP
W-15E I14 I BLACK
Iw-25 I 12 I YELLOW I GD-~ 1-7
TURN SIGNAL LAMP
INSULATOR TO INSTRUMENT PANEL WIRING
=TO TO BACK-UP LAMP SWITCH WIRING
-B-2. 8-2 L
63x813A
Fig. 4-Body Wiring (Station Wagon) Valiant

WIRING DIAGRAMS 8-1 05
-
'r
Z
\
z
-E
nn
1
s
J
c
TOWIRING
TOP l
-l
f&-
4
1-2 J
TOP LIFT
SWITCH ACCESSORY FEED 02A -
D.1 -
I
I
I
I
H-3ARlGHT FRONT
HORN E-3A
I -
11.7
RIGHT REAR L-B.2A-
Fig. &instrument Panel Wiring (Plymouth)

WIRING DIAGRAMS 8-1 07
WITH WINDSHIELD
WASHER SWITCH
WITHOUT WINDSHIELD
WASHER SWITCH fi-8-1A-A J6
ACCESSORY 1
CIRCUIT 1
BREAKER
x-21 pv-l
' I
7'I L V - 3j +v-3-
WINDSHIELD WIPER SWITCH (SINGLE SPEED)
- E.2 q-E.2c-b INSTRUMENT LAMP
-- ---- I
\ BEAM
f
I
I SPEEDOMETER
1
I
I
-- - 4 3 INDICATOR LAMP I
I
Le-- --I
RIGHT TURN SIGNAL
INDICATOR LAMP
I
I
7",'I I I
D-10
I
1-1
PRINTED CIRCUITS
VOLTAGE
.E.ZA G-4
LIMITER
-M-1 B
TO DOME LAMP
WIRING
I _. ~
I I TRACER
(WITH OPEN DOOR L.7 I 18 1 BLACK
INDICATOR LAMP)
LEGEND
WIRING SPLICE ---b---
INSULATORS VIEWED FROM TERMINAL SIDE
64 a 695
Fig. &Instrument Panel Wiring (Plymouth)

f
I
a
WIRING DIAGRAMS 8-109
Fig. 8-Body Wiring (Station Wagon) Plymouth
FUSE BLOCK
ACC
I AMMETER
12 BLACK
WINDOW LIFT
lED!
1
]SAFETY RELAY
TAIL GATE WINDOW LIFT SWITCH
I I
TOP LIFT SWITCH
12
12 RED 12 YELLOW
12 BLACK
1 I T 0 BODY
12 'RED
ACCESSORY
CIRCUIT BREAKER ACCESSORY
CIRCUIT BREAKER 64x674
TAIL GATE
WINDOW
LIFT WIRING 64x673
Fig. 9-Tail Gate Window lift Wiring

(Plymouth-Valiant) Fig. 1cI-Top lift Switch Wiring (Plymouth-Valiant)
8-1 10 WIRING DIAGRAMS
h
F2
"11
Rt
B
B 4
170-225 CUBIC INCH ENGINE 9-1
GROUP 9
ENGINE
PART I
170-225 CUBIC I N C H 6-CYLINDER ENGINES
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Special Tools .................................. 6 Testing Cylinders............................... 20
Torque Reference .............................. 7 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tune-up ...................................... 9 Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine Replacement ............................ 10 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder Head. ............................... 11 Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . 23
Rocker Arms and Shaft Assembly . . . . . . . . . . . . . . . . . . 13 Crankshaft Main Journals........................ 24
Valves and Valve Springs ....................... 13 Crankshaft Main Bearings ....................... 24
Refacing Valves and Valve h a t s . . . . . . . . . . . . . . . . . 15 Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . 24
Testing Valve Springs ........................... 15 Rear Main Bearing Oil Seal ...................... 25
Testing Valve Timing ............................ 16 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Timing Sprockets and Chain ...................... 16 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Timing Chain Case Cover Oil Seal . . . . . . . . . . . . . . . . 17 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Heli-Coil Insert-Worn Threads . . . . . . . . . . . . . . . . . . . 29
Camshaft Bearings ............................. 19
PART 2
318.361.413. 426 CUBIC I N C H 8-CYLINDER ENGINES
Page . Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Famshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. .
Special Tools-361 .
Special Tools-3 18 Cu In Engine . . . . . . . . . . . . . . . .
..
383.413. 426 Cu In Engines . . . .
. .
36
37
Camshaft Bearing; . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor Drive Shaft Bushings . . . . . . . . . . . . . . . . . . .
54
55
.
Torque Reference-3 18 Cu In Engine . . . . . . . . . . . . .
Torque Reference-361 383.413. 526 Cu In Engines . .
Tune.Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
39
40
Cylinder Block .................................
Piston and Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
57
58
Front Engine Mounts ............................ 41 Connecfing Rod Bearing Clearance ................ 60
Rear Engine Mount ............................. 41 Piston and Connecting Rod Assembly . . . . . . . . . . . . . . . 61
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Crankshaft Main Journals ........................ 61
Cylinder Head Assembly ........................ 43 Crankshaft Main Bearings ....................... 61
Rocker Arms and Shaft .......................... 44 Rear Main Bearing Oil Seals ..................... 62
Valves and Valve Springs . . . . . . . . . . . . . . . . . . . . . . 45 Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hydraulic Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Testing the Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . 50 Crankcase Ventilator Valve ...................... 68
Timing Sprockets and Chain . . . . . . . . . . . . . . . . . . . . . . 50 Heli-Coil Insert-Worn Threads . . . . . . . . . . . . . . . . . . . 68
Timing Chain Case Cover Oil Seal . . . . . . . . . . . . . . . . 52
PART b S E R V I C E DIAGNOSIS
Page Page
Engine ....................................... 69 Engine Oiling ................................. 71
9-2 170-225 CUBIC INCH ENGINE
SPECIFICATIONS
Valve Engine Type &

Model Application Engine Names No. Cyl. Arrangement Displacement
Valiant
W 1 (Std.) Standard 170 6 O.H.V. "G' 170 Cubic Inch
w1 (Opt.) Super 225 6 O.H.V. "RG" 225 Cubic Inch
Plymouth
VPl (Std.) 30D Economy "6" O.H.V. "RG" 225 Cubic Inch
VP2 (Std.) Fury V-800 O.H.V. "A" 318 Cubic Inch
VP2 (Opt.) Commando "361 " O.H.V. "8" 361 Cubic Inch
VP2 (Opt.) Commando "383" O.H.V. "B" 383 Cubic Inch
VP2 (Opt.) Commando "426" O.H.V. "B" 426 Cubic Inch
VP2 (Opt.) Police O.H.V. "B" 41 3 Cubic Inch
SIX CYLINDER ENGINE
SPECIFICATIONS
( 170-225 CUBIC I N C H ENGINE)
ENGINE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line OHV
Number of Cylinders.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40"
Stroke-1 7 0 Cubic Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 25"
225 Cubic Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 25"
Piston Displacement 170-225 Cu. In.
Compression Ratio-1 7 0 Cubic Inch. ................................... 8.50 to 1
225 Cubic Inch. .................................. 8.40 to 1
Compression Pressure with Engine Warm, Spark Plugs Removed, Wide Open
Throttle, at a Minimum Cranking Speed of 130 RPM. . . . . . . . . . . . . . . . . . . . 110-1 40 psi
Maximum Variation Between Cylinders (any one engine). . . . . . . . . . . . . . . . . . . 20 psi
Firing Order.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Baric Timing.. ................................................. 2%" B.T.D.C.
CRANKSHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully Counter-Balanced
Bearings.......................................................... Steel-Backed Babbitt
Main Bearing Journal Diameter. ...................................... 2.7495 to 2.7505"
Connecting Rod Journal Diameter. .................................... 2.1 865 to 2.1 875"
Maximum Out-Of-Round Permissible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .oo 1"
Number Main Bearings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clearance Desired. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005 to .OO 15"
Maximum Clearance Allowable Before Reconditioning. .................... .0025"
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002 to .007"
ThrustTaken By .................................................... No. 3 Main Bearing
Finish at Rear Seal Surface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagonal Knurling
Interchangeability of Bearings. ....................................... Upper Nos. 2,4
Lower Nos. 1, 2,4
MAIN BEARINGS (service)
All available in Standard and the following Undersizes.. . . . . . . . . . . . . . . . . . . .001, .002, .003,.010, .012"
SPECIFICATION& ( Continued1
CONNECTING RODS AND BEARINGS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drop Forged "I" Beam
length (Center to Center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-5.705 to 5.709"
225-6.697 to 6.701"
Weight (Less Bearing Shells). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-25.3 OZ.
225-26.8 OZ.
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel-Backed Babbitt
Diameter and Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 870 x 1.01 5"
Clearance Desired . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . .0005 to .OO 15"
Maximum Allowable before Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025"
Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 to .012"
Bearingsfor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard .001 .002,
.003, .010, .012" U.S.
Piston Pin Bore Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8995 to .9000"
CAMSHAFT
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chain
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel-Backed Babbitt
Number .......................................................... 4
Thrust Taken by .................................................... Cylinder Block
Clearance ........................................................ .001 to .003"
.
Maximum Allowable Before Reconditioning. . . . , . . . . . . . . . . . . . . . . . . . . . . . . .005"
CAMSHAFT BEARING 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"
CAMSHAFT BEARINGS
Diameter (after reaming)
No.1 ........................................................ 2.000 to 2.001"
No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.984 to 1.985"
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.969 to 1.970"
No.4 ........................................................ 1.953 to 1.954"
TIMING CHAIN
Number of Links ................................................... 50
Pit, .............................................................. .50"
Width ........................................................... .88"
TAPPETS
Type ............................................................ Mechanical
. .
Clearance in Block. . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . .0012 to .0025"
. .
Body Diameter.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9040 to .9045"
Cleqrance between Valve Stem and Rocker Arm Pad (Engine Hot). .. . . . . . . . . .010" Intake
.020" Exhaust
PISTONS
Type . . . . . . . . . . . . . .............................................. Horizontal Slot w/Steel Struts
Material .......................................................... Aluminum Alloy Tin Coated
.
Land Clearance (diametral). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .024 to .031"
Clearance at Top of Ski. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005 to .OO 15"
Weight (std. through .040 oversize). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 02.
Piston length (overall). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.5 1' I
SPECIFICATIONS---( Continued 1
PISTONS Cont'd
Ring Groove Depth
No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179"
No.2 ........................................................ .179"
No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181"
Pistonsfor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std .005. .020. 040" 0.S . .
PISTON PINS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Press Fit in Rod
Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9007-. 9009"
l ~ g t .h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.955-2.976w
Clearance in Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
00045 to 00075" .
Interference in Rod ................................................. .
0007 to 00 12" .
Piston Pins for Service............................................... Standard Only
Direction Offset in Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toward Right Side of Engine
PISTON RINGS
Number of Rmgs per Piston.......................................... 3
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Width of Rings
(Compression) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0775 to .0780"
(Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1860 to .1865"
Piston Ring Gaps (Compression). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 10 to .020"
Service Rings (Oil Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .015 to .062"
RING SIDE CLEARANCE (SERVICE RINGS)
(Compression)
Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015 to .0040"
lntennediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015 to .0040"
(Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .009" Maximum
VALVES-Into ke
Material .......................................................... Carbon Manganese Steel
Head Diameter .................................................... 1.61 5-1.625"
.
length (to gage dim line) ........................................... 4.6878-4.7028"
Stem Diameter..................................................... .
372 to 373" .
Stem to Guide Clearance ............................................ .
001 to 003" .
Maximum Allowable Before Reconditioning.............................. 004" .
Valve Face Angle .................................................. 45"
Adjustment ........................................................ Rocker Arm Screw
Lift .............................................................. 375".
VALVES-Exhaust
Material .......................................................... Nitrogen Treated Manganese
Chromium Nickel Steel
Head Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.355-1.365"
Length (to gauge dim. line) ..........................................
.
t
4.6878-4.702 8"
Stem Diameter ..................................................... .371 to.372"
Stem to Guide Clearance ............................................ .
002 to 004" .
Maximum Allowable Before Reconditioning .............................. 006".
Valve Face Angle .................................................. 47"
Adiustment ........................................................ Rocker Arm Screw
uft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 .
SPECIFICATIONL ( Continued 1
VALVE SPRINGS
Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.92"
Load when Compressed to (valve closed). .............................. 49-57 Ibs. @ 1'x6"
Load when Compressed to (valve open). ............................... 137-1 50 Ibs. @ 1%6"
Valve Springs 1.D.. ................................................. 1.01 0 to 1 .030N
CYLINDER HEAD
Combustion Chamber. .............................................. Wedge Type
Valve Seat Run-Out (maximum). ...................................... .002"
Intake Valve Seat Angle.. ........................................... 45O
Seat Width (finished). .............................................. .070to .090"
Exhaust Valve Seat Angle. .......................................... 45O
Seat Width (finished). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040 to .060"
Cylinder Head Gasket Compressed (thickness). .......................... .022@
CYLINDER BLOCK
Cylinder Bore (standard). ........................................... -
Cylinder Bore Out-of-Round (Max. allowable before reconditioning). . . . . . . . . .005"
Cylinder Bore Taper (Max. allowable before reconditioning). . . . . . . . . . . . . . . .o 10"
Reconditioning Working Limits (for taper and out-of-round) ................. .001"
Maximum Allowable Oversize Cylinder Bore. ........................... .040"
Tappet Bore Diameter. ............................................. .9050--.9058"
Distributor Lower Drive Shaft Bushing (press fit in block). .................. .0005-.0040"
Ream to .......................................................... A a6 5 4aa o w
Shaft to Bushing Clearance.. ......................................... .0007-.0027"
ENGINE LUBRICATION
Pump Type ....................................................... Rotary, Full Pressure
Capacity (qts.). .................................................... 4*
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft
Operating Pressure at 1000 RPM ..................................... 45 to 60 Ibs.
Pressure Drop Resulting from Clogged Filter. ............................ 7 to 9 Ibs.
OIL FILTER
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow
Spin On .......................................................... Replaceable
*When Filter Element i s Replaced, Add 1 qt.
OIL PUMP-INSPECTION LIMITS FOR REPLACEMENT
Oil Pump Cover.. ............................................................ .0015inch or more

Outer Rotor Length.. ......................................................... .649 inch or more
Outer Rotor Diameter. ........................................................ 2.469 inch or less
Inner Rotor Length.. .......................................................... .649or l e u
Clearance Over Rotors-Outer ................................................. .004inch or more
Inner .................................................. .004 inch or more
Outer Rotor Clearance. ....................................................... .012 inch
Tip Clearance Between Rotors. ................................................. .O 10 inch or more
9-6 170-225 CUBIC INCH ENGNE
OVERSIZE AND UNDERSIZE

ENGINE COMPONENT M A R K I N G S
Engine
Displacement Condition Identification Location of Identification
170 cu. in. ,001" U/S Crankshaft Maltese Cross Top of front pad-Right
225 cu. in. side of block
M-2-3 etc. (indicating
No. 2 & 3 main bearing
journal)
and/or Crankshaft counterweight
R-1-4 etc. (indicating
No. 1 & 4 connecting rod
journals)
.010" U/S Crankshaft X Top of front pad-Right

side of block
M-10 (indicates .010"
U/S all main journals)
and/or Crankshaft countsrweight
R- 10 (indicates .O 10"
U/S all rod journals)
.020" O/S Cylinder A Top of front pad-Right

Bores side of block
.008" O/S Tappets 4 Top of front pad-Right

side of block
SPECIAL TOOLS
1701225 CUBIC I N C H ENGINES
C-119. ........................................................... Cylinder Bore Gauge
C-385.. ......................................................... .Ring Compressor
C-647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spring Testing Fixture
C-756.. ......................................................... .Valve Guide Cleaner
C-771.. ......................................................... .Flywheel Turning Tool
C-823.. ......................................................... .Cylinder Bore Hone
C-897.. ......................................................... .Welch Plug Driver
C-3005. ........................................................ .Torque Wrench 100 Foot-Pounds (sensory type)
C-301.2. ........................................................ .Cylinder Ridge Reamer
C-3025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Valve Guide Wear Checking Sleeve
C-3026. ........................................................ .Exhaust Valve Guide Wear Checking Sleeve
C-3028. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tappet Bore Reamer
I C-3059. ........................................................ .Main Bearing Upper Shell Remover and Installer
C-3065. ......................................................... Cylinder Compression Gauge
C-3066. ........................................................ .Timing light Connector
C-3068. . . . . . . . . . . . . ............................ . . . . . . . . . . . . . . . . .Tappet and Push Rod Carrier
C-3 132A. ........................................................ Camshaft Bearing Remover and Installer
C-3167 .......................................................... Engine Repair Stand
C-322 1 .......................................................... Piston and Connecting Rod Remover and Installer
C-3339. ........................................................ .Dial Indicator Set
C-3422(A). ...................................................... .Valve Spring Compressor
C-3427. ........................................................ .Valve Guide Reamer .03V Oversize
SPECIAL TOOLS-1 70-225 CUBIC INCH ENGINE%(Continued 1

C.3430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.Valve Guide Reamer 015" Oversize
C.3433 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.Valve Guide Reamer 005" Oversize
C.3487 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Support Fixture
C.3501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Bore Deglazing Hone
C.3506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Case Cover Oil Seal Removing and Installing Tool
C.3626 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder head Holding Fixture
C-3661 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tappet Remover
C.3662 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Repair Stand Adapter
C.3724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Pin Removing and Installing Tool
C.3732A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vibration Damper Puller-Installer
C.3743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Main Bearing Oil Seal Installing Tool
C.3746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Stem Length Gauge
C.3804 ................................................... .Engine Lifting Fixture
C.3805 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Ring Remover and Installer
C.3806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixture to Adapt C-3487 to Six Cylinder Engine
TORQUE REFERENCE-1 70-225 CUBIC INCH ENGINES

Torque Thread
Foot-Pounds Size
Connecting Rod Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 %-24
Cylinder Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 36-14
Main Bearing Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Y2-13
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 14mm
Camshaft Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3 6 - 14
Carburetor to Manifold Nut ............................................ 30 %-16
Chain Case Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 in.-lbs. 5/;6-18
Torque Converter Housing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 %-16
Converter Brace to Aluminum Housing .................................... 40 36-14
Converter Brace to Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 %-16
Clutch Housing eolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 %-16
Crankshaft Rear Bearing Seal Retainer ................................... 30 YE-16
Cylinder Head Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in.-lbs. 1/4-20
Distributor Clamp Bolt ................................................. 200 in.-lbs . %-18
Engine Front Mounting to Frame Nut ..................................... 85 Y2-20
Engine Front Mounting to Block Nut ...................................... 45 36-20
Engine Rear Mount Bolts............................................... 35 36-14
%-24
Exhaust Manifold Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 %-24
Exhaust Pipe Flange Nut ............................................... 30 36-20
Exhaust Pipe Clamp Bolt ............................................... 20 34-24
Exhaust Pipe Support Clamp Bolt ........................................ 20 Y~s-24
Fan Attaching Bolt .................................................... 200 in.-lbs. %-I 8
Flywheel Housing to Cylinder Block Bolt .................................. 50 36-14
Flywheel Housing Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1/4 -20
Fuel Pump Attaching Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 YE-16
Alternator Bracket Bolt ................................................ 30 %-16
Alternator Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 in.-lbs. %-18
Alternator Adjusting Strap Bolt .......................................... 15 1-8
Alternator Adjusting Strap Mounting Bolt .................................. 30 %-16
Intake to Exhaust Manifold Bolt ......................................... 200 in.-lbs. %-18
Manifold Heat Control Counterweight Bolt ................................ 50 in.-lbs. 10-32
Oil Pan Drain Plug ................................................... 20 y2-20
Oil Pan Bolt ......................................................... 200 in.-lbs. %-18
Oil Pump Cover Bolt .................................................. 130 in.-lbs. 1/4-20
Oil Pump Attaching Bolt ............................................... 200 in.-lbs. %-I 8
Oil Filter Attaching Stud ............................................... 30 %-16
Oil Pressure Gauge Sending Unit ....................................... 60 in.-lbs. '/r N.P.T.F.
Rocker Shaft Bracket Bolt .............................................. 30 YE-16
Starter Mounting Bolt ................................................. 50 36- 14
Temperature Gauge Sending Unit ....................................... 180 in.-lbs. '/4 N.P.T.F.
Water Pump to Housing Bolt ........................................... 30 34-16
PART I
SIX CYLINDER ENGINE

The 6 cylinder engine, as shown in Figure 1 is mounted rotor type pump on the lower right side of
inclined toward the right at an angle of 30 degrees the cylinder block. A full flow replaceable element
from the vertical in the engine compartment. This type oil filter is mounted on the rear of the oil pump
design permits a lower hood line and allows space body. Oil is forced by the oil pump to a series of oil
in the engine compartment for the long intake mani- passages in the engine, as shown in Figure 2.
fold branches. The engine has in-line overhead valves The semi-series flow cooling system contains an
and wedge shaped combustion chambers and a nomi- aluminum water pump body with a pressed in ball
nal compression ratio of 8.5:I for the 170 cu. in. bearing and seal assembly and plastic impeller. The
engine and 8.4:I for the 2 25 cu. in. engine. water pump housing is integral with the cylinder
The lubrication system consists of an externally block.
Fig. 1-Engine End Sectional View

RIGHT REAR CYLINDER HEAD SCREW VALVE ROCKER SHAFT
FILTER BY-PASS VALV
DRILLED PASSAGES IN
NO. 4 CAMSHAFT
FILTER ELEMENT JOURNAL
FILTER INLET
PASSAGE
FILTER OUTLET PA
HIGH PRESSURE CAVITY

/
PRESSURE RELIEF VALVE
I
I
LONGITUDINAL
\ \ - T
ALL MAIN BEARINGS ARE LUBRICATED AS
SHOWN. CONNECTING ROD CRANKPIN
OIL GALLERY END BEARINGS ARE LUBRICATED BY
HOLES DRILLED IN THE CRANKSHAFT
BETWEEN THE MAIN AND PIN-JOURNALS
PUMP AND FILTER SIDE VIEW
STRAINER A 64x646
Fig. 2-Engine Oiling System
SERVICE PROCEDURES
1. TUNE-UP (7) Remove the distributor. Clean the cap and

rotor. Inspect for carbon tracking, cracks and COITO-
(1) Test the battery specific gravity, add water if
sion. Inspect the breaker plate, points, lead wire and
necessary, clean and tighten the battery connections. vacuum advance, replace if necessary. Adjust to
(2) Test the cranking voltage if below 9.6 volts specifications. Test coil and condenser.
and more than 130 amperes draw. See “Starting Motor (8) Install the distributor, distributor cap, and
Cranking Voltage” Electrical Group 8. spark plug cables. Reset the ignition timing with the
(3) Tighten the intake manifold bolts to 15 foot- vacuum advance line disconnected. The ignition tim-
pounds torque. ing should be set to compensate for altitudes and/
(4) Perform the cylinder compression test. The or gasoline grades as follows:
compression should not vary more than 20 pounds A. At low altitudes, with any good grade of the
for any one engine. recommended gasoline, either “regular” or “pre-
(5) Clean or replace spark plugs as necessary mium”, the engine will give its best performance if
and adjust gap to .035 inch. Tighten to 30 foot-pounds timed according to specifications.
torque. B. When using lower grade fuels, or after carbon
(6) Test the resistance of the spark plug cables has accumulated, objectionable spark ping may occur
and if the resistance is more than 30,000 ohms re- with the specified timing. In cases of this nature, ig-
place the cable. nition timing should be retarded, but not to exceed
9-1 0 170-225 CUBIC INCH ENGINE
5 degrees of crankshaft rotation later than specified. referring to Cooling System, Group 7 for proper
C. At high altitudes or when using higher quality adjustments.
gasoline, for example “premium” where “regular” is (14)Road test the vehicle as a final test.
specified or “super premium” where premium is
specified, there is less tendency for spark ping. In 2. ENGINE REPLACEMENT
such cases, improved performance may be obtained
by advancing the spark not to exceed 5 degrees of Removal
crankshaft rotation ahead of specified timing. (1) Scribe the hood hinge outlines on the hood
and remove the hood.
NOTE: It is recommended, however, that ve- (2) Drain the cooling system and remove the bat-
hicles operating at high speeds or hauling trailers
tery and the carburetor air cleaner.
have ignition timing set at not over the specified
setting. (3) Remove the radiator and heater hoses and
remove the radiator.
D. Within the foregoing limits, namely, from 5
degrees ahead to 5 degrees later than specified timing, (4)Remove the closed vent system from the cylin-
a good rule to follow is to advance the spark until der head cover.
a slight ping is heard when accelerating from 15 (5) Disconnect the fuel lines, carburetor linkage
mph in direct drive at wide open throttle. and wiring to the engine.
(9) Set carburetor idle mixture adjustment. Ad- (6)Disconnect the exhaust pipe at the manifold.
just the throttle stop screw to specifications. Per- (7)Raise the vehicle on a hoist.
form a combustion analysis.
(8) Drain the converter housing and the trans-
(10)Test the fuel pump for pressure and vacuum. mission. Remove the oil cooler lines, filler tube and
Refer to “Fuel System” Group 14, Specifications. push button cable. (If so equipped).
(11)Inspect the manifold heat control valve in the (9) Remove the clutch torque shaft, brake cables
exhaust manifold for proper operation and apply and rods.
Manifold Heat Control Valve Solvent Part Number
1879318 to the bushing and shaft. (10)Remove the speedometer cable and the gear
shift rods.
(12)Every 6 months remove the filter element
and blow out dirt gently with an air hose. Direct air (11)Disconnect the propeller shaft and tie-up out
from inside out, and keep noozle 2 inches away from of way.
the element to avoid damaging. Clean the metal (12)Install the engine support fixture Tool C-
housing and replace the element. Every 32,000 3806 to support the rear of the engine.
miles, install a new factory recommended MoPar (13)Remove the engine rear support crossmem-
filter element. Service the unit more frequently when ber (Figs. 4 and 5).
driving under severe conditions, such as in dusty
areas. Fig. 3.
(13)Inspect and adjust the accessory belt drives
62x272
Fig. 3-Cleaning Filter Element Fig. &Rear Engine Mount (Valiant)
170-225 CUBIC INCH ENGINE 9-1 1
, . . ,-\
RIGHT
--/Fig. 7-Front Engine Mounts (Plymouth)
CROSS MEMBER
BRACKET 4 I
I
I (3) Install the front engine mount bolts. Do not
tighten.
62x273 (4) Install the engine support fixture Tool (2-3806.
Fig. 5-Rear Engine Mount (Plymouth)
(5)Remove the chain hoist and engine lifting
fixture.
(6)Raise the vehicle on a hoist.
(14)Remove the transmission bolts from the clutch
housing. (7) Position the rear of engine and install the
transmission.
(15)Remove the transmission.
(8) Install the engine rear support crossmember.
(16)Lower the vehicle.
(9)Connect the propeller shaft at the transmis-
(17)Install the engine lifting fixture Tool C-3804
sion.
to the cylinder head and attach a chain hoist to
the fixture eyebolt. (10)Install the speedometer cable and gear shift
rods.
(18)Remove the engine support fixture.
(11)Install the clutch torque shaft, brake cables
(19)Remove the front engine mount bolts (Figs. and rods.
6 and 7).
(12)Install the cooler Lines, and transmission filler
(20)Lift the engine from the engine compart- tube.
ment and install on an engine repair stand.
(13)Lower the vehicle.
lnsfallaflon (14)Tighten the front engine mount bolts to 85
(1) Instgll the engine lifting fixture Tool C-3804 foot-pounds torque.
and attach a chain hoist to the fixture eyebolt. (15)Connect the exhaust pipe at the manifold
(2)Lower the engine into the engine compart- using a new gasket.
ment until the front of the engine is positioned on the (16)Connect the fuel lines, carburetor linkage
front engine mounts. and wiring to the engine.
(17)Install the closed vent sy#tem on the cylinder
head cover.
(18)Install the radiator hoses, battery and car-
buretor air cleaner.
(19)Fill the cooling system and the transmis-
sion.
(20) Install the hood.
3. CYLINDER HEAD
The chrome alloy cast iron cylinder head, as
Fig. 6-Front Engine Mounts (Valiant) shown in Figure 8 is held in place by 14 bolts. The
DOWEL HOLE
FRONT 4
LAN1 PASSAGES
COOLANT PASSAGE
4 '-
COOLANT PASSAGE (6)
cnnnua I v n Lv 1-4
60x129
Fig. 8-Cylinder Head
spark plugs are located at the wide edge of the com- their respective slots in holder, Tool C-3068.
bustion chambers and aluminum spark plug tubes (13) Remove 14 head bolts and remove the cy-
serve as spark plug gaskets. linder head.
Removal (14) Place the cylinder head in holding fixture
Tool (2-3626 and remove the spark plu'gs and tubes.
(1) Drain the cooling system.
(2) Remove the carburetor air cleaner and fuel lnsfallatlon
line. (1) Clean all gasket Surfaces ,of the cylinder block
(3) Disconnect the accelerator linkage. and cylinder head and install spark plugs.
(4) Remove the vacuum control tube a t the carbu- (2) Inspect all surfaces with a straight edge if
retor and distributor.
(5) Disconnect the spark plug wires by pulling
there is any reason to suspect leakage.
-
straight out in line with the plug.
(6) Disconnect the heater hose and clamp holding
the by-pass hose.
(7) Disconnect the heat indicator sending unit
wire.
(8) Disconnect the exhaust pipe at the exhaust
manifold flange.
(9) Remove the intake and exhaust manifold and
carburetor as an assembly.
(10)Remove the closed vent system and the cy-
linder head cover.
(11) Remove the rocker arms and shaft assem-
bly.
(12) Remove the push rods and place them in Pig. 9-Cylinder Head Tightening Sequence
(3)Coat the new gasket with MoPar Sealer, Part (11)Install the vacuum control tube from the
Number 1122893. Install the gasket and the cylinder carburetor to the distributor.
head. (12)Connect the exhaust pipe to the exhaust,
(4)Install the cylinder head bolts. Starting at the manifold flange.
top center, tighten all cylinder head bolts to 65 foot- 0 3 ) Install the fuel line and the carburetor air
pounds torque in sequence (Fig. 9). Repeat the pro- cleaner.
cedure, retightening all cylinder head bolts to 65
(14)Fill the cooling system.
foot-pounds torque.
(15) Operate the engine until normal operating
(5)Install the rocker arms and shaft assembly
temperature is reached (approximately 180° F. water
with “FLAT” on the end of the rocker shaft “ON
temperature).
TOP” and pointing toward the front of the engine,
as shown in Figure 10 to provide proper lubrication (16)Allow the engine to idle at 550 rpm at this
to the rocker assemblies. Install the rocker shaft re- 180° F. temperature for five minutes.
tainers between the rocker arms so they seat on the (17)Adjust the intake valves to .010 inch clear-
rocker shaft and not on the extended bushing of the ance and the exhaust valves to .020 inch.
rocker arm. Be sure to install the long retainer in the (18)Place the new cylinder head cover gasket in
center position only. Install the rocker shaft bolts position and install the cylinder head cover. Tighten
(long bolt at rear of engine) and tighten to 30 foot- nuts to 40 inch-pounds torque.
pounds torque. (19)Install the closed vent system.
(6)Loosen the 3 bolts holding the intake mani-
fold to the exhaust manifold. This is required to 4. ROCKER ARMS A N D
maintain proper alignment. SHAFT ASSEMBLY
(7) Install the intake and exhaust manifold and Stamped steel rocker arms are arranged on a single
the carburetor assembly to the cylinder head with the rocker arm shaft. Hardened steel spacers are used
cup side of the conical washers against the manifolds. between the pairs of rocker arms. The rocker shaft is
%Tightennuts to 10 foot-pounds torque. held in place by bolts and stamped steel retainers
(8) Tighten 3 bolts holding the intake manifold attached to the seven brackets on the cylinder head.
to the exhaust manifold to 15 foot-pounds torque.
Removal
NOTE: Sequence: Tighten inner bolt first, then (1)Remove the closed vent system.
the outer two bolts. (2)Remove the cylinder head cover and gasket.
(9)Connect the heater hose and by-pass hose (3) Remove the rocker shaft bolts and retainers.
clamp.
(4)Remove the rocker arms and shaft assembly.
(10)Connect the heat indicator sending unit wire,
the accelerator linkage and spark plug wires. lnst allation
(1)The rocker arms and shaft assembly must be
installed, as shown in Figure 10. The flat on the
end of the rocker shaft must be on top and point
toward the front of the engine. This is necessary to
t
FRONT
T
A
LF, ON ROCKER SHAFT provide proper lubrication to the rocker assemblies.
(2)Install the rocker shaft retainers between the
1% ,ADJUSTING SCREW rocker arms so they seat on the rocker shaft and not
on the extended bushing of the rocker arm.
-ROCKER ARM Be sure to install the long retainer in the center
position only.
(3)Install the rocker shaft bolts. Install the long
bolt at the rear of the engine. Tighten to 30 foot-
pounds torque.
(4) Adjust tappets. Hot; intake .010 inches, ex-
haust .020inches.
60x243 5. VALVES AND VALVE SPRINGS
Fig. 10-Rocker Shaft Installed Valves are arranged in line in the cylinder head
TS>OL
CYLINDER HEAD ASSEMBLY

/
Fig. 13-Measuring Valve Guide Tool C-3339
valve) should measure .371 to .372 inch. If the wear

Fig. 11-Compressing Valve Spring (Tool C-3422A) exceeds .002 inch, replace the valve.
(3) Remove carbon and varnish deposits from the
and operate in guides that are integral with the inside of the valve guides, with Tool C-756.
cylinder heads. (4) Measure the valve stem guide clearance as
Removal follows:
(1) With cylinder head removed, compress the
Install sleeve Tool (2-3026 over the valve stem and
install valve (Fig. 12). The special sleeve places the
valve springs, using Tool C-3422A (Fig. 11).
valve at the correct height for measuring with a
(2) Remove the valve retaining locks, valve dial indicator.
spring retainers, valve stem cup seals and the valve
(5) Attach the dial indicator Tool (2-3339 to the
springs.
cylinder head and set it at right angle of the valve
NOTE: Remove any burrs from the valve stem stem being measured (Fig. 13).
lock grooves to prevent damage to the valve guide (6) Move valve to and from the indicator. The
when the valves are removed. total dial indicator reading should not exceed .012
Valve Inspection inch on intake valves and .017 inch on exhaust valves.
Ream the guides for valves with oversize stems if
(1) Clean the valves thoroughly and discard the dial indicator reading is excessive or if the
burned, warped and cracked valves. stems are scuffed or scored.
(2) Measure the valve stems for wear. The intake Service valves are available in standard, .005,
valve stem diameter (new valve) should measure .372 .015 and .030 inch oversizes. Reamer to accommo-
to .373 inch and exhaust valve stem diameter (new date the oversize valve stem are as follows: Reamer
VALVE P
60x154
Fig. 12-Measuring Wear with Sleeve (Tool C-3026) Fig. 1 L V a I v e Face and Seat Angle
(6)When the seat is properly positioned the width
T 7
EXHAUST of the intake seats should be 5/G4 to 3/32 inch. The
INTAKE
VALVE VALVE width of the exhaust seats should be 3/64 to N6 inch.
7. TESTING VALVE SPRINGS

(1) Whenever the valves have been removed for
c--STEM inspection, reconditioning or replacement, the valve
springs should be tested. To test a spring, determine
the length at which the spring is to be tested. As
VALVE SPRING RETAINER an example, the compressed length of the spring
LOCK GROOVES to be tested is 15/l6 inches. Turn the table of Tool
C-647until the surface is in line with the 1S/l6 inch
mark on the threaded stud and the zero mark to the
front. Place the spring over the stud on table and lift
54x330C
the compressing lever to set the tone device. Pull on
torque wrench until ping is heard. Take the reading
Fig. 15-Intake and Exhaust Valve on torque wrench at this instant. Multiply this read-
ing by two. This will give the spring load at the test
Tool C-3433 (.005” OS),Reamer Tool C-3430 (.015” length. Fractional measurements are idicated on the
O S ) . , Reamer Tool C-3427(.030”OS.). table for finer adjustments. The valve springs should
(7)Slowly turn reamer by hand and clean guide test 137 to 150 lbs. when compressed to 15/16 inches.
thoroughly before installing a new valve. Do not at- Replace springs that do not meet these specifications.
tempt to ream the valve guides from standard di- (2)Inspect each valve spring for squareness with
rectly to .030 inch. Use step procedure of .005, .015 a steel square and surface plate, test springs from
and .030 inch so the valve guides may be reamed both ends, as shown in Figure 16.
true in relation to the valve seat. If the spring is more than inch out of square,
install a new spring.
6. REFACING VALVES AND
VALVE SEATS lnstullutton
(1)Coat the valve stems with lubrication oil and
(1)The intake and exhaust valve seats and the
insert them in the cylinder head.
intake valve face have a 45 degree angle. The exhaust
valve face has a 43 degree angle. The valve face (2)If valves or seats are reground, test the valve
and valve seat angles, are shown in Figure 14. stem height with Tool C-3746.If the valve is too long,
grind off the tip until the length is within the limits.
(2)Inspect the remaining margin after the valves
are refaced (Fig. 15). Valves with less than 3/G4 inch (3)Install new cup seals on all valve stems (long
margin should be replaced. seal on intake valve and short seal on exhaust valve)
and over valve guides (Figs. 17 and 18).-Install
(3)When refacing the valve seats, it is impor- valve springs and retainers. Install springs so that
tant that the correct size valve guide pilot be used for the closed coils are against the cylinder head.
reseating stones. A true and complete surface must
be obtained.
(4)Measure the concentricity of the valve seat
using dial indicator No. 13725. The total runout
should not exceed .002 inch (total indicator reading).
(5)Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat the valve seat lightly with Prussian Blue
then set the valve in place. Rotate the valve with
light pressure. If the blue is transferred to the center
of the valve face, the contact is satisfactory. If the
blue is transferred to the top edge of the valve face,
lower the valve seat with a 30° stone. If the blue is 58x1 45 A
transferred to the bottom edge of the valve face raise
the valve seat with a 60° stone. Fig. 16-Inspecting Valve Spring Squarenerr
0
EXHAUST 1 I -DAMPER PULLEY
L T O O L
/A SPRING
59x51A
Fig. 19-Removing Puller Assembly (Tool C-3732A)
Fig. 17-Valve Assembly
dicator to zero. Rotate the crankshaft clockwise (nor-
(4) Compress the valve springs with Tool C-3422A, mal running direction) until the valve has lifted .019
install locks and release tool. If the valves and/or inch. “he timing of the crankshaft pulley should now
seats are reground, measure the installed height of read from 12 degrees before top dead center to dead
springs. Make sure measurement is taken from the center. Readjust the lash. 1
bottom of the springs seat in the cylinder head to (3) If the reading is not within the specified limits:
the bottom surface of the spring retainer. (If spacers (a) Inspect the sprocket index marks.
are installed, measure from the top of spacer). If the (b) Inspect the timing chain for wear.
height is greater than 11s6 inches, install a x.~ inch (c) Inspect the accuracy of the “DC” mark on
spacer in the head counterbore to bring the spring the timing indicator.
height back to normal 1 s/s inches to 1 inches.
9. TIMING SPROCKETS AND CHAIN
8. TESTING VALVE TIMING Removal
(1) Rotate the crankshaft until No. 6 exhaust (1)Drain the cooling system.
valve is closing and No. 6 intake valve is opening. In- (2)Remove the radiator and fan.
stall a dial indicator so that the indicator pointer con- (3) Install Tool C3732A and pull the vibration
tacts the valve spring retainer on No. 1 intake valve damper assembly off the end of the crankshaft (Fig.
parallel to the axis of the valve stem. 19).
(2) Turn No. 1 intake adjusting screw in one com- (4) Loosen oil pans bolts to allow clearance and
plete turn to remove the lash. Adjust the dial in- remove the chain case cover and gasket.
/-----
(5) Slide the crankshaft oil slinger off the end of
the crankshaft.
bolt.
(6) Remove the crankshaft sprocket attaching bolt.
(7) Remove the timing chain with the camshaft
sprocket.
lnstallation
(1) Turn the crankshaft to line up the centerline
of the camshaft and crankshaft with the timing mark
on the crankshaft sprocket.
(2) Install the camshaft sprocket and the timing
chain.
(3) Line up the timing marks on the sprockets
with the centerline of the crankshaft and camshaft
Fig. 18-Installing Valves and Cup Seals (Fig. 20).
CHAIN CASE COVER
LIP OF
SEAL
RETAINER
i
60x
Fig. 22-Puller Blocks Expanded to Puller Position
Fig. 20-Alignment of Timing Marks
(Tool C-3506)
(4) Tighten the camshaft sprocket lock bolt to 35 (4) If the chain movement exceeds inch, install
foot-pounds torque. a new timing chain.
Checking Timing Chain for Stretch (5) If the chain is satisfactory, slide the crank-
(1) Place a scale next to the timing chain so that shaft oil slinger over the shaft and up against the
any movement of the chain may be measured. sprocket (flange away from sprocket).
(2) Place a torque wrench and socket over the
10. TIMING CHAIN CASE COVER
camshaft sprocket lock bolt and apply torque in the OIL SEAL REPLACEMENT
direction of the crankshaft rotation to take up the
slack; 30 foot-pounds (cylinder head installed) or 15 Removal
foot-pounds (cylinder head removed). With a torque It is normal to find particles of neoprene collected
applied to the camshaft sprocket bolt, the crankshaft between the seal retainer and crankshaft oil slinger
should not be permitted to move. It may be necessary after the seal has been in operation.
to block the crankshaft to prevent rotation. (1) Position puller screw of Tool C-3506 through
(3) Holding a scale with dimensional reading even case cover, the inside of case cover up. Position the
with the edge of a chain link, apply torque in the puller locks directly opposite each other, and force
reverse direction 30 foot-pounds (cylinder head in- the angular lip between the neoprene and flange of
stalled) or 15 foot-pounds (cylinder head removed) the seal retainer.
and note the amount of chain movement (Fig. 21). (2) Place the washer and nut on the puller screw.
CHAIN CASE COVER
60x161
Fig. 21-Measuring Chain Stretch Fig. 23-Removing Oil Seal (Tool C-3506)
9-1 8 170-225 CUBIC INCH ENGINE
FEELER GAUGE 1 ** -a&*,*
INSTALLING PLATE ,
id
SFAI \
PULLER SCREW
(TOOL) ‘N
AS
E
ER
)
CHAIN CASE
COVER-
.- ~- 60x162
Fig. 24-Positioning Installer Plate (Tool C-3506) Fig. 26-Measuring Seal for Proper Seating
Tighten the nut forcing blocks into gap to a point of (4) Install the flat washer and nut on the puller
distorting the seal retainer lip (Fig. 22). Puller is screw; hold screw and tighten nut (Fig. 25).
only positioned a t this point. (5) The seal is properly installed when the neo-
(3) Place sleeve over the retainer and place re- prene is tight against the face of the cover. Try to
moving and installing plate into sleeve. insert a .0015 inch feeler gauge between the neo-
(4) Place the flat washer and nut on the puller prene and the cover (Fig. 26) if the seal is installed
screw. Hold the center screw and tighten lock nut properly, the feeler gauge cannot be inserted.
to remove seal (Fig. 23).
Installing Chain Case Cover
Installation of Oil Seal (1) Be sure the mating surfaces of the chain case
(1) Insert the puller screw through the removing cover and cylinder block are clean and free from
and installing plate so that the thin shoulder will be burrs.
facing up. (2) Using a new gasket, slide the chain case cover
(2) Insert the puller screw with the plate through over the locating dowels and tighten the bolts to 15
the seal opening (inside of chain case cover facing foot-pounds. Be sure all the oil pan gaskets are in
UP). place and tighten the oil pan bolts to 200 inch-pounds.
(3) Place the seal in the cover opening, with the
Installing a Vibration Damper and
neoprene down. Place the seal installing plate into
Pulley Assembly
the new seal, with the protective recess toward lip
of the seal retainer (Fig. 24). (1) Place the damper pulley assembly hub key in
INSTALLING PLATE (TOOL) >d
I 1
Fig. 25-Instaling New Seal (Tool C-3506) Fig. 27-Installing Damper

170-225 CUBIC INCH ENGINE -
9-19
damage the cam bearing with the cam lobes.
ln stallation
(1) Lubricate the camshaft lobes and camshaft
bearing journals and insert the camshaft in the cylin-
der block (Fig. 29).
NOTE: Whenever an engine i s rebuilt and a new
camshaft and/or new tappets are installed, one quart
of MoPar Engine Supplement, part Number 1879406
should be added to the engine oil to aid in break-
in. The oil mixture should be left in the engine for a
minimum of 500 miles. Drain the oil mixture a t the
next normal oil change.
NOTE: When replacing the camshaft, all of the
tappet faces must be inspected for crown with a
Fig. 28-Camshaft and Sprocket Assembly straight edge. If any negative crown (dish) is o b
served, the tappet must be replaced. The tappet must
the slot in the crankshaft, and slide the hub on the have a definite crown.
crankshaft.
lnstallcrfion of Distributor
(2)Place the installing tool, part of puller set Before installing the distributor, time the engine as
Tool C-3732in position and press the damper pulley follows:
assembly on the crankshaft (Fig. 27).
NOTE: The distributor rotates clockwise.
(1)Rotate the crankshaft until the mark on the
11. CAMSHAFT
inner edge of the crankshaft pulley is in line with
The camshaft has an integral oil pump and distrib- the “0” (TDC) mark on the timing chain case
utor drive gear and fuel pump eccentric, as shown in cover. No. 1 cyl. compression stroke).
Figure 28. (2)With distributor “0”rings in position, hold the
Rearward camshaft thrust is taken by the rear face distributor over the mounting pad.
of the cast iron camshaft sprocket hub, bearing di-
rectly on the front of the cylinder block, eliminating (3)Turn the rotor to point forward, corresponding
the need for a thrust plate. to 4 o’clock.
The helical oil pump distributor drive gear and the (4) Install the distributor so that with the distrib-
camshaft lobe taper both tend to produce only a utor fully seated on the engine, the gear has spiraled
rearward thrust. to bring the rotor to a 5 o’clock position.
(5) Turn the housing until the ignition points are
Removal
separating and rotor is under No. 1cap tower.
(1)Remove the tappets, using Tool C-3661.
(6)Install hold down bolt and connect the pri-
(2)Remove the timing sprockets, distributor and mary wire.
the oil pump.
(7)Adjust the timing to specification, using a
(3)Remove the fuel pump. timing light, and connect the vacuum line.
(4) Remove the camshaft, being careful not to
12. CAMSHAFT BEARINGS ( Engiae
Removed from Vehicle)
CAMSHAFT Removal
(1)With the camshaft removed, drive out the
rear cam bearing welch plug.
(2)Install the proper size adapters and horse
. , .. ’ “
shoe washers (part of Tool C-3132A)at the back of
each bearing shell and drive out all the bearing
shells.
f2 1 60x149
lnstallation
Fig. 29-Installing Camshaft (1)Install the new camshaft bearings with Tool
CAMSHAFT BEARING OIL HOLE
bored and honed, and new pistons and rings fitted.
\ :-- 8 a
Whatever type of boring equipment is used, boring
and honing operation should be closely coordinated
with the fitting of pistons and rings in order that
specified clearances may be maintained.
Honing Cylinder Bores
Before honing, stuff plenty of clean rags under the
bores, over the crankshaft to keep the abrasive ma-
terials from entering the crankcase area.
(1)Used carefully, the cylinder bore resizing hone
Tool C-823, equipped with 220 grit stones, is the
best tool for this job. In addition to deglazing, it will
reduce taper and out-of-round as well as removing
Fig. 30-Removing Camshaft Bearings (Tool C-3132A)
light scuffing, scoring or scratches. Usually a few
C-3132A by sliding the new camshaft bearing shell strokes will clean up a bore and maintain the required
over the proper adapter. limits.
(2)Position the bearing in the tool. Install the (2)Deglazing of the cylinder walls may be done
horseshoe lock and drive the bearing shell into place using a cylinder surfacing hone, Tool C-3501,equip-
(Fig. 30). The camshaft bearing oil hole must be in ped with 280 grit stones (C-3501-3801). If the cylin-
exact alignment with the drilled oil passage from the der bore is straight and round 20-60 strokes depend-
main bearing. ing on the bore condition will be sufficient to provide
a satisfactory surface. Inspect cylinder walls after
(3)Install the remaining shells in like manner. each 20 strokes. Use honing oil C-3501-3880or a
Install No. 1 camshaft bearing 3/32 inch inward from
light honing oil available from a major oil distributor.
the front face of the cylinder block.
Do not use engine or transmission oil, mineral spirits
(4) Apply sealer to the plug and use Tool C-897 or kerosene.
to install a new welch plug at the rear of the camshaft. (3)Honing. should be done by moving the hone
Be sure this plug does not leak.
up and down fast enough to get a cross-hatch pattern.
When hone marks intercept at 60°, the cross hatch
13. CYLINDER BLOCK angle is most satisfactory for proper seating of the
(1)Remove the top ridge of the cylinder bores rings. (See.Fig. 31).
using Tool C-3012 before removidg pistons from the (4) After honing, it is necessary that the block
cylinder block. Keep the tops of the pistons covered be cleaned again to remove all traces of abrasives.
during this operation.
(2)Pistons and connecting rods must be removed
from the top of cylinder block. Rotate the crankshaft
so that each connecting rod is centered in the cylinder
bore.
(3)Remove the connecting rod cap.
(4)Install Tool C-3221 on one connecting rod
bolt and protector over the other bolt. Push each pis-
ton and rod assembly out of cylinder bore.
Be careful not to nick the crankshaft journals.
(5)Install the bearing caps on the mating rods.
14. TESTING CYLINDERS

lnspection
The cylinder walls should be tested for out-of-
round and taper with Tool C-119. If the cylinder
bores show more than .005” out-of-round, or a taper
of more than . O W or if the cylinder walls are badly
scuffed or scored, the cylinder block should be re- Fig. 31-Cross Hatch Pattern
CAUTION: Be sure all abrasives are removed
from engine parts after honing. It is recommended PISTON RING
that a solution of soap and water be used with a brush
FEELER GAGE
and the parts then thoroughly dried. The bore can
be considered clean when it can be wiped clean RING GROOVE
with a white cloth and cloth remains clean. Oil bores
after cleaning to prevent rusting.
15. PISTONS
The pistons are cam ground so that the diameter
at the pin boss is less than its diameter across the
thrust face. This allows for expansion under normal
operating conditions. The expansion forces the pin
bosses away from each other, and the piston assumes
a more round shape. Inspect pistons for taper and
elliptical shape before they are fitted into the cyl- Fig. 33-Measuring Piston Ring Clearance
inder bores. (See Fig. 32).
Fitting Rings
Finished Pistons (1) Measure the piston ring gap about two inches
All pistons are machined to the same weight in from the bottom of the cylinder bore in which it is
grams, regardless of oversize to maintain piston bal- to be fitted. (An inverted piston can be used to push
ance. For cylinder bores which have been honed or the rings down to insure positioning rings squarely
rebored, all service pistons include pins and are in the cylinder wall).
available in standard and the following oversizes: (2) Insert the feeler stock in gap. The ring gap
.005, .020, .040 inch.
should be .010 to .047 inch for compression rings
Fit ting Pistons and .015 to .062 inch for the oil ring steel rails in
The piston and cylinder wall must be clean and dry. standard size bores. Maximum gap in .005 inch o/s
The specified clearance between the piston and the bores should be .060 inch for compression rings
cylinder wall is .0005 to .0015 inch. and .070 inch for oil ring steel rails.
(1) Pistons and cylinder bores should be meas- (3) Measure the side clearance between the piston
ured at normal room temperature, 70 degrees F. ring and ring land, as shown in Figure 33.
The clearance should be .0015 to .004 inch for the
(2) Measure the piston diameter at the top of the
top compression ring and the intermediate ring, and
skirt 90 degrees to the piston pin axis.
.001 to .009 inch for the oil control ring.
(3) Measure the cylinder bores halfway down the
(4) Starting with the oil ring expander, place ex-
cylinder bore and transverse to the engine crankshaft
pander ring in the lower ring groove and install the
center line.
oil control ring using instructions in the package.
.024 TO .031 IN. LESS
r T H A N DIAMETER AT ( C ) l
ANVIL (TOOL)
SCREW (TOOL)
THE ELLIPTICAL SHAPE OF DIAMETERS AT (C) AND (D)
THE PISTON SKIRT SHOULD CAN BE EQUAL OR DIAMETER
BE ,008 TO .010 IN. LESS AT AT (D) CAN BE .0015 IN.
DIAMETER (A) THAN ACROSS GREATER THAN (C) ONNECTING ROD
THE THRUST FACES AT DIAM-
ETER (B). MEASUREMENT 58x195 B GUID€.-LARGE (TOO
IS MADE '/a IN. BELOW
LOWER RING GROOVE 6Ox221A
Fig. 34-Tool Arrangement for Removing Piston
Fig. 32-Piston Measurements Pin (Tool C-3724)
INDENT-ASSEMBLE TOWARDS FRONT OF
ENGINE
PRESS
,/”
n
-MAIN SCREW
(TOOL)
PILOT (TOOL)
OIL HOLE-ASSEMBLE
58x166 TOWARDS RIGHT SIDE
j OFENGINE
Fig. 35-Removing Piston Pin (Tool C-37241
(5)Install the compression rings in the middle

and top grooves. Using ring installer, Tool C-3805,be
sure the mark “TOP” on each compression ring is to
the top of piston.
16. PISTON PIN
60x142A
Removal
(1) Arrange Tool (2-3724 parts for the removal Fig. 37Aonnecting Rod Oil Hole
of the piston pin (Fig. 34).
(2) Install the pilot on the main screw. (6) Remove the tool from the piston.
(3)Install the screw through the piston pin.
fnstallatlon
(4)Install the anvil over the threaded end of the (1) Measure the piston pin fit in the piston. It
main screw with the small end of anvil against the should be a sliding fit in the piston at 70 degrees F.
piston boss. Be sure spring is removed from anvil. Piston pins are supplied in standard sizes only.
(5)Install nut loosely on the main screw and place (2) Lubricate the piston pin holes in the piston
the assembly on the press (Fig. 35). Press the piston and connecting rod.
pin out of the connecting rod.
(3) Arrange the tool parts for installation of the
NOTE: When the pin falls free from the connect- piston pin (Fig. 36).
ing rod, stop the press to prevent damage to the bot-
tom of the anvil.
SPRING (TOOL)
PISTON PIN \
58x196 B GUIDE-LARGE (TOOL)
Fig. 36-Tool Arrangement for installing Piston

Pin (Tool C-3724) Fig. 38-Installing Piston Plin (Tool C-3724)
(4) Install the spring inside the pilot and install
the spring and pilot in the anvil.
(5) Install the piston pin over the main screw.
(6) Place the piston, with “Notch Front” up, over
the pilot so that the pilot extends through the piston
pin holes.
(7) Position the connecting rod over the pilot
which extends through the piston hole. The oil hole
in the connecting rod must point toward the direc-
AIN SCREW
tion, shown in Figure 37. (TOOL)
(8) Install the main screw and piston pin in the
piston (Fig. 38).
(9) Install the nut on the main screw to hold the
assembly together. Place the assembly on a press 58x168 B
(Fig. 38). Fig. 39-Testing Fit of Arton Pin in Connecting
(10) Press in the piston pin until the piston pin Rod (Tool C-3724)
bottoms on the pilot, properly positioning the pin in
the connecting rod. connecting rod journal.
(11) Remove the tool and arrange the tool parts (2) Install the bearing cap and tighten to 45 foot-
and piston assembly in the same manner, as shown pounds torque.
in Figure 34 for measuring the pin fit. (3) Turn connecting rod ?4 turn in each direction.
(12) Place the assembly in a vise (Fig. 39). A slight drag should be felt which indicates clearance
(13) Attach the torque wrench to nut and test is satisfactory. The correct clearance is from .0005
torque up to 15 foot-pounds. If the connecting rod to .0015 inch.
moves downward on the piston pin, reject this con- (4) The side play should be from .006 to .012
necting rod and piston pin combination. Install a new inch.
connecting rod and repeat the installation and testing
procedure. Installing P iston and Connecting Rod
If the connecting rod does not move under 15 foot-
Assembly in Cylinder Block
pounds torque, the piston and connecting rod inter- (1) Compression ring gaps should be located on the
ference is satisfactory. left side of the engine and staggered about 60° apart.
Neither gap should line up with the oil ring rail gaps.
(14) Remove the tool.
(2) Rotate oil ring expander so that the ends are
17. CONNECTING RODS at the right side of the engine. Rotate steel rails so
that the gaps are approximately opposite and posi-
Installing Connecting Rod Bearings tioned above the piston pin holes.
(1) Install the connecting rod bearings so that the (3) Immerse the piston head and rings in clean
small formed tang fits into the machined groove in engine oil. Slide the ring compressor, -Tool C-385,
the connecting rod. over the piston and tighten with special wrench (part
(2) The limits of taper or out-of-round on any of Tool C-385). Position of rings must not change
crankshaft journal should be held to .001 inch. Bear- during this operation.
ings are available in standard .001,.002, .003, .010 (4) The notch on the top of the piston must point
and .012 inch undersize. toward the front of the engine so that squirt hole
(3) Install the bearings in pairs. Do not use a new in the connecting rod is toward the right side of the
bearing with an old bearing. Do not file the rods or engine.
the bearing caps. (5) Screw the connecting rod bolt protector (part
of Tool C-3221) on one rod bolt, and insert the rod
18. MEASURING THE CONNECTING ROD and piston into the cylinder bore. Rotate the crank-
BEARING CLEARANCE shaft so that the connecting rod journal i s on the
Shim Stock Method center of the cylinder bore.
(1) Place an oiled .001 inch feeler stock (342 inch (6) Attach the puller part of Tool C-3221 on the
wide and 34 inch long) between the bearing and the other bolt, and guide the rod over the crankshaft
9-24 1701225 CUBIC INCH ENGINE
20. CRANKSHAFT M A I N BEARINGS

The Nos. 1, 2 and 4 lower main bearings are inter-
changeable (Fig. 41). The Nos. 2 and 4 upper main
bearings are interchangeable.
The No. 1 upper main bearing is not interchanga-
able and i s chamfered on the tab side for timing
chain oiling and can be identified by a red marking
on the edge of the bearing; Upper main bearings are
grooved and lower main bearings are plain and are
not interchangeable. The No. 3 upper and lower
main bearings are flanged to carry the crankshaft
thrust loads are are not interchangeable with any.
other main bearings in the engine. Bearings that
are not badly worn, scored or pitted should be rein-
60x147 b .
stalled in the same bearing bore.
Fig. 40-Removing and Installing Connecting Rod The bearing caps are not interchangeable and the
(Tool C-3221) numbers should be marked at removal to insure cor-
rect assembly. Bearings are available in standard and
journal (Fig. 40). Be careful not to nick the con- the following undersizes: .001, .002, .003, .010 and
necting rod journals. .012 inch. Never install an undersize bearing that will
(7) Tap the piston down in the cylinder bore, using reduce the clearance below specifications.
the handle of a hammer. At the same time, guide the
connecting rod into position on the crankshaft jour- Removal
nal. (1)Remove the oil pan and inspect the bearing
(8) Install the rod caps, tighten nuts to 45 foot- cap numbers.
pounds torque. (2) Remove bearing caps one at a time. Remove
upper bearing by inserting Tool C-3059 (Fig. 42)
19. CRANKSHAFT M A I N JOURNALS into the oil hole on the crankshaft.
The crankshaft journals should be inspected for (3) Slowly rotate the crankshaft clockwise, forcing
excessive wear, taper and scoring. Journal grinding out the upper bearing.
should not exceed .012 inch under the standard jour-
nal diameter. Do not grind the thrust faces of No. 3 21. MEASURING THE M A I N
main bearing. Do not nick the connecting rod or BEARING CLEARANCE
main bearing journal fillets. After regrinding, re- Shim Stock Method
move the rough edges from the crankshaft oil holes (1)Position the crankshaft in block.
and clean out all oil passages.
1 4
THRUST BEARING -
LOWER
PI#INSTALLING 51x 5 3 A
V 60x143 Fig. 42-Removing and Installing Upper Main

Fig. 41-Main Bearing Identification Bearing (Tool C-3059)
ENGINE OILING 9-25
(2) Smooth the edges of a Y2x1 inch piece of soft 3743 (with bridge removed) until the tool is seated
copper or brass shim stock, .001inch thickness. in the bearing bore.
(3)Lubricate the main bearing journals and po- (3)Hold tool in this position and cut off the por-
sition the shim stock across the center ma'in journals. tion of the seal that extends above the block on both
(4)Install the bearing in the center main bear- sides.
ing cap, bearing tang in groove on cap, lubricate Bearing Cap
bearing and seat cap on block. Tighten bolts to 85
(1) Install a new seal in the seal retainer so that
foot-pounds torque.
the ends protrude (Fig. 43).
(5) If a slight drag is felt as the crankshaft is ro-
(2) Install the bridge on the tool and tap the seal
tated, not over v4 turn in either direction the clear-
down into position until the tool is seated.
ance is .001inch or less and is considered satisfactory.
If however, no drag is felt, the bearing is too large (3)Trim off the portion of the seal that protrudes
or the crankshaft cannot be rotated, the bearing is above the cap (Fig. 44).
too small and should be replaced with the correct size. (4) Install the two side seals in the grooves in the
It is permissible to use one .001 inch undersize seal retainer.
bearing shell with one standard bearing shell, or one (5) When installing the seal retainer, tighten
.002 inch undersize bearing shell with one .001 inch screws to 30 foot-pounds torque.
undersize shell. Always use the smaller diameter
bearing half as the upper. Do not use a new bearing ENGINE OILING SYST6M
with a used bearing and never use an upper bearing 23. OIL PAN (Fig. 4 5 )
half more than .001 inch smaller than the lower
bearing half. Removal 170 or 225 Cubic Inch Engine
Valiant I
(6) Fit the remaining bearings in the same man-
(1) Raise the vehicle on hoist. Drain the oil pan.
ner.
(7) Measure the crankshaft end play to .002-
.007 inch. If end play is more than .007 inch, install a
new center bearing.
22. REPLACEMENT OF THE REAR M A I N

BEARING OIL SEAL-
Crankshaft Removed
Cylinder Block
(1) Install a new oil seal in the cylinder block so
that both ends protrude.
(2) Tap seal down into position, using Tool C-
Fig. &Trimming Rear Main Bearing Oil Seal

(Tool c-3743)
REAR GASKET (NEOPRENE) FRONT GASKET (NEOPRENE)
TOOL) ir
SIDE GASKET-LEFT (CORK)
-
\l
'"t SIDE GASKET-RIGHT

SIDE SEAL GROOVES 60x133 (CORK)
Fig. 43-Installing Rear Main Bearing Oil Seal 60x144
(Tool c-3743) Fig. 45-Oil Pan and Gaskets
9-26 ENGINE OILING
(2)Using tie rod end puller, Tool C-3742, re-

move the steering and idler arm ball joints from the
steering linkage center link. Remove the dust shield
and the motor mount stud nuts.
(3) Lower the vehicle and remove the horns and
mounting brackets, then disconnect the negative
ground cable from the battery.
(4)Install the engine lifter plate Tool C-3804 and
fixture C-3809. Raise the engine from 1V2 to 2 inches.
(5) Again raise the vehicle on the hoist, then re
move the oil pan.
225 Cubic Inch Engine f Plymouth 1
(1) Raise the vehicle on a hoist. Drain oil pan.
(2)Using tie rod end puller, Tool C-3742,remove
the steering and idler arm ball joints from the steer- Fig. 4dPostioning Oil Pickup Tube and Screen
ing linkage center link. Remove the dust shield.
(3) Remove the oil pan attaching bolts, rotate the (4) Install the horns and mounting brackets, and
engine crankshaft to clear the counterweights, then install the air cleaner.
remove the oil pan. (5) Again raise the vehicle on the hoist and install
the motor mount stud nuts. Tighten to 85 foot
Cleaning and Inspection pounds torque.
Clean the oil pan in solvent and wipe dry with a (6)Lower the vehicle and fill with the proper
clean cloth. Scrape all gasket material from the grade and quantity of motor oil.
mounting surface of the pan and crankcase, as
shown in Figure 45. 225 Cubic Inch Engine I Plymouth 1
Inspect the oil drain plug and plug hole for stripped (1) Using a new oil pan gasket set, install the oil
or damaged threads and repair as necessary. Install pan and tighten bolts to 200 inch pounds torque.
a new drain plug gasket. (2)Connect the steering and idler arm ball joints
Inspect the oil pan mounting flange for bends or to the center link. Tighten the retaining nuts to 40
distortion. Straighten the flange if necessary. foot pounds torque and secure with cotter pins. In-
Clean the oil screen and pipe thoroughly in clean stall the dust shield.
solvent. Inspect the condition of the screen. (3) Lower the vehicle and fill with the proper
Install the oil screen and pipe. Turn in pipe until grade and quantity of motor oil.
it begins to tighten in the crankcase, continue tight-
ening until screen is positioned, as shown in Figure
24. OIL PUMP
46. Hold a steel rule against the flat surface inside
the case and measure from the edge of rule to the Removal
edge of the oil screen. The measurement should be (1) Drain the radiator, disconnect the upper and
1% inches with the screen properly positioned. lower hoses.
The screen must be an interference with the bottom (2)Disconnect the fuel line at the fuel pump In-
of the oil pan. let.
Installation (3) Disconnect the throttle linkage at the carbu-
170 or 225 Cubic Inch Engine (Valiant1 retor and lay it over the engine.
(1) Using a new pan gasket, install the oil pan and (4)With the vehicle on a hoist, support the front of
tighten bolts to 200 inch-pounds. the engine with a jack stand placed under the right
(2)Connect the steering and idler arm ball joints front corner of the engine oil pan. (Do not support
to the center link. Tighten the retaining nuts to 40 the engine at the crankshaft pulley or vibration damp
foot-pounds torque, and secure with cotter pins. In- w.1 Remove the front engine mounts.
stall the dust shield. (5) Cut a piece of wooden 2x4, eight inches long.
(3) Lower the vehicle on the hoist, then lower the (6)Raise the front of the engine just high enough
engine down into position. Remove the lifting fixture to insert the piece of 2x4 between the front rail of
and plate. the “K” member and the right front lower portion
ENGINE OILING 9-27
\
LND ENGINE SHIFTED
Fig. 47-Positioning Block

Fig. 49-Engine Relocated
of the engine oil pan. Position the block, as shown in
Figure 47 so one end is against the edge of the right
front engine mount support where it is welded to BODY 1 GASKET
the “K”member.
(7) Lower the front of the engine so it rests on the
2x4 block near the right front corner of the oil pan.
(8) Exert a light pressure, with a pry bar, against
the right side of the engine, as shown in Figure 48.
(9) This will cause the 2x4 block and the front of
the engine to slide to the left approximately 1V2
inches, as shown in Fikure 49.
(10) This movement will also cause the engine to W AND LOCKWASHER
tip slightly toward the left.
(11) Remove the engine oil filter, and remove
.’‘ SCREW AND LOCKWASHER
the oil pump cover and outer rotor. 60x2066
CAUTION: The outer rotor will drop out when

the pump cover is removed. Do not allow the rotor Fig. 50-Oil Pump (Disassembled View)
to be damaged by falling.
STRAIGHT EDGE
FEELER GAUGE
c 60x140A
Fig. 48-Moving Engine Fig. 51-Measuring Oil Pump Cover Flatness

9-28 ENGINE OILING
k
A
INNER ROTOR
Fig. 52-Measuring Outer Rotor Thickness Fig. 54-Measuring Clearance Over Rotors
(12)If the above instructions have been followed inches, replace the outer rotor.
closely, just enough clearance will be provided be- (4) If the inner rotor length measures less than
tween the engine and the “K” member to allow re- .649 inch (Fig. 53), replace the inner rotor.
moval of the oil pump.
(5) Slide the outer rotor and inner rotor into the
Disassembly Fig. 50 I pump body and place a straightedge across the face
(1) Remove the pump cover and seal ring. between the bolt holes (Fig. 54).
(2)Press off the drive gear. Support the gear to (6) If a feeler gauge of more than .004 inch can
keep the load off of the aluminum body. be inserted between the rotors and straightedge, re-
place the pump body.
(3) Remove the pump rotor and shaft and lift out
the outer pump rotor. (7)Remove the inner rotor and shaft leaving the
(4) Remove the oil pressure relief valve plug and outer rotor in the pump cavity.
lift out spring and plunger (Fig. 50). (8) Press the outer rotor body to one side with the
fingers and measure the clearance between the outer
Inspection and Repair rotor and the pump body (Fig. 55). If the measure-
(1) Clean all parts thoroughly. The mating face ment is more than .012 inch, replace the oil pump
of the oil pump cover should be smooth. Replace the body.
cover if it is scratched or grooved. (9) If the clearance between the inner rotor and
(2)Lay a straightedge across the oil pump cover outer rotor (Fig. 56) is more than .010 inch, replace
surface (Fig. 51). If a .0015 inch feeler gauge can the inner and outer rotors.
be inserted between the cover and straightedge, the
cover should be replaced. ITER ROTOR ,
(3) If the outer rotor length measures less than -a#%.

.649 inch (Fig. 52), and the diameter less than 2.469
Fig. 53-Measuring Inner Rotor Thickness Fig. 55-Measuring Outer Rotor Clearance
ENGINE OILING 9-29
- STANDARD SCREW FITS IN ... PL
ELI-COIL INSERT IN ... TAPPED HOLE. 63x845
Fig. 57-Heli-Coil Installation
(4) Connect the fuel line, throttle linkage, upper

Fig. 56-Measuring Clearance Between Rotors and lower radiator hoses.
(5) Refill the radiator.
(10)Inspect the oil pump relief valve plunger for
scoring and for free operation in its bore. Small
scores may be removed with 400 grit wet or dry paper 25. O I L FILTER
providing extreme care is used not to round off the The oil filter should be replaced every 6 months
sharp edge portion of the valve. to coincide with an engine oil change.
(11)For 170-225 cubic inch engines the relief (1) Using Tool (2-3845, unscrew the filter from
valve has a free length of 2 9/32 to 2 inch and is base of oil pump and discard.
red in color. (2)Wipe the base clean.
(12)If the oil pressure is low, inspect for worn (3) Screw the new filter on the base until the
bearings, or look for other causes of possible loss of gasket on the filter contacts the base.
oil pressure. (4)To obtain an effective seal, tighten filter by
Assern bly hand the additional number of turns indicated on the
(1)Assemble the pump, using new parts as re- replacement filter. Start engine and inspect for leaks.
quired. 26. REPAIR O F DAMAGED O R
(2)Install new oil seal rings between the cover W O R N THREADS
and the body. Tighten the cover bolts to 130 inch- Damaged or worn threads can be repaired by the
pounds torque. use of Heli-Coils. Essentially, this repair consists
lnstallation of drilling out the worn or damaged threads, tapping
the hole with a special Heli-Coil Tap, and installing
(1)Install the oil pump, without the outer rotor
a Heli-Coil Insert into the tapped holes. This brings
and cover, using a new gasket.
the hole back to its original thread size. (See Fig. 57.)
(2)Install the outer rotor, seal, pump cover and The following chart lists the threaded hole sizes
oil filter. which are used in the engine block and the necessary
(3) Center the engine to its original position. Using tools and inserts for the repair of damaged or worn
a jack stand to support the front end of the engine, thread. Heli-Coil tools and inserts are readily avail-
and install the front engine mounts. able from automotive parts jobbers.
INSERTING EXTRACT-
HELI-COIL INSERT DRILL TAP TOOL ING TOOL
thread Part Insert Part Part Part
Size No. Length Size No. No. No.
%-20 1 1 85-4 w '% (.266) 4 CPB 528-4~ 1227-6
%-18 1 185-5 1 5/s2" Q (.332) 5 CPB 528-5~ 1227-6
34-16 1 1 85-6 %6" X (.332) 6 CPB 528-6N 1227-6
'36-1 4 1 185-7 21/42" 1 9 h (.453) 7 CPB 528-7~ 1227-16
%-13 1 i 85-8 %iff % (516) a CPB 528-8N 1227-16
9-30 8-CYLINDER ENGINES
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OVERSIZE AND UNDERSIZE
ENGINE COMPONENT M A R K I N G S
Engine
Displacement Condition ldentification Location of Identification
31 8 cu. in. .OO 1" U/S Crankshaft Maltese Cross Following engine serial number
M-2-3 etc. (indicating
No. 2 & 3 main bearing
iournal)
ioumal)
.010" U/S Crankshaft B Following engine serial number

M (indicates .010" U/S
all main journals)
R (indicating .010" U/S
all rod journals)
.020" O/S Cylinder A Following engine serial number

Bores
.008" O/S Tappets 4 Following engine serial number
361 cu. in. .001" U/S Crankshaft Maltese Cross Top pad-Front of engine
383 cu. in. M-2-3 etc. (indicating
41 3 cu. in. No. 2 & 3 main bearing
426 cu. in. journal)
journals)
.010" U/S Crankshaft Maltese Cross and X Top pad-Front of engine

M-10 (indicates .010"
U/S all main ioumals)
and/or Crankshaft countemeight
R-10 (indicates ,010" U/S
all rod journals)
.020" O/S Cylinder A Top pad-Front of engine

Bores
.008" O/S Tappets 4 Top pad-Front of engine
.005" O/S Valve Stems 0,s. Single bolt boss on end of

the head
SPECIAL TOOLS
318 CUBIC I N C H ENGINE
C-119 ... . . . . . . . . . . . . ............................ . . . . . . . . . . . . . . . . . . . Cylinder Bore Gauge

C-385 ... . . . . . . . . . . . . . ............................ . . . . . . . . . . . . . . . . . . Ring Compressor
C-647. ........................................................... .Spring Tester
C-690. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spring Scale
C-756 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide Cleaner
C-823 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Resizing Hone
C-897. ............................................................. Driver
C-3012 ............................................................. Cylinder Ridge Reamer
C-3025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Valve Guide Wear Checking Sleeve
C-3026. ............................................................ Exhaust Valve Guide Wear Checking Sleeve
C-3028. ........................................................... .Tappet Bare Reamer
C-3049.. .......................................................... .Piston Pin Reamer
C-3052. ............................................................ Distributor Drive Shaft Bushing Puller
C-3053. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Drive Shaft Bushing Installer
C-3054 ............................................................. Spark Plug Socket
C-3059. ........................................................... .Bearing Remover
C-3068. ........................................................... .Tappet and Push Rod Carrier
C-3 132A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Remover and Installer
C-3167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Repair Stand
C-322 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Remover and Installer
C-3339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-3422A.. ......................................................... .Valve Spring Compressor
C-3427. ........................................................... .Valve Guide Reamer .030" O.S.
C-3466. ........................................................... .lifting Bracket
C-3487 ............................................................. Engine Support Fixture
C-3501 ............................................................. Cylinder Hone
C-3506. ........................................................... .Chain Case Cover Seal Installer and Remover
C-3509.. .......................................................... .Camshaft Gear Holding Tool
C-3511 . . . . . . . . . . . . . . . ........................... . . . . . . . . . . . . . . . . . . .Rear Main Bearing Seal Installer
C-3586 ............................................................. Ring Installer
C-3626. ........................................................... .Cylinder Head Holding Fixtures
C-3662. ........................................................... .Engine Repair Stand Adapter
C-3688. ........................................................... .Vibration Damper Puller-Installer
C-3695. ........................................................... .Compressor Rocker Arm
C-3841. ........................................................... .Alternator Belt Adjusting Tool
C-3927. ........................................................... .Valve Stem length Gauge
SPECIAL TOOLS
361,383,413 & 426 CUBIC I N C H ENGINES
C-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Bore Indicator

C-385 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Ring Compressor
C-647. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Spring Testing Fixture
C-756. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Guide Cleaner
C-823. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Bore Resizing Hone and 390 Extensions
Necessary with 383, 41 3 and 426 Engines
C-897. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Core Hole Plug Driver
C-3025. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Valve Guide Wear Checking Sleeve
C-3026. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Valve Guide Wear Checking Sleeve
C-3028 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappet Bore Reamer
C-3052. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Drive Shaft Bushing Puller
C-3053 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Distributor Drive Shaft Bushing Installer-Burnisher
C-3054. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spark Plug Socket
C-3059. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Bearing Upper Shell Remover and Replacer
C-3068. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tappet and Push Rod Carrier
C-3 132A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Bearing Remover and Replacer
C-3 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tappet Checking Pliers
C-3 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Repair Stand
C-322 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod Remover and Replacer
C-3339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-3012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Ridge Reamer
C-3422A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Spring Compressor
C-3427. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Guide Reamer (.030" OS.)
C-3430. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Guide Reamer (.015" OS.)
C-3433. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Guide Reamer (.OOS'' O.S.)
C-3466. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Lifting Plate
C-3487. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Support Fixture
C-3501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Bore Deglazing Hone
C-3506. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Case Cover Oil Seal Remover and Replacer
C-3509. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Gear Installer
C-3625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Main Bearing Oil Seal Installer
(361 and 383 cubic inch engine)
C-3626. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Head Holding Fixtures
XsY 12 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Ring Remover and Replacer
(361 cubic inch engine)
C-3648. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Stem length Gauge
C-3661 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tappet Remover
C-3662. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Repair S t a d Adapter
C-3671 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Ring Remover and Replacer
C-3673. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Ring Remover and Replacer
C-3684. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Pin Remover and Replacer
C-3688. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Front End Puller Kit
C-3743. ....................................................... .Rear Main Bearing Oil Seal Installer
(413 and 426 cubic inch engine)
C-3845. ....................................................... .Oil Filter Remover
TORQUE REFERENCE
318 CUBIC INCH ENGINE
Toque Thread
Foot-Pounds Size
Connecting Rod Nut-Plain ............................................. 45 36-24

Cylinder Head Bolt ................................................... 85 1/2-13
Main Bearing Cap ................................................... 85 !h-13
Camshaft Nut ....................................................... 125
Camshaft Lockbolt .................................................... 35
Camshaft Thrust Plate................................................. 210 in.-lbs. %-18
Chain Case Cover (Cast) .............................................. 35 36-16
Clutch Housing Bolt., ................................................. 30 %-16
Clutch Housing Vent Hole .............................................. 100 in.-lbs. %-20
Clutch Housing Pan Drain Plug .......................................... 35
Crankcase Vent Outlet Pipe ............................................ 15 in.-lbs. %-24
Crankshaft Bolt ...................................................... 135 %-16
Cylinder Head Cover ................................................. 36 in.-lbs.
Engine Front Mounting
To Engine Bosses................................................. 45
To Frame ....................................................... 85
To Frame Bracket Stud ............................................. 20
Engine Rear Mounting
To Transmission .................................................. 35
To Frame ....................................................... 35
Flywheel Housing to Cylinder Block ....................................... 50
Flywheel Housing Cover ............................................... 100 in.-lbs. A
! -20
Intake Manifold ...................................................... 40 36-16
Oil level indicator Tube Bracket ........................................ 130 in.-lbs. %-28
Oil Pan Drain Plug ................................................... 35 %-la
Oil Pan Bolt ......................................................... 15 %-18
Oil Pump Cover Bolt.................................................. 15 %-20
Oil Pump Attaching Bolt ............................................... 35 36-16
Oil Filler Tube ....................................................... 30
Vibration Damper Bolt ................................................ 200 in.-lbs. %e24
361.383.413. 426 CUBIC INCH ENGINES

Torque Thread
Foot-Pounds Size
Connecting Rod Nut-Plain ............................................. 45 34-24

Cylinder Head Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 8 6 - 14
Main Bearing Cap Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 1/2-13

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 14mm
Camshaft Lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 86-14
Carburetor to Manifold Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 946-24
Chain Case Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 946-18
Torque Converter Housing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 '9%-16
Clutch Housing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 %-16
Crankshaft Rear Bearing Seal Retainer ................................... 30 %-16
Crankshaft Bolt (Vibration Damper)...................................... 135 %-16
Cylinder Head Cover Stud and Nut ...................................... 40 in.-lbs 'A -28
Distributor Clamp Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 946-18
Engine Front Mounting to Frame Nut ..................................... 85 1/2-20
Engine Front Mounting to Block Nut ...................................... 45 ~ ~ - 2 0
Exhaust Manifold Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 34-16
Exhaust Pipe Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ~ ~ - 2 0
Exhaust Pipe Clamp Bolt ............................................... 20 %*24
Exhaust Pipe Support Clamp Bolt ........................................ 20 %-24
Fan Attaching Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18 946-18
Fan Belt Idler Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 86-20
Fan Belt Idler Pulley Bracket Bolt ........................................ 30 %-16
Flywheel Housing to Cylinder Block Bolt .................................. 50 8 6 - 14
Flywheel Housing Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 !4 -20
Fuel Pump Attaching Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 34-16
Alternator Mounting Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 946-24
Alternator Adjusting Strap Bolt .......................................... 15 946-16
Alternator Adjusting Strap Mounting Bolt .................................. 30 '9%-16
Intake Manifold Bolt .................................................. 50 34-16
Manifold Heat Control Counterweight Bolt ................................ 50 in.-lbs. 10-32
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 9%-18
Oil Pan Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 %-18
Oil Pump Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 946-18
Oil Pump Attaching Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 34-16
Rocker Shaft Bracket Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 %-16
Starter Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 8 6 - 14
Vibration Damper Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 946-18

Valve Tappet Cover End Bolt . . . . . . . . . . . . . . . . . . . . . ...................... 9 '/4 -20
Water Pump to Housing Bolt ........................................... 30 %-16
Water Pump Housing to Cylinder Block Bolt ............................... 30 %-16
A/C Compressor to Engine Bolt ........................................ 30 9%-16
PART 2
V8 ENGINES
Seven V-8 engines are used for Plymouth Models. carburetor and uses regular fuel, and one is equipped
The engines differ in piston displacement, bore diam- with a four bore carburetor, hi-performance cam-
eter, power output and carburetor equipment. All shaft and valve springs using premium fuel.
engines are equipped with valves in head. The 413 cubic inch engine has a 10.0 to 1 com-
The 318 cubic inch engine has a 9.0 to 1 compres- pression ratio, hydraulic tappets, hi-performance cam-
sion ratio, mechanical tappets and is equipped with shaft and valve springs using premium fuel.
a two bore carburetor using regular fuel. The 426 cubic inch engine has a 10.5 to 1 compres-
There are two 361 cubic inch engines available. sion ratio, hydraulic tappets, hi-performance cam-
Both engines have a 9.0 to 1 compression ratio and shaft and valve springs using premium fuel.
hydraulic tappets. One is equipped with a two bore The engine oiling system consists of a rotor type
carburetor and uses regular fuel, and one is equipped
oil pump and a full flow oil filter. 318 cubic inch
with a four bore carburetor, hi-performance cam-
shaft and valve springs using premium fuel. engine pump is mounted internally and 361, 383-426
There are two 383 cubic inch engines and both cubic inch engines are mounted externally. Oil is
engines have a 10.0 to 1 compression ratio and hy- forced by the oil pump to a series of oil passages in
draulic tappets. One is equipped with a two bore the engine, as shown in figures 61 and 62.
SERVICE PROCEDURES
1. TUNE-UP ing should be set to compensate for altitudes and/or

gasoline grades as follows:
(1) Test the battery specific gravity, add water if A. At low altitudes, with any good grade of the
necessary, clean and tighten the battery connections. recommended gasoline, either “regular” or “premi-
(2) Test the cranking voltage if below 9.6 volts um”, the engine will give its best performance if
and more than 130 amperes draw see Starting Motor timed according to specifications.
Cranking Voltage Electrical Section of this manual. B. When using lower grade fuels, or after carbon
(3) Tighten the intake manifold bolts to 40 foot- has accumulated, objectionable spark ping may occur
pounds torque for 318 cubic inch engine and 50 foot- with the specified timing. In cases of this nature,
pounds torque for 361, 383, 413 and 426 cubic inch ignition timing should be retarded, but not to exceed
engines. 5 degrees of crankshaft rotation later than specified.
(4) Perform the cylinder compression test. The C. At high altitudes or when using higher quality
compression should not vary more than 20 pounds gasoline, for example “premium” where “regular” is
for any one engine. specified, or “super premium” where premium is
specified, there is less tendency for spark ping. In
(5) Clean or replace the spark plugs as necessary such cases, improved performance may be obtained
and adjust the gap to .035 inch. Tighten to 30 foot- by advancing the spark not to exceed 5 degrees of
pounds torque using new gaskets. crankshaft rotation ahead of specified timing.
(6) Test the resistance of the spark plug cables
and if the resistance is more than 30,000 ohms, NOTE: It is recommended, however, that the
replace the cable. vehicle operating at high speeds or hauling trailers
have the ignition timing set at not over the specified
(7) Remove the distributor. Clean the cap and setting.
rotor. Inspect for carbon tracking, cracks and corro-
sion. Inspect the breaker plate, points, lead wire and D. Within the foregoing limits, namely, from 5 de-
vacuum advance, replace if necessary. Adjust to grees ahead to 5 degrees later than specified timing,
specifications. Test coil and condenser. a good rule to follow is to advance the spark
(8) Install the distributor, distributor cap, and until a slight ping is heard when accelerating from 15
spark plug cables. Reset the ignition timing with the mph in direct drive at wide open throttle.
vacuum advance line disconnected. The ignition tim- (9) Set carburetor idle mixture adjustment. Ad-
t VIEW A
276 A
Fig. 1-Cleaning Filter Element Fig. 3-Engine Front Mounts (361, 383, 413 & 426
Cubic Inch)
just the throttle stop screw to specifications. Perform
a combustion analysis. 2. FRONT ENGINE MOUNTS (Figs. 2
(10) Test the fuel pump for pressure and vacuum. and 3)
Refer to “Fuel System” Group 14, Specifications. Removal
(11) Inspect the manifold heat control valve in the (1) Disconnect throttle linkage at transmission and
right exhaust manifold for proper operation and ap- at carburetor.
ply Manifold Heat Control Valve Solvent Part Num-
(2) Raise hood and position fan to clear radiator
ber 1879318 to the bushing and shaft.
hose and radiator top tank.
(12) Every 6 months, remove the air cleaner filter
element and blow out dirt gently with air hose. Direct (3) Remove prevailing torque nuts from insula-
air from inside out, and keep nozzle 2 inches away tor studs.
from element to avoid damaging. Clean the metal (4) Raise the engine just enough to remove front
housing and replace the element (Fig. 1).Every 32,000 engine mount assembly.
miles, install a new factory recommended MoPar filter
lnst allation
element. Service the unit more frequently when driv-
ing under severe conditions, such as in dusty areas. (1) Install insulator to engine bracket and tighten
(13) Inspect and adjust the accessory belt drives
referring to “Cooling System,” Group 7, for proper (2) Lower the engine and install washers and
adjustments. prevailing torque nuts to insulator studs; tighten nuts
(14) Road test the vehicle as a final test.
(3) Connect throttle to transmission and to car-
buretor linkage.
3. REAR ENGINE MOUNT (Fig. 4 )

Removal
(1) Raise vehicle on hoist.
(2) Install transmission jack.
(3) Remove rear engine crossmember from frame
and remove rear mount.
lnstallation
(1) Install rear engine mount to crossmember and
tighten nut to 150 inch-pounds torque.
(2) Install rear crossmember to frame and tight-
Fig. 2-Engine Front Mounts (318 Cubic Inch) en bolts to 75 foot-pounds torque.
(11) Remove the engine front mounts. Raise the

engine with lifting tool and work engine out of the
chassis.
(12) Place the engine in repair stand C-3167 and
adapter C-3662 for disassembly using transmission
mounting bolts.
installation
(1) Attaching the engine lifting fixture Tool C-
3466 to the carburetor flange studs on intake mani-
fold.
(2) Attach a crane or other suitable lifting tool to
the fixture eyebolt.
--L
(3) Remove the engine from the repair stand
and lower the engine carefully until the engine is
positioned in the chassis with front engine mounts in
place.
(4) Install the engine support fixture Tool C-3487
62x273 on the chassis to support the rear of the engine.
Fig. 4-Engine Rear Mounts Remove the crane.
(5) Raise the vehicle on a hoist, install the trans-
(3) Remove transmission jack. mission, engine rear support crossmember, tighten
(4) Install rear engine mount to transmission bolts front engine mounts, remove the engine support fix-
and tighten to 35 foot-pounds torque. ture, Tool C-3487.
(5) Lower the vehicle. (6) Connect the propeller shaft, wires, linkage,
speedometer cable, oil cooler lines at the transmis-
4. ENGINE ASSEMBLY sion, connect exhaust pipes to manifolds. Install the
transmission filler tube.
Removal (7) Lower the vehicle and remove the engine lift-
(1) Scribe the outline of the hinge brackets on the ing fixture Tool C-3466 from the engine. Install the
hood to assure proper adjustment when installing. carburetor and fuel lines.
Remove the hood.
(8) Install the radiator, fan shroud, hoses, oil
(2) Drain the cooling system and remove the bat- cooler lines and connect all wires and linkage.
tery.
(9) Install the hood using scribe marks for the
(3) Remove all hoses, the fan shroud (on air con- proper alignment.
ditioned vehicles), oil cooler lines and radiator.
(10) Close all the drain cocks and fill cooling sys-
(4) Disconnect the fuel lines, linkage and wires tem, install battery.
attached to engine units and remove the air cleaner
(11)Fill the engine crankcase and transmission.
and carburetor.
Refer to “Lubrication” Group 0, for quantities and
(5) Attach the engine lifting fixture Tool C-3466 lubricants to use. Inspect the entire system for
to the carburetor flange studs on the intake manifold. leaks and correct as necessary.
(6) Raise the vehicle on a hoist and install the
NOTE: Whenever an engine has been rebuilt
engine support fixture Tool C-3487 on the chassis to
and/or a new camshaft and/or new tappets have been
support the rear of the engine.
installed, add one quart of MoPar Engine Supplement
(7) Drain the transmission. Part Number 1879406 to engine oil to aid break-in.
(8) Disconnect the exhaust pipes at the mani- The oil mixture should be left in engine for a mini-
folds, propeller shaft, wires linkage, speedometer mum of 500 miles, and drained at the next normal oil
cable, and the oil cooler lines at the transmission. change.
(9) Remove the engine rear support crossmem- (12) Start the engine and run until normal opera-
ber and remove the transmission from the vehicle. ting temperature is reached.
(10) Lower the vehicle and attach a crane or (13) On 318 Cubic inch engine only adjust the
other suitable lifting tool to the fixture eyebolt. tappets.
(14) Test the timing (with vacuum advance line

removed) and adjust carburetor, transmission linkage
as necessary. Connect vacuum line install air cleaner
and road test the vehicle.
TOOL
5. CYLINDER HEAD ASSEMBLY
Removal
(1) Drain the cooling system. Remove the car-
buretor aik cleaner, fuel line, alternator and distribu-
tor vacuum line.
(2) Disconnect the throttle linkage, coil wires,
heat indicator sending unit wire, heater hoses at the
engine.
(3) Remove the distributor cap and the spark
plug cables and the engine closed vent system. Fig. 6-Compressing Exhaust Valve Spring (Tool
(4) Remove the intake manifold attaching bolts C-3695)
and remove the manifold, carburetor and coil as an there is any reason to suspect leakage.
assembly. (2) Coat the new gaskets with Mopar Sealer Part
(5) On 361, 383, 413 and 426 Cubic inch en- Number 1122893.
gines only, remove the tappet chamber cover and
(3) Remove the cylinder heads from the holding
spark plugs located under the exhaust manifolds.
fixtures Tool C-3626 and install on the engine.
(6) Remove the cylinder head covers, closed vent
system and exhaust manifolds. (All engines.) (4) 318 Cubic Inch Engine a. Install and tighten
all head bolts starting at top center, to 85 foot-pounds
(7) On 361, 383, 413 and 426 Cubic inch engines torque sequence, as shown in Figure 5. Repeat the
only, remove the rocker arms and shaft assemblies, procedure, retightening all head bolts to 85 foot-
push rods and place them in their respective slots in pounds torque.
holder, Tool C-3068.
b. Install the push rods with the small ends in the
(8) Remove head bolts from each cylinder head tappets. When using Tool C-3695 (Fig. 6), rocker
and remove cylinder heads. Place cylinder heads in arm valve spring compressor, to. position large end of
holding fixture, Tool C-3626. push rod under rocker arm, make certain low point
NOTE: The 318 Cubic Inch Engine push rods of camshaft is under tappet.
are removed with cylinder head and rocker arm as- c. Install new intake manifold gaskets and seals.
semblies. (5) 361, 383, 413 and 426 Cubic Inch Engines
lnst allation a. Torque all head bolts to 70 foot-pounds torque in
(1) Inspect all surfaces with a straightedge if sequence, as shown in Figure 7. Repeat the proce-
dure retighten all head bolts to 70 foot-pounds torque.
b. Install the push rods with small ends in tappets
maintaining alignment using rod, as shown in Figure
8.
Fig. 5-Cylinder Head Tightening Sequence Fig. 7-Cylinder Head Tightening Sequence (361,
(318 Cubic Inch) 383, 413 & 426 Cu. In.)
944 8-CYLINDER ENGINES
EXHAUST VALVE
ROCKER ARMS
-I
559
-
Fig. 8-Push Rods Installed (361, 383, 413 & 426
Cubic Inch)
INTAKE ROCKER ARMS m 3 3
C. Install the rocker arm and shaft assembly
starting each push rod into its respective rocker
arm socket making sure to install the long stamped
steel retainers in the number two and four positions. Fig. 9-Rocker Shaft Assembly (318 Cubic Inch)
CAUTION: Use Extreme care in tightening bolts
to 30 foot-pounds torque so the tappets have time to stall the valve covers with new gaskets, tighten to 40
bleed down to their operating length. Bulged tappet inch-pounds torque.
bodies, bent push rods, and permanently noisy opera-
tion may result if tappets are forced down too 6. ROCKER ARMS AND SHAFT
rapidly.
Removal I 3 7 8 Cubic Inch Engine)
d. Install tappet chamber cover and tighten end
bolts to 9 foot-pounds torque. For cleaning, inspection or installation of new
e. Install the valve covers with new gaskets and parts, remove the cylinder heads from the engine on
tighten to 40 inch-pounds torque. 318 Cubic Inch Engines. Refer to Paragraph 5.
(6) Install the intake manifold, tighten manifold
bolts to 40 foot-pounds torque for 318 cubic inch en-
gine and 50 foot-pounds torque for 361, 383, 413
and 426 cubic inch engines. ROCKER SHAFT * 7lr
(7) Install the exhaust manifolds, use new gaskets

on the 318 cubic inch engine, no gaskets are re-
quired for the 361, 383, 413 and 426 cubic inch en-
gines, tighten to 30 foot-pounds torque.
I
(8) Install the spark plugs with new gaskets.
Tighten to 30 foot-pounds torque.
(9) Install the distributor cap and spark plug
cables and the engine closed vent system.
(10) Install the carburetor and the coil (if re-
moved), throttle linkage, coil wires, heat indicator
sending unit wire, and the heater hoses.
(11) Install alternator, distributor vacuum line,
I <ER ARM
I
fuel line, and carburetor air cleaner.
(12) Fill the cooling system. Start the engine and
-- -
R 57P2
run until normal operating temperature is reached.

(13) 318 Cubic Inch Engine Adjust the tappets
to .013 inch for intake and .021 inch for exhaust. In- Fig. 10-Installing Rocker Arms (318 Cubic Inch)
Remove the lock plug, slide rocker shaft out of

rocker shaft struts disengaging rocker arms and
springs. (Fig. 9).
Installat ion
Slide the rocker shaft into bore of strut and at the
same time engage intake rocker arm (Fig. 10). In-
stall spring and engage exhaust rocker arm. Install
remainder of the rocker arms in same sequence. Make
sure that head bolt holes in rocker shaft line up with
head bolt holes in rocker shaft strut. In addition, the
plug hole in strut must also line up with hole in rocker
shaft. Tap in rocker arm shaft plug. (Fig. 11).Install
Fig. 12-Rocker Arms installed
plugs in both ends of rocker arm shaft.
Removal 36 I, 383,4 13,426 Cubic Inch tainers in the number two and four positions.
Engine 1
(1) Remove the cylinder head cover and gasket. NOTE: Use extreme care i n tightening the bolts
so that tappets have time to bleed down to their
(2) Remove the bolts that attach the rocker arm
operating length. Bulged tappet bodies, bent push
shaft to the cylinder head and remove the rocker
rods and permanent noisy operation may result i f the
arms and shaft as an assembly.
tappets are forced down too rapidly.
(3)If the rocker arm assemblies have been disas-
sembled for cleaning, inspection, or replacement, re- (2) Tighten the bolts to 30 foot-pounds torque.
fer to Figure 12 for proper reassembly.
7. VALVES AND VALVE SPRINGS
Installation NOTE: Intake and exhaust valves operate in
Install the rocker shafts so that the 3/la inch diam- guides that are integral with the heads.
eter rocker arm lubrication holes point downward
into the rocker arm, and so that the 15' angle of these Removal
holes point outward towards the valve end of the (1) With the cylinder head removed, compress
the rocker arms. (See Fig. 13). the valve springs, using Tool C-3422A, as shown in
NOTE: The 15" angle of the rocker arm lubri- Figure 14.
cation holes is determined from the center line of the
bolt holes through the shaft which are used to attach
the shaft assembly to the cylinder head.
(1) Install the rocker arms and shaft assembly
making sure to install the long stamped steel re-
INTAKE ROCKER ARM EXHAUST ARM
\
ROCKER SHAFT LOCK PLUG
\
Q
Q 1.
ADJUSTING SCREW a
ROCKER ARM
INTAKE PASSAGES LUBRICATION HOLES
\/ EXHAUST CROSSOVER PASSAGE

RIGHT BANK
I
LEFT BANK
63x711 INTAKE PASSAGES 62 X 23
Fig. 1I-Cylinder Head Assembly (318 Cubic Inch) Fig. 13-Rocker Arm lubrication Holes
OL
CYLINDER HEAD
ASSEMBLY
Fig. 16-Measuring Guide Wear Using Tool C-3339

(Typical)
D
(4) Measure the valve stem guide clearance as
follows: Install sleeve, Tool (2-3025on intake valve
58xl41A and Tool (2-3026on exhaust valve over valve stem
to hold valve at working height in head, as shown in
Fig. 14-Compressing Valve Spring Using Tool Fig. 15.
C-3422A (Typical)
(5) The special sleeve places the valve at the cor-
(2)Remove the valve retaining locks, valve spring rect height for measuring with a dial indicator. Attach
retainers, valve stem cup seals and valve springs. the dial indicator Tool C-3339 to cylinder head and
NOTE: Remove any burrs from the valve stem set it at a right angle to the valve stem being meas-
lock grooves to prevent damage to the valve guide sured (Fig. 16). Move valve to and from the indica-
when the valves are removed. tor. Total movement should not exceed .008 inch
on intake valves and .014 inch on exhaust valves for
Valve lnspectlon
318 Cubic Inch Engine and .010inch on intake valve,
(1) Clean the valves thoroughly, and discard and .014 inch on the exhaust valves for 361, 383,
burned, warped and cracked valves. 413 and 426 Cubic Inch Engine.
(2)Measure the valve stems for wear. The new
(6)If the tolerance is excessive, ream guides and
intake valve stem diameter should measure .372 to install valve with oversize stems. Reamer Tool C-3433
.373 inch and exhaust valve stem diameter should will ream guides for .005 inch oversize valve stems.
measure .371 to .372 inch. If the wear exceeds .002 Tool C-3430for .015 inch oversize, Tool C-3427 for
inch, replace the valve.
.030 inch oversize. Turn reamer by hand, and clean
(3) Remove the carbon and varnish deposits from guides thoroughly when finished. Use .005 inch
the inside of the valve guides with cleaner, Tool reamer first and, if necessary, the .015 inch, then the
C-756. .030 inch so the guides remain true in relation to the
seat.
Refactng Valves and Valve Seats
The intake and exhaust valve faces have a 45'
angle. Always inspect the remaining margin after
the valves are refaced (Fig. 17). Valves with less
than 3/64 inch margin should be replaced.
(1)The angle of both valve and seat should be
identical. When refacing the valve seats it is import-
ant that the correct size valve guide pilot be used for
reseating stones. A true and complete surface must
be obtained.
(2) Measure the concentricity of the valve seat
using dial indicator No. 13725. The total runout
~
should not exceed .003 inch (total indicator reading).
Fig. 15-Installing Tool C-3026 (Typical) (3)Inspect the valve seat with Prussian Blue to
-i
INTAKE
7
EXHAUST
V
1
VALVE VALVE
+------ STEM -
VALVE SPRING RETAINER
L
LOCK GROOVES IT
MAXIMUM MEASUREMENT 58x144 B

Fig. 18-Measuring Valve Stem Length (Typical)
54x330C Testing Valve Springs

(1) Whenever the valves have been removed for
Fig. 17-Intake and Exhaust Valve Faces inspection, reconditioning or replacement, the valve
springs should be tested. To test a spring, determine
determine where the valve contacts the seat. To do the length at which the spring is to be tested. As an
this, coat the valve seat lightly with Prussian Blue example, the compressed length of the spring to be
then set the valve in place. Rotate the valve with tested is 115/32 inches. Turn the table of Tool (3-647
light pressure. If the blue is transferred to the center until surface is in line with the 11%2 inch mark on
of the valve face, the contact is satisfactory. If the the threaded stud and the zero mark to the front.
blue is transferred to the top edge of the valve face, Place spring over stud on table and lift the compress-
lower the valve seat with a 30" stone. If the blue is ing lever to set the tone device. Pull on torque wrench
transferred to the bottom edge of the valve face until a ping is heard. Take the reading on torque
raise the valve seat with a 60" stone. wrench at this instant. Multiply this reading by two.
(4)When the seat is properly positioned the width This will give the spring load at the test length. Frac-
of the intake seats should be 1/16 to 3/32 inch. The tional measurements are indicated on the table for
width of the exhaust seats should be 3/64 to 1/16 finer adjustments. The valve springs should test 49 to
inch. 57 pounds when compressed to 11s6inches and 137
(5)When the valves and seats are reground, the to 150 when compressed to 15/16 inches for 318 cubic
position of the valve in the cylinder head is changed, inch engine. For 361, 383, 413 and 426 cubic inch
the valve stems will extend farther out of the cylin- engines see specifications. Replace springs that do not
der heads. This increased dimension will decrease meet specifications.
valve spring compression, and also for 361, 383, 413 (2)Inspect each valve spring for squareness at
and 426 Cubic Inch Engines only it will shorten the both ends with a steel square and surface plate, as
operating length of the hydraulic tappet. This means shown in Figure 19.
that the plunger is operating closer to its bottomed
position, and less clearance is available for thermal (3)If the spring is more than inch out of
expansion of the valve mechanism during high speed square, install a new spring.
driving.
(6)The design of the valve mechanism includes
a safety factor to allow for a limited amount of wear,
and the refacing of valves and seats.
(7)To insure that the limits have not been ex-
ceeded, the dimension from valve spring seat in head
to valve tip should be measured with gauge Tool
C-3927 for 318 Cubic Inch Engine and gauge Tool
C-3648for 361,383,413 and 426 Cubic Inch Engines,
as shown in Figure 18.
If the valve stem extends above the gauge, grind
the end of the stem to fall between the maximum
and the minimum. Fig. 19-Inspecting Valve Spring Squarenerr
inch spacer in head counterbore to bring spring
height back to normal.
8. HYDRAULIC TAPPETS
(361,383,413 and 426 Cubic Inch
Engines Only)
Preliminary to Hydraulic Tappets
(1) Before disassembling any part of the engine to
EXHAUST correct tappet noise, check the oil pressure and the
VALVE
oil level in the oil pan. The pressure should be 45 to
\ 65 pounds at 1000 RPM.
(2) The oil level in the pan should never be
above “full” mark on the dipstick, or below the
\
INTAKE VALVE
“add oil” mark. Either of these two conditions could
be responsible for noisy tappets.
4 59 x 51
“~ (3) O i l Level too High-If the oil level is above
“full” mark on the dipstick, it is possible for the con-
necting rods to dip into oil while the engine is run-
Fig. 20-Valve Assembly (Disassembled View) ning and create foam. Foam in the oil pan would be
fed to the hydraulic tappets by the oil pump causing
lnstallation them to go flat and allowing the valves to seat noisily.
(1) Coat the valve stems with lubricating oil and (4) O i l Level too Low-Low oil level may allow
insert them in position in the cylinder head. the oil pump to take in air which, when fed to tap-
(2) Install new cup seals on the intake and ex- pets, causes them to lose length and allows the valves
haust valve stems and over valve guides, as shown in to seat noisily. Any leaks on intake side of the pump
Figure 20 and 21 and install valve springs and re- through which air can be drawn will create the same
tainers. tappet action. When tappet noise is due to aeration,
(3) Compress the valve springs with Tool C-3422A. it may be intermittent or constant, and usually more
Install locks and release tool. than one tappet will be noisy. When oil level and
leaks have been corrected, the engine should be op-
NOTE: If t h e valves and/or seats are reground, erated at fast idle for sufficient time to allow all of
measure the installed height of springs. Make sure air inside of tappets to be bled out.
measurement is taken from the bottom of the spring
seat in cylinder head to the bottom surface of spring Tappet Noises
retainer. (If spacers are installed, measure from the (1) To determine the source of tappet noise, oper-
top of spacer). If height is greater than 1 1 % 6 inches ate the engine at idle with the cylinder head covers
for 318 Cubic Inch Engine o r l e x 4 inches f o r 361, removed.
383, 413 and 426 Cubic I n c h Engines, install a 5 6 (2) Feel each valve spring or rocker arm to detect
* . the noisy tappet. The noisy tappet will cause the
RETAINE affected spring and/or rocker arm to vibrate or feel
SPRING rough in operation.
NOTE: W o r n valve guides o r cocked springs are
sometimes mistaken for noisy tappets. If such is the
case, noise may be dampened by applying side thrust
o n valve spring. Inspect rocker a r m push rod rockets
and push r o d ends f o r wear. If noise is not appreci-
ably reduced, it can be assumed t h e noise is in the
tappet.
(3) Valve tappet noise ranges from a light noise
to a heavy click. A light noise is usually caused by ex-
cessive leakdown around the unit plunger, (which
147B will necessitate replacing tappet) or by the plunger
Fig. 21-Installing Valve and Cup Seals partially sticking in the tappet body cylinder. A heavy
click is caused either by a tappet check valve not

seating, or by foreign particles becoming wedged be-
tween the plunger and tappet body, causing plunger
to stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and the rocker arm as the valve closes.
In either case, the tappet assembly should be removed
for inspection and cleaning.
Removal of Tappets
(1) Tappets can be removed without removing
the intake manifold or cylinder heads by following
this recommended procedure: Remove the cylinder
head covers.
(2) Remove the rocker arms and shaft assembly.
(3) Remove the push rods and place them in their
Fig. 23-Showing location of External Numbering
respective holes in Tool C-3068.
Pad (361, 383, 413 & 426 Cubic Engines)
(4)Slide the puller Tool C-3661 through the push
rod opening in the cylinder head and seat tool firmly always be fitted to the original body. It is advisable to
in the head of the tappet. work on one tappet a t a time to avoid mixing of
(5) Pull the tappet out of the bore with a twisting parts.
motion, as shown in Figure 22.
Disassembly Fig. 24 I
If all tappets are to be removed, remove the hy- (1) Pry out the plunger retainer spring clip.
draulic tappets and place them in their repective
holes in tappet and push rod holder, Tool C-3068. (2) Clean the varnish deposits from the inside of
This will insure installation of the tappets in their tappet body above the plunger gap.
original location. If there is a diamond shaped mark- (3) Invert the tappet body and remove the plun-
ing stamped on the engine numbering pad it indicates ger cap, plunger, flat check valve, check valve spring,
that all tappet bodies are .008 inch oversize. (See check valve retainer and plunger spring.
Fig. 23) (4)Separate the plunger, check valve retainer,
CAUTION: Do not disassemble a tappet on a check valve spring. Place all parts in their respective
dirty work bench. The plunger and tappet bodies place in the tappet holder, Tool C-3068.
are not interchangeable. The plunger and valve must Cleaning and Assembly
(1) Clean all tappet parts in a solvent that will re-
move all varnish and carbon.
(* +PLUNGER RETAINING SPRING CLIP
WAWNGER CAP
L /TAPPET PLUNGER
! /FLAT VALVE
VALVE SPRING
VALVE RETAINER
PLUNGER SPRING
52x3898
TAPPET BODY
T
Fig. %Hydraulic Tappet Assembly
Fig. 22-Removing Tappet Using Tool C-3661 (Disassembled View)
(2) Replace the tappets that are unfit for further

service with new assemblies.
(3)Assemble the tappets, as shown in Figure
24.
Inspection
(1)If the tappet or bore in cylinder block is
scored, scuffed, or shows signs of sticking, ream the
bore to next oversize, using Tool C-3028.
(2)If plunger shows signs of scoring or wear and
valve is pitted, or if valve seat on end of plunger indi-
cates any condition that would prevent valve from
seating, install a new tappet assembly.
Testtng
(1)Fill a pan with clean kerosene. 51x971D
(2)Remove the cap from the plunger and com- Fig. 25-Testing lappet Using Tool C-3160
pletely submerge the tappet in an upright position.
(3)Allow the tappet to fill with kerosene, remove
the tappet, and replace the cap. (4)Install a dial indicator so that the plunger
contacts the valve spring retainer as nearly perpen-
(4)Hold the tappet in an upright position and in- dicular as possible. Zero the indicator.
sert the lower jaw of pliers, Tool C-3160, in the
groove of tappet body (Fig. 25). (5) Turn the crankshaft clockwise (normal run-
ning direction) until intake valve has lifted ,041
(5) Engage the jaw of the pliers with the top of the inches for 318 Cubic Inch Engine or .013 inches for
tappet plunger. Test leakdown by compressing the 361 and 383 Cubic Inch Engines with 2 BBL Car-
pliers. If plunger collapses almost instantly as pres- buretor or .034 for 361, 383, 413 and 426 Cubic
sure is applied, disassemble the tappet, clean and Inch Engines with 4 BBL Carburetor.
test again.
The timing on the timing indicator, located on the
(6)If the tappet still does not operate satisfactorily chain cover, should read from 10 degrees BTDC to 2
after cleaning, install a new tappet assembly. degrees ATDC. If the reading is not within the speci-
lnstallation fied limits: Inspect the timing sprocket index marks,
(1)Lubricate the tappets. inspect the timing chain for wear, and check the ac-
(2)Install the tappets and push rods in their orig- curacy of the “0”mark on the timing indicator. Turn
inal positions. the crankshaft counter-clockwise until the valve is
closed and remove the indicator and readjust lash
(3)Install the rocker arm and shaft assembly.
(318cubic Inch Engine) or remove spacer on the 361,
(4) Start and operate the engine. To prevent dam- 383,413and 426 Cubic Inch Engines.
age to valve mechanism, the engine must not be run
above fast idle until all of hydraulic tappets have CAUTION: Do not turn crankshaft any further
filled with oil and have become quiet. Warm up to clockwise as the valve spring might bottom and result
normal operating temperature. in serious damage.
9. TESTING THE VALVE TIMING 10. TIMING SPROCKETS AND CHAIN

(All Engines1
(1) Turn crankshaft until the No. 6 exhaust valve Removal
is closing and the No. 6 intake valve is opening. (1) Drain the cooling system and remove the radia-
(2)For 318 Cubic Inch Engine, Turn NO. 1 in- tor and water pump assembly.
take valve adjusting screw in one complete turn. (2)Remove the bolt holding the vibration damper
(Second valve on the left bank). on the crankshaft.
(3)361, 383, 413 and 426 Cubic Inch Engines, (3)Remove two of the pulley bolts, install Tool
Insert a y4 inch spacer between the rocker arm pad C-3688 and pull the damper assembly off the end of
and the stem tip of the No. 1 intake valve (second crankshaft, as shown in Figure 26.
valve on the left bank). Allow the spring load to bleed (4)On the 318 cubic inch engine remove the fuel
the tappet down giving in effect a solid tappet. line and fuel pump.
CHAIN CASE COVER TOOL \
TIMING INDICATOR 4 ARM (TOOL)

CYLINDER BLOCK
TIMING MARK
BRATION DAMPER
Fig. 26-Removing Vibrat'ion Damper Assembly

Using Tool C-3688 Fig. 28-Camshaft Holding Tool C-3509 (361, 383,
413 & 426 Cu. In.)
(5) Remove the chain case cover and gasket, using
extreme caution to avoid damaging the oil pan gas-
ket. It is normal to find particles of neoprene collect- modify Tool C-3509 by grinding off the index lug
ed between the crankshaft seal retainer and the holding upper arm on the tool and rotate arm 180".
crankshaft oil slinger. Install Tool C-3509 in place of distributor drive gear
and shaft, as shown in Figure 28, and attach the tool
(6) Slide the crankshaft oil slinger off the end of with the distributor retainer plate bolt.
the crankshaft.
(1) Place both the camshaft sprocket and crank-
(7) Remove the camshaft sprocket attaching bolt. shaft sprocket on the bench with timing marks on the
(8) Remove the timing chain with the crankshaft exact imaginary center line through both camshaft
and camshaft sprockets. and crankshaft bores.
lnstalling Timing Chain (2) Place the timing chain around both sprockets.
On 318 Cubic Inch Engine when installing the (3) Turn the crankshaft and camshaft to line up
timing chain, use Tool C-3509 to prevent the cam- with the keyway location in crankshaft sprocket and
shaft from contacting the welch plug in the rear of the dowel holes in the camshaft sprocket.
the engine block. Remove the distributor and the oil (4) Lift the sprockets and chain (keep sprockets
pump-distributor drive gear. Locate tool against rear tight against the chain in position as described).
side of cam gear and attach the tool with distributor (5) Slide both sprockets evenly over their respec-
retainer plate bolt (Fig. 27). The tool should remain tive shafts.
installed until the camshaft and crankshaft sprockets
and timing chain have been installed. (6) Use a straightedge to check alignment of the
On 361, 383, 413 and 426 Cubic Inch Engines timing marks (Fig. 29).
STRAIGHT EDGE
Fig. 27-Camshaft Holding Tool C-3509 (318 Cubic Fig. 29-Alignment of Timing Marks Using a
Inch) Straight Edge (Typical)
TORQUE WRENCH---- NOTE: With a torque applied to the camshaft
sprocket bolt, the crankshaft should not be permitted
to move. It may be necessary to block the crankshaft
to prevent rotation.
(5) If the chain is satisfactory, slide the crankshaft
oil slinger over shaft and up against the sprocket
(flange away from sprocket).
11. T I M I N G C H A I N CASE C OVER

O I L SEAL REPLACEMENT
Removal
(1) Position the puller screw of Tool C-3506
through case cover, the inside of case cover up. Posi-
tion the puller blocks directly opposite each other,
and force the angular lip between neoprene and
Fig. 30-Measuring Chain Stretch (Typical) flange of the seal retainer.
(2) Place the washer and nut on puller screw.
(7) Install the washer and camshaft sprocket bolt Tighten the nut as tight as possible by hand, forc-
and tighten to 35 foot-pounds torque. ing the blocks into the gap to a point of distorting
the seal retainer lip (Fig. 31). This is important (pull-
Testing Timing Chain for Stretch er is only poistioned at this point).
(1) Place a scale next to the timing chain so that
(3) Place the sleeve over the retainer and place
any movement of the chain may be measured.
removing and installing plate into sleeve.
(2)Place a torque wrench and socket over the
(4) Place the flat washer and nut on puller screw.
camshaft sprocket attaching bolt and apply torque Hold the center screw and tighten the lock nut to
in the direction of crankshaft rotation to take up the remove the seal (Fig. 32).
slack; 30 foot-pounds torque (with cylinder head in-
stalled) or 15 foot-pounds torque (cylinder heads re- installation of Oil Seal
moved). (1)Insert the puller screw through the removing
(3) Holding a scale with dimensional reading even and installing plate so that the thin shoulder will be
with the edge of a chain link, apply torque in the refacing up.
verse direction 30 foot-pounds (with cylinder heads (2) Insert the puller screw with plate through the
installed) or 15 foot-pounds (cylinder heads removed), seal opening (inside of chain case cover facing up).
and note the amount of chain movement, as shown in
(3) Place the seal in the cover opening, with neo-
Figure 30.
prene down. Place the seal installing plate into the
(4)Install a new timing chain, if its movement ex- new seal, with protective recess toward lip of seal
ceeds 3/ls inch for 318 Cubic Inch Engine and 1 1 % ~ retainer (Fig. 33).
inch for the 361,383,413and 426 Cubic Inch Engines.
PULLER SCREW (TOOL)
REMOVING A
INSTALLING P
Fig. 31-Puller Blocks Expanded to Puller Position

Tool C-3506 Fig. 32-Removing Oil Seal Tool C-3506
INSTALLING. /I
PLATE
(TOOL) lm/
X
c
I
58x154
Fig. 35-Measuring Seal for Proper Seating
Fig. 33-Positioning Installer Plate on New Seal
To01 C-3506 (3) On 318 Cubic Inch Engine, install the fuel
pump lines.
NOTE: Lip of the neoprene seal must be toward (4)Install the water pump and housing assembly
the source of oil. using new gaskets. Tighten bolts to 30 foot-pounds
(4) Install the flat washer and nut on puller screw, torque.
hold screw and tighten the nut (Fig. 34).
Insfalling Vibration Damper
(5) The seal is properly installed when neoprene
(1) Install the hub on the crankshaft.
is tight against the face of the cover. Try to insert a
.0015 feeler gauge between the neoprene and the (2) Place the installing tool, part of puller set Tool
cover (Fig. 35). If this seal is installed properly, the (2-3688 in position and press the damper hub on the
feeler gauge cannot be inserted. It is normal to find crankshaft (Fig. 36).
particles of neoprene collected between the seal re- (3) Slide the pulley over the shaft and attach with
tainer and crankshaft oil slinger after the seal has bolts and lockwashers.
been in operation. (4) Tighten the bolts to 15 foot-pounds torque.
lnsfalling Chain Case Cover (5) Install damper hub retainer washer and bolt.
(1) Be sure the mating surfaces of the chain case Tighten to 135 foot-pounds torque.
cover and cylinder block are clean and free from (6) Install radiator, fan and belt, hoses and close
burrs. the drains.
(2) Using a new gasket slide the chain case cover (7) Fill the cooling system.
over the locating dowels and tighten bolts to 15 foot-
pounds torque. Use extreme caution to avoid damag- 12. CAMSHAFT
ing the oil pan gasket.
Removal
The camshaft thrust is forward with the 318 Cubic
CHAIN CASE COVER

TIMING INDICATOR
CYLINDER BLOCK
TIMING MARK
IBRATION DAMPER
58x155 A Fig. 36-Installing Vibration Damper Assembly

Fig. 34-Installing New Seal Tool C-3506 (Tool C-3688)
Inch Engine, and a thrust plate is used to control the

.002 to .006 inch end play. The 361, 383, 413 and
426 Cubic Inch Engines camshaft thrust is rearward
only. Thrust is taken by the rear face of the cast iron
camshaft sprocket hub, bearing directly on the front
face of the cylinder block, eliminating the need for
-
a thrust plate.
(1) With the tappets and timing sprockets removed,
remove the distributor and lift out the oil pump and
the distributor drive shaft. CRANKSHAFT MAIN BEARING OIL HOLE
(2) On 361, 383, 413 and 426 Cubic Inch Engines,
remove the fuel pump to allow the push rod to drop
away from the cam eccentric. Fig. 37-Removing Camshaft Bearing Using
(3) Remove the camshaft being careful not to dam- Tool C-3132A
age the cam bearings with the cam lobes.
lnstallation (2) Position the bearing in the tool. Install the
horse shoe lock and by reversing the removal proce-
(1) Lubricate the camshaft lobes and camshaft
dure, carefully drive bearing shell into place, as
bearing journals and insert the camshaft to within
shown in Figure 37.
Y2 inch of its final position in the cylinder block.
(3) Install the remaining shells in like manner.
(2) Install Tool C-3509 as described in paragraph
“Timing Chain and Sprocket”. NOTE: Install the No. 1 camshaft bearing 1/32“
(3) Push the camshafcinto the final position. inward from the front face of the cylinder block.
(4) Keep the tool in place until the sprockets and The oil holes in the camshaft bearings and cylinder
the chain have been installed. Complete installation block must be in exact alignment to insure proper
as described in Paragraph “Timing Chain and Sprock- lubrication (Fig. 37).
ets”. Camshaft bearing index can be inspected after
installation by inserting a pencil flashlight in the bear-
NOTE: Whenever and engine has been rebuilt
ing shell. The camshaft bearing oil hole should be
and a new camshaft and/or new tappets have been
perfectly aligned with the drilled oil passage from
installed, one quart of factory recommended oil ad-
the main bearing. Also the Number 4 bearing must
ditive should be added to the engine oil to aid in
index with the two oil passages to the cylinder heads.
break-in. The oil mixture should be left in the engine
If the camshaft bearing shell oil holes are not in exact
for a minimum of 500 miles. Drain the oil mixture
alignment, remove and reinstall them correctly. Apply
at the next normal oil change.
MoPar Sealer to the plug and use Tool C-897 to install
NOTE: Whenever the camshaft is replaced, all a new core hole plug at the rear of camshaft. Be sure
of the tappet faces must be inspected for crown with this plug does not leak.
a straightedge. If any negative (crown dish) is ob-
served, the tappet must be replaced.
13. CAMSHAFT BEARINGS

( Engine Removed from Vehicle 1
Removal
(1) With the engine completeljr disassembled, drive
out the rear cam bearing welch plug.
(2) Install the proper size adapters and horse shoe
washers (part of Tool C-3132A) at the back of each
bearing shell to be removed and drive out the bearing
shells.
lnstallation
i 58x159
(1) Install the new camshaft bearings with Tool
C-3132A by sliding the new camshaft bearing shell Fig. 38-Removing Distributor Drive Shaft Bushing
over the proper adapter. Using Tool C-3052
Fig. 39-Installing Distributor Drive Shaft Bushing

Using Tool C-3053
Fig. 41-Position of Distributor Drive Shaft (318
Cubic Inch)
14. DISTRIBUTOR DRIVE
SHAFT BUSHING (1) Rotate the crankshaft until the No. 1 cylinder
Removal is at top dead center on the firing stroke.
(1) Insert Tool C-3052 into the old bushing and (2) When in this position, the straight line on the
thread down until a tight fit is obtained (Fig. 38). vibration damper should be under (“0”) on the timing
(2) Hold the puller screw and tighten puller nut indicator.
until the bushing is removed. (3) Coat the shaft and drive gear with engine oil.
Install the distributor drive gear so when the gear
/nstallation spirals into place on the camshaft. The slot in the top
(1) Slide a new bushing over the burnishing end of the distributor drive gear should be pointing to the
of Tool C-3053 and insert the tool bushing into the first intake manifold bolt on the left side of engine
bore, as shown in Figure 39. (Fig. 41) for the 318 Cubic Inch Engine and parallel
(2) Drive the bushing and tool into position, using with the centerline of the crankshaft, as shown in
a soft hammer. (Fig. 42) for the 361, 383, 413 and 426 Cubic Inch
(3) As the burnisher is pulled through the bushing Engines.
by tightening puller nut, the bushing is expanded lnst allation of Distributor
tight in the block and burnished to correct size, as (1) On 318 Cubic Inch Engine, hold the distributor
shown in Figure 40. DO NOT REAM THIS BUSHING. over the mounting pad on the cylinder block with the
Distributor Timing vacuum chamber pointing to number 8 spark plug.
Before installing the distributor and oil pump drive r(g.
shaft, time the engine as follows: DISTRIBUTOR AND OIL

PUMP DRIVE
GEAR
I
- -
CENTER LINE OF CRANKSHAFT 58x163A
Fig. 42-Distributor Drive Gear Installed (361,

Fig. 40-Burnishing Distributor Drive Shaft Bushing
Using Tool C-3053 383,413 8 426 Cu. In. )
(2) On 361, 383, 413 and 426 Cubic Inch Engines, bored and honed, and new pistons and rings fitted.
hold the distributor over the mounting pad on the Whatever type of boring equipment is used, boring
cylinder block with the vacuum chamber pointing to- and honing operation should be closely coordinated
ward the center of the engine. with the fitting of pistons and rings in order that
(3) Turn the rotor until it points to the approxi- specified clearances may be maintained.
mate location of the No. 1 tower terminal in the dis- Honing Cylinder Bores
tributor cap.
Before honing, stuff plenty of clean rags under the
(4) Place the distributor gasket in position. bores, over the crankshaft to keep the abrasive ma-
(5) Lower the distributor and engage the shaft terials from entering the crankcase area.
in the slot of the distributor drive shaft gear. (1) Use carefully, the cylinder bore resizing hone
(6) Turn the distributor counter-clockwise for 318 Tool C-823, equipped with 220 grit stones, is the best
cubic inch engine and clockwise for 361, 383,413 and tool for this job. In addition to deglazing, it will re-
426 cubic inch engine until the breaker contacts are duce taper and out-of-round as well as removing light
just separating and install hold down clamp. scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required limits
15. CYLINDER BLOCK (2) Deglazing of the cylinder walls may be done
Cleaning and Inspection using a cylinder surfacing hone, Tool (2-3501,
equipped with 280 grit stones (Tool C-3501-3810). If
(1) With the engine in repair stand C-3167 and the the cylinder bore is straight and round, 20-60 strokes
cylinder heads, oil pan and timing chain removed depending on the bore condition will be sufficient to
clean the cylinder block thoroughly. Inspect all core provide a satisfactory.surface. Inspect cylinder walls
plugs for evidence of leaking. after each 20 strokes. Use honing oil C-3501-3880 or a
(2) If new core plugs are installed coat the edges of light honing oil available from major oil distributors.
the plug and core hole with MoPar Sealer and drive Do not use engine or transmission oil, mineral spirits
the plugs in place with a suitable driver. or kerosene.
(3) Examine the block for cracks or fractures. (3) Honing should be done by moving the hone up
(4) Remove the top ridge of the cylinder bores with and down fast enough to get a cross-hatch pattern.
a reliable ridge reamer before removing the pistons When hone marks intersect at 60°, the cross hatch
from the cylinder block. Be sure to keep the tops of angle is most satisfactory for proper seating of rings
the pistons covered during this operation. (See Figure 43).
NOTE: Pistons and connecting rods must be re-
moved from the top of the cylinder block. When re-
moving the piston and connecting rod assemblies C ROS S - HATCH PATTERN
‘L
from the engine, rotate crankshaft so each connecting

m d i s centered in the cylinder bore.
(5) Remove the oil strainer and tube. On 318 Cubic
Inch Engines, remove with the oil pump.
(6) Mark all bearing caps as necessary for proper
location.
(7) Remove the connecting rod cap.
(8) Install Tool C-3221 on one connecting rod bolt
and protector over the other bolt and push each pis-
ton and rod assembly out of the cylinder bore.
(9) After removal, install the bearing cap on the
mating rod.
Cylinder Bore Inspection
The cylinder walls should be measured for out-of-
round and taper with Tool C-119. If the cylinder
bores show more than .005” out-of-round, or a taper
of more than .010” or if the cylinder walls are badly
scuffed or scored, the cylinder block should be re- Fig. 43-Cross Hatch Pattern
v- a .027 T O ,035IN. LESS for taper and elliptical shape before they are fitted
PISTON ! ITHAN DIAMETERAT ( a 1 into the cylinder bore (See Figs. 44 and 45).
Finished Pistons
All pistons are machined to the same weight in
grams, regardless of oversize to maintain piston bal-
ance. For cylinder bores which have been honed or
rebored, pistons are available in standard and the
following oversizes: .005, .020, .040 inch.
318 Cubic Inch Engine
THE ELLIPTICAL SHAPE OF Fittifig Pistons
THE PISTON SKIRT SHOULD DIAMETERS AT (C) AND (D)
BE .009 T O .010 I N . LESS C A N BE EQUAL OR HAVE A
Piston fitting should be done at normal room tem-
A T DIAMETER (A) T H A N ?0.0005 IN. TAPER I N perature, 70". Use a spring scale and a strip of $4
ACROSS THE THRUST PISTON SKIRT
inch wide feeler stock .0015 inch thickness. The feeler
FACES A T DIAMETER (B).
64x644
stock should be long enough to extend into the cylin-
der bore to the full length of the piston travel. The
Fig. 44-Piston Measurements (318 Cubic Inch) cylinder bore and piston must be clean.
(1) Coat the cylinder bore lightly with SAE 1OW
(4) After honing, it is necessary that the block be
engine oil. Insert the piston in the bore upside down
cleaned again to remove all traces of abrasives.
with the feeler stock between the thrust face of the
CAUTION: Be sure all abrasives are removed piston and the cylinder wall.
from engine parts after honing. It is recommended (2) Hold the piston and draw the feeler stock
that a solution of soap and water be used with a straight out, with the spring scale Tool C-690 as shown
brush and the parts then thoroughly dried. The bore in Figure 46. The amount of pull required should be
can be considered clean when it can be wiped clean from 5 to 10 pounds.
with a white cloth and cloth remains clean. Oil bores
after cleaning to prevent rusting. 36 1 I 3 8 3 , 4 1 3 & 426 Cubic Inch Engines
Fitting Pistons
16. PISTON AND RINGS The piston and cylinder wall must be clean and
dry. The specified clearance between the piston at
The pistons are cam ground so that the diameter
the top of the skirt and the cylinder wall is .0003 to
at the pin boss is less than its diameter across the
.0013 inch.
thrust face. This allows for expansion under normal
The piston diameter should be measured at the
operating conditions. Under operating temperatures,
expansion forces the pin bosses away from each other, top of the skirt 90" to the piston pin axis. The cylinder
bores on used engines should be measured halfway
thus, causing the piston to assume a more nearly
round shape. It is important that pistons be checked down the cylinder bore and 90" to the engine crank-
THE ELLIPTICAL SHAPE OF DIAMETERS AT (C) AND (D)

THE PISTON SKIRT SHOULD CAN BE EQUAL OR DIAMETER
BE .010 TO .012 IN. LESS AT AT (D) CAN BE .0015 IN.
DIAMETER (A) THAN ACROSS GREATER THAN (C)
THE THRUST FACES AT DIAM-
ETER (B). MEASUREMENT
IS MADE '18 IN. BELOW
LOWER RING GROOVE 60x220
Fig. 45-Piston Measurements (361, 383, 413 &
426 Cubic Inch) Fig. 46-Filling Piston In Cylinder Bore
shaft center line. Pistons and cylinder bores should C-3671for the 413 Cubic Inch Engine.
be measured at normal room temperature 70” F.
All service pistons include the pin, and are avail- Piston Pin 1318 Cubic fnch Engine)
able in standard and the following oversizes: .005, Removal
.020,and .040inch. (1)Mark all pistons and connecting rods as neces-
sary for proper location.
Piston Rings (2)Remove piston pin lock rings and press out
(1)Measure the piston ring gap about 2 inches piston pins.
from the bottom of the cylinder bore in which it is
to be used. (An inverted piston can be used to push Fitting Piston Pins
the rings down into position. This will insure the (1)The piston pin fit in the connecting rod and
rings being exactly square with the cylinder wall piston should be a tight thumb push fit at normal
before measuring). room temperature, 70 degrees F.
(2) Insert the feeler stock in the gap. For 318 Cubic (2)If there is excessive clearance between the pis-
Inch Engine, the ring gap should be from .010 inch ton pin and piston, ream piston and connecting rod to
to .047 inch for the compression rings and .015 inch next oversize. Piston pins are available in standard,
to .062inch for the oil ring steel rails in standard size .003,.008inch oversize.
bores (for new service rings). For 361, 383, 413 and (3)If there is excessive clearance between the
426 Cubic Inch Engines, the ring gap should be piston pin and connecting rod, replace the connect-
between .013 to .052 inch for the compression rings ing rod bushing and fit the bushing to the piston pin.
and .015 to .062 inch for the oil ring steel rails in
(4)New pistons are supplied with fitted pins.
standard size bores (for new service rings). All
engines, maximum gap in .005inch O / S bores should Installation of Piston Pin
be .060 inch for compression rings and .070 inch for (1) Assemble pistons and rods for the left hand
oil ring steel rails. cylinder bank (1-3-5-7) with piston boss marked
(3)Measure the side clearance between piston “Front” and indent on piston head on the same side
ring and ring land. The clearance should be .0015 to as the large chamfer on large end of connecting rod.
.003 inch for the top compression ring and the inter- Assemble pistons and rods to be used in the right
mediate ring, and .001to .009 for the oil control ring. cylinder bank (2-4-6-8) with “Front” and indent oppo-
(For new service rings.) (Fig. 47.) site the large chamfer in the connecting rod.
(4)Install the oil ring in the lower ring groove us-
ing the instructions in the service ring package. 17. PISTON PINS (361,383,413 & 426
(5) Install the compression rings in the middle and Cubic lnch Engines)
top grooves with side marked “TOP” up; use ring in- Removal
staller Tool C-3586 for the 318 Cubic Inch Engine, (1)Arrange Tool (2-3684parts for the removal of
Tool C-3628 for the 361 Cubic Inch Engine, Tool piston pin, as shown in Figure 48.
C-3673 for the 383 and 426 Cubic Inch Engines, Tool
(2)Install the pilot on the main screw.
(3)Install the screw through the piston pin.
PISTON RING-
FEELER GAGE
ANVIL (TOOL)
RING GROOV
PILOT (TOOL)
SCREW (TOOL)
ONNECTING ROD
58x195 B GUIDE-LARGE (TOO
Fig. 47-Measuring Piston Ring Clearance Fig. 48-Removing Piston Pin Using Tool C-3684
(3) Arrange the tool parts for installation of pis-
ton pin, as shown in Figure 50.
(4) Install the spring inside the pilot and install
-MAIN SCREW the spring and pilot in the anvil. Install the piston
(TOOL) pin over the main screw.
PILOT (TOOL) (5)Place the piston, with “front” up, over the
pilot so that the pilot extends through the piston pin
hole.
(6) Position the connection rod over the pilot which
extends through the piston hole.
NOTE: Assemble rods to pistons of the right
+-ANVIL (TOOL)
cylinder bank (2,4, 6 and 8) with the indent on the
piston head opposite to the large chamfer on the large
bore end of connecting rod. Assemble the rods to
pistons of the left cylinder bank (1, 3, 5 and 7) with
Fig. 49-Removing Piston Pin from Connecting Rod the indent on the piston head on the same side as
Tool C-3684 the large chamfer on the large bore end of connecting
rod.
(4) Install the anvil over the threaded end of the (7)Install the main screw and piston pin in the
main screw with the small end of the anvil against piston, as shown in Figure 51.
the piston boss.
(8) Install the nut on puller screw to hold assembly
NOTE: Be sure spring is removed from anvil. together. Place assembly on a press, as shown in Fig-
(5)Install nut loosely on the main screw and place ure 51.
the assembly on a press, as shown in Figure 49. (9) Press in the piston pin until the piston pin
(6) Press the piston pin out of the connecting rod. bottoms on the pilot properly positioning the pin in
the connecting rod.
NOTE: When the pin falls free from the con-
necting rod, stop the press to prevent damage to the (10)Remove the tool and arrange tool parts and
bottom of the anvil. piston assembly in the same manner, as shown in
Figure 48.
(7)Remove the tool from the piston.
(11)Place the assembly in a vise, as shown in
lnstallation Figure 52.
(1)Test the piston pin fit in the piston. It should be (12)Attach the torque wrench to nut and test
a sliding fit in the piston at 70°F. Piston pins are torque up to 15 foot-pounds torque. If the connecting
supplied in standard sizes only. rod moves downward on piston pin, reject this con-
(2)Lubricate the piston pin holes in the piston and
connecting rod.
ANVIL (TOOL) -PRESS
SPRING (TOOL)
PILOT (TOOL) MAIN SCREW
MAIN SCREW
GUIDE-LARGE (TOOL)
58x196 B
Fig. 5 6 T o o l Arrangement for Installing Piston Pin
Tool C-3684 Fig. 51--lns!$ling Pirton+in
‘TORQUE WRENCH
SOCKET
m- ANVIL (TOOL)
MAIN SCREW
(TOOL)
5 5 x 162
Fig. 54-Showing Location of Internal Marking of
58x168 B No. 3 Counterweight
Fig. 52-Testing Fit of Piston Pin in Connecting Rod

size. The position of the undersize journal or journals
Tool C-3684
will be stamped on the machined surface of No. 3
counterweight (Fig. 54).
necting rod and piston combination. Obtain a con- Connecting rod journals will be identified by the
necting rod with proper small end bore diameter and letter “R” and main bearing journals by the letter
repeat the installation and checking procedure. “M”. For example “M-1” indicates that No. 1 main
(13)If the connecting rod does not move under bearing is .001inch undersize.
15 foot-pounds torque, the piston pin and connecting
rod interference is satisfactory, the tool may be re- 19. CONNECTING ROD BEARINGS
moved. installation
NOTE: Fit all rods on one bank until complet6a.
18. CONNECTING ROblDENTIFICATION
I
Do not alternate from one bank to another, because
A Maltese Cross stamped on the engine numbering when the rods are assembled to pistons correctly,
pad (Fig. 53) indicates that the engine is equipped they are not interchangeable from one bank to an-
with a crankshaft which has one or more connecting other.
rods and main bearing journals finished .001 inch Connecting rod bearings caps have a small “V”
undersize. However on 318 cubic inch engine with groove across the parting face. When installing a
a B following engine serial number and/or on 361, lower bearing, the ‘V” groove of the bearing must
383, 413 and 426 cubic inch engines with a “X” be placed on the “V” groove side of the cap. This
following a maltese cross indicates that all main provides lubrication of the cylinder wall in the op-
journals and/or all rod journals are .010 inch under- posite bank. Also, the tangs in the steel back must be
placed in the grooves in the rods and caps. The cbn-
necting rod side play for the 318 Cubic Inch Engine
should be .006 to .014inch (two rods) and .009 to .017
inch for the 361,383,413and 426 Cubic Inch Engines.
The limits of taper or out-of-round on any crank-
shaft journals should be held to .001 inch. Bearings
are available in .001,.002,.003,.010 and .012 inch
undersize. Install the bearings in pairs. Do not use a
new bearing half with an old bearing half. Do not file
the rods or bearing caps.
20. MEASURING CONNECTING ROD

BEARING CLEARANCE
Shim Stock Method
(1)Place an oiled .001 inch feeler stock (?hinch
wide and ?4 inch long) between bearing and connect-
ing rod journal.
(2) Install bearing cap and tighten to 45 foot-pounds connecting rod into position on the crankshaft jour-
torque. nal.
(3) Turn the connecting rod ‘/4 turn in each di- (7)The notch or groove on the top of the piston
rection. A slight drag should be felt which indicates must be pointing toward front of the engine and the
clearance is satisfactory. The correct clearance is larger chamfer of the connecting rod bore must be
from .0005to .0015inch. installed toward the crankshaft journal fillet.
(4)The side play for the 318 Cubic Inch Engine (8) Install the rod caps, and tighten nuts to 45 foot-
should be .006 to .014 inch (two rods) and .009 to pounds torque.
.017 inch for 361, 383, 413 and 426 Cubic Inch En-
gines. 22. CRANKSHAFT M A I N JOURNALS
21. PISTON AND CONNECTING R O D The crankshaft journals should be inspected for
ASSEMBLY excessive wear, taper and scoring. Journal grinding
lrlst allation should not exceed .012 inch under the standard
journal diameter. DO NOT grind the thrust faces of
(1)Before installing the pistons, rods, and rod No. 3 main bearing. DO NOT nick the crankpin or
assemblies in the bore, be sure that compression ring
main bearing fillets. After regrinding, remove the
gaps are staggered so that neither are in line with the rough edges from the crankshaft oil holes and clean
oil ring rail gaps.
out all the oil passages.
(2) The oil ring expander ends should be positioned
toward the outside of the “V” of the engine. The oil 23. CRANKSHAFT M A I N BEARINGS
ring rail gaps should be positioned opposite each
other and above the position pin holes. The upper main bearings are not interchangeable
with the lower main bearings. On 318 cubic inch en-
(3)Immerse the piston head and rings in clean
gines (Fig. 56),bearing numbers 1, 2 and 4 are inter-
engine oil, slide the ring compressor, Tool C-385,
changeable as complete bearings. On 361, 383, 413
over the piston and tighten with the special wrench
and 426 cubic inch engines (Fig. 57),bearings 2,4 and
(part of Tool (2-385).
5 are interchangeable as complete bearings. The No. 1
(4) Be sure the position of the rings does not upper main bearing is not interchangeable and is
change during this operation. Screw the connecting chamfered on the tab side for timing chain oiling
rod bolt protector (part of Tool (2-3221)on one rod and can be identified by a red marking on the edge
bolt, and insert the rod and piston into cylinder bore. of the bearing.
NOTE: Rotate the crankshaft SO that the con- On both engines, number 3 bearing halves are
necting rod journal is on center of the cylinder bore. flanged to carry the thrust load and are not inter-
(5)Attach t h e puller part of Tool C-3321 on the changeable with the other four bearings. Bearings
other bolt, and guide the rod over the crankshaft that are not badly worn or pitted must be reinstalled
journal, as shown in Figure 55. in the same position.
The bearing caps are not interchangeable and
(6)Tap the piston down in the cylinder bore, using
should be marked at removal to insure the correct
the handle of a hammer. At the same time, guide the
assembly. Bearing shells are available in standard and
THRUST BEARING
Fig. 55-Removing or Installing Connecting Rod

Using Tool C-3221 Fig. 56-Main Bearing Identification (318 Cubic Inch)
-
(3) Install the bearing in the center main bearing
cap, bearing tank in groove in cap, lubricate bearing
c and seat cap or block. Tighten bolts to 85 foot-pounds
UPPER
torque.
(4) If a slight drag is felt as the crankshaft is
turned (move no more than 34 turn in either direc-
tion), the clearance is .001 inch or less and is con-
sidered satisfactory.
If, however, no drag is felt, the bearing is too
large or the crankshaft cannot be rotated, the bearing
is too small and should be replaced with the correct
I
size.
(5) Measure crankshaft end play to .002-.007 inch.
x172 If end play is less than .002” or more than .007”,
install a new Number 3 main bearing.
Fig. 57-Main Bearing identification (361,383,413
& 426 Cubic inch) (6) Fit the remaining bearings in same manner.
Only one main bearing should be selectively fitted
the following undersizes: .001, .002, .003, .010 and while all other main bearing caps are properly
.012 inch. Never install an undersize bearing shell torqued.
that will reduce the clearance below specifications. It is permissible to use one .001 inch undersize
bearing shell with one standard bearing shell or one
Removal
.002 inch bearing shell. Always use the smaller diam-
(1) Remove the oil pan and mark the bearing caps eter bearing half as the upper. Never use a new
before removal. bearing with a used bearing and never use an upper
(2) Remove the bearing caps one at a time. Remove bearing half more than .001 inch smaller than the
the upper half of the bearing by inserting Tool C-3059 lower bearing half.
(Fig. 58) into the oil hole of the crankshaft.
(3) Slowly rotate the crankshaft clockwise, forcing lnstallatlon of the Upper Main Bearing
out the upper half of bearing shell. NOTE: When installing a new upper bearing shell,
slightly chamfer the sharp edges from the plain side.
Measuring Main Bearlng Clearance
IShim Stock Method) (1) Start bearing in place, and insert Tool C-3059
(1) Smooth the edges of a V2 x ?4 inch piece of into the oil hole of the crankshaft (Fig. 58).
soft copper or brass shim stock, .001 inch thickness. (2) Slowly rotate the crankshaft counter-clockwise
(2)Lubricate the main bearing journals and posi- sliding the bearing into position.
tion the shim stock across the center main journal. (3) After all bearings have been fitted, tighten all
caps to 85 foot-pounds torque. The crankshaft end
play should be .002 to .007 inch.
24. REPLACEMENT OF THE REAR M A I N

BEARING OIL SEALS (Crankshaft
Removed 1
Upper Seal
(1) Install a new rear bearing oil seal in the cylin-
der block so that both ends protrude.
(2) Use Tool C-3511 for 318 cubic inch engine and
Tool C-3625 for 361 and 383 cubic inch engine or
Tool C-3743 for 413 and 426 cubic inch engine with
bridge removed, tap the seal down into position until
the tool is seated in the bearing bore.
(3) Hold the tool in this position and cut off the
Fig. 58demoving or Installing Main Bearing portion of the seal that extends above the block on
(1001 C-3059) both sides.
ENGINE OILING 9-63
BRIDGE
(PART OF TOOL)
SIDE SEAL c -1' I.,

GROOVES
58x238
Fig. 59-Installing Rear Main Bearing lower Oil Seal Fig. 60-Trimming Rear Main Bearing lower Oil Seal
Lower Seal 318 Cubic lnch Engine from the cap. Figure 60.
(1) Install a new rear main bearing oil seal in the Side Seals
cap with Tool C-3511. Seals are cut to proper length. Under no circum-
(2) Hold the tool in this position and cut off the stances should these seals be cut off. Perform the
ends of seal flush with cap. following operation as rapidly as pbssible. These side
(3) Install the bearing shell and cap seals with the seals are made from a material that expands quickly
bearing cap and tighten to 85 foot-pounds torque. when oiled. A slight oil leak may be encountered
when starting the engine if sufficient time has not
36 I , 383,4 13 8t 426 Cubic lnch Engines elapsed to adequately expand the seals.
(1) Install a new seal in the seal retainer so that
(1) Apply mineral spirits or diesel fuel to side seals.
the ends protrude. Figure 59.
(2) Install seal immediately in seal retainer grooves.
(2) Install the bridge on Tool C-3625 for 361 and
383 cubic inch engine or Tool C-3743 for 413 and 426 (3) Install seal retainer and tighten screws to 30
cubic inch engine, tap the seal down into position foot-pounds torque.
until the tool is seated. NOTE: Failure to pre-oil seals will result in oil
(3) Trim off the portion of the seal that protrudes leak.
ENGINE OILING SYSTEM

25. OIL PAN lnstallat ion
(1) Inspect the alignment of the oil strainer. The
Removal bottom of the strainer must be parallel with the
(1) Disconnect the negative (ground) cable from the machined surface of the cylinder block. The bottom
battery, and remove the dipstick. of the strainer must touch the bottom of the oil pan.
(2) Raise the vehicle on a hoist, drain the oil. (2) Install the oil pan using a new gasket and seals
On 318 cubic inch engines; remove the engine to On 318 cubic inch engine, and install the engine to
torque converter housing brace. converter housing brace.
(3) Connect the exhaust cross-over pipe to mani-
(3) Remove the steering and idle arm ball joints folds. (If so equipped.)
from the steering linkage center link.
(4) Connect the steering and idler arm ball joints
(4) Remove the exhaust cross-over pipe from the to the steering linkage center link.
exhaust manifolds and leave it hang without discon- (5) Lower the vehicle, install the dipstick, fill with
necting it from the muffler. the proper grade and quantity of motor oil, connect
(5) Remove the oil pan bolts and the oil pan. battery ground.
9-64 ENGINE OILING
ENGINE OILING 9-65
RIGHT BANK 4
LUBRICATION
RIGHT ROCKER SHAFT
TO ROCKER SHAFT
NO. 4 CAMSHAFT
BEARING
LEFT MAIN OIL GALLERY
RIGHT MAIN OIL GALLERY
LEFT ROCKER SHAFT
OIL FILTER
W/ I OIL ~RESSURE
IL PUMP RELIEF VALVE ^.
3YX14
Fig. 62-Engine Oiling System (361,383,413 & 426 Cubic Inch)
26. OIL PUMP (Fig. 63) and filter assembly from the left front lower corner
of the engine.
Removal
On the 318 cubic inch engine, remove the oil pump Disassembly
from the rear main bearing cap. (1)Remove the cover screws and remove the cover
361, 383, 413 and 426 cubic inch engines, remove from the (361,383, 413 and 426 cubic inch engines)
the oil pump attaching bolts and remove the pump
RELIEF VALVE
PLUNGER INNER ROTOR
/
SEAL RING
58x173
63x931
Fig. 64-Oil Pump and Filter (Disassembled View
Fig. 63-Oil Pump Assembly (318 Cubic Inch) 361,383,413 & 426 Cubic Inch)
9-66 ENGINE OILING
COVER
STRAIGHT
EDGE
\\
GAUGE -
/
58x1 74 ";n
5 Ix67A
Fig. 65-Measuring Oil Pump Flatness Fig. 67-Measuring Inner Rotor Thickness
filter base (Fig. 64). .942inch for 361,383,413and 426 cubic inch engines,
(2)Remove the pump rotor and shaft and lift out a new rotor should be installed.
the outer pump rotor. (4)Place the outer rotor in pump body. Press the
(3)Remove the oil pressure relief valve plug care- rotor to one side with the fingers and measure the
fully as it is under spring pressure. Remove the spring clearance between the rotor and pump body. If the
and the valve. measurement is more than .012 inch, install a new
oil pump body (Fig. 68). (This test is not necessary
(4) Clean all parts thoroughly.
if a new pump body is being used.)
lnspection and Repair (5)Place the inner rotor in the outer rotor. Meas-
(1) Lay a straightedge across the oil pump cover ure the clearance between the inner rotor and outer
surface (Fig. 65). If a .0015 inch feeler gauge can rotor. If measurement is more than ,010inch for 318
be inserted between the cover and the straightedge, cubic inch engines or .010 inch (Fig. 69), for 361,
the cover should be replaced. 383, 413 and 426 cubic inch engine, install new
(2)For the 318 cubic inch engine, the outer rotor pump rotors.
length should not be less than .825 inch (Fig. 66) (6)Place a straightedge across the pump body (be-
and the outer diameter less than 2.469 inch. On the tween bolt holes). If feeler gauge of more than .004
361,383,413and 426 cubic inch engines these dimen-
sions should not be less than .943 and 2.469 inch
OUTER ROTOR
respectively.
(3)If the inner rotor thickness measures less than
.825 inch for the 318 cubic inch engine (Fig. 67) or
Fig. 68-Measuring Outer Rotor Clearance
OUTER ROTOR
DIAMETER
51x66A
Fig. 66-Measuring Outer Thickness Fig. 69-Measuring Clearance Between Rotors

ENGINE OILING 9-67
I
Fig. 70-Measuring Clearance Over Rotors
I
TOOL
inch (Fig. 70) can be inserted between the rotors 58x239
and a straightedge, install a new pump body and/or
rotors. Fig. 71-Removing Oil Filter (Tool C-3654)
(7) Inspect the oil pump relief valve plunger for
(2)Install new oil and seal rings between the
scoring and for free operation in its bore. Small
cover and body. Tighten cover bolts to 10 foot-pounds
scores may be removed with 400 grit wet or dry torque for 318 cubic inch engine and 35 foot-pounds
paper providing extreme care is used not to round
torque for 361, 383, 413 and 426 cubic inch engines.
off the sharp edge portion of the valve.
(3)Install the oil pump and tighten attaching bolts
(8)For 318 cubic inch engine the relief valve has
a free length of 2s2
to 23/s+ inch. For 361, 383,
413 and 426 cubic inch engines the relief valve has Oil Filter
a free length of 29/32to 219/64inch and is red in color. The oil filter should be replaced every six months
(9) If the oil pressure is low, inspect for worn bear- to coincide with an engine oil change.
ings, or look for other causes of possible loss of oil (1)Using Tool (2-3654(Fig. 71), unscrew the filter
pressure. from the base on the bottom side of the engine and
Assembly and Installation discard.
(1)Assemble the oil pump, using new parts as (2)Wipe the base clean.
required. (3)Screw a new filter on the base until the gasket
INTAKE MANIFOLD
INTAUE MANIFOLD
-CONNECTING TUBE
CONNECTING TUBE
1
1
\
FLOW CONTROL VAiVE
THIS WASHE R IS COLOR CODED TO IDENTIFY VENT

VALVE ASSEMBLY SEE SPECIFICATIONS
61 x265A
SIX - C Y L I N D E R ENGINES V-8 ENGINES
Fig. 72-Closed Crankcase Ventilating System

9-68 ENGINE OILING
on the filter contacts the base. To obtain an effective
seal, tighten filter by hand the additional number of
turns indicated on the replacement filter. Start engine
and inspect for leaks.
27. CRANKCASE VENTILATOR VALVE
All models are equipped with a positive crank-
case ventilating system. This system is similar; but
Fig. 73-Heli-Coil Installation
not identical, to systems used on the previous models
(Fig. 72). attempt to clean the valve.) On 170 cubic inch engines
The system must be kept clean to maintain good use MoPar Ventilator Valve identified by a stamped
engine performance and durability as deposits will number 6 on the end, a step on the end face, or a
accumulate in the valve, hoses and the carburetor white end washer. On all other engines, use MoPar
parts, therefore, the ventilation system should be Ventilator Valve, identified by a letter "H" stamped
inspected at least every six months and the valve on the end, a flat end or a.black end washer. With
replaced once a year preferrable to coincide with the a new valve installed, if the vacuum can be felt with
annual engine performance evaluation. This service the engine idling, the system is satisfactory. If the
will be required more frequently if the vehicle is
vacuum cannot be felt, it will be necessary to clean
used extensively for short trips - driving less than the ventilator hose and the passages in the lower
10 miles-with frequent idling, such as city traffic. part of the carburetor. The carburetor must be re-
With the engine running at idle, remove the ventil- moved and cleaned by dipping the lower part of the
ator valve and cap assembly from the rocker cover. If carburetor in solvent. A pipe cleaner or small wire
the valve is not plugged, a hissing noise will usually may be used in cleaning the passages. It is not neces-
be heard as air passes through the valve and a strong
sary to disassemble the carburetor for this service.
vacuum should be felt when a finger is placed over
the valve inlet. Replace the ventilator valve and
cap assembly and remove the inlet breather cap. With 28. REPAIR OF DAMAGED OR
the engine still running at idle, loosely hold a piece WORN THREADS
of stiff paper or a parts tag over the oil fill pipe. Damaged or worn threads can be repaired by the
Within a few seconds, it should be sucked against the use of Heli-Coils. Essentially, this repair consists of
oil fill pipe with a holding force. If this occurs, drilling out the worn or damaged threads, tapping the
a final test should be made to be certain the valve hole with a special Heli-Coil Tap, and installing a
shuttle is free. A clicking noise should be heard Heli-Coil Insert into the tapped holes. This brings
when the valve is shaken (engine not running). If the the hole back to its original thread size (See Fig. 73).
noise is heard, the unit is satisfactory and no further The following chart lists the threaded hole sizes
service is necessary. which are used in the engine block and the necessary
If the valve does not click when shaken or if the tools and inserts for the repair of damaged or worn
paper is not sucked against the fill pipe, the valve thread. Heli-Coil tools and inserts are readily available
should be replaced and the system retested. (Do not from automotive parts jobbers.
~~
INSERTlNG EXTRACT-
Thread Part Insert Part Part Par)

1/1-20 1 185-4 %" '% (.266) 4 CPB 528-4N 1227-6

%-18 1 185-5 1%" Q (.332) 5 CPB 528-5N 1227-6
%-16 1 185-6 %a" x (397) 6 CPB 528-6N 1227-6
7%- 14 1 185-7 21h" 29h (.453) 7 CPB 528-7N 1227-16
1/1-13 1 185-8 %" 3% (.516) 8 CPB 528-8N 1227-16
ENGINE DIAGNOSIS 9-69
PART 111
SERVICE DIAGNOSIS
Engine Wi I I (a) Weak battery. (a) Test the battery specific gravity
kt Start and recharge or replace as
necessary.
Corroded or loose battery connections. (b) Clean and tighten the battery
connections. Apply a coat of
petrolatum to the terminals.
Faulty coil or condenser. (e) Test and replace if necessary.*
Dirty or corroded distributor contact (d) Clean or replace as necessary. *
points.
Moisture on ignition wires and (e) Wipe wires and cap clean and dry.
distributor cap.
Incorrect spark plug gap. (f) Set the gap at .035”.
Incorrect ignition timing. (g) Refer to “Ignition Timing.”*
Faulty ignition cables. (h) Replace any cracked or shorted
cables.
Dirt or water in fuel line or carburetor. (i) Clean the lines and carburetor. **
Cat buretor flooded. (j) Adjust the float level-check
seats. * *
Incorrect carburetor float setting. (k) Adjust the float level--check
seats. **
Faulty fuel pump. (1) Install a new fuel pump.**
Carburetor percolating. No fuel (m) Measure the float level.** Adjust
in the carburetor. the bowl vent. Inspect the
operation of the manifold control
valve.
Faulty starting motor. (n) Refer to “Starting Motor.”*
engine Stalls Idle speed set too low. (a) Adjust carburetor. **
Idle mixture too clean or too rich. (b) Adjust carburetor. **
Incorrect carburetor float setting. (e) Adjust float setting. **
Incorrect choke adjustment. (d) Adjust Choke.**
Leak in intake manifold. (e) Inspect intake manifold gasket
and replace if necessary. * * *
Dirty, burned or incorrectly gapped (f) Replace points and adjust. *
distributor contact points.
Worn or burned distributor rotor. (g) Install a new rotor.
Incorrect ignition wiring. (h) Install the correct wiring.
Faulty coil or condenser. (i) Test and replace if necessary.*
Incorrect ignition timing. (a) Refer to “Ignition Timing.” *
Worn or burned distributor rotor. (b) Install a new rotor.
Wrong mechanical or vacuum advance (e) Install correct vacuum advance
(distributor). unit. Adjust the mechanical
advance.
Excessive play in distributor shaft. (d) Remove and repair distributor. *
Worn distributor shaft cam. (e) Remove and repair distributor. *
Dirty or incorrectly gapped spark plugs. (f) Clean plugs and set gap at .035”.
Dirt or water in fuel line or carburetor. (g) Clean lines and carburetor.**
*Refer to the “Electrical and Instruments” Group 8 for service procedures.
**Refer to the “Fuel System” Group 14 for service procedures.
***Refer to the “Engine” Group 9 for service procedures.
e
9-70 ENGINE DIAGNOSIS
SERVICE DIAGNOSIS--- (Continued1

Engine Loss of (h) Incorrect carburetor float setting. (h) Adjust float level.**
Power (Cont’d.) (i) Faulty fuel pump. (i) Install a new pump.
(j) Incorrect valve timing. (j) Refer to “Checking Valve
Timing” * * *.
(k) Blown cylinder head gasket. (k) Install a new head gasket,***
(1) Low compression. (1) Test the compression of each
cylinder. * * *
(m) Burned, warped, pitted valves. (m) Install new valves. ***
(n) Plugged or restricted exhaust system. (n) Install new parts as necessary.
(0) Faulty ignition cables. ( 0 ) Replace any cracked or shorted
cables.
(p) Faulty coil or condenser. (p) Test and replace as necessary.*
Engine Misses on (a) Dirty, burned, or incorrectly gapped (a) Replace the points and adjust.*
Accelerator distributor contact points.
(b) Dirty, or gap too wide in spark plugs. (b) Clean the spark plugs and set the
gap at .035”.
(c) Incorrect ignition timing. (c) Refer to “Ignition Timing.”*
(d) Dirt in carburetor. (d) Clean the carburetor. **
(e) Acceleration pump in carburetor. (e) Install a new pump.**
(f) Burned, warped or pitted valves. (f) Install new valves. ***
(g) Fault coil or condenser. (g) Test and replace if necessary.*
Engine Misses a t (a) Dirt or water in fuel line or carburetor. (a) Clean the lines and the
High Speed carburetor. **
(b) Dirty jets in carburetor. (b) Clean the jets.**
(c) Dirty or incorrectly gapped distributor (c) Clean or replace as necessary.*
contact points.
(d) Dirty or gap set too wide in spark plug. (d) Clean the spark plugs and set the
gap at .035”.
(e) Worn distributor shaft cam. (e) Remove and repair the
distributor. *
(f) Worn or burned distributor rotor. (f) Install a new rotor.
(g) Excessive play in distributor shaft. (g) Remove and repair the
distributor. *
(h) Faulty coil or condenser. (h) Test and replace if necessary.*
(i) Incorrect ignition timing. (i) Refer to “Ignition Timing.”*
Noisy Valves (a) High or low oil level in crankcase. (a) Check for correct oil level.***
(b) Thin or diluted oil. (b) Change oil.***
(c) Low oil pressure. (c) Check the engine oil level.***
(d) Dirt in tappets. (d) Clean the tappets. ***
(e) Bent push rods. (e) Install new push rods.***
(f) Worn rocker arms. (f) Inspect the oil supply to
rockers. * * *
(8) Worn tappets. (g) Install new tappets. ***
(h) Worn valve guides. (h) Ream and install new valves
with O/S stems.***
(i) Excessive run-out of valve seats or (i) Grind the valve seats and
valve faces. valveb. * * *
ENGINE DIAGNOSIS -
9-71
SERVICE DIAGNOSIS- (Continued1
Connecting Rod (a) Insufficient oil supply. (a) Check engine oil level. Inspect oil
Noise pump relief valve, damper and
spring. * * *
(b) Low oil pressure. (b) Check the engine oil level.***
(c) Thin or diluted oil. (c) Change oil to correct viscosity.
(d) Excessive bearing clearance. (d) Measure the bearings for correct
clearances or failures. ***
(e) Connecting rod journals out-of-round (e) Remove the Crankshaft and
regrind journals. * * *
(f) Misaligned connecting rods. (f) Replace the bent connecting
rods. * * *
M a i n Bearing Noise (a) Insufficient oil supply. (a) Check the engine oil level.
Inspect the oil pump relief valve,
damper and spring. * * *
(b) Low oil pressure. (b) Check the engine oil level.***
(c) Thin or diluted oil. (c) Change the oil to correct viscosity.
(d) Excessive bearing clearance. (d) Measure the bearings for correct
clearances or failures. * * *
(e) Excessive end play. (e) Check No. 3 main bearing for
wear on flanges.***
(f) Crankshaft journal out-of-round or (f) Remove the crankshaft and
worn. regrind journals.
(g) Loose flywheel or torque converter. (g) Tighten to the correct torque.
Oil Pumping a t Rings (a) Worn, scuffed, or broken rings. (a) Hone cylinder bores and install
new rings. * * *
(b) Carbon in oil ring slots. (b) Install new rings.***
(c) Rings fitted too tight in grooves. (c) Remove the rings. Check the
grooves. If groove is not proper
width, replace the piston. ***
Oil Pressure Drop (a) Low oil level. (a) Check the engine oil level.
(b) Faulty oil pressure sending unit. (b) Install a new sending unit.
(c) Thin or diluted oil. (c) Change the oil to correct viscosity.
(d) Oil pump relief valve stuck. (d) Remove the valve and inspect,
clean, and reinstall.
(e) Oil pump suction tube loose bent or (e) Remove the oil pan and install
cracked. a new tube if necessary.
(f) Clogged oil filter. (f) Install a new oil filter.
(g) Excessive bearing clearance. (g) Measure the bearings for the
correct clearance. * * *
EXHAUST SYSTEM 11-1
GROUP 11
CONTENTS
Page Page
Torque Reference. ............................. 1 Manifold Heat Control Valve (8-Cylinder)
Intake and Exhaust Manifold Assembly 3 18 Cu. In. Engine. ........................ 4
(6-Cylinder)............................... 1 Manifold Heat Control Valve (8-Cylinder)
Manifold Heat Control Valve (6-Cylinder). . . . . . . . . . 2 361 Cu. In. Engine.. ....................... 4
Intake Manifold (8-Cylinder). .................... 3 Exhaust Pipes, Mufflers and Tail Pipes. ............. 5
Exhaust Manifold (8-Cylinder). ................... 3 Service Diagnosis. ............................. 7
TORQUE REFERENCE
Foot-Pounds
6-Cylinder 8-Cylinder
Ball Joint Screw.. .......................................... 20

Comerter Housing Bracket Screw.. ............................ 15
Exhaust Manifold Nuts. ..................................... 30
Exhaust Pipe Flange Nuts .................................... 30 40
Exhaust Pipe Support Clamp Bolts. ............................ 10
Heat Control Counterweight Clamp Bolt. ....................... 50 Inch Pounds 50 Inch Pounds
Intake to Exhaust Manifold Bolts. ............................. 15
Manifold to Cylinder Head Nuts. ............................. 10
PLYMOUTH A N D VALIANT (6 Cylinder Engine)

The intake and exhaust manifold, Figs. 1and 2 are haust heat to a heat chamber beneath the carburetor
located on the same side of the engine. A thermostatic to help vaporize the fuel.
heat control valve is incorporated to direct the ex-
SERVICE PROCEDURES
1. INTAKE AND EXHAUST MANIFOLD (4) Disconnect the exhaust pipe at the exhaust
ASSEMBLY manifold flange.
(Figs. 1 and 21 (5) Remove the nuts and conical washers holding
Removal the intake and exhaust manifolds to the cylinder head.
(1) Remove the air cleaner. (Fig. 1).
(6) Remove the assembly from the cylinder head.
(2) Remove the vacuum control tube at the carbu-
retor and distributor. (7) Remove the three bolts holding the intake mani-
(3) Remove the fuel line and remove the carbu- fold to the exhaust manifold (Fig. 1).
retor. (8) Separate the manifolds and discard the gasket.
11-2 EXHAUST SYSTEM
(5)Install the triangular washers on the front and

rear end lower manifold studs, also on the upper and
lower exhaust manifold studs on number 2 and 5
cylinders.
The six triangular washers should be positioned
squarely on the machined surfaces of both the intake
and exhaust manifold retaining pads. These washers
must be installed with the conical side pointing away
from the manifold. Install the washers and nuts only
when the engine and exhaust system is cold.
(6) Install the other conical washers with the cup
side against the manifold.
(7)Tighten all manifold nuts to 10 foot-pounds
torque. Do not over tighten these nuts as they can be
easily stripped.
6OX845A (8)Tighten the three bolts holding the intake
Fig. 1-Intake Manifold (6 Cylinder) manifold to the exhaust manifold to 15 foot-pounds
torque.
(9)Connect the exhaust pipe to the exhaust mani-
(9) Clean the manifolds in solvent and dry with
fold flange and tighten nuts to 30 foot-pounds torque.
compressed air.
(10)Install the carburetor and connect the fuel
(10) Inspect the mating surfaces of the manifolds
line, throttle linkage and vacuum control tube.
for parallelism with a straightedge.
(11)Install the air cleaner.
(11) Inspect the manifolds for cracks or distortion.
fnstallatlon 2. MANIFOLD HEAT CONTROL VALVE
(1) Install a new gasket between the intake and (Fig. 3)
exhaust manifold.
The heat control valve should be inspected and
(2) Install the three bolts holding the intake mani-
lubricated with solvent 1879318 at every lubrication
fold to the exhaust manifold. Do not tighten the bolts.
or engine tune-up. With the engine idling, accelerate
(3) Position the intake and exhaust manifold on momentarily to wide open throttle. The counterweight
the cylinder head using a new gasket. should respond by moving counter-clockwise approxi-
(4) Install the brass washers and special nuts on mately Y2 inch and return to its normal position. If no
the end manifold studs. movement is observed, the shaft is frozen or the coil
spring is weak or broken.
CHOKE POCKET
I
LXHAUS’ MAqIFOLD STOP RETAINER
I \
--
COUNTERWEIGHT SHAFT
4 3 60xlOlOB
FLANGE- 60 x 8448
Fig. 2-Exhaust Manifold (6 Cylinder) Fig. 3-Manifold Heat Control Valve
EXHAUST SYSTEM 11-3
Removal (2) Place a new coil spring in the shaft slot, and
position with outer end (tongue) of coil spring in
(1) Remove the counterweight, key and stop from
the upper left hand position.
the end of the shaft.
(2) Unhook the coil spring from the pin and re- (3) Wrap the outer end (tongue) of the coil spring
move from the valve shaft slot. clockwise and engage under the pin.
(3) If the valve shaft is frozen in the manifold, (4)Place the counterweight assembly on the shaft
apply manifold heat control valve solvent. MoPar (with the shield in an upward position) and insert
Part Number 1879318 to both ends of the shaft and the key in the shaft slot.
allow to stand for several minutes. Work the shaft (5) Center the counterweight assembly on the shaft
back and forth until it turns freely. and turn the valve counter-clockwise until the bumper
passes the pin
lnstallatlon (6)Press the counterweight on the shaft until it
(1) Position the shaft in the extreme clockwise posi- is seated. Tighten the clamp bolt 50 inch-pounds with
tion. torque wrench Tool C-3380.
PLYMOUTH (8 Cylind,er Engines)

3. INTAKE MANIFOLDS (Figs. 4 and 5 1 (2) Remove the alternator.
(318 Cu. In. Engine) (3) Disconnect the exhaust pipes at the exhaust
With the intake manifold removed. (See Group 9 manifold flanges.
“Engine”.) (4)Remove the nuts that hold the exhaust mani-
(1) Clean the manifold in solvent. Blow dry with folds to the cylinder heads.
compressed air. (5)Slide the manifolds off the studs and away from
(2) Inspect the exhaust crossover passage and pres- the cylinder heads.
sure test for leakage into any of the intake passages. (6) Clean the intake and exhaust manifolds in sol-
(3) Inspect the mating surfaces for parallelism. vent. Blow dry with compressed air.
(4)Use new gaskets when installing the manifold. (7) Inspect the manifolds for cracks and distortion.
4. EXHAUST MANIFOLD
Removal
(1) Disconnect the spark plug cables.
FOR AUTOMATIC
1 3
MI25
TEMPERATURE
SENDING UNIT
I
EXHAUST CROSS
OVER PASSAGE
\
CARBURETOR
MOUNTING FLANGE
EXHA~JSTCROSSOVER PASSAGE^ CARBURETOR
60 x 843 MOUNTING FLANGE
Fig. A l n t a k e Manifold (31’8 Cu. In. Engine) Fig. 5-Intake Manifold I361 Cu. In. Engine)
11-4 EXHAUST SYSTEM
lnrtallation
(1)Place the exhaust manifolds on the studs on INSTALLED POSITION
the cylinder heads and install the nuts. Tighten to VALVE /
30 foot-pounds torque. I
(2) Connect the exhaust pipes at the exhaust mani-
folds. Tighten the nuts to 40 foot-pounds torque.
(3) Install the alternator and adjust the belt ten-
sion.
(4) Connect spark plug cables to the spark plugs.
6. MANIFOLD HEAT CONTROL VALVE

/
. THERMOSTATIC
( 8 Cylinder 31 8 Cu. In. Engine1 FREE POSITION
Inspect operation of heat control valve at every VALVE 58x235 A
lubrication and oil change period. With engine idling
Fig. 7-Positioning Thermostatic Spring
accelerate to wide open throttle and release quickly.
The counterweight should respond by moving clock- (2) Place the new coil in position over shaft slot,
wise approximately Y2 inch and returning to its nor- with outer end (tongue) of coil in upper left hand
mal position. If no movement is observed, the valve position. Press the inner end of the coil into slot of
shaft may be frozen or the coil is weak or broken. the shaft and seat firmly.
In either case, the heat control valve should be
disassembled and replaced with new parts. (3) Move the outer end (tongue) counter-clockwise
and hook under pin, as shown in Figure 7.
Removal Fig. 6 I (4) Place the counterweight assembly over the shaft
(1)Loosen the retaining nut and remove the coun- (with weight in upward position) and insert the lock
terweight assembly from the end of the shaft, expos- in the shaft slot, as shown in Figure 8. Center the
ing the thermostatic coil. counterweight on the shaft and turn the assembly
(2) Unhook the coil from the pin and remove by clockwise until the stop passes the pin. Press the
sliding out of valve shaft slot. counterweight on the shaft until seated, install stop,
(3) If the valve shaft is frozen in the manifold, and tighten the clamp bolt 50 inch-pounds with torque
apply manifold heat control valve solvent, MoPar wrench Tool C-3380. I f the fabric on the stop is worn,
Part Number 1879318 and allow to stand several min- replace with new stop. (Fig. 6.) Test the valve for the
utes. Loosen by turning the shaft clockwise or coun- proper operation.
ter-clockwise (depending on frozen position) until the 6. MANIFOLD HEAT CONTROL VALVE
shaft is free. (361 Cu. In. Engine)
lnrtaliation Inspect the operation of the heat control valve (Fig.
(1) Position the valve shaft in the extreme counter- COUNTERWEIGHT
clockwise position. ASSEMBLY- ,g
COUNTERWEIGHT
I
,/'THERMOSTATIC CLAMP BOLT
Fig. &-Manifold Heat Control Valve (318 Cu. ,COIL 58x236
In. Engine) Fig. 8-installing Counterweight A3rembly
EXHAUST SYSTEM 11-5
lnstallation
COUNTERWEIGHT
(1) Place the heat control valve in the fully clock-
wise position.
- (2) Position the thermostatic spring in the valve
shaft slot with the tongue of the spring facing down-
ward on the left hand side.
(3) Turn the thermostatic spring end upward and
place the tongue of the spring behind the pin.
(4)Install the counterweight assembly on the valve
shaft being sure the stop is positioned against the
RETAINER pin.
(5) Tighten the counterweight clamp bolt 50 inch-
/SPRING pounds with torque wrench Tool C-3380.
63 x 432 c (6) Test the operation of the manifold heat control
valve.
Fig. -Manifold Heat Control Valve
7. EXHAUST PIPES MUFFLERS AND TAIL
9) and apply manifold heat control valve solvent PIPES (Figs. 10, 1 1 and 121
MoPar Part No. 1879318 to both ends of the valve Removal
shaft. With engine idling, accelerate the engine and (1) Remove the clamps from the exhaust pipes,
release quickly. The counterweight should respond mufflers and tail pipes.
by moving counter-clockwise approximately Y2 inch
(2) Disconnect the exhaust pipe at the exhaust
and return to its normal position.
manifold and remove the exhaust pipe.
Removal (3) Remove the muffler and extension pipe assem-
(1) Loosen the retaining nut and remove the coun- bly.
terweight assembly from the end of the shaft, ex- (4)Raise the rear of the vehicle to relieve the body
posing the thermostatic coil. weight from the rear springs.
(2) Unhook the coil from the pin and remove by (5) Remove the tail pipes.
sliding out of valve shaft slot.
installation
(3) If the valve shaft is frozen in the manifold,
apply manifold heat control valve solvent, MoPar Part (1) Assemble the exhaust system loosely.
No. 1879318, and allow to stand several minutes. (2) Connect the exhaust pipes at the exhaust mani-
Loosen by rotating the shaft back and forth until the folds. Tighten the nuts to 40 foot-pounds torque.
shaft turns easily. (3) Adjust the hanger heights.
NUT
PLAINWASYR/, HANGER
BO!T ,SCREW A N D WASHER
NUT NYT
PLAINWASHER
-SADDLE GASKET?
"U" BO1.T
MUFFLER \
PIPE / BO'LT
64 x 403
Fig. 1L E x h a u s t System (Valiant)

11-6 EXHAUST SYSTEM
6 4 x 405
-NUT
Fig. 1 1-Exhaust System (Plymouth)(LCylinder)
(4) Tighten all the slip joint clamps to 10 foot- (6) Tighten the ball joint screws to 20 foot-pounds
pounds torque. Work from rear to front of vehicle. torque. The lower surfaces of the flanges should be
(5) Tighten all the support clamps to 10 foot-pounds parallel to each other and perpendicular to the pipe
torque. axis.
SUPPORT
LOCKWASHER
U BOLT
PIPE
Fig. 12-Exhaust System (Plymouth) (6-Cylinder)

EXHAUST SYSTEM 11-7
SERVICE DIAGNOSIS
Leaks at the pipe joints. (a) Tighten the clamps at the leaking
joints.
Burned or blown out muffler. (b) Replace the muffler assembly.
Burned or rusted out exhaust pipe. (c) Replace the exhaust pipe.
Exhaust pipe leaking at the manifold (d) Install a new gasket and tighten
flange. the exhaust pipe flange nuts 40
foot-pounds torque.
Exhaust manifold cracked or broken. (e) Replace the manifold.
Leak between the manifold and cylinder (f) Tighten the manifold to cylinder
block. block nuts 30 foot-pounds torque.
Leaking Exhaust Leaks at the pipe joints. (a) Tighten the clamps at the leaking
Gases joints.
Damaged or improperly installed (b) Replace gaskets as necessary.
gaskets.
Restriction in muffler or tail pipe. (c) Remove the restriction, if possible
or replace as necessary.
Engine Hard t o Heat control valve frozen in the open (a) Free up the manifold heat control
W a r m Up or Will position. valve using solvent MoPar Part
Not Return to No. 1879318.
Normal Idle
Noise in Manifold Thermostatic spring broken. (a) Replace the spring.

Weak or broken anti-rattle spring. (b) Replace the spring.
Manifold Heat Thermostatic spring broken. (a) Replace the t.hermostatic spring.
Control Valve Broken or weak anti-rattle spring. (b) Replace the spring.
Rattle
FUEL SYSTEM 14-1
FUEL SYSTEM (PUMP. CARBURETOR. TANK)

CONTENTS
Page Page
PART 1-HOLLEY CARBURETOR PART 5 - W 3 CARBURETOR
Specifications ................................. 1 Specifications .................................. 6
Carburetor Disassembly ......................... 10 Carburetor Disassembly ......................... 60
Carburetor Adjustments ......................... 14 Carburetor Adjustments ......................... 66
Automatic Choke ............................... 16 Automatic Choke .............................. 69
Closed Crankcase Vent System . . . . . . . . . . . . . . . . . . . 17 Closed Crankcase Vent System . . . . . . . . . . . . . . . . . . . 69
PART 2-BBS CARBURETOR PART &THROTTLE LINKAGE
Specifications ................................. 3 170-225 Cubic Inch Engine ...................... 71

Carburetor Disassembly ......................... 20 Engine ..........................
225 Cubic Inch 72
Carburetor Adjustments ......................... 24 318 Engine .......................... 73
Automatic Choke ............................... 27 361-383 Cubic Inch Engine ...................... 74
Closed Crankcase Vent System . . . . . . . . . . . . . . . . . . . 27
PART 7-FUEL PUMP AND TANK
PART 3-BBD CARBURETOR Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Testing the Fuel Pump ........................... 75
Specifications................................. 5 Fuel Tank-Removal
Carburetor Disassembly ......................... 36 106" W/B Models......................... 79
Carburetor Adjustments ......................... 34 Fuel Tank-Removal
Automatic Choke ............................... 37 116" W/B Models . . . . . . . . . . . . . . . . . . . . . . . . . 80
Closed Crankcase Vent System . . . . . . . . . . . . . . . . . . . 37 Fuel Tank-Removal
106" W/B Station Wagon Models . . . . . . . . . . . . 81
PART &AFB CARBURETOR
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carburetor Disassembly .........................
Carburetor Adjustments .........................
6
48
54
Fuel Tank-Removal
116" W/B Station Wagon Models. . . . . . . . . . . .
PART 8-SERVICE DIAGNOSIS

81 I
Automatic Choke ............................... 57 Carburetor ................................... 83
Closed Crankcase Vent System . . . . . . . . . . . . . . . . . . . 57 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
HOLLEY 1920 R SERIES CARBURETORS
SPECIFICATIONS
CARBURETOR
Type .................................. Single Throat Down Draft
Model ................................. Holley-#l920
Manual Trans......................... R-2765A . R-2767A . R-2769A .
Automatic Trans...................... - R-2766A . R-2768A . R-2770A
.
Engine Displacement (Cu In.). . . . . . . . . . . . . . . 170 170 225 225 225 225
Bore ............................... 19h l'M6 11M6 l"6 1'M6 111h
Venturi............................. 1% 1946 19-46 19-46 1946 1946
14-2 FUEL SYSTEM
HOLLEY 1920 R SERIES CARBURETORS
SPECIFICATIONS--- ( Continued 1
Main Metering Jet

Standard ........................... 53 58 57 56 57 56
One Step Lean. ..................... - - 56 55 56 55
2 Steps Lean.. ...................... 55 54 55 54
ADJUSTMENTS
Float Setting ............................ Use Gauge Use Gauge Use Gauge
Fuel level Height (Wet). .................. M6" 'Ma" 'M6" H6" M6" 'W
Vacuum Kick. ........................... %6" 1 l!." 1%" 5/52" 1%" 942"
Cam Position Adjustment. .................. 1%" 1%" 1%" 1%" 1%" 1%"
Choke Unloader (See Fast Idle Index Adj.) . . . . - - - - - -
Bowl Vent Valve.. ....................... M6" M6" M6" M6" H6" 1
h "
Idle Mixture Screw (turns open) Approx.. . . . . . 1 1 1 1 1 1
Idle Speed (Curb Idle rpm). . . . . . . . . . . . . . . . 550 550 550 550 550 550
Fast Idle Speed (Engine Hot and Screw on
Lowest Step of Cam rpm)
Manual Trans.. . . c . . . . . . . . . . . . . . . 700 - 70 - 700 -
Automatic Trans.. . . . . . . . . . . . . . . . . - 700 - 700 - 700
CHOKE
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic Coil Spring
Type .................................. Well Well Well Well Well Well
Setting ................ ................. 2 Notches Rich 2 Notches Rich 2 Notches Rich
FUEL PUMP
SPECIFICATIONS
FUEL PUMP 6 V-8 V-8

ENGINE DISPLACEMENT 170 Cu. In.
225 Cu. In. 3 18 Cu. In. 361, 383, 426 Cu. In.
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carter Carter Carter
,..
Model ................................. MS-3674s MS-3673s MS-3672s
Type .................................. Diaphragm Diaphragm Diaphragm
Number of Valves.. ...................... 2 2 2
Driven By ............................... Camshaft Camshaft Camshaft
Pump Pressure (pounds). . . . . . . . . . . . . . . . . . . 3!h to 5 3!h to 5 3 E b 5
FUEL T A N K
SPECIFICATIONS
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Under Trunk Compartment (All except 116" W/B Station Wagon)
Station Wagon-left Rear Quarter Panel
Capacity (gals.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106" W/B-18 1 16" W/&l9-Conventional
106" W/B-18 1 16" W/B-2 1-Station Wagon
FUEL SYSTEM 14-3
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FUEL SYSTEM 14-7
SPECIAL TOOLS
T109-22. . . . . . . . . . . . . . . . . . . . . Bending Tool

T109-28.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %” Gauge, Vacuum Kick
T109-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . .020” Wire Gauge, Secondary Throttle Lever
T109-31.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %” Gauge, Fast Idle Cam Position and Choke Unloader
T109-32 . . . . . . . . . . . . . . . . . . . .... Gauge, Vacuum Kick (Manual) Choke Unloader
T109-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %” Gauge, Vacuum Kick (Auto. Trans.)
T109-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %” Gauge, Vacuum Kick Adjustment
T109-39.. . . . . . . . . . . . . . . . . . . . . . . . . . 1%4” Gauge, Vacuum Kick (Automatic)
T i 09-4 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Bending Tool, Fast Idle and Unloader
T109-43.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plug Remover, (Pump Jet)
T109-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw Driver Bit
T109-59. . . . . . . . . . . . . . . ......................... Screw Driver Bit
T109-59T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screw Driver Bit, (Accelerator Pump Jet)
T109-80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8” Gauge, Unloader
T109-106.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .%z” Float Gauge
T109-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . %s“ Gauge, Fast Idle Cam (Manual)
T109-166.. . . . . . . . . . . . . . . 1M4p’Gauge, Vacuum Kick (Manual Trans.)
T109-2 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bending Tool
TlO9-2 14. . . . . . . . . . . . . . . .
T109-220.. . . . . . . . . . . . . . . . . . . . . . . . . . ..%sf’ Gauge, Float (Taxi)
T109-238.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l%4” Gauge, Fast Idle Cam (Automatic)
T109-282. . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . .!A’‘ Gauge, Float
T109-287s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Elevating Legs
73519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Float Gauge (%z”)
73598 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Plug, Remover and Installer
73605. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bending Tool (Float Lip)
73606. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jet Remover and Installer (Main Metering)
73608 . . . . . . . . . . . . . . . .
73609 . . . . . . . . . . . . . . . .
C-3225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-3400. . . . . . . . . . . . . . . .
C-3748. . . . . . . . . . . . . . . . .
C-3886. . . . . . . . . . . . . . . .
C-3903. . . . . . . . . . . . . . . .
”si’! Drill., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. 6 Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum Kick, (Manual Trans.) 225 cu. in. T109-39 1%)
No. 13 Drill. . . . . . . . . . . . . . . . . . . . . . . . . .................... .Vacuum Kick (Manual Trans.) 170 cu. in. T109-28 (%SI
No. 18 Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum Kick (Auto. Trans.) 170 cu. in. T109-166 (l’h)
No. 23 Drill.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vacuum Kick (Auto. Trans.) 225 cu. in. T109-154 (5/L)
FUEL SYSTEM
The fuel system consists of the fuel tank, fuel into the engine in quantities suitable for all engine
pump, fuel filter, carburetor, fuel lines and vacuuum speed and load conditions.
line (See Fig. 1).
The fuel tank assembly consists of the tank, filler The for 1964 and Valiant
neck cap, air vent, and a fuel gauge sending unit. Models is a paper element sealed, disposable type
In operation, the fuel pump draws fuel from the unit, located in the fuel line between the fuel pump
tank and forces it to the filter and carburetor. The and the carburetor. The filter unit should be replaced
carburetor meters the fuel into the air stream drawn every 16,000 miles, or once each year.
14-8 HOLLY CARBURETOR
‘5
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HOLLY CARBURETOR 14-9
SPRING STAGED
CHOKE
CHOKE VACUUM
DIAPHRAGM
CHOKE OPERATING LINK FUEL INLET

NEEDLE VALVE
AND SEAT
BOWL VENT RO PUMP DIAPHRAGM STEM
VACUUM HOSE
FAST
IDLE CAM -
FAST IDLE SPEED
PUMP LEVER
DJUSTING SCREW
DISTRIBUTOR VACUUM
ADVANCE TUBE FITTING
ADJUSTING SCREW-
REPAIR
BLOCK
THROTTLE LEVER INK 64x291
Fig. 1-Carburetor Assembly (R-2765A and R-2766A)
CHOKE OPERATING LINK CHOKE LEVER ,CHOKE VALVE
VACUUM
CHOKE DIAPHRAGM
“E” CLIP FUEL INLET
BOWL V
VALVE ROD PUMP
DIAPHRAGM STEM
\
FAST IDLE ROD
PUMP LEVER
DIAPHRAGM
VACUUM HOSE
DLE MIXTURE ADJUSTING SCREW
FAST IDLE CAM -.- --

.... . .-
nlSTRIRIIT(3R
VACUUM ADVANCE
TUBE FITTING
THROTTLE LEVER 64x290
Fig. 2-Carburetor Assembly (R-2769A and R-2770A)

PART 1
HOLLY CARBUR E T 0RS

(1920 R
The Holley carburetors models R-2765A, and R- pump is operated by a cam connected by linkage to
2766A used on the 170 cubic inch engine, are the throttle shaft. An override spring on the pump
equipped with a spring staged choke, as shown in insures a prolonged discharge of fuel for smoother
Figure 1. Since all the Holley carburetors are serviced operation.
in the same manner, the staged choke adjustment will A power valve mounted in the metering body, ac-
be covered separately and indicated as such in the tuated by manifold vacuum, delivers the additional
service procedures. fuel necessary for full power and high speed oper-
The Holley carburetors used on the 225 cubic inch ation.
engine (high performance) R-2769A and R-2770A, The fuel bowl is vented by an external vent valve
with manual and automatic transmisssions are serv- located in the top of the bowl. The vent valve is con-
iced the same as the previously mentioned carbure- nected by linkage to the throttle shaft, so that the
tors. (Refer to Fig. 2). Since the service procedures valve is opened a prescribed distance when the ve-
are identical on all Holley carburetors, the illustra- hicle is at idle or completely shut down.
tions showing the various disasssembly procedures When overhauling the carburetor, several items of
will not always show any one specific carburetor. importance should be observed to assure a good job.
The spring staged choke, shown in Figure 1 (1) All parts (except the choke diaphragm) should
is a device incorporated in the choke mechanism be carefully cleaned in a suitable solvent, then in-
which limits the choke blade closing torque when spected for damage or wear.
cranking the engine at temperatures below zero. The (2) Use air pressure only, to clear the various
spring staging of the choke is suited for the engine’s orifices and channels.
starting mixture requirements at both the low and
(3) Replace questionable parts with new ones.
moderate temperatures.
When inspecting parts removed from carburetor, it is
Fuel from the bowl flows into the four basic fuel at times rather difficult to be sure they are satis-
metering systems, which are: the idle system, the factory for further service. It is, therefore, recom-
main metering system, the power enrichment system mended that in such cases new parts be installed.
and the accelerating pump system.
(4) Always use a complete repair kit when over-
The choke valve located in the bore of the carbu- hauling the carburetor. Using the code number
retor is connected to a well-type automatic choke. stamped on the flat surface next to the fast idle ad-
Additional fuel for acceleration is supplied by a justing screw, refer to the parts catalogue for the
diaphragm type, mechanically operated pump. The correct repair kit for the carburetor being worked on.
SERVICE PROCEDURES
1. CARBURETOR (4) Remove the vacuum diaphragm and bracket
assembly and place to one side to be cleaned as a
Disassembly (Figs. I , 2 and 3 1
separate item. As the vacuum diaphragm bracket i s
(1) Place the carburetor assembly on the repair being removed, the bowl vent valve rod, spring and
stand, Tool C-3886. washer will fall out. Do not lose the spring and flat
(2) Remove the vacuum hose between the car- washer (Refer to Figure 4).
buretor throttle body fitting and the vacuum dia- (5) Using a Y8’’wrench, remove the fuel inlet
phragm. needle valve and seat.
(3) Remove the “E” clip from the choke opera- (6) Remove the economizer retaining screws, then
ting link and disengage the link from the diaphragm lift economizer cover, diaphragm and stem out of
plunger (stem) and the choke lever (Refer to Figure the carburetor, as shownin Figure 5-
1or 2). (7) Remove the fuel bowl attaching screws, then
HOLLY CARBURETOR 14-1 1
BOWL VENT VALVE. eA BOWL VENT ROD
/
ECONOMIZER \
DIAPHRAGM
COVER
7'"
/ING
CHOKE
VACUUM
DIAPHRAGM
TUBE
BAFFLE FLOAT
Fig. +Removing or Installing Bowl Vent Rod
Fig. &Removing or Installing the Fuel Bowl
remove the fuel bowl, baffle and gasket, as shown ECONOMIZER B
in Figure 6. Slide the base out of the bowl. Discard
the gasket.
(8) Using a suitable tool, remove the float retain-
ing clip, then slide the float off the fulcrum pin.
(9) Remove the screws that attach the econo-
mizer body and plugs, then remove the economizer
body as shown in Figure 7.
(10) Tilt the pump lever on its pivot until the
hook on the pump diaphragm stem can be released.
Slide the pump diaphragm and spring out of the
fuel bowl (Refer to Fig. 8).
(11) To disassemble the pump diaphragm, com-
press the spacer slightly toward the diaphragm until
the ball drops out. Slide spacer and spring off the
diaphragm stem, as shown in Figure 8.
(12) Using Tool C-3748,remove the main jet from Fig. 7-Removing or Installing Economizer Bady
the economizer body (See Fig. 9).
(13) Using a suitable tool, remove the pump cam
retaining clip. Slide the cam off the pivot and dis-
engage the link from the throttle lever.
ECONOMIZER
PLATE
STEM /
GASKET /
VACUUM HOLE
64x293 64x 296
Fig. 5-Removing or Installing the Economizer Fig. 8-Pump Diaphragm and Spring
(14)Remove the fast idle cam retaining screw, in the throttle body. If wear is extreme, it is recom-
then remove the cam, and at the same time, disen- mended that the carburetor assembly be replaced
gage the choke link. rather than installing a new shaft in the old body.
(15) Remove the idle air mixture adjusting screw During manufacture, the location of the idle trans-
and spring from the throttle flange. fer port and the spark advance control ports to the
throttle valve is carefully established for one partic-
(16)Remove the fast idle and curb idle speed
ular assembly.
screws and springs from the throttle lever.
If a new shaft should be installed in an old, worn
(17) Invert the carburetor and remove the bowl throttle body, it would be very unlikely that the orig-
vent operating lever and dog retaining screw, then inal relationship of the ports to the valve would be
remove the lever and dog from the end of the throt- obtained. Changing the relationship of the valve to
tle shaft. the ports would adversely affect normal car opera-
(18)Remove the screws that hold the choke valve tion between the speeds of 15 and 30 miles per hour.
to the choke shaft. However, if it has been determined that a new shaft
CAUT1ON: These screws are staked to prevent
or valve is to be installed, adhere to the following
instructions:
loosening, and extreme care is necessary, to avoid
breaking off in the choke shaft. (2) Mark the position of the throttle valve in the
bore.
(18)Lift out the choke valve. Withdraw the choke
shaft and lever out of the carburetor. (3) Remove the screws that hold the throttle valve
to the shaft, then slide the valve out of the bore.
The carburetor assembly now has been disassem-
CAUTION: These screws are staked on the o p
bled as far as necessary for cleaning and inspection.
posite side and care should be used at removal so as
It is usually not advisable to remove the throttle
not to break in the shaft.
shaft and valve from the throttle flange, unless wear
or damage necessitates the installation of new parts. (4)Slide the throttle shaft out of the throttle body.
(5) Install a new throttle shaft and lever (or new
Cleaning the Carburetor Parts valve).
The recommended solvent for gum deposits is de- (6)Install NEW screws but do not tighten. Hold
natured alcohol which is easily obtainable. However, the valve in place, with the fingers pressing on the
there are other commercial solvents which may be high side of valve. Tap the valve lightly with a screw
used with satisfactory results. driver to seat in the throttle bore. Tighten the screws
The choke diaphragm can be damaged by solvents. securely and stake by squeezing with pliers.
Avoid placing the diaphragm assembly in ANY liquid. (7) Install the idle mixture screw and spring in
Clean the external surfaces with a clean cloth or a the throttle body (The tapered portion must be
soft wire brush. Shake dirt or other foreign material straight and smooth. If the tapered portion is grooved
from the stem side of the diaphragm. Depressing the or ridged, a new idle mixture screw should be in-
diaphragm plunger (stem) to the retracted position, stalled to insure having correct idle mixture control).
will provide an additional hole for the removal of Do not use a screw driver. Turn the screw lightly
dirt. Compressed air can be used to remove loose dirt against its seat with the fingers. Back off one full turn
but should not be connected to the vacuum inlet for the approximate adjustment.
fitting.
IMPORTANT: 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 certain no trace of moisture remains.
Never clean jets with a wire, drill, or other mechan-
ical means, because the orifices may become enlarged, PO
making the mixture too rich for proper performance. VA
PIVOT
inspection and Reassembly-
Throttle Body ECONOMIZER BO6Y 64x297
(1) Inspect the throttle shaft for extessive wear Fig. %-Economizer Body Assembly
Assembling the Carburetor (12) Install the fuel inlet needle, seat and new
(1) Slide the choke shaft into the airhorn, then in- gasket. Tighten seat securely. Test the float setting
stall the choke valve. as follows:
(2) Install the choke valve attaching screw but do Measuring the Float Setting
not tighten. Hold the valve closed, with the fingers With the carburetor inverted, slide the float gauge
pressing on the high side of the valve. Tap the valve into position and test the setting on the “touch” leg
lightly with a screw driver to seat in the airhorn. of the gauge, as shown in Figure 10. The float should
Tighten the attaching screws securely and stake by just touch the gauge. Reverse the gauge and test the
squeezing with pliers. “NO touch” leg. The float should just clear the gauge.
(3) Test the choke valve for binding by rotating If an adjustment is necessary, bend the float tab
the lever through the extent of its full travel. (which touches the head of the fuel inlet needle)
using needle nose pliers.
(4) Install the fast idle and curb idle speed screws
NOTE: Do not allow the float tab to contact the
and springs in the throttle lever.
float needle head during this operation as the syn-
(5) Slide the pump spring over the pump dia- thetic rubber tip of the needle can be c o m p r e d ,
phragm stem. Install the assembly in position in the giving a false setting.
fuel bowl and at the same time, engage the hook on
Retest the float setting as described above after
the diaphragm stem with the recess in the pump lever
adjustment.
(Fig. 8).
(1) Slide the economizer diaphragm and stem as-
(6) Install the main jet in the economizer body, sembly into position, making sure the vacuum holes
using Tool C-3748(Refer to Fig. 9). are aligned and that the stem is on the power valve
(7) Turn carburetor with bowl opening up then (Refer to Fig. 5). Install the cover and retaining
position the main well and equalizer body in the car- screws. Tighten screws securely.
buretor, as shown in Figure 7. Install screws and (2) Slide the baffle into position in the fuel bowl,
tighten securely. Be sure the pump spring is correctly place the fuel bowl gasket on the cover. Place the fuel
centered. bowl in position, install screws and washers and tight-
(8) Engage the pump cam link with the cam and en alternately (Be sure gasket is sealed in the recess
throttle lever, then install cam and secure with clip. section of the main body. Tighten the screws gently
When installing the link, be sure link is in the center so as to compress only the lockwasher. Screws drawn
hole of throttle lever. down too tightly could distort the fuel bowl and cause
(9) Engage the choke link with the choke lever a leak).
and fast idle cam. Place the cam in position, then (3)Slide the bowl vent rod down into position at
install retaining screw. Tighten the screw securely. the same time thread the spring over the rod. Secure
(10) Position the bowl vent operating lever and with clip (Refer to Fig. 4).
dog on the end of the throttle shaft and secure with lnstalling the Vacuum Diaphragm
the retaining screw. (1) Slide the bowl vent rod return spring and
(11) Slide the float into position over the fulcrum washer over the end of the rod, then install in posi-
pin and secure with retainer clip. tion on the airhorn. Hold the rod centered in its
grooves, using a finger.
(2) Install the vacuum diaphragm assembly on
the airhorn, being sure the vent rod is in position. In-
stall the diaphragm attaching screws and tighten
securely.
(3) Install the choke operating link in position be-
tween the diaphragm plunger (stem) and the choke
lever. Install the “E” clip to secure.
(4) Inspect the vacuum diaphragm fitting and re
move any dirt or foreign material which could plug
the vacuum passage. Inspect the rubber hose for
cracks, before placing it on the correct fitting (Refer
to Fig. 1.)
64x298 Do not connect the vacuum hose to the diaphragm
Fig. I G M e a r u r i n g the Float Setting fitting until after the vacuum kick adjustment has
been made (See Carburetor Adjustments). slight closing pressure on the choke valve, as shown.
2. CARBURETOR ADJUSTMENTS (4) An adjustment will be necessary, if a slight
drag is not obtained as the drill or gauge is being
It is very important that the following adjustments
removed.
be made on a reconditioned carbuetor and in the
The adjustment of this opening will require the
sequence listed.
removal of the choke operating link.
Fast ldle Speed and Cam Position CAUTION: Damage to the diaphragm and the
Adjustment choke lever slot can result, if the link is not removed
NOTE: The cam position adjustment is only per- for the bending operation.
formed on the non-spring staged choke carburetors. (5) Remove the “E” clip and disengage the choke
The fast idle engine speed adjustment should be operating link from the diaphragm stem (plunger),
made on the vehicle, as described in the Paragraph then disengage the link from the choke lever (The
Fast Idle Speed Adjustment. However, the Fast Idle best bending results will be obtained by using a vise
Cam Position Adjustment can be made on the bench and a pair of pliers).
as follows: (6) Bend the choke operating link at the angle to
(1) With the fast idle speed adjusting screw con- provide the correct choke valve opening.
tacting the lowest step on the fast idle cam, as shown CAUTION: A correction in the length of the
in Figure 11, move the choke valve toward the closed link of .010 inch, will result in a change of .010 inch
position with light pressure. Insert a inch drill in the choke valve opening.
or gauge between the choke valve and the wall of the
As an example, if the choke valve opening is .010
air horn.
inch error, the correction in the link length would be
(2) An adjustment will be necessary if a slight .010 inch.
drag is not obtained as the drill or gauge is being A “2” inch micrometer will be helpful in establish-
removed. ing the original length of the link, as shown in Figure
(3) If an adjustment is necessary, bend the fast 13, before completing the adjustment.
idle rod, using Tool T109-213, until the correct valve
(7) Install the choke operating link and retest the
opening has been obtained (Refer to Fig. 11).
choke valve opening, using a gauge or drill (Refer to
NOTE: When the correct fast idle position cam Fig. 13.)
adjustment has been made, the choke unloader (wide Reinstall the vacuum hose to the diaphragm fitting
open kick) adjustment has also been obtained. No and make the following test:
further adjustment is required.
(8) With no vacuum applied to the diaphragm,
Vacuum Kick Adjustment-(This test can be made
some clearance should exist between the choke opera-
On or Off the Vehicle). ting link and the choke lever slot, in both the open
To make the vacuum kick adjustment, the vacuum and closed choke valve positions, as shown in Figure
diaphragm must be energized (either a distributor 14.
testing machine with a vacuum source, or vacuum NOTE: This clearance is necessary to allow the
supplied by another vehicle). choke valve to close for starting and to fully open,
(1) With the engine Not running, open the throttle
GAUGE OR DRILL
valve far enough to allow the choke valve to be
moved to the closed position.
(2) Disconnect the vacuum hose from the dia-
phragm and connect the hose from the vacuum -A/ CHOKE VALVE
supply, as shown in Figure 12. (A minimum of 10
inches of mercury (HG) will be required.)
(3) Insert a number 13 drill (170 cu. in. engine, BEND FAST
manual transmission, or a T109-28 3/ls inch) IDLE ROD AT
gauge between the choke valve and the wall of the THIS ANGLE
airhorn or a No. 18 drill (170 cu. in. engine, automat-
FAST IDLE SPEED
ic transmission) or a T109-166 inch) gauge in
the above location. Use a No. 6 drill or gauge T109-
b ADJUSTING SCREW
ON LOWEST STEP
39 (13/s4 inch) on the 225 cu. in. engine (manual (AGAINST THE FACE
transmission) or a No. 23 drill or gauge T109-154 OF THE NEXT STEP)
(S/32inch) on the 225 cu. in. engine (automatic 64x299
transmission), as above (Refer to Fig. 12). Apply a Fig. 1 1-Fast ldle Cam Position Adjustment
GAUGE OR DRILL setting the idle to compensate for the alternator load.
On vehicles equipped with automatic transmission, un-
PRESSURE snap the ball joint connection at the accelerator shaft
IKE VALVE bell crank. If this is not done, it is possible that the
-
MINIMUM OF 10
carburetor throttle will be held open against the stop
INCHES OF & in the transmission. The carburetor would therefore
VACUUM ON
DIAPHRAGM not respond to adjustment of the idle speed screw.
REQUIRED- After the proper idle speed has been obtained at the
CHOKE OPERATING
LINK carburetor, screw the ball joint connector up or down
until the ball on the bell crank will exactly mate with
the socket. Snap into place.
- DIAPHRAGM STEM
RETRACTED BY To make the idle speed adjustment, proceed as
TO VACUUM follows:
VACUUM- (1) Turn the idle speed screw in or out to obtain
SUPPLY 64x300
550 rpm (Be sure that the choke valve is fully open
Fig. 112-Measuring the Choke Vacuum Kick Setting and that the fast idle adjusting screw is not contacting
the cam).
after the engine reaches the normal operating tem-
perature. (2) Adjust the idle mixture screw to obtain the
highest rpm. While making the adjustment, carefully
If a clearance does not exist in both of these posi- watch the tachometer and notice that the speed can
tions, a retest of the operating link adjustment should be decreased by turning the screw in either direction
be made. from the setting that gave the highest rpm reading.
NOTE: Free movement of the choke valve be- (3) From the highest idle speed setting, turn the
tween the closed and open positions is very necessary. mixture screw clockwise (leaner) until the speed
This free movement should also exist between the starts to drop. Turn the screw in the opposite direc-
kick and the open choke valve positions with the tion (counter-clockwise)just far enough to recover the
engine running. If binding does exist, the choke oper- speed that was lost.
ating link has been improperly bent and should be This procedure will assure that the idle has been
corrected. set to the leanest mixture possible for smooth idle.
Idle Speed Adjustment Curb Idle I This setting is very important.
To make the idle speed adjustment, the engine must Since the correct speed was originally set using
be thoroughly warmed up. A much more reliable the fast idle speed screw, the speed obtained after
idle adjustment can usually be obtained if the vehicle finding the leanest smooth idle setting will probably
has been driven a minimum of five miles. For the best be too fast.
results, it is recommended that a tachometer be used (4) Readjust the speed screw to obtain correct
in this adjustment (Before making the idle speed ad- idle speed. Repeat steps 2 and 3 above.
justment, observe the following precautions).
Because the alternator can charge at idle speeds CHOKE VALVE
and impose a load on the engine, the Headlamps
should be turned on the high beam. This will assure LEVER \ OPEN
CLEARANCE
CHOKE OPERATING LINK CHOKE

OPERATING
LINK
CHOKE LEVER CHOKE VALVE

CLOSED
CHOKE
OPERATING
LINK CLEARANCE
64x301 64x302
Fig. 13-Choke Operating link Measurements Fig. 14-Choke Operating link Clearances
Fast idle Speed Adjustment l On the

Vehicle 1 SCALE
To set the fast idle speed on the car, connect a

tachometer to the vehicle, then set the curb idle speed
and proceed as follows:
(1) With the engine running and the transmission
in the neutral position, open the throttle slightly.
(2) Close the choke valve about 20 degrees then
allow the throttle to close. Return the choke valve to
the open position.
(3) The fast idle speed adjusting screw should
contact the lowest step on the fast idle cam, as shown
in Figure 15.
(4) With the engine warmed-up to the normal SURFACE OF FUEL 64x304
operating temperature, turn the fast idle speed ad-
justing screw in or out to secure 700 rpm. Reposition Fig. l&Measuring the Wet Fuel level
the cam and throttle after every screw adjustment.
operating arm until the correct clearance has been
W e t Fuel Level obtained or bend the vent rod at the horizontal por-
With the engine running and the vehicle on a level tion above bowl. Be sure the vent rod does not bind
floor, the fuel level can be measured through the in the guide after adjusting.
economizer diaphragm opening. Using a 6" scale with
a depth gauge, measure the distance from the mach-
ined surface of the opening to the exact fuel surface,
as shown in Figure 16. The measurement should be
3. AUTOMATIC CHOKE-WELL TYPE
'%6. To function properly, it is important that all parts
Bowl Vent Adjustment be clean and move freely. Other than an occasional
cleaning, the choke requires no servicing. However,
With the throttle valve at curb idle speed, it should
be possible to insert a ?46" (.0625") drill between it is very important that the choke control unit work
the bowl vent and the seat, as shown in Figure 17. freely in the well and at the choke shaft. Move the
This measurement should never exceed .090 inch choke rod up and down to check for free movement
(3/3 2" drill). on the pivot. If the unit binds, a new choke unit
If an adjustment is necessary, bend the tab on the should be installed.
FAST CHOKE VALVE

ADJU WIDE OPEN
SCRE'
FAST IDLE CAM
FAST IDLE SPEED

ADJUSTING
SCREW
-
ON THE LOWEST
I STEP OF THE \
, 'x FAST IDLE CAM 'VALVE SEAT
,i
64x303 64x305
Fig. 1L F a s t Idle Speed Adjustment (On the Vehicle) Fig. 17-Measuring the Bowl Vent Opening
HOLLY CARBURETOR 1417
NOTE: The well type choke unit, is serviced as

an assembly. Do not attempt to repair, or change the
setting.
When installing the well type choke unit, be cer-
tain that the coil housing does not contact the sides
of the well in the exhaust manifold. Any contact at
this point will affect choke operation. DO NOT lubri-
cate any parts of the choke or the control unit. This
causes an accumulation of dirt which will result in
binding of the mechanism.
Spring Stuged Choke Adjustment
The following steps are required to test this ad-
justment:
(1) Press against the choke lever firmly.
(2) Measure the cl->arance between the hub lever
and the shaft lever, as shown in Figure 18. Fig. 118-Spring Staged Choke Adjustment
(3) The clearance in this position, should be from
.010 to .025 inches. the crankcase vent tube cap and is connected to the
carburetor throttle body through a rubber tube.
(4) If an adjustment is necessary, bend the fast
idle rod slightly, using Tool T109-213, until the cor- The function of the valve is to control the unburned
rect clearance has been obtained. (The cam position fuels that originate in the crankcase. The gases are
and unloader setting resulting from such bending of returned to the intake manifold, fed back into the
the choke link are satisfactory.) combustion chambers and then expelled out through
the exhaust system as completely burned products.
4. CLOSED CRANKCASE VENT SYSTEM For service procedures of this system, refer to
The closed crankcase ventilator valve is located in Group 9, “Engine”.
-CARBURETOR
Fig. 1-Fuel System (Engine Comparlment)

14-1 8 BBS CARBURETOR
/AIR HORN
/ACCELERATOR PUMP STEM
'BOWL VENT VALVE
DlSTRlBlJTOR VACUUM ADVANCE

TUBE FITTING
-FUEL INLET FITTING
THROTTLE BODY
41N BODY
IDLE MIXTURE ADJUSTING SCREWS
CHOKE VALVE- 4 ACCELERATOR PUMP ARM
SPRING STAGED CHOKE

FAST IDLE CAM LINK
CHOKE VACUUM DIAPHRAGM - ACCELERATOR PUMP ROD
VACUUM HOSE
FAST IDLE CAM
CHOKE OPERATING LINK
THROTTLE LEVER
FAST IDLE SPEED ADJUSTING SCREW
CURB IDLE SPEED ADJUSTING SCREW
Fig. 1-Carburetor Assembly (BBS 3675, 3676, 36815)

BBS CARBURETO'R 14-19
ACCELERATOR PUMP STEM
AIR HORN
DISTRIBUTOR
VA,CUUM ADVANCE
TUBE FITTING BOWL VENT VALVE
ACCELERATOR PUMP ARM
FUEL INLET FITTING

THROTTLE BODY
IDLE MIXTURE ADJUSTING SCREW

CHOKE VALVE
FAST IDLE CAM LINK

CHOKE VACUUM DIAPHRAGM
VACUUM DIAPHRAGM HOSE

ACCELERATOR PUMP ROD
FAST IDLE CAM
FAST IDLE SPEED

ADJUSTING SCREW-
z=-<
r REPAIR BLOCK
CURB IDLE SPEED

THROTTLE LEVER
ADJUSTING SCREW
64 x 266
-
__
Fig. 2-Carburetor Assembly (BBS 3677, 3679, 3680, 36649

14-20 BBS CARURETOR
PART 2
BBS SERIES CARBURETOR

The BBS 36758 and the BBS 3676s carburetors 225 cu. in. engine (High Performance) with manual
are single downdraft carburetors used on the 170 and automatic transmission are serviced the same as
cu. in. engine are equipped with a spring staged choke the previously mentioned BBS Carburetors.
as shown in Figure- 1. Since all the BBS carburetors
are serviced in the same manner, the staged choke
Since the service
procedures are identical on all
BBS carburetors, the illustrations showing the various
adjustment will be covered separately and indicated
as such in the service procedures. The BBS 3679s disassembly will not always show any one specific
and the BBS 36803 carburetors used on the 225 cu. carburetor.
in. engine are equipped with a spring staged choke, The spring staged choke, shown in Figure 1 in-
mechanism, but have the cable control throttle lever, corporates the choke mechanism which limits the
as shown in Figure 2. choke blade closing torque when cranking the engine
The BBS 36813 and the BBS 36648 carburetors at temperatures below zero. Thus the spring staging
used on the 170/225 cu. in. engine (taxi application) of the choke is necessary for the engine’s starting
and the BBS 3677s and the BBS 3678s used on the mixture requirements at the low temperatures.
SERVICE PROCEDURES
Disassembly (Figs. I and 2) separate item. A liquid cleaner may damage the dia-
phragm material.
(1) Place the carburetor assembly on the repair
block, To01 C-3225. (7) Tilt the air horn toward the throttle lever far
(2) Remove the hairpin clip and disengage the enough to disengage the fast idle cam link from the
accelerator pump operating rod. fast idle cam, as shown in Figure 3. Lift the airhorn
up and away from the main body. Discard the gasket.
(3)-Remove the vacuum hose between the car-
buretor main body and the vacuum diaphragm. (8) Disengage the accelerator pump plunger from
(4) Remove the clip from the choke operating link the rocker arm by pushing up on the bottom of
and disengage the link from the diaphragm plunger plunger and sliding the plunger shaft off the hook.
(stem) and the choke lever (Refer to Fig. 1). Slide the plunger out of the airhorn and remove the
ACCELERATOR
STEP UP PISTON
STEP UP
TEP UP PISTON
SPRING
(GASKET AT
BOnOM OF WELL)
O N RETAINING SCREW
IDLE MIXTURE
ADJUSTING SCREW 64 x 267 64x268
-.I-
Fig. &Removing or Installing the Air Horn Fig. &Removing or Installing Step-up Piston
BBS CARURETOR 14-2 1
(14) Invert the carburetor and drop out the accel-

erator pump check balls from their respective seats.
(15) Using Tool T109-43 plug remover, remove
the accelerator pump jet plug. Using Tool T109-59,
remove the accelerator pump jet, as shown in Figure
7.
(16) Unscrew and remove the idle mixture adjust-
ing screw and spring.
The carburetor now has been disassembled into
three main units, namely, the air horn, main body
MAIN and throttle body and the component parts of each
disassembled as far as necessary for cleaning and in-
spection.
shaft or valve from the throttle body, unless wear or
Fig. 5-Removing or Installing Main Metering Jet damage necessitates the installation of new parts.
Cleaning the Carburetor Parts
bowl vent valve, spring seat and spring. If the old The recommended solvent for gum deposits is de-
plunger can be used again, or if a new plunger is to natured alcohol which is easily obtainable. However,
be installed, place the plunger in a jar of clean gaso- there are other commercial solvents which may be
line or kerosene to prevent the leather from drying used with satisfactory results.
out. The choke diaphragm can be damaged by solvents.
(9) Lift out the float fulcrum pin retainer, then Avoid placing the diaphragm assembly in ANY
lift out the floats and fulcrum pin. liquid. Clean the external surfaces with a clean cloth
(10) Remove the fuel inlet needle valve, seat and or soft wire brush. Shake dirt or other foreign mater-
gasket from the main body. ial from the stem side of the diaphragm. Depressing
(11) Remove the step-up piston retaining screw, the diaphragm stem (plunger) to the retracted posi-
and slide the step-up and rod out of the well, as tion, will provide an additional hole for the removal
shown in Figure 4. Now lift out the step-up piston of dirt. Compressed air can be used to remove loose
spring. Remove the step-up piston gasket from the dirt but should not be connected to the vacuum dia-
bottom of the well. phragm fitting.
(12) Remove the main metering jet and gasket, IMPORTANT: If the commercial solvent or
as shown in Figure 5. cleaner recommends the use of water as a rinsel it
should be "HOT". After rinsing, all trace of water
(13) Unscrew and remove the idle orifice tube, as must be blown from the passages with air pressure. It
shown in Figure 6. is further advisable to rinse all parts in clean kero-
,ACCELERATOR PUMP
$*
/IDLE ORIFICE TUBE
64x270 ACCELERATOR PUMP 64x271

DISCHARGE CHECK BALL-
Fig. &Removing or Installing Idle Orifice Tube Fig. 7-Removing or Installing Accelerator Pump Jet
14-22 BBS CARBURETOR
CHECK BALL
-ne or gasoline to be ce*ain no trace of moisture
remains. Never clean jets with a wire, drill, or other
-INSTALL THE
mechanical means, because the orifices may be come ACCELERATOR
enlarged, marking the mixture too rich for prop- PUMP INLET
CHECK BALL
er performance. AT BOTTOM
OF WELL
inspection and Reassembly
Throttle Body
(1) Inspect the throttle shaft for excessive wear in AC(ZELERP
DISC:I
the throttle body. If wear is extreme, it is recom- PASSAGE
mended that the throttle body assembly be replaced
rather than installing a new shaft in the old body.
64 x 273
During manufacture, the location of the idle trans-
fer port and the spark advance control ports to the Fig. 9-Installing Accelerator Pump Discharge and
throttle valve is carefully established for one partic- Intake Check Balls
ular assembly (See Fig. 8).
If a new shaft should be installed in an old worn driver to seat in the throttle bore. Tighten the screws
throttle body, it would be very likely that the original securely and stake by squeezing with pliers.
relationship of the ports to the valve would be ob- (7) Install the idle mixture screw and spring in
tained. Changing the relationship of the valve to the the throttle body (The tapered position must be
ports would adversely affect normal car operation straight and smooth. If the tapered portion is grooved
between the speeds of 15 and 30 miles per hour. or ridged, a new idle mixture screw should be in-
However, if it has been determined that a new shaft stalled to insure having correct idle mixture con-
or valve is to be installed, adhere to the following in- trol). Do not use a screw driver. Turn the screw light-
structions: ly against its seat with the fingers. Back off 1 full turn
(2) Mark the position of the throttle valve in the for approximate adjustment.
bore, so that it can be reinstalled in the same position. Main Body
(3) Remove the screws that hold the throttle valve (1) Install the accelerator pump discharge and in-
to the shaft, then slide the valve out of the bore. take check balls in their respective passages, as shown
in Figure 9.
CAUTION: These screws are staked on the o p
(2) To test the accelerator pump system; fuel inlet
and discharge check balls pour gasoline into the car-
not to break off in the shaft.
buretor ‘bowl, approximately V2 inch deep. Remove
(4) Slide the throttle shaft out of the throttle body. the pump plunger from the jar of gasoline and slide
(5) Install a new throttle shaft and lever (or new down into the pump cylinder. Raise the plunger and
valve). press lightly on the plunger shaft to expel air from the
(6). Install NEW screws but do not tighten. Hold pump passage.
the valve in place, with the fingers pressing on the BRASS ROD (PRESS D O W N NO FUEL TO BE EMITTED FROM
high side of valve. Tap the valve lightly with a screw TO SEALBALL) /PUMP DISCHARGE PASSAGE
IDLE TRANSFER PORT SPARK ADVANCE IDLE SPEED

CONTROL PO
EMITfED FfOM
THE PUMP
INTAKE
APPROXIMATELY i / 2 INCH-
THROTTLE BODY OF FUEL I N THE BOWL 64x274
VENT HOLE
Fig. 10-Testing Accelerator Pump Intake and
Fig. &Ports in Relation to Throttle Valve Discharge Check Bulls
BBS CARBURETOR 14-23
(3) Using a small clean brass rod, hold the dis- material which is not affected by gasoline and is stable
charge check ball down firmly on its seat. Again raise over a wide range of temperatures. The tip is flexible
the plunger and press downward. No fuel should be enough to make a good seal on the needle seat.
emitted from either the intake or discharge passage, The use of this inlet needle requires a care
as shown in Figure 10. wrhen adjusting the float setting. Care should be
If any fuel does emit from either passage, it indi- tiiken to perform this operation accurately in order
cates the presence of dirt or a damaged chcx k ball. tc secure the best performance and fuel economy.
Clean the passage again and repeat test. If .leakage (1) To correctly set the float height, when the
is still evident, install a NEW check ball. I Ph&
n f a i n 1 .,
~
carburetor is being overhauled, install the floats with

inlet check ball is located at the bottom of the plunger the fulcrum pin and pin retainer in the main body.
well.
(2) Install the needle, seat and gasket in the body
(4) Install the accelerator pump jet, as shown and tighten securely.
in Figure 7. Tighten securely, using Tool T109-59T.
(3) Invert the main body so that the weight of the
Install a new plug and drive tightly in place.
floats only, is forcing the needle against the seat. Hold
(5) Install the idle orifice tube (Refer to Fig. 6). the finger against the retainer to fully seat the ful-
Tighten securely. crum pin.
(6) Install the main metering jet and gasket (Refer (4) Using Tool T109-282 or T109-220; or a T
to Fig. 5). Tighten securely. scale, measure the float, as shown in Figure 12. There
(7) Before installing the step-up piston, be sure should be % or 5/le inch (Taxi) (depending on car-
the step-up rod is able to move freely each side of the buretor, refer to Specifications,) from the surface of
vertical position, as shown in Figure 11. The step-up the fuel bowl to the crown of each float at the center.
rod must be straight and smooth.
If an adjustment is necessary, bend the lip of the
(8) Slide the step-up piston gasket down into po- float lever either in or out until correct setting has
sition in the piston well, then install the step-up piston been obtained.
spring and step-up piston and rod (Refer to Fig. 4).
Install the retaining screw and tighten securely. Care- CAUTION: Do not attempt to change the setting
fully guide the step-up into the main metering jet. Be without removing the float, as the synthetic rubber
sure the step-up piston slides freely in its cylinder. A tip can be compressed sufficiently to cause a false
step-up piston stuck in the UP position will cause a setting which will affect correct level of fuel in the
rich mixture at part throttle, whereas a piston stuck bowl. After being compressed, the tip is very slow
in the DOWN position will cause a lean mixture at to recover its original shape. Remeasure as described
wide open throttle and poor acceleration. in Step 4 above.
NOTE: It is very important that the float lip be
Measuring fhe Float Setting perpendicular to the needle or slanted not more than
The carburetors are equipped with a synthetic rub- 10 degrees away from the needle when the float is set
ber tipped fuel inlet needle. The needle tip is a rubber correctly.
APPLY PRESSURE TO RETAINE GAUGE T O TOUCH
T O SEAT FULCRUM PIN FLOATS AT CROWN
I
GAUGE
TED
Fig. 11-Step-up Rod Free Play Fig. 12-Measuring the Float Setting
”#W -, ,CHOKE VALVE
(5) Place a new gasket on the throttle body and L WIDE OPEN
position the main body making sure they are aligned.
Air Horn T SCREW
Inspect the freedom of the choke mechanism in the
air horn. The shaft must float free to operate correct-
ly. Clean thoroughly.
(1) Assemble the pump plunger, spring and spring
seat and slide the plunger shank through the opening
in the air horn. Install the bowl vent cap over the
plunger shank, then engage with pump rocker arm.
(On the BBS-3681s carburetor, be sure the hairpin DRILL Od GAUGI
INSERTED
clip is in the upper position on the plunger rod; all
others in the middle position.)
(2) Place a new gasket on the main body, then in-
BETWEEN
VALVE AND SEAT
i Y
1 64x275
stall the air horn by tilting the air horn, as shown in Fig. 1 L M e a s u r i n g the Bowl Vent Opening
Figure 3, in order to engage the fast idle link with
the fast idle cam. After engaging the link, slowly medium and short pump stroke holes in the throttle
lower the air horn and at the same time guide the lever. Normally, the bowl vent clip on the pump stem
accelerator plunger into its well. will be at the middle notch and the pump operating
(3) Install the air horn .attaching screws. Tighten rod in the medium stroke hole.
securely. The proper procedure is to adjust the amount of
(4) Install the accelerator pump operating rod and bowl vent opening instead of measuring and setting
secure with the hairpin clip. Normal operation of the the height of the pump plunger.
accelerator pump is obtained by installing the pump To test or set the adjustment, proceed as follows:
rod in the center hole of the throttle arm (On the
BBS-3681s carburetor, be sure the pump rod is in the (1) Back off the idle speed adjusting screw. Open
short stroke hole of the throttle arm). the choke valve, so that when the throttle valves are
closed, the fast idle adjusting screw will not contact
installing the Vacuum Diuphrgam the fast idle cam.
(1) Install the diaphragm assembly on the air horn
(2) Be sure the pump operating rod is in the me-
and tighten the attaching screws securely. dium stroke hole in the throttle lever, and that the
(2) Install the choke operating link in position be- bowl vent clip on the pump stem is in the center
tween the diaphragm plunger (stem) and the choke notch.
lever. Install the clip to secure.
(3) Close the throttle valves tightly. It should be
(3) Inspect the vacuum diaphragm fitting and re- just possible to insert a inch drill (.060”) between
move any dirt or foreign material which could plug the bowl vent and the air horn, as shown in Figure 13.
the passage. Inspect the rubber hose for cracks,
before placing it on the correct fitting (Refer to If an adjustment is necessary, bend the pump op-
Fig. 1). erating rod, using Tool T109-213, at the lower angle,
Do not connect the vacuum hose to the diaphragm until the correct bowl vent opening has been ob-
fitting until after the vacuum kick adjustment has tained.
been made (See Carburetor Adjustments). This is an important adjustment, since too much
lift at the bowl vent will result in considerable loss in
2. CARBURETOR ADJUSTMENTS low speed fuel economy.
It is very important that the following adjustments If the pump operating rod is moved to either the
be made on a reconditioned carburetor, and in the short or long stroke position, a corresponding change
sequence listed: must be made in the location of the bowl vent clip,
and the amount of lift of the bowl vent must be
Accelerutor Pump and Bow/ Vent retested and adjusted.
When assembling the accelerator pump to the air
horn, note that the hair pin clip (which opens the bowl NOTE: The accelerator pump travel it automat-
vent) can be placed in any one of the three position- ically taken care of when the bowl vent is properly
ing notches. These notches correspond to the long, adjusted.
Fast idle Speed and Cam Position L D R l L L OR GAUGE

Adjustment r’ LIGHT CLOSING
PRESSURE AGAINST
The fast idle engine speed adjustment should be P CHOKE VALVE
made on the car, as described in the Paragraph “Fast
Idle Speed Adjustment”. However, the Fast Idle Cam
Position Adjustment can be made on the bench. FAST IDLE SPEED &
(1) With the fast idle speed adjusting screw con- ADJUSTING SCREW
ON LOWEST STEP
tacting the lowest step on the fast idle cam, as shown
in Figure 14, move the choke valve toward the closed
OF THE FAST 4
IDLE CAM
position with light pressure. Insert a drill or gauge
between the choke valve and the wall of the airhorn
(Refer to Specifications for Drill or Gauge Size).
(2) An adjustment will be necessary if a slight
b 64 x 276
removed. Fig. 1 A F a s t Idle Cam Position Adiurtment

(3) If an adjustment is necessary, bend the fast
idle rod at the upper angle, using Tool T109-213, (6) Bend the choke operating link at the angle to
until the correct valve opening has been obtained provide the correct choke valve opening.
(Refer to Figure 14).
CAUTION: A correction in the length of the link
Vacuum Kick Adjustment--(This test can be of .010 inch, will result in a change of .015 inch in
made On or Off the vehicle). the choke valve opening.
To make the vacuum kick adjustment, the vacuum
diaphragm must be energized (either a distributor As an example, if the choke valve opening is 0.015
testing machine with a vacuum source, or vacuum inch in error, the correction in the link length would
supplied by another vehicle). To make this adjust- be .010 inch.
ment, proceed as follows: A 2 inch micrometer will be helpful in establishing
the original length of the link, as shown in Figure 16,
before completing the adjustment.
valves far enough to allow the choke valve to be
moved to the closed position. (7) Install the choke operating link and recheck
the choke valve opening, using a gauge or drill (Refer
(2) Disconnect the vacuum hose from the dia- to Fig. 15).
phragm and connect the hose from the vacuum supp Reinstall the vacuum hose to the diaphragm and
as shown in Figure 15 (A minimum of 10 inches of
make the following check:
mercury (HG) will be required).
(3) Use a inch drill or gauge for Manual some clearance should exist between the choke opera-
Transmission or a YS inch drill or gauge for Auto- ting link and the choke lever slot, in both the open
matic Transmission and insert the gauge between
the choke valve and the wall of the air horn. Apply DRILL OR GAUGE
a slight closing pressure to the choke shaft.
drag is not obtained as the drill or gauge is being OF 10 INCHES
OF VACUUM
.,_cl LIGHT CLOSING PRESSURE
AGAINST VALVE
removed. REQUIRED d?

removal of the choke operating link.
CAUTION: Damage to the diaphragm and the
choke lever slot can result, if the link is not removed
for the bending operation.
(5) Remove the clip and disengage the choke
operating link from the diaphragm stem, then dis-
engage the link from the choke lever (The best bend- 64x277
ing results will be obtained by using a vise and a pair
of pliers). Fig. 1’SVacuum Kick Adjustment
CHOKE- VALVE CLOSED
and closed choke valve positions, as shown in Fig-
ure 17.
NOTE: This clearance is necessary to allow the
choke valve to close for starting as well as fully open
perature.
If a clearance does not exist in both of these posi-
tions, a recheck of the operating link adjustment
should be made.
NOTE: Free movement of the choke valve be=
tween the closed and open positions is very necessary.
This free movement should also exist between the
kick and the open choke valve positions with the
engine running. If binding does exist, the choke
operating link has been improperly bent and should
be corrected.
(9) Readjust the idle speed screw to obtain the
correct idle speed after making the adjustment.
ldle Speed Adjustment I Curb Idle I
To make the idle speed adjustment, the engine
must be thoroughly warmed up. A much more relia-
ble idle adjustment can usually be obtained if the Fig. 17-Choke Operating link Clearances
vehicle has been driven a minimum of five miles. For
the best results, it is recommended that a tachometer crank will exactly mate with the socket. Snap into
be used in this adjustment (Before making the idle place.
speed adjustment, observe the following precau- To make the idle speed adjustment, proceed as
tions:) follows:
Because the alternator can charge at idle speeds (1) Turn the idle speed screw in or out to obtain
and impose a load on the engine, the headlamps 550 rpm (Be sure that the choke valve is fully open
should be turned on the high beam. This will assure and that the fast idle adjusting screw is not contacting
setting the idle to compensate for the alternator the cam).
load. On vehicles equipped with automatic trans- (2) Adjust the idle mixture screw to obtain the
mission, unsnap the ball joint connection at the highest rpm. While making the adjustment, carefully
accelerator shaft bell crank. If this is not done, it is watch the tachometer and notice that the speed can
possible that the carburetor throttle will be held be decreased by turning the screw in either direction
open against the stop in the transmission. The carbu- from the setting that gave the highest rpm reading.
retor would therefore not respond to adjustment (3) From the highest idle speed setting, turn the
of the idle speed screw. After the proper idle speed mixture screw clockwise (leaner) until the speed starts
has been obtained at the carburetor, screw the ball to drop. Turn the screw in the opposite direction
joint connector up or down until the ball on the bell (counter-clockwise) just far enough to recover the
speed that was lost.
This procedure will assure that the idle has been
set to the leanest mixture possible for smooth idle.
This setting i s very important.
Since the correct speed was originally set using the
speed screw, the speed obtained after finding the
leanest smooth idle setting will probably be too fast.
(4) Readjust the speed screw to obtain the correct
idle speed. Repeat steps 2 and 3 above.
F a s t ldle Speed Adjustment (On the
Vehicle 1
Fig. 16-Choke Operating link Measurements To set the fast idle speed on the vehicle, connect a
tachometer to the vehicle, then set the curb idle speed.
(1) With the engine running, and the transmission
in the neutral position, open the throttle slightly.
(2) Close the choke valve about 20 degrees then
allow the throttle to close. Return the choke valve to
the open position.
(3) The fast idle speed adjusting screw should be
contacting the lowest step on the fast idle cam, as
shown in Figure 19.
(4) With the engine warmed-up to the normal
operating temperature, turn the fast idle speed ad-
STEP ON THE
justing screw in or out to secure 700 rpm. Reposition FAST IDLE CAM
the cam and throttle after every screw adiustment.
Choke Unloader t Wide Open Kick1

(1) Hold the throttle valve in the wide open posi- Fig. 19-Fast Idle Speed Adjustment (On the Vehicle)
tion, insert Tool T109-28 or X8'' drill between the
upper edge of the choke valve and the inner wall of
When installing the well type choke unit, be certain
the air horn, as shown in Figure 18.
that the coil housing does not contact the sides of the
(2) If no drag is felt, or if too much drag is ap- well in the exhaust manifold. Any contact at this
parent, bend the unloader tang on the throttle lever, point will affect choke operation. DO NOT lubricate
unti the correct clearance has been obtained. any parts of the choke or the control unit. This causes
an accumulation of dirt which will result in binding of
3. AUTOMATIC CHOKE-WELL TYPE the mechanism.
To function properly, it is important that all parts
be clean and move freely. Other than an occasional Spring Staged Choke Adjustment
cleaning, the choke requires no servicing. However, (1) Push on the hub lever with the finger, at the
it is very important that the choke control unit work closed choke position. A small opening should exist
freely in the well and at the choke shaft. Move the between the shaft and the hub levers, as shown in
choke rod up and down to test for free movemet in Figure 20.
the pivot. If the unit binds, a new choke unit should
be installed. (2) Using a drill or gauge, measure the opening.
The opening should be from .020 to .030 inches.
NOTE: The Well Type Choke Unit is serviced as
(3) If an adjustment is necessary, bend the hub
an assembly. Do not attempt to repair, or change the lever tang until the correct opening has been
setting.
obtained.
rRqr
DRILL OR GAUGE
STAGED SPRING
SHAFT HUB, LEVER
APPLY PRESSURE
O N HUB LEVER
BE
64x280
Fig. 18-Measuring the Choke Unloader Setting Fig. 20-Spring Staged Choke Adjustment
4. CLOSED CRANKCASE VENT SYSTEM the float so that the lip bears firmly against the needle.
Additional fuel may be admitted by slightly depress-
The closed crankcase ventilator valve is located in ing the float. If the fuel pressure in the line is
the crankcase vent tube cap and is connected to the insufficient to force additional fuel into the bowl, add
carburetor throttle body via a rubber tube. the necessary fuel from a clean container.
The function of the valve is to control the unburned
fuels that originate in the crankcase. The gases are CAUTION: Since the manifolds may be hot, it is
returned to the intake manifold, fed back into the dangerous to spill fuel on these surfaces. Therefore,
combustion chambers and then expelled out through take the necessary precautions to avoid spillage.
the exhaust system as completely burned products. (5) With only the pressure of the buoyant float
For servicing procedures of this valve, refer to holding the float lip against the inlet needle, measure
Group 9 “Engine” the float setting, using Tool T109-282 or T109-220;
or a “T” scale. There should be 34 inch from the
13. MEASURING THE FLOAT SETTIN- surface of the bowl (gasket removed) to the crown
(On the Vehicle) of the floats at the center (%/le”on Taxi).
If an adjustment is necessary, hold the float on the
To measure the float setting with the carburetor bottom of the bowl, then bend the float lip toward or
mounted on the vehicle, proceed as follows: away from the needle. Remeasure the % inch or Ka
(1) Remove the accelerator pump operating rod. inch taxi setting again, then repeat the lip bending
(2) Remove two of the long air horn attaching operation as required.
screws and two short screws, then install the two short CAUTION: When bemding the float lip, do not
screws in place of the two long screws removed. This allow the lip to push against the needle as the tip can
will hold the main body to the throttle body. Tighten be compressed sufficiently to cause a false setting
screws securely. which will affect correct level of the fuel in the bowl.
(3) Remove the remaining air horn screws, then After being compressed, the tip is very slow to recover
- tilt the air horn far enough to disengage the fast idle its original shape.
cam link from the fast idle cam. Remove the air horn It is very important that the float lip be perpen-
and gasket. dicular to the needle or slanted not more than 10
Measure the float setting as follows: degrees away from the needle when the float is cor-
(4) Seat the float fulcrum pin by pressing on the rectly set.
fulcrum retainer. (6) Reassemble the air horn as described previ-
There should be enough fuel in the bowl to raise ously.
BBD CARBURETOR 14-29
g
ROD IN INNER HOLE
BOWL VENT VALVE 4
FUEL INLET NEEDLE \T

VALVE AND SEAT
\THROTTLE LEVER
IDLE MIXTURE ADJUSTING SCREWS (2)

\ROD IN CENTER HOLE
ELEVATOR LEGS (SET OF 4) A, -'--
FAST IDLE CAM LINK CHOKE VALVE
FAST IDLE CAM CHOKE LEVER
THROTTLE LEVER
FAST IDLE DISTRIBUTOR

SPEED ADJUSTING VACUUM ADVANCE
SCREW TUBE FITTING
DIAPHRAGM STEM
IDLE SPEED
ADJUSTING SCREW
) (CURB IDLE)
\
CHOKE VACUUM
DIAPHRAGM
CLOSED CRANKCASE
VENT TUBE FITTING 64x254
Fig. 1-Carburetor Assembly (BBD 3682S, 36835)

14-30 BBD CARBURETOR
PART 3
CARBURETOR (BBD SERIES)

B B D 4 6 8 2 S AND BBD-3683s
Often, the carburetor is blamed for a great variety should be cleaned in a suitable solvent then inspect-
of trouble which is classed as “POOR CAR PER- ed for damage or wear.
F O R W C E . ” Therefore, be definitely sure that the
trouble is not located elsewhere before disassembling (3) Use air pressure only, to clean the orifices or
the carburetor. channels.
When overhauling the carburetor, several items of (4) Replace questionable parts with NEW ONES.
importance should be observed to assure a good job: When checking parts removed from the carburetor,
(1) The carburetor must be completely disassem- it is at times difficult to be sure they are satisfactory
bled. for further service. It is therefore recommended that
(2) All parts (except the diaphragm assembly) in such case, NEW parts be installed.
SERVICE PROCEDURES
Disassembly (Fig. I 1 separate item. A liquid cleaner may damage the dia-
(1) Place the carburetor assembly on the repair phragm material.
block To01 C-3225.
(7) Remove the air horn retaining screws and lift
(2) Remove the hairpin clips and disengage the the air horn straight up and away from the main
accelerator pump operating rod. body, as shown in Figure 2. Discard the gasket.
(3) Remove the hairpin clip and disengage the (8) Disengage the accelerator pump plunger from
fast idle connector rod from the fast idle cam and the rocker arm by pushing up on the bottom of
choke lever. plunger and sliding the plunger shaft off the hook.
(4) Remove the vacuum hose between the carbu- Slide the plunger out of the air horn and remove the
retor main body and the vacuum diaphragm. bowl vent valve, spring seat and spring.
(5) Remove the clip from the choke operating link If the old plunger can be used again, or if a new
and disengage the link from the diaphragm plunger plunger is to be installed, place the plunger in a jar
(stem) and the choke lever. of clean gasoline or kerosene to prevent the leather
STEP-UP PISTON
AIK n v m GA
‘ F .
ON
63x474
Fig. &Removing or Installing the Air Horn Fig. LRernoving or Installing Step-up Piston
~~ ~
from drying out.

(9) Remove the fuel inlet needle valve, seat and
gasket from the main body.
(10) Lift out the float fulcrum pin retainer, then
lift out the floats and fulcrum pin.
(11) Remove the step-up piston retaining screw,
and slide the step-up piston and rods out of the well,
as shown in Figure 3. Lift out the step-up piston
spring. Remove the step-up piston gasket from the
bottom of the well.
(12) Remove the main metering jets and gaskets,
as shown in Figure 4.
(13) Remove the venturi cluster screws then lift CLUSTER SCREWS
64 x 255
the venturi cluster and gaskets up and away from the
main body, as shown in Figure 5. Discard the gaskets. Fig. 5-Removing or Installing Venturi Cluster
Do not remove the idle orifice tubes or main vent
tubes from the cluster. They can be cleaned in a and throttle body and the component parts of each
solvent and dried with compressed air. disassembled as far as necessary for cleaning and
(14)Invert the carburetor and drop out the accel- inspection.
erator pump discharge check ball.
Cleaning the Carburetor Parts
(15) Remove the idle mixture adjusting screws
and springs from the throttle body. The recommended solvent for gum deposits is dena-
(16) Remove the screws that attach the throttle tured alcohol which is easily obtainable. However,
body to the main body. Separate the bodies and dis- there are other commercial solvents which may be
card the gasket. used with satisfactory results.
It is usually not advisable to remove the throttle The choke diaphragm can be damaged by solvents.
shaft or valves from the throttle body, unless wear Avoid placing the diaphragm assembly in ANY
or damage necessitates .the installation of new parts. liquid. Clean the external surfaces with a clean cloth
or soft wire brush. Shake dirt or foreign material
(17) Test the freeness of the choke mechanism in from the stem side of the diaphragm. Depressing the
the air horn. The choke shaft must float free to diaphragm stem (plunger) to the retracted position,
operate correctly. If the choke shaft sticks in the will provide an additional hole for the removal of
bearings, or appears to be gummed from deposits in dirt. Compressed air can be used to remove loose dirt
the air horn, a thorough cleaning will be required. but should not be connected to the vacuum inlet
The carburetor now has been disassembled into fitting.
three main units, nariiely, the air horn, main body
IMPORTANT: If the commercial solvent or
cleaner recommends the use of water as a rinse, it
li
should be "HOT". After the rinsing, all trace of
water must be blown from the passages with air pres-
sure. It i s further advisable to rinse all parts in clean
kerosene or gasoline to be certain no trace of moisture
remains. Never clean jets with a wire, drill or other
mechanical means, because the orifices may become
enlarged, making the mixture too rich for proper per-
formance.
fnspecting and Reassembly-

Throttle Body
(1) Inspect the throttle shaft for excessive wear in
the throttle body. (I€ wear is extreme, it is recom-
mended that the throttle body assembly be replaced
rather than installing a new shaft in the old body).
Fig. &Removing or Installing Main Metering Jets During manufacture, the location of the idle trans-
the valves in place, with the fingers pressing on the

IDLE TRANSFER PORTS high sides of the valves. Tap the valves lightly with
n
THROTTLE VALVES SPARK ADVANCE
a screw driver to seat valves in the throttle bores.
Tighten the screws securely and stake by squeezing
with pliers.
(7) Install the idle mixture screws and springs in
the throttle body. (The tapered portion must be
straight and smooth. If the tapered portion is grooved
or ridged, new idle mixture screws should be installed
to insure having the correct idle mixture control). Do
Not Use a Screw Driver. Turn the screws lightly
against their seats with the fingers. Back off 1full turn
for approximate adjustment.
Main Body
Fig. &Ports in Relation to Throttle Valves (1) Invert the main body and place a new gasket
in position, then place the throttle body on the main
fer port and the spark advance control ports to the body and align. Install screws and tighten securely.
throttle valve, is carefully established for one partic- (2) Install the accelerator pump discharge check
ular assembly. (See Fig. 6). ball in the discharge passage, as shown in Figure 7.
If a new shaft should be installed in an old, worn To test the accelerator pump system; fuel inlet and
throttle body, it would be very unlikely that the orig- discharge check balls, proceed as follows:
inal relationship of the ports to the valves would be (3) Pour clean gasoline into the carburetor bowl,
obtained. Changing the relationship of the valves to approximately VZ inch deep. Remove the pump
the ports would adversely affect normal car opera- plunger from the jar of gasoline and slide it down into
tion between the speed of 15 and 20 miles per hour. the pump cylinder. Raise the plunger and press light-
However, if it has been determined that a new shaft ly on the plunger shaft to expel1 air from the pump
or valves is to be installed, adhere to the following passage.
instructions:
(4) Using a small clean brass rod, hold the dis-
(2) Mark the position of the throttle valves to the charge check ball down firmly on its seat. Again raise
shaft, then slide the valves out of the bores. the plunger and press downward. No fuel should be
CAUTION: These screws are staked on the op- emitted from either the intake or discharge passage,
posite side and care should be used at removal so as as shown in Figure 8.
not to break off in the shaft. If any fuel does emit from either passage, it indi-
(4) Slide the throttle shaft out of the throttle body. cates the presence of dirt or a damaged check ball.
Remove the fast idle speed screw lever. Clean the passage again and repeat test. If leakage
(5) Slide the fast idle speed screw lever over the
new throttle shaft and insert into the throttle body. !#I NO FUEL---
TO BE EMITTED
(6) Install the throttle valves in their respective
bores (with the valve numbers toward manifold
flange). Install NEW screws but do not tighten. Hold
h 'NO FUEL
TO BE EFlTTE
)ISCHARGE PASSAGE
I 64x256
Fig. 7-Installing Accelerator Pump Discharge Fig. 8-Testing Accelerator Pump Intake and Discharge
Check Ball Check Balls
BBD CAR8URETOR 14-33
is still evident, install a new check ball. The fuel inlet
check ball is located at the bottom of the plunger well
and should rattle freely when the carburetor is shak-
en. Remove the fuel from the bowl.
(5) Install new gaskets on the venturi cluster, then
install in position in the main body. (Refer to Fig. 5).
Install the idle bleed screws and tighten securely.
(6) Install the main metering jets and gaskets,
tighten securely. (Refer to Fig. 4).
(7) Before installing the step-up piston, be sure
the step-up rods are able to move freely each side of
the vertical position, as shown in Figure 9. The step-
up rods must be straight and smooth.
FLOAT GAUGE 63x480
(8) Slide the step-up piston gasket down into po- 0
sition in the piston well, then install the s,tep-up pis- Fig. 10-Measuring the Float Setting
ton spring and step-up piston and rods. Carefully
guide the step-up rods into the main metering jets.
(Refer to Fig. 3). Install the retaining screw and To correctly set the float height, when the carbu-
tighten securely. retor is being overhauled, proceed as follows:
A step-up piston stuck in the UP position will (1) Install the floats with the fulcrum pin and pin
cause a rich mixture at part throttle a piston stuck retainer in the main body.
in the DOWN position will cause a lean mixture at (2) Install the needle, seat and gasket in the body
wide open throttle and poor acceleration. and tighten securely.
Measuring the Float Setting (3) Invert the main body so that the weight of the
floats only, is forcing the needle against the seat. Hold
The carburetors are equipped with a synthetic a finger against the retainer to fully seat the fulcrum
rubber tipped fuel inlet needle. The needle tip is a pin.
rubber material which is not affected by gasoline (4) Using Tool T109-282 or a “T” scale, measure
and is stable over a wide range of temperatures. The the float, as shown in Figure 10. There should be v4
tip is flexible enough to make a good seal on the inch from the surface of the fuel bowl to the crown
needle seat, and to give increased resistance to of each float at the center.
flooding. If an adjustment is necessary, hold the floats on
The use of this inlet needle requires a new pro- the bottom of the bowl and bend the float lip toward
cedure in adjusting the float setting. Care should be or away from the needle. Remeasure the 34 inch set-
taken to perform this accurately in order to secure the
ting again then repeat the lip bending operation as
best performance and fuel economy. required.
SPRING SEAT
BOWL VENT VALVE

r? BOWL VENT VALVE
OPERATING CLIP 3 CLIP POSITIONS (3)
a
a
STEP-UP RODS MGSTMOVE FREELY 6Ox120A 60x122
Fig. 9-Step-up Piston and 2 Stage Rods Fig. 1 1-Accelerator Pump Assembly
14-34 BBBD CARBURETOR
CAUTION: When bending the float lip, do not

allow the lip to push against the needle as the syn-
thetic rubber tip can be compressed suficiently to
cause a false setting which will affect correct level of
fuel in the bowl. After being compressed the tip i s
very slow to recover its original shape.
It is very important that the float lip be perpendic-
ular to the needle or slanted not more than ten de-
grees away from the needle when the float is set
correctly.
Air Horn
(1) Assemble the pump plunger, spring and spring
seat, as shown in Figure 11. Slide the plunger shaft
through the opening in the air horn. Install the bowl
vent valve over the plunger shaft, then engage with Fig. 12-Measuring Bowl Vent Opening
the pump rocker arm.
medium and short pump stroke holes in the throttle
(2) Place a new gasket on the main body, then in-
lever. Normally, the bowl vent clip on the pump stem
stall the air horn (Refer to Fig. 2). Install attaching
will be at the middle notch and the pump operating
screws and tighten securely. (When installing air horn,
rod in the medium stroke hole.
be sure the leather on the plunger does not fold back).
The proper procedure is to adjust the amount of
(3) Engage the fast idle connector rod in the bowl vent opening instead of measuring and setting
choke lever and fast idle cam. Secure with the hair- the height of the pump plunger.
pin clip. (1) To test or set the adjustment; back off the idle
(4) Engage the accelerator pump operating rod in speed adjusting screw. Open the choke valve so that
the inner hole in the rocker arm and in the center the fast idle cam allows the throttle valves to be com-
hole in the throttle lever (Refer to Fig. 1). Install pletely seated in the bores.
clips to secure. (2) Be sure the pump operating rod is in the me-
lnstalling the Vacuum Diaphragm dium stroke hole in the throttle lever, and that the
bowl vent clip on the pump stem is in the center
(1) Install the diaphragm assembly on the air horn
notch.
and tighten the attaching screws securely.
(2) Install the choke operating link in position be-
just possible to insert a l/le inch drill between the
bowl vent and its seat, as shown in Figure 12.
lever. Install the clip to secure.
3 an adjustment is necessary, bend the pump op-
(3) Inspect the vacuum diaphragm fitting and re-
move any dirt or foreign material which could plug L-GAUGE
OR DRILL
the passage. Inspect the rubber hose for cracks, before LIGHT CLOSING PRESSURE
ON CHOKE VALVE
placing it on the correct fitting. (Refer to Fig. 1).
Do not connect the vacuum hose to the diaphragm
fitting until after the vacuum kick adjustment has
been made. (See Carburetor Adjustments). h FAST IDLE SPEED
2. CARBURETOR ADJUSTMENTS
It is very important that the following adjustments
be made on a reconditioned carburetor, and in the
sequence listed:
Accelerator Pump and Bowl Vent
horn, note that the hairpin clip (which opens the bowl
If1 - -
SCREWY
64 x 258
vent) can be placed in any one of the three position-
ing notches. These notches correspond to the long, Fig. 1 L F a r t Idle Cam Position Adjustment
erating rod, using Tool T109-213, at the lower angle, testing machine with a vacuum source, or vacuum
until the correct bowl vent opening has been obtained. supplied by another vehicle).
This is an important adjustment, since too much (1) With the engine Not running, open the throttle
lift at the bowl vent will result in considerable loss in valves far enough to allow the choke valve to be
low speed fuel economy. moved to the closed position.
If the pump operating rod is moved to either the
short or long stroke position, a corresponding change
phragm and connect the hose from the vacuum sup-
must be made in the location of the bowl vent clip, ply, as shown in Figure 14. (A minimum of 10 inches
and the amount of lift of the bowl vent remeasured of mercury (HG) will be required).
and adjusted.
The acceleration pump travel is automatically taken (3) Insert a 3/16 inch (Manual Transmission)
care of when the bowl vent is properly adiusted. and (Automatic Transmission) size drill or gauge
between the choke valve and the wall of the air
Fast ldle Speed and Cam Position horn. (Refer to Fig. 14). Apply a slight closing
Adjustment pressure to the choke shaft.
The fast idle engine speed adjustment should be (4) An ajustment will be necessary if a slight
made on the car, as described in the paragraph “Fast drag is not obtained as the drill or gauge is being re-
Idle Speed Adjustment”. However, the Fast Idle Cam moved.
Position Adjustment can be made on the bench. The adjustment of this opening will require the re-
(1) With the fast idle speed adjusting screw con- moval of the choke operating link.
tacting the lowest step on the fast idle cam, as shown CAUTION: Damage to the diaphragm and the
in Figure 13, move the choke valve toward the closed choke lever slot can result, if the link is not removed
position with light pressure. Insert a drill or gauge for the bending operation.
between the choke valve and the wall of the air horn. (5) Remove the clip and disengage the choke
(Refer to specifications for drill or gauge size). operating link from the diaphragm stem, then dis-
(2) An adjustment will be necessary if a slight engage the link from the choke lever. (The best bend-
drag is not obtained as the drill or gauge is being ing results will be obtained‘ by using a vise and a pair
removed. of pliers).
(3) If an adjustment is necessary, bend the fast (6) Bend the choke operating link at the angle to
idle rod at the upper angle, using Tool T109-213, provide the correct choke valve opening.
until the correct valve opening has been. obtained.
(Refer to Fig. 13). CAUTION: A correction in the length of the link
of .010 inch, will result in a change of .015 inch in
Vacuum Kick Adjustment-This test can be made the choke valve opening.
On or Off the vehicle.)
To make the vacuum kick adjustment, the vacuum As an example, if the choke valve opening is 0.015
diaphragm must be energized (either a distributor inch in error, the correction in the link length would
be .010 inch.
LIGHT CLOSING PRESSURE
A “2” inch micrometer will be helpful in establish-
ON CHOKE VALVE ing the original length of the link, as shown in Figure
15, before completing the adjustment.
MINIMUM OF
10 INCHES OF OR DRILL
(7) Install the choke operating link and retest the
VACUUM ON
DIAPHRAGM
TO VACUUM
SOURCE
I
:HOKE
- urERATlNG
LINK
RETRACTED BY 64 x 259
Fig. 1 L T e s t i n g the Choke Vacuum Kick Fig. 1’5-Choke Operating link Measurements
CHOKE VALVE
Fig. 17-Measuring the Choke Unloader Setting
sition. Insert Tool T109-31 or Vq” drill shank between

the upper edge of the choke valve and the inner wall
0
of the air horn, as shown in Figure 17.
(2) If no drag is felt, or if too much drag is ap-
parent bend the unloader tang on the throttle lever,
until the correct clearance has been obtained.
Fig. 16-Choke Operating link Clearances ldle Speed Adjustment (Curb idle 1
To make the idle speed adjustment, the engine must
choke valve opening, using a gauge or drill. (Refer to be thoroughly warmed up. A much more reliable idle
Figure 14). adjustment can usually be obtained if the vehicle has
Reinstall the vacuum hose to the diaphragm and been driven a minimum of five miles. For the best
make the following check: results, it is recommended that a tachometer be used
in this adjustment. (Before making the idle speed
adjustment, observe the following precautions:)
some clearance should exist between the choke oper- Because the alternator can charge at idle speeds
ating link and the choke lever slot, in both the open and impose a load on the engine, the headlights
and closed choke valve positions, as shown in Figure should be turned on (high beam). This will assure
16.
setting the idle to compensate for the alternator load.
NOTE: This clearance is necessary to allow the On vehicles equipped with the automatic transmis-
choke valve to close for starting as well as fully open sion, disconnect the transmission control rod from the
after the engine reaches the normal operating tem- ball joint on the carburetor lever so that the stop in
perature. the transmission will not interfere with the free move-
If a clearance does not exist in both of these posi- ment of the carburetor throttle lever.
tions, a recheck of the operating link adjustment (1) To make the idle speed adjustment, turn the
should be made. idle speed screw in or out to obtain 500 rpm (On
NOTE: Free movement of the choke valve be-
vehicles with air conditioning set the idle speed at
500 rpm, with air condition On).. Be sure that the
tween the c l d and open positions is very necessary.
choke valve is fully open and that the fast idle ad-
This free movement should also exist between the justing screw is not contacting the fast idle cam.
kick and the open choke valve positions with the
(2) Turn each idle mixture screw to obtain the
engine running. If binding does exist, the choke oper-
highest rpm. While making the adjustment, carefully
ating link has been improperly bent and should be
watch the tachometer and notice that the speed can
corrected.
be decreased by turning the screws in either direction
Choke Unlouder t W i d e Open Kick) from the setting that gave the highest rpm reading.
(1) Hold the throttle valves in the wide open po- (3) Readjust to 500 rpm with the idle speed screw.
(4) Turn each idle mixture adjusting screw in the
clockwise direction (leaner) until there is a slight
drop in rpm. Turn each screw out counter-clockwise
(richer) just enough to regain the lost rpm.
set to the leanest mixture possible for smooth idle.
This setting is very important.
Since the correct speed was originally set using the
speed screw, the speed obtained after finding 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 if necessary. After
the proper idle speed has been obtained, refer to
Figure 3 of the “Throttle Linkage” on Page 73 for
the procedure on adjusting the transmission control
rod.
Fig. 1’8-Fast ldle Speed Adjustment (On the Vehicle)
Fast ldle Speed Adjustment I On the
Vehicle 1 pivot. If the unit binds, a new choke unit should be
To set the fast idle speed on the vehicle, connect a installed.
tachometer to the vehicle, then set the curb idle
speed. NOTE: The Well Type Choke Unit, is serviced as
(1) With the engine running and the transmission an assembly. Do not attempt to repair.
in the neutral position, open the throttle slightly. When installing the well type choke unit be certain
(2) Close the choke valve about 20 degrees then that the coil housing does not contact the sides of the
allow the throttle to close. Return the choke valve to well in the intake manifold. Any contact at this point
the open position. will affect choke operation. Do Not Lubricate any
(3) The fast idle speed adjusting screw should be parts of the choke or the control unit. This causes an
contacting the lowest step on the fast idle cam, as accumulation of dirt which will result in binding of
shown in Figure 18. the choke mechanism.
(4) With the engine warmed-up to the normal
operating temperature, turn the fast idle speed adjust- 4. CLOSED CRANKCASE VENT SYSTEM
ing screw in or out to secure 700 rpm. Reposition the The closed crankcase ventilator valve is located in
tam and throttle after each screw adjustment. the crankcase vent tube cap and is connected to the
carburetor throttle body via a rubber tube.
3. A U T O M A T I C CHOKE-WELL TYPE The function of the valve is to control the unburned
To function properly, it is important that all parts fuels that originate in the crankcase. The gases are
be clean and move freely. Other than an occasional returned to the intake manifold, fed back into the
cleaning, the choke requires no servicing. However, combustion chambers and then expelled out through
it is very important that the choke control unit work
freely in the welli ana* at’ tne
’’ cnoKe * -’ Move tne
‘ ‘ snart.
.. - .. .
For servicing proceaures OI~ -”
tnis valve, refer to
I
..?
_
choke rod up an(1 down to check movement on the Group 9, “Engine”.
CARBURETOR B B D 3684s
Dirt, dust, water and gummy deposits are some of All parts (except the choke diaphragm) should be
the main causes for Poor mrburetor operation- Proper carefully cleaned in a suitable solvent and inspected
cleaning, however, and installation of new parts, for damage and wear. Replace questionable parts with
where required, will return the carburetor to its
newones.
originally designed performance.
When overhauling the carburetor, several items of Use air Pressure Only, to clear the v~fiousofifices
importance should be observed to assure a good job. and passages.
BOWL VENT VALV CHOKE LEVER
CHOKE VACUUM DIAPHRAGM
UNLOADER TANG
FAST IDLE CAM

CLOSED CRANKCASE VENT FITTING
ACCELERATOR PUMP ROD
FAST IDLE LEVER
FAST IDLE SPEED ADJUSTING SCREW
FAST IDLE CONNECTOR ROD
THROTTLE LEVER IDLE SPEED SCREW (CURB IDLE)

CHOKE VALVE
\ CHOKE LEVER
FAST IDLE SPEED

ADJUSTING SCREW \ CARBURETOR IDENTIFICATION TAG
MAIN BODY
CHOKE VACUUM DIA DISTRIBUTOR VACUUM

ADVANCE TUBE FITTING
THROTTLE BODY
3-
ELEVATOR LEGS (SET OF 4)
CLOSED CRANKCASE VENT FITTING

64x241
Fig. 1-Carburetor Assembly (BBD 36849

SERVICE PROCEDURES
1 CARBURETOR BBD-3684s VENTURI CLUSTER
Disassembly (Fig. I I
(1) Insert three elevating legs Tool T109-287s and
one elevating leg Tool T109-288s through the car- SPECIAL TOOL
buretor throttle body stud holes (These tools are used
to protect the throttle valves from damage and to ACCELERATOR
provide a suitable base for working). PUMP INTAKE
(2) Remove the hairpin clip and disengage the CHECK BALL
fast idle connector rod from the throttle and fast idle
ACCELERATOR
levers. PUMP INTAKE PASSAGE
(3) Remove the hairpin clip and disengage the
accelerator pump rod from the throttle lever and the QlMAiN
METERING JETS 64x242
pump rocker arm.
Fig. 3-Removing or Installing Main Metering Jets
(4) Remove the vacuum hose between the carbu-
retor throttle body fitting and the vacuum diaphragm.
( 5 ) Remove the pin spring from the choke oper- of clean gasoline or kerosene to prevent the leather
ating link and disengage the link from the diaphragm from drying out.
plunger (stem) and the choke lever. (Refer to Fig. 1). (9) Remove the fuel inlet needle valve, seat and
(6)Remove the vacuum diaphragm and bracket gasket from the main body.
assembly and place to one side, to be cleaned as a (10) Lift out the float fulcrum pin retainer, and
separate item. A liquid cleaner may damage the dia- lift out the floats and fulcrum pin.
phragm material. (11) Remove the step-up piston and retaining screw
(7) Remove the air horn retaining screws and lift and slide the step-up piston and rods out of well, as
the air horn straight up and away from the main shown in Figure 2. Lift out the step-up piston spring.
body. Discard the gasket (2 screws recessed). Remove the step-up piston gasket from the bottom of
(8) Disengage the accelerator pump plunger from the well.
the accelerator pump arm by pushing up on the bot- (12) Remove the main metering jets and gaskets,
tom of the plunger and sliding the plunger shaft off as shown in Figure 3.
the hook. Slide the plunger out of the air horn and (13) Remove the venturi cluster screws, then lift
remove the compression spring and seat. the venturi cluster and gaskets up and away from the
If the old plunger can be used again or if a new main body, as shown in Figure 4. Discard the
plunger is to be installed, place the plunger in a jar gaskets.
TUBE FITTING DISCHARGE

PASSAGE
STEP-UP PISTO L AND CHECK
BALL
.IN METERING
IETC
,I.I"
STEP-UP P I S T ~ N GASKET
(AT BOTTOM OF WELL) SCREWS
RETAINING SCREW A 63x438 64x243
Fig. 2-Removing or Installing Step U p Piston Fig. &Removing or Installing Venturi Cluster
NOTE: Do not remove the idle orifice tubes or original relationship of the ports to the valves would
the main vent tubes from the cluster. They can be be obtained. Changing the relationship of the valves
cleaned in a solvent and dried with compressed air. to the ports would adversely affect normal vehicle
(14) Invert the carburetor and drop out the accel- operation between the speeds of 15 and 30 miles per
erator pump discharge check ball. hour. If it has been determined, however, that a new
shaft or valve is to be installed, adhere to the fol-
(15) Remove the idle mixture adjusting screws
and springs from the throttle body. lowing instructions.
(2) Mark the position of the throttle valves in the
(16) Remove the screws that attach the throttle
bores. Be sure the idle speed screw is backed off.
body to the main body. Separate the bodies and dis-
card the gasket. (3) Remove the screws that hold the throttle valves
to the shaft and slide the valves out of the bores.
three sub-assemblies, the air horn, main body and NOTE: These screws are staked on the opposite
throttle body and the components of each disassem- side and care should be used a t removal so as not to
bled as far as necessary for cleaning and inspection. break off in the shaft. Remove the staked end of the
It is usually not advisable to remove the throttle screws with a file.
shaft or valves from the throttle body, unless wear or (4) Slide the throttle shaft and lever out of the
damage necessitates the installation of new parts. body.
Cleaning the Curburetor Parts (5) Install a new throttle shaft and lever.
The recommended solvent for gum deposits is de- (6) Install the throttle valves in their respective
natured alcohol which is easily obtainable. However, bores (with the valve numbers toward the manifold).
there are other commercial solvents which may be Install new screws but do not tighten. Hold the valves
used with satisfactory results. in place, with the fingers pressing on the high sides of
The'choke diaphragm can be damaged by solvents. the valves. Tap the valves lightly with a screw driver
Avoid placing the diaphragm assembly in ANY liquid. to seat in the throttle bores. Tighten the screws
Clean the external surfaces with a clean cloth or soft securely and stake by squeezing with pliers.
wire brush. Shake dirt or other foreign material from (7) Install the idle mixture screws and springs in
the stem side of the diaphragm. Depressing the dia- the throttle body. (The tapered portion must be
phragm plunger (stem) to the retracted position, will straight and smooth. If the tapered portion is grooved
provide an additional hole for the removal of dirt. or ridged, new idle mixture screws should be installed
Compressed air can be used to remove loose dirt but to insure having correct idle mixture control.) Do
should not be connected to the vacuum inlet fitting. Not Use a Screw Driver. Turn the screws lightly
IMPORTANT: If the commercial solvent or against their seats with the fingers. Back off one full
cleaner recommends the use of water as a rinse it turn for approximate adjustment.
should be "HOT". After the rinsing, all trace of water
must be blown from the passages with air pressure. It Muin Body
is further advisable to rinse all parts in clean kerosene (1) Invert the main body and place a new gasket
or gasoline to be certain no trace of moisture remains. in position and place the throttle body on the main
Never clean jets with a wire, drill or other mechanical body and align. Install screws and tighten securely.
means, because the orifices may become enlarged,
making the mixture too rich for proper performance. IDLE TRANSFER PORTS SPARK ADVANCE PORT
lnspection and Reassembly-

Throttle Body
(1) Inspect the throttle shaft and throttle body
for excessive wear. If either or both are worn to the
point where the carburetor operation will be affected,
replace as required. VENT HOLE
fer port and the spark advance control ports to the
throttle valve, is carefully established for one par-
ticular assembly. @efer to Figure 5.) VENT HOLE THROTTLE VALVES 64x244
If a new shaft should be installed in an old worn
throttle body, it would be very unlikely that the Fig. %Ports in Relation to Throttle Valves
ACCELERATOR (8) Slide the step-up piston gasket down into posi-
PUMP tion in the piston well, then install the step-up piston
/ PLUNGER
spring, step-up piston and rods. Carefully guide the
step-up rods into the main metering jets (Fig. 2.) In-
NO FUEL T O
BE EMITTED stall the retaining screw and tighten securely. Test the
i PAST PUMP
INTAKE
CHECK
BALL
piston for free operation in the well.
Install the retaining screw and tighten securely.
Test the piston for free operation in the well.
A step-up piston stuck in the Up position will cause
N
‘;O FUEL
TO BE
a rich mixture at part throttle; a piston stuck in
ZMlTTED PAST the Down position will cause a lean mixture at wide
DISCHARGE open throttle and poor acceleration.
CHECK
BALL Measuring the Float Setting
64x245 The carburetors are equipped with a rubber-tipped
Fig. &Testing Accelerator Pump Intake and fuel inlet needle. The rubber tip is flexible enough to
Discharge Check Balls make a good seal on the needle seat, and to give in-
creased resistance to flooding.
The use of the rubber tipped needle requires care
(2) Install the accelerator pump discharge check to perform the float setting operation accurately in
ball in the discharge passage and test the accelerator order to secure the best performance and fuel econ-
pump system; fuel inlet and discharge check balls as omy.
follows:
(1) To correctly set the float height when the
(3) Pour clean gasoline into the carburetor bowl, carburetor is being overhauled, install the floats with
approximately Y2 inch deep. Remove the pump the fulcrum pin and pin retainer in the main body.
plunger from the jar of gasoline, flex the leather
several times, then silde it down into the pump cylin- (2) Install the rubber-tipped needle, seat and gas-
der. Raise the plunger and press lightly on the ket in the body and tighten securely.
plunger shaft to expel1 all air from the pump passage. (3) Invert the main body so that the weight of
the float only is forcing the needle against the seat.
charge check ball down firmly on its seat. Again raise Hold a finger against the retainer to fully seat the
fulcrum pin.
the plunger and press downward. No fuel should be
emitted from either the intake or discharge passage, (4) Using Tool T109-282, or a “T” scale, measure
as shown in Figure 6. the float, as shown in Figure 8. There should be 5/le
If any fuel does emit from either passage, it indi- inch from the surface of the fuel bowl to the crown
cates the presence of dirt or a damaged check ball of each float at the center.
seat. Retest the passage again and repeat the test. If If an adjustment is necessary, hold the floats on
leakage is still evident, install a new check ball. The
fuel inlet check ball is located at the bottom of the
plunger well.
(5) Install new gaskets on the venturi cluster, and
install in position in the main body. Install the cluster
screws and tighten securely. Test pump discharge by
pressing pump plunger down. Two fine streams of fuel
should be forced from the cluster. If either stream is
restricted or diverted, remove cluster and reclean.
After test, pour the fuel from the bowl and remove
the pump plunger.
(6) Install the main metering jets and gaskets.
Tighten securely. (Refer to Fig. 3.)
(7) Before installing the step-up piston, be sure 60x106
the step-up rods are able to move freely, each side of STEP-UP RODS MUST MOVE FREELY
the vertical position, as shown in Figure 7. The step-
up rods must be straight and smooth. Fig. 7-Step Up Rods Fme Play
GAUGE TOUCHING
CROWN OF FLOAT /nsfalllng the Vacuum Dlcrphrgam
AT THE CENTER
(1) Install the diaphragm assembly on the air
horn and tighten the attaching screws securely.
(2) Install the choke operating link in position
between the diaphragm plunger (stem) and the choke
lever. Install the pin spring to secure.
the passage. Inspect the rubber hose for cracks, before
placing it on the correct fitting. (Refer to Fig. 1.)
I
ONLY WEIGHT OF FLOAT
FLOAT GAUGE been made. (See Carburetor Adjustments.)
AGAINST NEEDLE 63x443
Fig. 8-Measuring the Float Setting 2. CARBURETOR ADJUSTMENTS
the bottom of the bowl and bend the float lip toward It is very important that the following adjustments
or away from the needle. Reset the 5/la inch setting are made on a reconditioned carburetor and in the
again and repeat the lip bending operation as re- sequence listed:
quired. Accelerator Pump
CAUTION: When bending the float lip, do not (1) Back off the idle speed adjusting screw. Open
allow the lip to push against the needle as the synthet- the choke valve so that the fast idle cam allows the
ic rubber tip can be compressed sufficiently to cause a throttle valves to be completely seated in the bores.
false setting which will affect correct level of fuel in Be sure that the pump connector rod is installed in
the bowl. After being compressed, the tip is very slow the center hole of the throttle lever.
to recover its original shape. (2) Close the throttle valves tightly. Measure the
It is very important that the float lip be perpendic- distance between the top of the air horn and the end
ular to the needle or slanted not more than ten de- of plunger shaft, as shown in Figure 9. This meas-
grees away from the needle when the float height is urement should be 1” + or - l/s4 inch.
correct.
(3) To adjust the pump setting, bend the pump
Air Horn connector rod, using Tool T109-213, at the lower
(1) Test the freeness of the choke mechanism in angle of rod, until the correct travel has been ob-
the air horn. The choke shaft must float free to tained.
operate correctly. If the choke shaft sticks in the Fast /die Speed and Cam Posltlon
bearings, or appears to be gummed from deposits in Adjustment
the air horn, a thorough cleaning will be required. The fast idle engine speed adjustment should be
(2) Remove the accelerator pump plunger from
the gasoline, slide the compression spring and spring
seat over the shaft. Install the assembly in the air
horn and engage with the accelerator pump arm.
(3) Place a new gasket on the main body, and
install the air horn. Install attaching screws and
tighten securely. (When installing the air horn, be
sure the leather on the plunger does not wrinkle or
fold back).
(4) Engage the accelerator pump rod with the
pump rocker arm and install the loose end in the
center hole of throttle level. Install the hairpin clip to
secure.
(5) Engage the fast idle connector rod in the fast
idle lever and throttle lever. Install the hairpin clip to 64x246
secure. Fig. 9-Measuring Accelerator Pump Travel
DRILL OR GAUGE AT
Vacuum Kick Adiustment-(This test can be made
On or Off the vehicle).
LIGHT FINGER PRESSURE
CLOSING CHOKE VALVE To make the vacuum kick adjustment, the vacuum
diaphragm must be energized (either a distributor
testing machine with a vacuum source, or vacuum
supplied by another vehicle).
PEED moved to the closed position.
ply, as shown in Figure 11. (A minimum of 10 inches
of mercury (HG) will be required).
(3) Insert a I/l/s4 inch drill or gauge between the
choke valve and the wall of the air horn. (Refer to
Fig. 11).Apply a slight closing pressure to the choke
shaft to hold the drill or gauge in position.
CAM SCREW (4) An adjustment will be necessary if a slight
Fig. lOLFast Idle Cam Position kdjustrnent drag is not obtained as the drill or gauge is being
removed.
made on the car, as described in the paragraph “Fast removal of the choke operating link.
Idle Speed Adjustment”. However, the Fast Idle Cam
Position Adjustment can be made on the bench. CAUTION: Damage to the diaphragm and the
choke lever slot can result, if the link i s not removed
(1) With the fast idle speed adjusting screw con- for the bending operation.
in Figure 10, move the choke valve toward the closed (5) Remove the pin spring and disengage the
position with light pressure. Insert a inch drill choke operating link from the diaphragm stem
or gauge between the choke valve and the wall of the (plunger), then disengage the link from the choke
air horn. lever. (The best bending results will be obtained by
using a vise and a pair of pliers).
(2) An adjustment will be necessary if a slight drag
is not obtained as the drill or gauge is being removed. (6) Bend the choke operating link at the angle to
provide the correct choke valve opening.
(3) If an adjustment is necessary, bend the stop
on the choke shaft, using Tool T109-22 until the CAUTION: A correction in the length of the
correct valve opening has been obtained. (Refer to link of .010 inch, will result in a change of .015 inch
Fig. 10). in the choke valve opening.
DRILL OR GAUGE AT (7) Bend the choke operating link to provide the
WIDEST CHOKE OPENING correct choke valve opening. (A correction in the
w
length of the link of .010 inch, will result in a change
LIGHT CLOSING CHOKE of .010inch in the choke valve opening).
PRESSURE BY FINGER d L ,OPERATING
LINK CHOKE OPERATING LINK
/
DIAPHRAGM m DISTRIBUTOR
VACUUM
ADVANCE
BY Be&
VACUUM-K, TUBE FITTING
CHOKE
TUBE FITTING
64x248 64x249
Fig. 1 1-Measuring the Choke Vacuum Kick Setting Fig. 12-Choke Operating link Measurements
CLEARANCE AT OPEN CHOKE CHOKE VALVE WIDE OPEN some clearance should exist between the choke oper-
I ,1/ ating link and the choke lever slot, in both the open
and closed choke valve positions, as shown in Figure
13.
I a d a
perature.
CLEARANCE AT CLOSED CHOKE CHOKE VALVE CLOSED
\ / should be made.
tween the closed and open positions i s very necessary.
This free movement should also exist between the
kick and the open choke valve positions with the en-
gine running. If binding does exist, the choke opera-
ting link has been improperly bent and should be
corrected.
~ - .. - Choke Unloader Wide Open KlckI
Fig. 13-Choke Operating link Clearances (1) Hold the throttle valves in the wide open posi-
tion. Insert Tool T109-31 (or a Y,” drill shank) be-
As an example, if the choke valve opening is .010 tween the upper edge of the choke valve and the
inch in error, the correction in the link length would inner wall of the air horn, as shown in Figure 14.
be .010 inch.
A “2” inch micrometer will be helpful in establish- (2) With a finger lightly pressing against the valve,
ing the original length of the link, as shown in Figure a slight drag should be felt as the gauge is being
12, before completing the adjustment. withdrawn. If an adjustment is necessary, bend the
tang on the fast idle lever, using Tool T109-22, as
(8) Install .the choke operating link and recheck shown in Figure 15 until the correct clearance has
the choke valve opening, using a gauge or drill. (Re- been obtained.
fer to Figure 11).
Reinstall the vacuum hose to the diaphragm fitting Bowl Vent Adjustment
and make the following test: (1) With the throttle valves at curb idle, there
(9) With no vacuum applied to the diaphragm, should be l/ls inch clearance between the bowl vent
valve and the air horn, when measured (at the center
DRILL OR GAUGE of the vent valve and the seat) with a gauge or drill
CLOSING PRESSURE shank.
INST CHOKE VALVE BOWL VENT VALVE -PB, UNLOADER
ADJUSTING a; R-.
TANG
/
-
. BEND AT THIS ANGLE
SPECIAL TOOL
THROTTLE IN WI
OPEN POSITION
64x251
Fig. 16Measuring Choke Unloader Setting 64x252
(Wide Open Kick) Fig. 15-Bending the Unloader Tang
BBD CARBURETOR --
14-45
(2) If an adjustment is necessary, bend the short Hoar Setting ( On the Vehicle)
tang on the vent valve operating lever, using Tool
T109-22 until the correct clearance has been obtained. (1) To measure the float setting with the carbu-
(Refer to Fig. 15). retor mounted on the engine, remove the hairpin clip
and disengage the accelerator pump rod from the
throttle lever and the pump rocker arm. Disconnect
Idle Speed Adjustment ( Curb Idle I
the automatic choke rod by unsnapping the clip.
To make the idle speed adjustment, the engine (2) Remove the air horn attaching screws and lift
must be thoroughly warmed up. A more reliable idle the air horn straight up and away from the main
adjustment can usually be obtained if the vehicle body. Remove the gasket.
has been driven a minimum of five miles. For best
results, it is recommended that a tachometer be used (3) Set the float fulcrum pin by pressing a finger
in this adjustment. against the fulcrum pin retainer.
The following precautions should be taken before There should be enough fuel in the bowl to raise
making the idle speed adjustment: the floats so that the lip bears firmly against the
Because the alternator can charge at idle speeds needle. Additional fuel may be admitted by slightly
and impose a load on the engine, the headlamps depressing the float. If the fuel pressure in the line is
should be turned on the high beam. This will assure insufficient to force the additional fuel into the bowl,
setting the idle to compensate for the alternator load. add the necessary fuel from a clean container.
On vehicles equipped with automatic transmissioh, WARNING: Since the manifolds may be hot, it
loosen the nut in the sliding link of the carburetor to i s dangerous to spill fuel onto these surfaces. Take
bellcrank rod so that the stop in the transmission will the necessary precautions to avoid spillage.
not interfere with the free movement of the carburet- (4) With only the pressure from the buoyant float
or throttle lever. holding the lip against the inlet needle, measure the
(1) To make the idle speed adjustment, turn the float setting, using Tool T109-282, or a “T” scale.
idle speed screw in or out to obtain 500 rpm. (On There should be X,;inch from the surface of the
cars with air conditioning, set the idle speed at 500 bowl (gasket removed) to the crown of the floats at
rpm, with air conditioning on). Be sure the choke the center.
valve is fully open and that the fast idle adjusting If an adjustment is necessary, hold the floats on
screw is not contacting the fast idle cam. the bottom of the bowl, then bend the float lip toward
(2) Turn each idle mixture screw in or out to or away from the needle. Recheck the 3,; inch set-
obtain the highest rpm. While making the adjustment, ting again, then repeat the lip bending operation as
carefully watch the tachometer and notice that the required.
speed can be decreased by turning the screws in
NOTE: When bending the float lip, do not allow
either direction from the setting that gave the highest
the lip to push against the needle as the rubber tip
rpm reading.
can be compressed suficiently to cause a false setting
(3) Readjust to 500 rpm with the idle speed screw, which will affect correct level of fuel in the bowl.
with air conditioning ON.
After being compressed, the rubber tip i s very slow
(4) Turn each idle mixture adjusting screw in to recover its original shape. It is very important that
the clockwise direction (leaner) until there is a slight the float lip be perpendicular to the needle or slanted
drop in rpm. Turn each screw out, counter-clockwise not more than 10 degrees away from the needle when
(richer) just enough to regain the lost rpm. the float is set correctly.
set to the leanest mixture possible for smooth idle. (5) After the float has been correctly set, reas-
This setting is very important. semble the air horn.
Since the correct speed was originally set, using
the speed screw, the speed obtained after finding F a s t Idle Speed Adjustment ( O n the
the leanest smooth idle will probably be too fast. Vehicle 1
(5) Readjust the speed screw to obtain the cor- To set the fast idle speed on the vehicle, connect a
rect idle speed. Repeat steps 2 and 4 above if nec- tachometer to the vehicle, then set the curb idle
essary. speed.
After the proper idle speed has been obtained, (1) With the engine running and the transmission
move the sliding link to the rear against the stop and in the neutral position, open the throttle slightly.
tighten the nut securely. (2) Close the choke valve about 20 degrees then
CHOKE VALVE FAST IDLE SPEED

WIDE OPEN ADJUSTING
h d SCREW ON
LOWEST
THE FAST
IDLE CAM
FAST IDLE CAM

/”
61x163
64x253
Fig. 16-Fast Idle Speed Adjustment (On the Car) Fig. 17-Closed Crankcase Vent System
allow the throttle to close. Return the choke valve to When installing the well type choke unit, be cer-
the open position. tain that the coil housing does not contact the sides of
(3) The fast idle speed adjusting screw should the well in the intake manifold. Any contact at this
contact the lowest step on the fast idle cam, as shown point will affect choke operation.
in Figure 16. Do not lubricate any parts of the choke or the
(4) With the engine warmed-up to the normal control unit. This causes an accumulation of dirt
operating temperature, turn the fast idle speed ad- which will result in binding of the choke mechanism.
justing screw in or out to secure 700 rpm. Reposition
the cam and throttle after each screw adjustment. 4. CLOSED CRANKCASE VENT SYSTEM
The closed crankcase ventilator valve is located
3. AUTOMATIC CHOKE-WELL TYPE in the crankcase vent tube cap and is connected to
To function properly, it is important that all parts the carburetor throttle body with a rubber tube. (See
be clean and move freely. Other than an occasional Fig. 17).
cleaning, the choke requires no servicing. It is very The function of the valve is to control the un-
important, however, that the choke control unit work burned fuels that originate in the crankcase. The
freely in the well and at the choke shaft. gases are returned to the intake manifold, fed back
Move the choke rod up and down to check for free into the combustion chambers and then expelled out
movement on the pivot. If the unit binds, a new through the exhaust system as completely burned
choke unit should be installed. The Well Type Choke products.
Unit is serviced as an assembly. Do not attempt to For servicing procedures of this system, refer to
repair or change the index setting. Group 9, “Engine”.
AFB CARBURETOR 14-47
ACCELERATOR
PLUNGER STEM
UD MAIN BODY
SHAFT ARM (OUTER)

VACUUM DIAPHRAGM BRACKET
PRIMARY
SHAFT D OTHROTTLE
G / ' ' F /
STEP UP PISTON ACCELERATOR PUMP ARM
CHOKE OPERATING LINK CHOKE LEVER CHOKE VALVE
COVER PLATE
I
CHOKE VACUUM
DIAPHRAGM 1
FAST IDLE
INNECTOR ROD
DIAPHRAGM A
VACUUM HOSE 7 ,FAST IDLE CAM
:URB IDLE SPEED

,ADJUSTING
SCREW
IDLE MIXTURE
ADJUSTING SCREWS
FAST IDLE SPEED
ADJUSTING SCREW
CLOSED CRAI~KCASE
VENT TUBE FITTING
/
ELEVATING LEGS (SET OF 4)
A'CCELERATOR PUMP
CONNECTOR ROD 64x341
Fig. 1-Carburetor Assembly (AFB-3611SI

14-48 AFB CARBURETOR
PART 4
CARBURETOR (AFB SERIES)

The AFB (aluminum four barrel) carburetor con- All the major castings of the carburetor are
tains many features, some of which are the locations aluminum, with the throttle body cast integral with
for the step-up rods and pistons. The step-up rods, the main body. This allows an overall height reduc-
pistons and springs are accessible for service without tion in the carburetor. The section containing the
removing the air horn or the carburetor from the accelerator pump is termed the primary side of the
engine. The venturi assemblies (primary and second- carburetor. The rear section is the secondary. The
ary) are replaceable and contain many of the calibra-
five conventional systems used in previous four bar-
tion points for both the high and low speed system.
One fuel bowl feeds both the primary and secondary- rel carburetors are also used in this unit. The five
nozzles on the right side while the other fi
-- -n-n!ional systems are, two float systems, two low
takes care of tbn n r i m n r t r nnrl e n n n n r l m r r r n r ,vstems. hrimarv side onlv), two high speed
I .
I
the left side. Tklis provides improved performance in systems, one accelerator Pump system and one
cornering, quick:stops and acceleration. automatic choke control system.
SERVICE PROCEDURES
1. SERVICING THE CARBURETOR until it can be disengaged from the fast idle cam.
Dirt, dust, water and gummy deposits are some of (3) Remove the clevis clip that holds the throttle
the main causes for poor carburetor operation. How- connector rod in the center hole of the accelerator
ever, proper cleaning and the installation of new pump arm. Remove the hairpin clip that attaches the
parts, where required, will return the carburetor to its lower end of the rod in the primary throttle shaft
originally designed performance. lever. Disengage the rod from the arm and lever,
When overhauling the AFB Carburetor, several then remove from the carburetor.
items of importance should be observed to assure a (4) Remove the vacuum hose between the car-
good job. buretor throttle body and the vacuum diaphragm.
The carburetor should be carefully disassembled.
All parts (except the choke diaphragm assembly) (5) Remove the hairpin clip from the choke
should be cleaned in a suitable solvent, then inspected operating link and disengage the link from the dia-
for wear or damage. phragm plunger (stem) and the choke lever. (Refer
Air pressure only should be used to clean the to Fig. 1).
various orifices and channels. (6) Remove the vacuum diaphragm and bracket
Questionable parts should be replaced with new assembly and place to one side to be cleaned as a
ones. When inspecting parts removed from the car- special item. A liquid cleaner other than mineral
buretor, it is at times rather difficult to determine if spirits, may damage the diaphragm material.
they are satisfactory for further service. It is recom- (7) Remove the screws attaching the step-up pis-
mended therefore, in such cases, that new parts be in- ton and the rod cover plates. Hold the cover down
stalled. with a finger to prevent the piston and rods from
flying out. Lift off the plates and slide the step-up
2. DISASSEMBLING THE CARBURETOR pistons and rods out of the air horn, as shown in
(Fig. 1 1 Figure 2. Remove the step-up piston springs.
(1) Place the carburetor assembly on the repair (8) Remove the ten screws that attach the air
stand Tool C-3400 or T109-287s elevating legs. These horn to the main body. (1 screw in hole in air horn.)
tools are used to protect the throttle valves from Lift air horn straight up and away from the main
damage and to provide a suitable base for working. body. When removing the air horn, use? care so as
(2) Remove the hairpin clip that attaches the not to bend or damage the floats. Remove the accel-
fast idle connector rod to the choke lever. Disengage erator pump and plunger lower spring from the pump
the rod from the lever, then swing the rod at an arc cylinder.
STEP UP PISTON
pump arm, at the same time, disengage the link from
the arm and the pump stem. Slide the accelerator
pump plunger and spring out of the air horn. Remove
gasket.
(4) Place the accelerator pump plunger in a jar
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.
(6) Test the freeness of the choke mechanism in
the air horn. The choke shaft must float free to
operate correctly. If the choke shaft sticks in the
bearings, or appears to be gummed from deposits in
the air horn, a thorough cleaning will be required.
Fig. 2-Removing or Installing Step Up Pistons and Rods
Main Body Disassembly
Disassembling the Air Horn (1) Remove the screws that attach the accelerator
Place the air horn in an inverted position on the pump jet housing to the main body. Lift out the
bench (to protect the floats) then proceed to dis- jet housing and gasket, as shown in Figure 3. Dis-
assemble as follows: card the gasket. Invert the main body and drop out
the discharge check needle from the discharge pas-
(1) Using a suitable Tool, remove the float ful- sage.
crum pins (left and right) then lift the floats up and
out of the bosses on the air horn. It is suggested (2) Using Tool T109-58, remove the main meter-
that the float on the pump side be marked so that
ing jets (primary side), as shown in Figure 4.
the floats can be re-installed in their respective posi- NOTE: The primary and secondary main meter-
tions. ing jets are not interchangeable. It is very important
(2) Remove the two needle valves from their re- that these jets be installed in the respective locations
spective seats, after marking the one on the pump in the main body at reassembly.
side for identification. Using a wide blade screw (3) Again using Tool T109-58, remove the main
driver, remove the needle valve seats. Be sure each metering jets (secondary side), as shown in Figure 4.
needle valve is returned to its original seat at re- (4) Remove the screws that attach the primary
assembly. venturi (choke and pump side) to the main body.
(3) Remove the spring clip that holds the throttle Lift the venturi straight up and away from the main
connector rod in the center hole of the pump arm. body, as shown in Figure 5. Discard the gaskets.
Remove the pump arm pivot screw and lift off the
NOTE: The venturi assemblies are not inter-
PECIAL TOOL
NDARY VENTURI
ATTACHING SCREWS
!,fi c d I 63x501 A
Fig. 3-Removing or Installing Accelerator Pump

Jet Housing Fig. LRemoving or Installing Main Metering Jets

two units, namely the air horn and the main and
throttle body casting. The component parts of each
have been disassembled as far as necessary for
cleaning and inspection.
shafts or valves, unless wear or damage necessitates
the installation of new parts. During the manufacture
of the carburetor, the location of the idle transfer
ports and the idle discharge ports to the valve is care-
fully established for one particular assembly, as shown
in Figure 7. The valves are milled to give the proper
port relation.
If new throttle shafts should be installed in an old
worn body, it would be very unlikely that the original
- ~ .
Fig. SLRernoving or Installing Primary Venturi relationship of these ports to the valves would be
obtained. A very slight change in the port relation-
changeable, side for side and must be reinstalled in ship to the valves would adversely affect normal car-
their original locations at reassembly. buretor operation, between the speeds of 15 and 30
miles per hour.
(5) Remove the screws that attach the secondary
It is recommended that if the throttle shafts are
venturi (choke and pump side) to the main body.
excessively worn, that a new carburetor be installed.
Lift the secondary venturi assemblies straight up and
However, if the throttle valves have become nicked,
away from the body, as shown in Figure 6.
burred or damaged, new valves may be installed, pro-
(6)Using Tool T109-59, screw driver bit, remove viding the following instructions are carefully fol-
the accelerator pump intake check valve located in- lowed:
side the fuel bowl, adjacent to the accelerator pump
cylinder. CAUTION: The screws that attach the throttle
valves are staked on the opposite side and care should
(7) Remove the two idle mixture adjusting screws
be used in removal so as not to break the screws in
and springs from the throttle body portion of the
the throttle shaft. Remove the staked portion of the
main casting. screws with a file.
SECOP
VEN
(PUMP -
* "
Remove the screws that attach the primary throt-
tle valves to the throttle shaft and slide valve (or
valves) out of the bores.
Remove the screws that attach the secondary throt-
tle valves to the throttle shaft and slide valve (or
GA
valves) out of the bores.
IDLE DISCHARGE fl
SECONDARY VENTURI
NOZZILE BLEEDER TUBE \
NOZZLE BLEE
D O NOT REMOVE TUBES FROM VENTURI
63x504A
Fig. &Removing or Installing Secondary Venturi Fig. 7-Portr in Relation to Throttle Valves
AFB CARBURETOR 14-5 1
(2) Tap the valves lightly in this position, tighten
VALVE
screws securely. Stake screws by squeezing with
pliers.
(3) Install the two idle mixture adjusting screws
and springs in the throttle body portion of the cast-
I
ing. The tapered portion must be straight and
8 smooth. If the tapered portion is grooved or ridged,
a new idle mixture. adjusting screw should be in-
stalled to insure having correct idle mixture control.
D9 not use a screw driver. The adjustment should
be made with the fingers. Turn the idle mixture
adjusting screws lightly against their seats, then back
off one full turn for an approximate adjustment.
(4) Place new secondary venturi gaskets in posi-
PRIMARY VALVE 53x946A
(ALUMINUM) tion, then install the secondary venturi (pump and
choke side) by lowering straight down on gaskets.
Fig. 8-Throttle Valve Identification Install attaching screws and tighten securely.
The primary valves and secondary valves are not NOTE: Be sure all the metering holes and vent
interchangeable and should be kept separate in tubes are clean, in both the primary and secondary
order that each may be returned to its respective venturi.
bore. (See Fig. 8). (5) Place new primary venturi gaskets in position,
then install the primary venturi (pump and choke
3. CLEANING THE CARBURETOR PARTS side) by lowering straight down on the gaskets. (Refer
The recommended solvent for gum deposits is de- to Fig. 5). Install attaching screws and tighten secure-
natured alcohol, which is easily obtainable. How- 1Y*
ever, there are other commercial solvents which may
(6) Install the primary and secondary main me-
be used with satisfactory results.
tering jets, using Tool T109-58. (Refer to Fig. 4).
The choke diaphragm can be damaged by solvents.
Tighten jets securely.
Avoid placing the diaphragm assembly in ANY
liquid. Clean the external surfaces with a clean cloth (7) Install the accelerator pump intake check ball,
or soft wire brush. Shake dirt or other foreign material using Tool T 109-59.
from the stem side of the diaphragm. Depressing the Accelerator Pump Test
diaphragm stem to the retracted position, will provide
(1) Pour clean gasoline into the carburetor bowl
an additional hole for the removal of dirt. Com-
(approximately VZ inch deep). Remove the accelera-
pressed air can be used to remove loose dirt, but
tor pump plunger from the jar of gasoline. Flex the
should not be connected to the vacuum inlet fitting.
leather several times, then slide into the pump
IMPORTANT: If the commercial solvent or cylinder.
cleaner recommends the use of a water rinse, it should (2) Install the accelerator pump discharge check
be "HOT". After rinsing, all trace of water must be needle in the discharge passage. Raise the pump
blown from the passages with air pressure. It i s plunger and press lightly on the plunger shaft to
further advisable to rinse all parts in clean kerosene expel air from the pump passages. Using a small
or gasoline to be certain no trace of moisture remains. clean brass rod, hold the discharge check needle
Never clean jets with a wire, drill or other me- firmly on its seat. Again raise the plunger and press
chanical means, because the orifices may become en- downward. No fuel should be emitted from either
larged, making the mixture too rich for proper per- the intake or discharge passage.
formance.
(3) If fuel does emit from the intake passage,
inspection and Reassembly remove the intake check ball and reclean the pas-
(1) Slide the primary throttle valve (or valves) sage. Fuel leakage at the discharge check needle
into their respective bores, install new screws, but indicates the presence of dirt or a damaged check
do not tighten. Be sure the idle speed adjusting needle. Clean again and then install a new check
screw is backed out. Hold the valves in place with needle. Retest for leakage.
the fingers. (Fingers pressing on the high side of (4) If either the intake check assembly or dis-
valves). charge check needle leaks after above test and service
fix, attempt to reseat as follows: (5) Slide the right and left floats into position in
Remove the intake check assembly from the throt- the air horn, then install the float fulcrum pins.
tle body. Install a new check assembly, then retest
NOTE: (Be sure the marked float is installed on
as described in Steps 1, 2 and 3.
the pump side of the air horn). See disassembly
Discharge Check Needle procedures.
(1) With the discharge check needle installed, (6) After the floats have been installed, measure
insert a piece of drill rod down on the needle. Lightly the float alignment, level and drop settings as follows:
tap the dril rod with a hammer to form a new
Float Alignment Setting
seat. Remove and discard the old needle and install
a new one. Retest as described previously. If the (1) Sight down the side of each float shell to
service fix does not correct the condition, a new car- determine if the side of the float is parallel to the
buretor will have to be installed. outer edge of the air horn casting, as shown in Fig. 9.
(2) Install the accelerator pump discharge check (2) If the sides of the float are not in alignment
needle, jet housing and gasket. Install housing and with the edge of casting, bend the float lever by
attaching screws. Tighten screws securely. applying pressure to the end of the float shell with
(3) Press down on the accelerator pump plunger the fingers while supporting the float lever with the
shaft, and as the plunger is being depressed, a clear thumb.
straight stream should emit from each jet. If the NOTE: To avoid damage to the float, apply only
streams are not identical, (if either one is diverted or enough pressure to bend the float lever.
restricted) a new accelerator pump jet housing should (3) After aligning the floats, remove as much clear-
be installed. After test, pour the gasoline from the ance as possible between the arms of the float lever
carburetor bowl and remove the pump plunger. and the lugs on the air horn. To do this, bend the
Assembling the Air Horn float lever. The arms of the float lever should be
parallel as possible to the inner surfaces of the lugs
(1) Slide the fuel inlet screen into the fuel line or the casting.
fitting, then install fitting in the air horn. Tighten
securely. Float Level Setting
(2) Test to see if the leather on the accelerator (1) With the air horn inverted, the air horn gas-
pump plunger is hard, cracked or worn. If any sign ket in place and the float needle seated, slide the
of wear or deterioration is evident, install a new float gauge (refer to specifications for carbwetor
plunger assembly. being worked on) between the top of the float (at
(3) When reassembling, make sure the large diam- outer end) and the air horn gasket, as shown in Figure
eter of the pivot screw enters the hole in the pump 10. Float should just touch the gauge.
arm and that the shoulder on the screw has not (2) Test the other float in the same manner. If
pinched the pump arm. an ,adjustment is necessary, bend the float ann
(4) Place a new air horn to main body gasket in
position on the air horn, then install the float needle J THESE SURFACES MUST BE PARALLEL \
valve seats. (Be sure each needle seat and needle is
reinstalled in its original position).
Tfie carburetors are equipped with synthetic rub-
ber tipped fuel inlet needles. The needle tip is a
rubber material which is not affected by gasoline and
is stable over a wide range of temperatures. The tip
is flexible enough to make a good seal on the needle FUEL
seat, and to give increased resistance to flooding. BAFi
The use of the new inlet needles requires that care
be used when making float adjustments. Avoid ap-
plying any pressure on the floats which might com-
press the tip of the fuel inlet needles.
NOTE: The tip can be compressed sufficiently to MINIMUM CLEARANCE WITHOUT BINDING 64x343
cause a false setting which will affect correct level of
fuel in the bowl. Fig. 9-Testing Float Alignment
GASKET IN PLACE FLOAT slide down in front, (bowl side) of the float chamber
baffles, or the air horn will not index correctly with
the main body and can cause the floats to hang up.
I ri- Be sure the leather on the plunger does not curl or
wrinkle. Accelerator pump operation will be affect-
ed if this precaution is not observed.
(4) Install the 10 air horn attaching screws and
tighten securely. (The two long screws should be in-
stalled in the holes that are located at the air cleaner
mounting surface. The 1 inch screw at the front and
the 1% inch at the rear).
\ /
64x344 The change from the low speed, best fuel economy,
Fig. IGMeasuring Float Height road load mixtures to the richer wide open throttle
full power mixtures is now accomplished in two steps.
using Tool T109-22, until the correct clearance has This has made it possible to secure best low speed
been obtained. After bending the arm, retest the float fuel economy without sacrificing performance in the
alignment. intermediate speed range. To do this, there is a new
step-up piston and spring assembly, new metering
Float Drop Setting rods with three diameters, and new style primary
metering jets, as shown in Figure 12.
(1) Holding the air horn in an upright position,
measure the distance from the top of the floats (outer (5) Slide the step-up piston spring into the piston
end) to the air horn gasket, as shown in Figwe 11. cylinders, followed by the step-up pistons and step-
This measurement should be 3/4 inch. If an adjust- up rods. Install the cover plates and attaching screws
ment is necessary, bend the stop tabs on the float while holding the step-up pistons down in position.
levers until the correct drop setting has been obtained. Tighten screws securely.
Bend the tab toward the needle seat to lessen the (6) Test the fit of the choke valve in the air horn.
drop, or away from the seat to increase the drop. The valve should be evenly spaced on all sides.
(2) After the floats have been tested and ad- Loosen screws and reposition if necessary.
justed, continue to assemble the carburetor as fol- (7) Engage the throttle connector rod with the
lows: primary throttle shaft lever, then install the hairpin
(3) Place the accelerator pump plunger lower clip. Install the clevis clip to the rod and pump arm.
spring in the pump cylinder, then lower the air horn (8) Engage the lower end of the fast idle connector
carefully down on the main body. Care must be rod with the fast idle cam, then swing in an arc to
taken to center the small brass main bleed tubes so lock in cam. Slide the other end of the rod into the
that they will pass through the holes in the air horn choke shaft lever and secure with the hairpin clip.
without being damaged.
Installing the Vacuum Diaphragm
NOTE: Be sure the fuel baffles on the air horn,
(1) Install the vacuum diaphragm assembly on the
GASKET IN PLACE
2 STAGE
STEP-UP
PISTON SPRING STEP-UPI PISTON COVER
I
SCREW
JET-OLDTYPE JET-NEW TYPE

fl 61x171
1.7 64x345
Fig. 1 1-Measuring Float Drop Fig. 12-Step Up Piston, Rod and Jet
air horn and tighten the attaching screws securely.

(2) Install the choke operating link in position
between the diaphragm plunger (stem) and the choke
CHOKE
lever. Install the hairpin clip to secure. IPERATING LINK
move any dirt or foreign material which could clog
VACUUM
the passage. Inspect the rubber hose for cracks, be- SOURCE
CHOKE LEVER
fore placing it on the correct throttle body fitting.
(Refer to Fig. 1).
, OFVACUUM
been made. (See Carburetor Adjustments.)
4. CARBURETOR ADJUSTMENTS TUBE FITTING
The following adjustments should be made with Fig. l k l e s t i n g the Vacuum Kick Setting
the carburetor on the bench for ease of working, and,
should be made in the following order: on the fast idle cam, but slides onto the bottom step
Fast ldle Speed and Cam Position
of the cam. The fast idle speed adjusting screw must
Adjustment touch or ride against the shoulder of the middle s t v
on the cam.
The fast idle engine speed adjustment should be (This special procedure is required, because the
made on the vehicle, as described in the Paragraph fast idle speed cam is spring loaded to follow the
“Fast Idle Speed Adjustment”. However, the Fast Idle choke valve).
Cam Position Adjustment can be made on the bench.
Vacuum Kick Adjustment-This test can be made
(1) Open the throttle valves far enough to allow On or Off the Vehicle).
the fast idle speed adjusting screw to clear the fast
idle cam. To make the vacuum kick adjustment, the vacuum
diaphragm must be energized (either a distributor
(2) Insert a inch drill or gauge between the
choke valve and the ais horn wall, as shown in Figure
supplied by another vehicle).
13.
(3) Close the throttle valves until the fast idle
speed adjusting screw contacts the fast idle cam.
moved to the closed position.
(4) Adjust the fast idle connector rod, using Tool
T109-213 by bending at the angle, until the fast idle
speed adjusting screw lightly contacts the middle step
DRILL OR GAUGE ?-!L of mercury (HG) will be required).
(3) Insert a Vs inch drill or gauge between the
choke valve and the wall of the air horn. (Refer to
Figure 14). Apply a slight closing pressure to the
choke shaft to hold the drill or gauge in position.
FAST IDLE SPEED
ADJUSTING SCREW drag is not obtained as the drill or gauge is being
ON THE LOWEST STEP removed.
OF THE CAM AND \ CONNECTOR The adjustment of this opening will require the
RIDING AGAINST THE
SHOULDER OF removal of the choke operating link.
-yQm
THE MIDDLE STEP a CAUTION: Damage to the diaphragm and the
choke lever slot can result, if the link is not removed
r . L.

(5) Remove the hairpin clip and disengage the
choke operating link from the diaphragm stem (plun-
Fig. 1 L F a s t ldle Cam Position Adjustment ger), then disengage the link from the choke lever.
LIGHT CLOSING PRESSURE
A CHOKE OPERATING LINK AGAINST CHOKE VALVE
\
Fig. 15-Choke Operating link Measurements
(The best bending results will be obtained by using

‘ a vise and a pair of pliers.)
(6) Bend the choke operating link at the angle to Fig. 17-Testing Choke Unloader (Wide Open Kick)
CAUTION: A correction in the length of the NOTE: This clearance is necessary to allow the
link of .015 inch, will result in a change of .010 inch choke valve to close for starting as well as fully open
in the choke valve opening. after the engine reaches the normal operating tem-
perature.
As an example, if the choke valve opening is .010
inch in error, the correction in the link length would If a clearance does not exist in both of these posi-
be .015 inch. tions, a recheck of the operating link adjustment
A “2” inch micrometer will be helpful in establish- should be made.
ing the original length of the link, as shown in Figure NOTE: Free movement of the choke valve be-
15, before completing the adjustment. tween the closed and open positions is very necessary.
(7) Install the choke operating link and retest the This free movement should also exist between the
choke valve opening, using a drill or gauge. (Refer to kick and the open choke valve positions with the en-
Figure 14). gine running. If binding does exist, the choke opera-
Reinstall the vacuum hose to the diaphragm and ting link has been improperly bent and should be
make the following check: corrected.
some clearance should exist between the choke oper- Choke Unloader Adjustment
With the throttle valves in the wide open position,
ating link and the choke lever slot, in both th.e open
it should be possible to insert Tool T109-80 (Ys inch)
and closed choke valve positions, as shown in Figure gauge between the upper edge of the choke valve
16. and the inner wall of the air horn, as shown in
CHOKE VALVE OPEN Figure 17.
If an adjustment is necessary, bend the unloader
CLEARANCE lip on the throttle shaft lever, using Tool T109-41,
until the correct opening has been obtained.
Accelerator Pump Adjustment
(1) Move the choke valve to wide open position,
to release the fast idle cam. Back off the idle speed
CHOKE VALVE CLOSED adjusting screw (curb idle) until the throttle valves
are seated in the bores.
CLEARANCE (2)Measure the distance from the top of the air
horn to the top of the plunger shaft, using a “T” scale,
as shown in Figure 18. This distance should be 7/la
inch.
64x350
(3) If an adjustment is necessary, bend the throttle
connector rod at the lower angle, using Tool T109-
Fig. 1 b C h o k e Operating link Clearances 213, until the correct travel has been obtained.
ACCELERATOR PUMP A I -F I
PLUNGER STEM
CURB
IDLE
SPEED
SCREW
BACKED OFF bm$
‘%
,-
BEND
CONt
AT THIS ANGLE - WI
64x356
Fig. 18-Measuring Accelerator Pump Travel Fig. 2OLMeasuring Clearance Between Closing Shoes
Secondary Throttle Lever Adjustment on the secondary throttle lever, using Tool T109-22,
(1) To measure the secondary throttle lever ad- until the correct clearance has been obtained.
justment, block the choke valve in the wide open po- Secondary Throttle Lock-Out Adjustment
sition and invert the carburetor. (1) Crack the throttle valves, then manually open
(2) Slowly open the primary throttle valves until and close the choke valve. The tang on the secondary
it is possible to measure 21/64 inch between the lower throttle lever should freely engage in the notch of
edge of the primary valve and the bore (opposite idle the lockout dog. (Refer to Fig. 19).
port) as shown in Figure 19. At this measurement, (2) If an adjustment is necessary, bend the tang
the secondary valves should just start to open. on the secondary throttle lever, until engagement has
(3) If an adjustment is necessary, bend the sec- been made. Use Tool T109-22 for this operation.
ondary throttle operating rod at the angle, using Tool
T-109-213, until the correct adjustment has been ob- (3) After adjustments have been made, reinstall
tained. carburetor on the engine, using a new gasket.
(4) With the primary and secondary throttle (4) It is suggested that the carburetor bowl be
valves in the tightly closed position, it should be pos- filled with clean gasoline. This will help prevent dirt
sible to insert Tool T109-20 (.020”) wire gauge, that is trapped in the fuel system, from being dis-
between the positive closing shoes on the secondary lodged by the free flow of fuel, as the carburetor is
throttle levers, as shown in Figure 20. primed.
(5) If an adjustment is necessary, bend the shoe ldle Speed Adjustment- I Curb ldle 1
To make the idle speed adjustment, the engine
SECONDARY THROTTLE VALVES
SHOULD JUSTSTART TO OPEN II BEND ROD AT
/THIS ANGLE must be thoroughly warmed up. A m’uch more reliable
idle adjustment can usually be obtained if the vehicle
PRIMARY has been driven a minimum of five miles. For the
THROTTLE best results, it is recommended that a tachometer be
VALVES used in this adjustment. (Before making the idle
speed adjustment observe the following precautions:)
Because the alternator can charge at idle speeds
TANG ON NOTCH OF THE and impose a load on the engine, the headlamps
LOCK-OUT DOG
SECONDARY should be turned on high beam. This will assure set-
THROTTLE LEVER
ting the idle to compensate for the alternator load.
CHOKE
VALVE OPEN On vehicles equipped with the automatic transmis-
sion, refer to the “Throttle Linkage Adjustment Illus-
tration” covering the AFB Carburetors (Fig. 4).
(1) To make the idle speed adjustment, turn the
64x354
idle speed screw in or out to obtain 500 rpm. (With
Fig. 1%Measuring Secondary Throttle Opening air conditioning On, set the idle speed at 500 rpm).
Be sure the choke valve is fully open and that the fast contacting the lowest step on the fast idle cam, as
idle adjusting screw is not contacting the fast idle shown in Figure 21.
cam. (4)With the engine warmed-up to the normal
(2) Turn each idle mixture screw to obtain the operating temperature, turn the fast idle speed ad-
highest rpm. While making the adjustment, carefully justing screw in or out to secure 700 rpm. Reposition
watch the tachometer and notice that the speed can the cam and throttle after each fast idle speed screw
be decreased by turning the screws in either direction ad i ustment.
from the setting that gave the highest rpm reading.
(3) Readjust to 500 rpm with the idle speed screw. 5. AUTOMATIC CHOKE-WELL TYPE
(4)Turn each idle mixture adjusting screw in the To function properly, it is important that all parts
clockwise direction (leaner) until there is a slight be clean and move freely. Other than the occasional
drop in rpm. Turn each screw out, counter-clockwise cleaning the automatic choke control requires no serv-
(richer)just enough to regain the lost rpm. icing. However, it is very important that the choke
This procedure will assure that the idle has been control unit works freely at the thermostatic coil
set to the leanest possible mixture for smooth idle. spring housing and at the choke shaft. Move the choke
This setting is very imprtant! rod up and down to test the free movement of the
Since the correct speed was originally set using the coil housing on the pivot. If unit binds, a new unit
speed screw, the speed obtained after finding the should be installed. The Well Type Choke Control
leanest smooth idle setting will probably be too fast. Unit i s serviced only as a complete unit. Do not at-
(5) Readjust the speed screw to obtain correct tempt to repair.
idle speed. Repeat steps 2 and 4 above if necessary. When installing the well type choke unit, make
After the proper idle speed has been obtained, certain that the coil housing does not contact the sides
move the sliding link to the rear, against the stop, and of the wall in the intake manifold. Any contact at this
tighten the nut securely. point will affect choke operation.
Do not lubricate any parts of the choke or control
F a s t Idle Speed Adjustment ( O n the unit since this causes dirt accumulation which would
Vehicle I result in binding of the choke mechanism.
To set the fast idle speed on the vehicle, connect a Do not attempt to change the calibration setting.
tachometer to the vehicle, then set the curb idle speed (Refer to specifications). This is predetermined and
and proceed, as follows: should it be changed, improper choke action would
(1) With the engine running and the transmission result.
in the neutral position, open the throttle slightly. Clean all choke parts using a suitable solvent and
(2) Close the choke valve about 20 degrees, then then blow dry with compressed air. Examine all
allow the throttle to close. Return the choke valve to choke parts for wear or damage. Worn or damaged
the wide open position. parts must be replaced with new in order to insure
proper choke operation.
CHOKE VALVE WIDE OPEN

CARBURETOR ASSEMBLY
FAST IDLE CAM
FAST IDLE CRANKCASE

SPEED ADJUSTING VENT VALVE
SCREW ON LOWEST
STEP OF CAM
64x357
Fig. 21-Fast ldle Speed Adjustment (On the Car) Fig. 22LClosed Crankcase Vent System
14-58 AFB CARBURETOR 7
6. CLOSED CRANKCASE VENT SYSTEM fuels that originate in the crankcase. The gases are
returned to the intake manifold, fed back into the
The closed crankcase ventilator valve is located in
combustion chambers and then expelled out through
the crankcase vent tube cap and is connnected to the
carburetor throttle body via a rubber tube. (See Fig.
22). For servicing procedures of this system, refer to
The function of the valve is to control the unburned Group 9, “Engine”.
WW3 CARBURETOR 14-59
ACCELERATOR PUMP
ROCKER ARM
CHOKE VACUUM
DIAPHRAGM
VACUUM TUBE
FAST IDLE
CAM - ISTRIBUTOR VACUUM
ADVANCE TUBE
FITTING
ACCELERATOR CLOSED CRANKCASE

ROD
/ VENT TUBE FITTING
FAST IDLE
SPEED ADJUSTING
REW
/
IDLE MIXTURE
ADJUSTING SCREW (2)
-T--
THROTTLE LEVER
CHOKE LEVER
CHOKE VALVE ACCELERATOR PUMP
IDLE SPEED
VACUUM HOSE
HOKE OPERATING
SPEED ADJUST
CHOKE VACUUM
DIAPHRAGM
64 x 312
Fig. 1 -Carburetor Assembly (WW31-239 WW3-2401

14-60 WW3 CARBURETOR
PART 5
CARBURETOR (WW-3 STROMBERG)

There are two models of WW series carburetor, where required, will return the carburetor to its orig
depending on the type of transmission with which the ihally designed performance.
vehicle is equipped. When overhauling the carburetor, several items of
The same basic design applies to all models re- importance should be observed to assure a good job.
gardless of adaptions. Refer to Specifications for (1) All parts (except the choke diaphragm) should
detailed information. be carefully cleaned in a suitable solvent, then in-
(1) Model WW3-239 is used when the vehicle is spected for damage or wear.
equipped with the standard 3 Speed Transmission (2) Use air pressure only, to clear the various ori-
only. fices and channels.
(2) Model WW3-240 is used when the vehicle is (3) Replace questionable parts with NEW on&.
equipped with the Automatic Transmission. When checking parts removed from the carburetor,
Dirt, dust, water and gummy deposits are some of it is at times rather difficult to be sure they are satis-
the main causes for poor carburetor operation. How- factory for further service. It is therefore recommend-
ever, proper cleaning and installation of new parts, ed that in such case, NEW parts be installed.
SERVICE PROCEDURES
1. CARBURETOR ( 5 ) Remove the “E” clip from the choke operating
link at the choke lever and disengage the link from
Disassembly I Fig. 1.J the vacuum diaphragm stem. (Refer to Fig. 1).
(1) Place the carburetor assembly on the repair
block Tool C-3225. (This Tool is used to protect the (6) Remove the vacuum diaphragm and bracket
throttle valves from damage and to provide a suitable assembly and place to one side to be cleaned as a
base for working.) Disconnect cross-over choke rod. separate item. A liquid cleaner may damage the dia-
phragm material.
(2) Remove the cotter pin that holds the pump
operating rod in the center hole of the throttle lever. (7) Remove the air horn attaching screws and re-
Disengage the rod from the lever. move the air horn.
(3) Remove the clip that retains the fast idle rod, (8) Disengage the accelerator pump plunger rod
then disconnect the rod. from the rocker arm by removing the clip; and the
(4) Remove the vacuum hose between the car- bowl vent valve. Slide the plunger and rod out of the
buretor air horn and the vacuum diaphragm. air horn. Slide the spring seat and compression
spring off the rod.
J. END WRENCH Place the accelerator pump plunger in a jar of
PISTON STAKED clean \gasoline or kerosene to prevent the leather
IN AIR HORN from drying out.
?
VACUUM DIAPHRPLGM (9) Remove the vacuum power piston from the
TUBE FITTING air h o h , using an open end wrench and a support,
as s h o h in Figure 2. (Exert sufficient pressure on
the end of the wrench to force the piston out of the
air horn. This assembly is staked and care should be
used at removal).
’ HORN
(10) Lift the idle tubes out of the main body, as
shown in Figure 3. (The idle tubes are interchange-
able).
64 x 313
(11) Remove the screw and gasket from the ac-
Fig. 2-Removing Vacuum Piston celerator pump discharge cluster, then lift off the
Fig. 5-High Speed Bleeders
(17) Remove the screws and lockwashers that hold

Fig. 3-Removing or Installing Idle lubes the throttle body to the main body. Lift off the
throttle body. Discard the gasket.
cluster and gasket, as shown in Figure 4. (18) With the main body in an inverted position,
(12) Invert the carburetor main body, and drop remove the main jet plugs, using Tool 73598 and
out the accelerator pump inlet and discharge check 73609. Discard the plug gaskets.
balls. (19) Using Tool 73606, remove the main meter-
NOTE: Do not attempt to remove the high-speed ing jets, as shown in Figure 7. Do not substitute the
bleeders located in the main discharge strut section main metering jets #388208 used in previous car-
of the carburetor main body. (See Fig. 5). buretors for #388539. (New type).
(13) Invert the carburetor main body and drop (20) Remove the main discharge jets (or tubes),
out the accelerator pump discharge check ball from using Tool 73608. This tool has tapered right hand
the center of the discharge strut section. (See Fig. 11). thread and should be screwed into the jet. The threads
that are formed in the jet during removal, will not
(14) Remove the fuel inlet needle valve seat and damage the jet.
gasket assembly. Discard the gasket.
(21) Unscrew and remove the idle mixture ad-
(15) Using a small screw driver, pry out the float justing screws and springs, from the throttle body.
fulcrum pin retaining spring. (Cup the hand over the The carburetor now has been disassembled into
float chamber to prevent the spring from flying out). three units, namely, the air horn, main body and
Lift out the float and fulcrum pin! throttle body, and the component parts of each dis-
(16) Remove the power by-pass jet and gasket, as assembled as far as necessary for cleaning and in-
shown in Figure-6. spection.
&
ELERATOR PUMP
HARGE CLUSTER
RATOR PUMP
DISCHARGE PASSAGE
64 x 315 63x467
Fig. &Removing or Installing Discharge Cluster Fig. &Removing or Installing Power By-Pass Jet
the throttle body. If wear is extreme, it is recom-
mended that the throttle body be replaced, rather
STYLE STYLE
than installing a new throttle shaft in the old body.
fer port and spark advance control ports to the valves
is carefully established for one particular assembly.
METERING (See Fig. 8 ) .
If a new shaft should be installed in an old worn
throttle body, it would be very unlikely that the orig-
inal relationship of these ports to the valves would be
obtained. Changing the port relationship would ad-
versely affect normal car operation between the
speeds of 15 and 30 miles per hour. However, if it
has been determined that a new shaft is to be in-
stalled, adhere closely to the following instructions:
(2) Mark the valves to be sure each is replaced in
54x425A
the same bore from whence removed.
Fig. 7-Removing or Installing Main Metering Jets (3) Remove the screws that hold the throttle valves
to the throttle shaft, then slide the valves out of the
NOTE: It i s usually not advisable to remove the throttle shaft.
throttle shaft o r valves unless wear o r damage neces- CAUTION: These screws are staked o n the o p
sitates installation of new parts. To install new valves
or throttle shaft, refer to ”Inspection and Reassem- not to break the screws in the shaft.
bly“.
(4) Slide the throttle shaft out of the throttle body.
2. CLEANING THE CARBURETOR PARTS (5) Install the new throttle shaft and lever in the
throttle body. The fast idle lever should rest against
The recommended solvent for gum deposits is de- the idle speed adjusting screw. The idle speed adjust-
natured alcohol which is easily obtainable. However, ing screw must be backed out when seating t h e valves
there are other commercial solvents which may be in the following operation.
used with satisfactory results. The “dash” stamped on the valves must be toward
The choke diaphragm can be damaged by solvents. the idle port and visible from the top of the throttle
Avoid placing the diaphragm assembly in ANY body when the valves are installed.
liquid. Clean the external surfaces with a clean cloth
or a soft wire brush. Shake dirt or other foreign (6) Slide the valves in position through the throt-
material from the stem side of the diaphragm. De- tle shaft, then insert NEW screws, but do not tighten.
pressing the diaphragm stem (plunger) to the retract- Now hold the valves in place with the fingers. (Fingers
ed position, will provide an additional hole for the
removal of dirt. Compressed air can be used to re- IDLE DISCHARGE PORTS
move loose dirt but should not be connected t o t h e
vacuum fitting of the diaphragm.
IMPORTANT: If the commercial solvent o r
cleaner recommends t h e use o f water as a rinse, it
should be ”HOT”. A f t e r rinsing, a l l trace of water
must be blown from t h e passages with air pressure. It
is further advisable t o rinse a l l parts in clean kero-
sene o r gasoline t o be certain no traee of moisture
remains. Never clean jets with a wire, drill or other
mechanical means because the orifices may become
enlarged, making the m i x t u r e too r i c h for proper per-
formance.
DASH MARKS
lnspection and Reassembly- ON THROTTLE VALVES 63x468
Throttle Body
(1) Inspect the throttle shaft for excessive wear in Fig. 8-Ports in Relation to Throttle Valves
DIAGONAL CUT TOWARD plished with a spring loaded two position power jet,
OPPOSITE SIDE actuated by vacuum on the power jet piston. The
purpose of this two stage action is to secure the best
fuel economy in the lower road load speed range
without sacrificing performance in the intermediate
speed range.
During initial or part throttle operation, the vac-
uum above the piston is sufficient to overcome the
compression spring and hold the piston in the up
position. As the throttle valves are opened the mani-
fold vacuum drops and the piston compression spring
moves the piston down to open the first stage valve
54x437 (upper) of the power by-pass jet, as shown in Fig-
Fig. 9-Installing Main Discharge Jets (or Tubes) ure 12. This meters additional fuel through the up-
per hole, into the main metering system.
pressing on the high side of the valves). With increased demand for power and a further
(7) Tap the valves lightly with a screw driver to
drop in vacuum, the piston moves down an additional
seat in the throttle bores. Holding the valves in this amount to open the second stage valve (lower) as
position, tighten screws securely and stake by squeez- shown in Figure 12, and meters an additional
amount of fuel through the hole at the bottom of the
ing with pliers.
power bypass jet.
(8) Install the two idle mixture adjusting screws When the demand for power is satisfied and the
and springs in the throttle body. (The tapered por- throttle opening is decreased, the manifold vacuum
tion must be straight and smooth). If the tapered builds up to raise the power piston and closes the
portion is grooved or ridged, a new idle mixture ad- 2nd stage valve (lower) cutting off the supply of
justing screw should be installed to insure having the fuel through the bottom hole of the jet. A further
correct idle mixture control. reduction of power closes the 1st stage valve (upper)
ldle Mixture Screw Adjustment cutting off the supply of fuel through the upper hole.
Do Not Use a Screw Driver. The adjustment
No changes in service procedures are required ex-
should be made with the fingers. Turn the idle mix- cept to be sure the power by-pass jet is clean.
ture adjusting screw lightly against its seat, then back (6) Install the accelerator pump inlet check ball
off one full turn for approximate adjustment. (3/ls inch diameter) in the check ball seat at the bot-
tom of the pump cylinder, as shown in Figure 10.
Reassembling the Carburetor Main Body
(7) Install the accelerator pump discharge check
(1) Place the main discharge jets (or tubes) firmly ball (% inch diameter) in the orifice in the center
on Tool 73608, as shown in Figure 9. Slide into passage of the discharge strut section of the main
position in the main body. Be sure the opening in body, as shown in Figure 11.
the end of tube (diagonal cut end) is facing the
opposite side of the small venturi. These two jets must
be seated firmly in the main body.
(2) Insert the main metering jets in the body over
the discharge jets (or tubes) just installed. Tighten
securely, using Tool 73606. (See Fig. 7).
(3)Slide new copper gaskets in the main jet plug
openings, then insert the plugs and tighten securely.
(4) Place the assembled throttle body on the in-
verted main body, using a new gasket. Install screws
and lockwashers, then tighten securely.
(5) Invert the carburetor and place on repair
block C-3225,then install the power by-pass jet and
new gaskets.
The change froin the lean road load mixture to the
57x1 15
richer wide open throttle maximum power mixture
is made with an intermediate step. This is accom- Fig. 1OLlnstalling Accelerator Pump Check Ball
Fig. 13-Testing Accelerator Pump Intake and

Fig. 11-Installing Discharge Check Ball Discharge Check Balls
Accelerator Pump Test (4) Reinstall check ball and test again. If still
(1) Pour clean gasoline into the carburetor bowl, leaking, place a piece of drill rod down on ball and
approximately I/i inch deep. Remove the accelerator rap sharply with a hammer. Remove old check
ball and install new ball. Then retest. (This operation
pump plunger from the jar of gasoline and slide down
into the pump cylinder. Raise the plunger and press forms a new ball seat in the carburetor casting).
lightly on the plunger shaft to expel the air from the (5) Install the discharge cluster gasket, cluster and
pump passage. screw. Tighten securely. (See Fig. 4).
Again depress the accelerator pump plunger. A
clear straight stream should emit from each cluster
charge check ball firmly down on its seat. Again
raise the plunger and press downward. No fuel should jet. If the streams are not identical (if either one is
be emitted from either the intake or discharge pas- diverted or restricted), a new discharge cluster should
sage, as shown in Figure 13. be installed.
After test, pour the gasoline from the carburetor
(3) If any fuel does emit from either the intake bowl and remove the accelerator pump plunger.
or discharge passages, it indicates the presence pf
dirt or an imperfect check ball seat. The passage (6)Test the float for leaks or damage. If satis-
should be recleaned and then thoroughly blown out factory for further service, install in position in the
with compressed air. Examine the check ball seat for carburetor bowl.
signs of damage that would not allow the ball to seat (7) Assemble the fuel inlet needle valve, seat and
properly. gasket, then insert in position in the main body.
Tighten securely. (If the needle is ridged or badly
POWER BYPASS JET POWER BYPASS JET worn, install a new needle valve and seat assembly).
1ST STAGE 2ND STAGE
, i
I"(
111
ii
1ST STAGE
ORIFICE
OPEN
2ND STAGEtVALVE
CLOSED
\ 2ND STAGEtVALVE
OPEN
\
61 x5QA
Fig. 12-Power By-Pass Jet (1st and 2nd GAUGE 64 x 318

Stage Operation) Fig. 1LMeasuring the Float Setting
(8) Install the float fulcrum pin retaining spring

in position and force under the lip of the boss to keep PLUNGER AND SPRING
the fulcrum pin in position.
\
Measuring the Float Height STAKE IN POSITION

The carburetors are equipped with a syntehtic rub-
ber tipped fuel inlet needle. The needle tip is a rub-
ber material which is not affected by gasoline and is
stable over a wide range of temperatures. The tip is
flexible enough to make a good seal on the needle
seat, and to give increased resistance to flooding.
The use of the new inlet needle requires care to AIR HORN/
perform the float setting operation accurately in or-
der to secure the best performance and fuel economy.
(1) To correctly set the float height when the car-
buretor is being overhauled, install the float with the 54x467
fulcrum pin and retaining spring in the main body. Fig. 16-Installing Vacuum Power Piston
(2) Install the needle, seat and gasket in the body
and tighten securely. perpendicular to the needle or slanted not more than
(3) Invert the main body so that the weight of 10 degrees away from the needle when the float is
the float only is forcing the needle against the seat. set correctly. Do not bend +o
l at lip by forcing float.
(4) Using Tool 73725 or a “T” scale measure the Use Tool 73605, as shown in Figure 15.
float, as shown in Figure 14. There should (5) To change the float setting, bend the float lip
inch from the surface of the fuel bowl (gasket& toward the needle to lower, and away from the needle
moved) to the top of the float at the center. to raise the float. Install the idle tubes in the main
If an adjustment is necessary, hold the float on body. (See Fig. 3.) These tubes are interchangeable.
the bottom of the bowl, then bend the float lip to-
ward or away from the needle, using Tool 73605. Re- Assembling the Air Horn (Fig. I I
test the x2 inch setting again then repeat the lip (1) Remove the accelerator pump plunger, from
bending operation as required. the jar of gasoline. If the leather is hard, cracked or
worn, install a new plunger and shaft.
CAUTION: When bending the float lip, do not
allow the lip to push against the needle as the syn- (2) Slide the compression spring over the plun-
thetic rubber tip can be compressed sufiiciently to ger shaft, followed by the bowl vent valve seat. Insert
cause a false setting which will affect correct level of the assembly through the air horn.
fuel in the bowl. After being compressed, the tip i s (3) Initall the vacuum power piston and plunger
very slow to recover its original shape. in the air horn, as shown in Figure 16. Lock in posi-
tion by prick punching on the retaining rim. Compress
NOTE: I t is very important that the float lip be
the piston plunger to be sure no binding exists. If the .
piston sticks or binds enough to hinder smooth oper-
TooLw ation, install a new piston assembly.

(4) Slide the bowl vent valve over the shaft and
down against the seat. Engage the pump shaft with
the pump arm and secure with the clip.
(5) Slide a new air horn gasket over the acceler-
ator pump plunger, and down against the air horn.
Lower the air horn straight down on the main body,
with the accelerator pump plunger sliding into its
well. (Be sure the leather on the pump does not curl
or fold back). Install the air horn retaining screws
and lockwashers, then tighten securely.
(6) Install the accelerator pump and choke con-
nector rods, then work the accelerator pump plunger
Fig. 15-Bending the Float Lip several times, to be sure it operates freely.
installing the Vacuum Diaphragm

(1)Install the diaphragm assembly on the air horn
GAUGE OR DRILL
\
CHOKE OPERATIN>
P G
IED
KE SHAFT
and tighten the attaching screws securely. LINK
(2)Install the choke operating link in position be-
lever. Install the “E” clip to secure.
1
the passage. Inspect the rubber hose for cracks, be-
fore placing it on the correct fitting. (Refer to Fig. l).
fitting until after the vacuum kick adjustment has MINIMUM 10 I
been made. (See Carburetor Adjustments).
64 x 321
3. CARBURETOR ADJUSTMENTS Fig. 18-Testing the Choke Vacuum Kick Setting
It is very importaht that the following adjustments
be made on a reconditioned carburetor and in the gauge (Automatic Transmission) between the choke
sequence listed namely, valve and the wall of the air horn.
Fast Idle Speed and Cam Position Adjustment (2)An adjustment will be necessary if a slight
Vacuum Kick Adjustment drag is not obtained as the drill or gauge is being
Unloader Adjustment (wide open kick) removed.
Accelerator Pump Travel Adjustment (3) If an adjustment is necessary, bend the fast
Fast Idle Speed and Cam Position Adjustment idle rod at the upper angle, using Tool T109-213,
Fast /die Speed and Cam Position until the correct valve opening has been obtained.
Adjustment @efer to Fig. 17).
The fast idle engine speed adjustment should be Vacuum Kick Adjustment-(This test can be made
made on the car, as described in the Paragraph “Fast On or off the vehicle).
Idle Speed Adjustment”. However, the Fast Idle Cam To make the vacuum kick adjustment, the vacuum
Position Adjustment can be made on the bench. diaphragm must be energized (either a distributor
(1) With the fast idle speed adjusting screw con- supplied by another vehicle).
in Figure 17,move the choke valve toward the closed (1) With the engine Not running, open the throttle
position with light pressure. Insert a 5/le inch drill or valves far enough to allow the choke valve to be
gauge (manual transmission) or a 17/s4 inch drill or moved to the closed position.
GAUGE OR DRILL
LIGHT CLOSING of mercury (HG) will be required.)
PRESSURE ON
CHOKE VALVE (3) Insert a 15/04 inch (manual transmission) or
f3/s4 inch (Automatic Transmission) size drill or gauge
between the choke valve and the wall of the air horn.
BEND FAST lDLl
(Refer to Fig. 18). Apply a slight closing pressure to
the choke shaft.
ADJUST VALVE (4) An adjustment will be necessary if a slight
OPENING FAST IDLE
ADJUSTING SCREW
FAST IDLE removed.
CAM
The adjustment of this opening will require the re-
FAST IDLE moval of the choke operating link.
ADJUSTING SCREW
ON LOWEST STEP CAUTION: Damage to the diaphragm and the
AGAINST FACE OF choke lever slot can result if the link is not removed
NEXT CAM STEP 320
Fig. 17-Fast Idle Cam Position Adjustment (5) Remove the clip and disengage the choke
and with no vacuum applied to the diaphragm, some

clearance should exist between the choke operating
link and the choke lever slot, in both the open and
closed choke valve positions, as shown in Figure 20.
perature.
should be made.
Fig. 19-Choke Operating link Measurement
tween the closed and open positions is very necessary.
operating link from the choke lever, then disengage This free movement should also exist between the
the link from the diaphragm stem. (The best bending kick and the open choke valve positions with the
results will be obtained by using a vise and a pair of engine running. If binding does exist, the choke oper-
pliers). ating link has been improperly bent and should be
(6) Bend the choke operating link at the angle to corrected.
CAUTION: A correction in the length of the link
Unlaader Adjustment [Wide Open Kick1
of .010 inch, will result in a change of .015 inch in the (1) To make the unloader adjustment, lightly hold
choke valve opening. the choke valve closed, then open the throttle valves
As an example, if the choke valve opening is .015 to wide open position. The choke valve should open
inch in error, the correction in the link length would sufficiently to allow a No. 1 or drill to be
be-.010 inch. inserted between the choke valve -and wall of air
A “2” inch micrometer will be helpful in estab- horn, as shown in Figure 21.
lishing the original length of the link, as shown in (2) To adjust, bend the tang on the throttle lever
Figure 19, before completing the adjustment. using Tool T109-214, as shown in Figure 21.
_ _ _ I
(7) Install the choke operating link and recheck (3) Hold the choke open and then open and close
the choke valve opening, using a gauge or drill. (Refer the throttle valves. Failure to obtain full throttle
to Fig. 18). operation indicates improper assembly or an adjust-
(8) Reinstall the vacuum hose to the diaphragm ment of the choke mechanism is required.
(4) With the throttle valves held in the open posi-
CHOKE VALVE
tion, open the choke valve slowly to wide open posi-
CHOKE OPERA OPEN /
LIGHT PRESSURE
AGAINST CHOKE a.
VALVE \A UGE OR DRILL
FAST IDLE b
ROD
CHOKE VALVE THROTTLE LEVER
CHOKE OPERATING
CLOSED HELD IN WIDE
K E
BEND
THRO
TO ADJUST VALVE
OPENING
323
Fig. 20--Choke Operating link Clearances Fig. 21-Unloader Adjustment (Wide Open Kick)
tion. There should be no bind throughout the entire

travel of choke mechanism.
Accelerator Pump and Bowl
Vent Adjustment
horn, note that the horseshoe clip (which opens the
bowl vent) can be placed in any one of the three
positioning notches. These notches correspond to the
long, medium and short pump stroke holes in the
throttle lever. Normally, the bowl vent clip on the ACCEL
. __--
pump stem will be at the middle notch and the pump (BENC
rod in the medium stroke hole.
The proper procedure is to adjust the amount of
bowl vent opening instead of measuring and setting 64 x 326
the height of the pump plunger. Fig. 23-Bending Accelerator Pump Rod
To test or set the adjustment, proceed as follows:
(1) Back off the idle speed adjusting screw. Open change must be made in the location of the bowl
the choke valve, so that when the throttle valves are vent clip, and the amount of the lift of the bowl vent
closed, the fast idle adjusting screw will not contact retested and adjusted.
the fast idlf cam. NOTE: The accelerator pump travel is automat-
(2) Be sure the pump rod is in the medium stroke ically taken care of when the bowl vent is properly
hole in the throttle lever, and that the bowl vent clip adiusted.
on the pump stem is in the center notch.
Idle Speed Adjustment t Curb Idle 1
just possible to insert a 5/64 inch drill between the To make the idle speed adjustment, the engine
bowl vent and the vent seat protruding through the must be thoroughly warmed up. A much more re-
air horn, as shown in Figure 22. liable idle adjustment can usually be obtained if the
If an adjustment is necessary, bend the pump rod, vehicle has been driven a minimum of five’miles. For
using Tool T109-213 at the lower angle, until the the best results, it is recommended that a tachometer
correct bowl vent opening has been obtained, as be used in this adjustment. (Before making the idle
shown in Figure 23. speed adjustment, observe the following precautions:)
This is an important adjustment, since too much Because the alternator can charge at idle speeds
lift at the bowl vent will result in considerable loss and impose a load on the engine, the headlights
in low speed fuel economy. should be turned on (high beam). This will assure I
Remember that if the pump rod is moved to either setting the idle to compensate for the alternator
the short or long stroke position, a corresponding vehicle load. On vehicles equipped with the automatic
transmission, disconnect the transmission control roc!
CHOKE VALVE from the ball joint on the carbclretor lever so that the
WIDE OPEN stop on the transmission will not interfere with the
-
free movement of the carburetor lever.
To make the idle speed adjustment, proceed as
b) follows:
THROTTLE IN (1) Turn the idle speed screw in or out to obtain
P LOSED POSITION
500 rpm. (With air conditioning On, set the idle speed‘
at 500 rpm). Be sure the choke valve is fully open
and the fast idle adjusting screw is not contacting the
fast idle cam.
CLIP IN CEI
GROOVE OF (2) Turn each idle mixture screw to obtain the
STEM highest rpm. While making the adjustment, carefully
watch the tachometer and notice that the speed can
ROD be decreased by turning the screws in either direction
OF . -64x 325 from the setting that gave the highest rpm reading.
Fig. 22-Measuring the Bowl Vent Valve Opening (3) Readjust to 500 rpm with the idle speed screw.
CHOKE VALVE CARBURETOR

WIDE OPEN POSIT1 ASSEMBLY
LOWEST STEP O N SPEED ADJUSTING

FAST IDLE CAM
64 x 327
Fig. 2 A F a s t Idle Speed Adjustment (On the Car) Fig. 25-Closed Crankcase Vent System
(4) Turn each idle mixture adjusting screw in the 4. A U T O M A T I C CHOKE-WELL TYPE
clockwise direction (leaner) until there is a slight To function properly, it is important that all parts
drop in rpm. Turn each screw out, counter-clockwise be clean and move freely. Other than the occasional
(richer) just enough to regain the lost rpm. cleaning, the automatic choke control requires no
This procedure will assure that the idle has been servicing. However, it is very important that the choke
set to the leanest mixture possible for smooth idle. control unit works freely at the thermostatic coil
This setting is very important. spring housing and at the choke shaft. Move the choke
Since the correct speed was originally set using rod up and down to check for free movement of the
the speed screw, the speed obtained after finding the coil housing on the pivot. If the unit binds, a new unit
leanest smooth idle setting will probably be too fast. should be installed.
(5) Readjust the speed screw to obtain correct The Well Type Choke Unit is serviced only as a
idle speed. Repeat steps 2 and 4 above if necessary. complete unit. Do not attempt to repair.
After the proper idle speed has been obtained, When installing the well type choke, make certain
refer to Figure 3 of the “Throttle Linkage” on page that the coil housing does not contact the sides of
73 for the procedure on adjusting the transmission the well. Any contact at this point will affect choke
control rod. operation.
Do not lubricate any parts of the choke or control
Fast Idle Speed Adjustment ( O n the
unit since this causes dirt accumulation which would
Vehicle J
result in binding of the choke mechanism.
To set the fast idle speed on the vehicle, connect a Do not attempt to change the calibration setting.
tachometer to the vehicle, then set the curb idle speed
This is predetermined and should it be changed, im-
and proceed as follows: proper choke action would result.
(1) With the engine running and the transmission
in the neutral position, open the throttle slightly. 5. CLOSED CRANKCASE VENT SYSTEM
(2) Close the choke valve about 20 degrees then The closed crankcase ventilator valve is located
allow the throttle to close. Return the choke valve to in the crankcase vent tube cap and is connected to
the open position. the carburetor throttle body via a rubber tube.
The function of the valve is to control the un-
burned fuels that originate in the crankcase. The
contacting the lowest step on the fast idle cam, as
gases are returned to the intake manifold, fed back
shown in Figure 24.
into the combustion chambers and then expelled out
(4) With the engine warmed-up to the normal through the exhaust system as completely burned
operating temperature, turn the fast idle speed ad- products. (See Fig. 25).
justing screw in or out to secure 700 rpm. Reposition For servicing procedures of this valve, refer to
the cam and throttle after each screw adjustment. Group 9, “Engine”.
14-70 THROTTLE LINKAGE
PART 6
THROlTLE LINKAGE
1. THROTTLE LINKAGE ADJUSTMENTS
Refer to Figures 1, 2, 3 and 4 for throttle linkage adjustment for all the cubic inch engines.
THROTTLE LINKAGE 14-71
z
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P
VI
z
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I-
I):
J
a
z
4
l-
I
5
a
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Y
2
4.
h: .-E
-I
c
E
J
4.
a
z
I
L
i
i
ii
THROTTLE LINKAGE 14-73
4
u)
9
m
X
m
9
0
rn
0
Y
.-C
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W
FUEL PUMP 14-75
PART 7
FUEL PUMP AND TANK

FUEL PUMP
Three different models of fuel pumps are used in As the camshaft rotates, the eccentric cam presses
production. The same basic design applies to all three down on the pump rocker arm. (On the 361-383 cubic
models. The service procedures for testing are the inch engine, a push rod operates between the cam-
same. shaft and the fuel pump rocker arm). This action
Fuel pump model MS-3674S, shown in Figure 1, lifts the pull rod and diaphragm upwards against the
is used exclusively on the 170/225 cubic inch 6 cyl- fuel pump main spring, thus creating a vacuum in
inder engine. Model MS-3673S, shown in Figure 2 is the valve housing and opens the inlet valve and fuel
used on the 318 cubic inch V-8 engine. Model MS- is drawn into the valve housing chamber. On the
36728, shown in Figure 3, is used on the 361-383 return stroke the main spring forces the diaphragm
cubic inch engine. to the down position, which closes the inlet valve and
The fuel pumps are driven by an eccentric cam expels the fuel in the valve housing chamber through
that is cast on the camshaft in the 170/225 and the outlet valve, to the fuel filter and the carburetor.
361-383 cubic inch engines, or by a pressed steel The fuel pump is of the pressed steel type and
eccentric cam mounted on the gear end of the cam- cannot be disassembled for service. If a pump mal-
shaft in the 318 cubic inch engine. function occurs, remove the old pump and install a
new one.
The fuel filters (ceramic or paper) should be
changed every 16,000 miles, to insure having an un-
restricted flow of fuel at all times. Do not attempt to
clean.
1. TESTING FUEL PUMPS (On the Engine)

If the fuel pump fails to supply fuel properly to the
carburetor, the following tests should be made before
removing the fuel pump from the vehicle.
If leakage is not apparent, test the pump for pres-
sure.
Pressure Test
(1) Insert a “T” fitting in the fuel line at the
64 x 413
Fig. 1-Fuel Pump Assembly (170-m5iCu. In. Engine)
64 x 415
64x414
Fig. ?’Fuel Pump Assembly
Fig. 2-Fuel Pump A’ssembly (31:8 Cu. In. Engine) (3611-383-41 3 and 426 Cu. In. Engines)
14-76 FUEL TANK
3% to 5 psi (or from 5 to 7 psi, depending on pump)

and remain constant or return to zero, very, very
slowly when the engine is stopped. An instant drop
R.P.M to zero indicates a leaky outlet valve. If the pressure
TACHOMETER is too low a weak diaphragm main spring, or im-
(ENGINE SPEED) proper assembly of the diaphragm may be the cause.
If the pressure is too high, the main spring is too
6 INCH strong.
MAXIMUM
Vacuum Test
The vacuum test should be made with the fuel line
disconnected from the carburetor. (This will allow
the pump to operate at full capacity, which it must
do to prime a dry carburetor).
F U V
58x345 Volume Test
Fig. &Pressure Testing the Fuel Pump The fuel pump should supply 1 quart of fuel in 1
minute or less at 500 rpm.
carburetor, as shown in Figure 4.
(2) Connect a 6 inch piece of hose between the Inlet Valve Test
“T” fitting and gauge Tool C-3411. (The hose should To test the inlet valve, connect a vacuum gauge bn
not exceed 6 inches. A longer hose may collect fuel the inlet fitting while the line is disconnected:
and the additional weight of the fuel would be added (1) Start the engine or turn over with starting
to the pressure of the pump and result in an inac- motor. There should be a noticeable vacuum present,
curate reading). not alternated by blowback.
(3) Vent the pump for a few seconds (this re- (2) If blowback is present, the inlet valve is not
lieves the air trapped in the fuel chamber). If this is seating properly and should be cleaned, or a new
not done, the pump will not operate at full capacity valve body installed.
and a low pressure reading will result. If the fuel pump does not perform to the above
(4) Connect a tachometer, then start the engine test requirements, the fuel pump should be removed
and run at 500 rpm. The reading should be from from the vehicle.
FUEL TANK
The fuel tank on both the conventional and the NOTE: If a vehicle is to stored for any appre-
Station Wagon Models (106” wheelbase) is located at ciable length of time, the gasoline should be drained
the rear of the body, under the trunk compartment from the entire system in order to prevent gum for-
floor, as shown in Figures 1 or 2. The filler tube is mation. If the vehicle has been undercoated, be sure
located in the left rear quarter panel. the tank vent tube is open. If this vent is plugged, a
The fuel tank on all models (116” wheelbase) ex- collapsed fuel tank will result.
cept the Station Wagon Models, is located at the rear
of the body under the trunk compartment floor, as The fuel tank on all 106” wheelbase models has
shown in Figures 3 and 4. In the Station Wagon a 18 gallon capacity. The fuel tank on all conven-
Models the fuel tank is mounted in the left rear tional 116” W/B Models has a 19 gallon capacity.
quarter panel beyond the wheel house, as shown in (The Station Wagon tank capacity is 21 gallons). The
Figure 5. fuel tank is fitted with a gauge unit, including the
The filler tube on the conventional models is ac- suction pipe, as shown in Figure 6. The filter on the
cessible through the center of the deck opening lower end of the suction pipe is a replaceable unit and
panel. Station Wagon models fill at the left rear prevents the entry of water or foreign material. When
upper quarter panel between the quarter post and installing a tank unit, be sure the filter is pushed
the fin. down on the pipe until seated.
FUEL TANK 14-77
ROOF SIDE RAIL SUPP
TANK ASSY. (COMPLETE)
63x644
Fig. 1-Fuel Tank Assembly Installed (106" W/B Models)
VENT TUBE ASSY.
HOSE-STA. W A G O N
HOSE-SEDAN
-SCREW - (5)
/ -/
' LVENT TUBE ASSY.
I -
I -- -;-- --
QUARTER PANEL - OUTER
Fig. 2-Filler Tube Assembly (Disassembled View) (106" W/B Models)

14-78 FUEL TANK
VIEW 6
QUARTER PANEL INNER
INSULATOR CEMENT
TANK GAUGE
63x369
Fig. &Fuel lank Assembly (Installation) Station Wagon 106” W/B Models
Fig. &Fuel Tank Assembly (Installation) 116” W I B Models

FUEL TANK 14-79
SERVICE PROCEDURES
1. FUEL TANK the tank, use a rubber lubricant around the joint and
work into the “0”ring recess, after sliding the dust
Removal- (106“ W / B Models 1 shield out of the way).
Should it become necessary to remove a fuel tank (6) Twist (or rotate) the filler tube approximately
for repair, gauge removal, or installation of a new 180 degrees, then work tube carefully out of the
tank, refer to Figures 1 and 2, then proceed as fol- tank and dust shield seal. Remove tube from the
lows: inside of the trunk compartment.
(1) Drain the fuel tank dry by disconnecting the
CAUTION: Do not pull the tube from side to
fuel line at the pump and then connect a siphon tube.
side or up and down, as rough treatment can cause
Collect the drained fuel in a suitable container. Dis-
the soldered sleeve to break its seal to the tank and
connect the fuel line and the wire lead to the gauge
thus cause a leak.
unit. (Right side near top of tank).
(7) Remove the nut that holds the tank retaining
(2) Disconnect the vent tube from the filler tube
strap to the “J” bolt. Allow the strap to drop or
at the connector.
hang then lower the tank and remove from under the
(3) Remove the 3 screws that hold the filler tube vehicle.
and gasket, to the rear quarter panel.
(8)Remove the tank gauge unit, using spanner
(4) Remove the 5 screws and washers that attach wrench Tool C-3582.Slide the gauge assembly out of
the filler tube seal to the floor pan, then remove the the fuel tank. Discard the gasket.
end of the vent tube from the seal.
(9) If necessary, test the operation of the fuel
(5) Grasp the filler tube with both hands, twist gauge, as described in Group 8, “Electrical System”.
the tube, and at the same time, force downward into
the tank, until the end of the tube clears the quarter lnstallut ion
panel. Remove the gasket. (If the tube is frozen in Before installing the fuel gauge, inspect the condi-
WHEEL HOUSE INNER

FUEL T A N K STRAP BRKT.
WHEELHOUSE C
QUARTER PANEL
I\, ?@EELHOUSE OUTER-

WHEELHOUSE INNER
L\ ’I
SCREW-(3) ASSY. COMPLETE

FUEL T A N K A
CAP ASS
FILLER TUBE ASSY.
G A G E ASSY.
QUARTER PANEL 0
FUEL T A N K ASSY.
ER ASSY. VIEW A 62x263
Fig. 5-Fuel lank Assembly (Installation) 1 16” W/B Models (Station Wagon)
14-80 FUEL TANK
FUEL SUPPLY TUBE for repair or installation of a new tank, refer to Figure
4, then proceed as follows:
(1) Drain the fuel tank (using the siphon method),
then disconnect the fuel line and the wire lead to
the gauge unit.
(2)Remove the screw that attaches the filler tube
to the body panel, then, with a twisting motion, pull
the filler tube out of the tank. (If the tube is frozen
in the tank, use a rubber lubricant around the joint
and work into the “0”ring recess).
SUCTION TUB (3) Remove the nut that holds the tank retaining
strap to the “J” bolt. Allow strap to hang, then drop
50x1280 tank and remove from under the vehicle.
Fig. &Fuel l a n k Sending Unit (4) Remove the tank unit (gauge), using spanner
wrench Tool C-3582.Slide the gauge assembly out
of the fuel tank. Discard the gasket.
tion of the filter on the end of the suction tube. If
the filter is plugged, install a new filter. Installation
(1) Install a new “0”ring in the tank filler tube Before installing the fuel gauge, inspect the condi-
sleeve. Insert a new gasket in the fuel gauge open- tion of the filter on the end of the suction tube. If
ing recess, then slide the gauge into the tank. Align the filter is plugged, install a new filter.
the positioning tangs on the gauge with those in the To install the fuel tank, refer to Figure 4, then
tank. Install the lockring, then tighten securely, using proceed as follows:
To01 C-3582.
(1) Install a new “0”ring in the tank filler tube
(2)Slide the tank under the vehicle and up into sleeve. Insert a new gasket in the fuel gauge open-
position. Hold the tank in this position, then raise ing recess, then slide the gauge into the tank. Align
the retaining strap and thread onto the “J” bolt. the positioning tangs on the gauge with those in the
Install the attaching nut, and tighten securely. (Not tank. Install the lockring, then tighten securely, using
over 60 inch pounds torque).
To01 C-3582.
(3) Lubricate the “0”ring, using a suitable rub-
(2)Slide the fuel tank under the vehicle. Raise the
ber lubricant, then slide the filler tube down through
tank far enough to engage the filler spout with the
the dust seal and into the tank, far enough to clear
opening in the rear panel.
the quarter panel. Twist (or rotate) the filler tube 180
degrees and align with opening in quarter panel. (3)Push the tank toward the rear to fully engage
Install a new gasket over the end of the tube, then, the filler spout in the opening.
slowly withdraw tube from the tank and into position (4) Hold the fuel tank in this position, then place
against the quarter panel. Align the attaching screw the hold down strap in position; feeding the attach-
holes; install the screws and tighten securely. Slide ing stud through the hole in the end of the strap.
the vent tube through the seal. Install the nut but do not tighten (2 or 3 threads).
(4) If the dust seal was disturbed during the re- (5) Guide the button head of the stud into the slot
moval operation, realign and tighten the attaching in the frame and down into position. Move the tank
screws secure1.y. slightly back and forth; front and rear until the em-
(5) Reconnect the vent tube to the filler tube con- bossed surface of the tank meshes with the embossed
nector. surface of the floor pan. (Be sure the insulator is in
(6) Reconnect the fuel supply line and the wire
place). With the tank held in this position, tighten
the strap bolt nut to 60 inch pounds.
lead to the gauge.
(7) Refill the tank and test for leaks. CAUTION: Do not exceed 60 inch pounds tor-
que, as additional pressure can distort the tank and
may cause leaks.
2. FUELTANK
(6) Slide the filler tube down into position through
Disassembly-( 1 1 6 ” W/B Models- the “0” ring with a twisting motion, until seated
Except Station Wagons 1 firmly in the tank. Align the screw hole and install
Should it become necessary to remove a fuel tank the attaching screw. Tighten securely.
FUEL TANK 14-81
(7) Connect the lead wire to the tank gauge unit, Installation
and reconnect the fuel line. Refill tank and test for Before installing the fuel gauge assembly, inspect
leaks. the filter on the end of the suction tube. If the filter
is plugged, install a new filter.
3. FUELTANK To install the fuel tank, refer to Figure 3, then
proceed as follows:
Disassembly [ 106” W / B Station (1) Install a new gasket in the fuel gauge opening
Wagon Models 1 recess, then slide the gauge into the tank. Align the
Should it become necessary to remove the Station positioning tangs on the gauge with those in the tank.
Wagon fuel tank for repair, gauge removal or the Install the lockring then tighten securely, using Tool
installation of a new tank, refer to Figure 3, then C-3582.
proceed as follows: (2) Slide the fuel tank under the vehicle and up
(1) Drain the fuel tank, by disconnecting the fuel to meet the filler tube. (Be sure a new “0”ring was
line at the fuel pump and connect a siphon tube. installed in the tank). Engage the tank spout with
Collect the drained fuel in a suitable container. the filler tube, then work the tank onto the tube. Hold
(2) Disconnect the fuel line at the tank and the in this position, then raise the retaining strap and
lead wire to the fuel gauge. thread onto the “J” bolt. Install the attaching nut, and
tighten to 60 inch pounds.
(3) Remove the nut that holds the tank retaining
strap to the “J” bolt. Allow strap to hang, then, using (3) Reconnect the fuel line and the lead wire to
care, slightly drop the right hand side of the tank and the fuel gauge unit.
with a twisting motion, work the tank off the end of (4) Refill the fuel tank and test for leaks.
the filler tube. (If the tube is frozen in the tank, use If the filler tube assembly was removed, it will be
a rubber lubricant around the joint and work into the necessary to install the tube assembly before install-
“0”ring recess. Drop tank and remove from under ing the tank. To install the filler tube assembly, refer
the vehicle. to Figure 3, then proceed as follows:
(4) Remove the tank unit (gauge), using span- (1) Place a new seal over the end of the filler
ner wrench Tool C-3582. Slide the gauge assembly tube and a new “0”ring in the tank recess. (Be sure
out of the fuel tank. Discard the gasket. and test the vent hose connections, as a leak at this
If it was found necessary to remove the filler tube point may allow fuel odor to enter the passenger
for repair or the installation of a new tube, proceed compartment).
as follows: (2) Slide the filler tube assembly (tube, seals, vent
(5) Remove the screws that attach the upper tube and hose) into position. Rotate the filler tube so
trim plate to the quarter panel, to expose the fuel tank that it can enter the tank.
vent tube clip. (3) Align the screw holes and install screws.
(6) Reach through the access hole (directly above Tighten securely.
the filler tube location) with the fingers, and unhook (4) Position both the inner panel to tube seal and
the vent hose from the clip. (Refer to Fig. 3.) the tube to floor pan seal. Install the attaching screws
(7) Remove the rear floor mat and raise the spare washers and tighten securely.
tire cover (rear floor section), to expose the filler (5) Reaching through the access hole, reposition
tube, vent tube and seal (filler tube to floor pan). the vent hose over the clip.
(8) Remove the screws and washers that attach (6) Reinstall the trim plate in the quarter panel.
the filler tube to the inner panel and floor pan seals. (7) Reinstall the rear floor pan filler and secure
Slide both seals toward the center of the filler tube. with screws.
(9) Remove the 3 screws that attach the outer (8) Reinstall the spare tire cover and the floor
end of the filler tube to the outer quarter panel skin. mat.
(10) Withdraw the complete assembly (tube, seals,
vent tube and hose) into the luggage area and out 4. FUEL TANK- ( 1 16” Station
of the vehicle. Discard the filler tube to outer skin W a g o n Models1
seal. Inspect the condition of the tube to floor pan
and inner panel seals for signs of deterioration or Disassembly
damage. Replace questionable seals with new ones at Should it become necessary to remove the Station
reassembly. Wagon fuel tank for repair or the installation of a new
14-82 FUEL TANK
tank, refer to Figure 5, then proceed as follows: tube. If the filler is corroded, install a new filter.
(1) Drain the fuel tank (using the siphon method), (1) Position the fuel tank gauge unit in the tank,
then disconnect the fuel line and the lead wire to the using a new gasket. Tighten securely, using Tool C-
gauge unit (under the rear fender, behind the wheel 3582.
house).
(2) Slide the hold down strap up under the quarter
(2) Disconnect the left rear shock absorber, then panel, inserting the end of the strap into the slot.
raise the vehicle on a frame contact hoist. (This will Allow the strap to hang.
allow the rear wheels to hang free).
(3) Install a new “0”ring in the neck of the tank.
(3) Remove the left rear wheel.
(Refer to Fig. 5).
(4) Remove the screws that attach the stone shield
(4) Slide the tank up under the quarter panel with
to the lower edge of the wheel house at the rear. Re- the gauge unit facing the front of vehicle and work
move the shield.
up into position, then push toward the rear of vehicle
(5) Remove the filler cap and the filler tube sleeve (Be sure the embossed side of the tank engages with
attaching screws. Using a suitable tool, pry out the the embossed surface of the support). Make sure the
filler tube (a press fit in the tank neck seal); being filler neck is aligned with the opening in the top of
careful not to damage the car finish. Slide the sleeve the quarter panel. Hold in this position, then raise the
out of the body opening. Remove the seal from the retaining strap and thread onto the “J” bolt. Install
sleeve and “0”ring from the filler tube. the attaching nut. Do not tighten.
(6) Remove the nut that holds the tank retaining (5) Place a new seal over the filler tube and down
strap to the “J” bolt. Allow strap to hang. against the flange. Inseit the filler tube down into the
(7) Slide the tank toward the front of vehicle, then neck of the tank. Force the tube into the “0”ring
work down and out from under the quarter panel. until the tube contacts the seal retainer. (Be sure the
Reach up under the quarter panel and disengage the anchor tab on the tube is aligned with a screw hole).
hold down strap from the bracket (if strap is to be Install screws and tighten securely.
replaced Refer to Fig. 5).
(6) Tighten fuel tank hold down strap bolt to 60
(8) Loosen the tank gauge unit, using a spanner
inch-pounds torque.
wrench Tool C-3582. Slide the unit up and out of the
tank. (7) Install the stone shield, connect the fuel line
Inspect the condition of the rubber “0”ring. If and lead wire to the gauge unit. Reinstall the button
cracked or deteriorated, install new “0”ring at re- plugs.
assembly. (8) Reinstall the left rear wheel.
lnstallatton (9) Lower the vehicle and connect the left rear
Before installing the fuel tank gauge unit, inspect shock absorber.
the condition of the filter on the end of the suction (10) Refill the fuel tank and test for leaks.
DIAGNOSIS-FUEL SYSTEM 14-83
PART 8-SERVICE DIAGNOSIS
CARBURETOR
Poor Idling (a) Idle air bleed carbonized (a) Disassemble the carburetor. Then, use compressed
or of incorrect size. air to clear idle bleed after soaking it in a suitable
solvent.
Idle discharged holes (b) Disassemble the carburetor. Then, use compressed
plugged or gummed. air to clear iJle discharge holes after soaking the
main and throttle bodies in a suitable solvent.
Throttle body carbonized (c) Disassemble the carburetor. Test the throttle
or worn throttle shaft. valve shaft for wear. If excessive wear is apparent,
replace the throttle body assembly.
Damaged or worn idle (d) Replace the worn or damaged idle needle. Adjust
mixture needle. the air mixture.
Low grade fuel or (e) Test the fuel level in the carburetor. Adjust as
incorrect float level. necessary to obtain the correct float level.
Loose main body to (f) Tighten the main body to throttle body screws
throttle body screws. securely to prevent air leaks and cracked housings.
Poor Acceleration Accelerator pump bypass (a) Disassemble the carburetor. Clean and inspect
seat corroded or bad. accelerator pump by-pass jet. Replace by-pass jet,
if it is in questionable condition.
Accelerator pump piston (b) Disassemble the carburetor. Replace accelerator
(or plunger leather too pump assembly if leather is hard, cracked or worn.
hard, worn, or loose Test follow-up spring for compression.
on stem.
.Faulty accelerator pump (c) Disassemble the carburetor. Use compressed air to
discharge ball. clear the discharge nozzle and channels after
soaking the main body in a suitable solvent.
Test the fuel pump capacity.
Faulty accelerator pump (d) Disassemble the carburetor. Test the accelerator
inlet check ball. pump inlet check ball for poor seat or release.
If part is faulty, replace.
Incorrect fuel or float (e) Test the fuel or float level in the carburetor.
level. Adjust as necessary to obtain correct float level.
Worn or corroded needle (f) Clean and inspect the needle valve and seat. If
valve and seat. found to be in questionable condition, replace
assembly. Then, test fuel pump pressure. Refer to
Specifications for correct fuel pump pressure.
Worn accelerator pump (g) Disassemble the Carburetor. Replace the worn
and throttle linkage. accelerator pump and throttle linkage and
measure for the correct position.
Automatic choke not (h) Test adjustment and operation of automatic choke.
operating properly. If necessary, replace the choke.
Carburetor Floods Cracked body. (a) Disassemble the carburetor. Replace the cracked
or Leaks body. Make sure main to throttle body screws
are tight.
Faulty body gaskets. (b) Disassemble the carburetor. Replace the faulty
gaskets and test for leakage. Be sure the screws
are tightened securely.
High float level. (c) Test the fuel level in the carburetor. Make the
necessary adjustment t o obtain correct float level.
14-84 DIAGNOSIS-FUEL SYSTEM
~~ ~~
SERVICE DIAGNOSI- ( Continued1

CARBURETOR
Worn needle valve and (d) Clean and inspect the needle valve and seat. If
seat. found to be in a questionable condition, replace the
complete assembly and test the fuel pump
pressure. Refer to Specifications for correct fuel
pump pressure.
Excessive fuel pump (e) Test the pump pressure. If the pressure is in
pressure. excess of recommended pressure (refer to
Specifications), replace fuel pump.
Poor Performance- (a) Restricted air cleaner. (a) Remove and clean the air cleaner.
Mixture Too Rich (b) Leaking float. (b) Disassemble the carburetor. Replace leaking
float. Test the float level and correct as
necessary, to the proper level.
High float level. (c) Adjust the float level as necessary to secure the
proper level.
Excessive fuel pump (d) Test the fuel pump pressure. Refer to
pressure. Specifications for recommended pressure. If
pressure is in excess of recommended pressure,
replace the fuel pump assembly.
Worn metering jet. (e) Disassemble the carburetor. Replace the worn
metering jet, using a new jet of the correct size
and type.
FUEL PUMP
Fuel P u m p Leaks Worn, ruptured or torn diaphragm. (a) Install a new fuel pump.
-Fuel Loose diaphragm mounting plates. (b) Install a new fuel pump.
Loose inlet or outlet line fittings. (c) Tighten the line fittings.
Fuel P u m p Leaks Cracked or deteriorated pull rod oil (a) Install a new pump.
-Oil seal.
Loose rocker arm pivot pin. (b) Install a new fuel pump.
Loose pump mounting bolts. (c) Tighten the mounting bolts
securely.
Defective pump to block gasket. (d) Install a new gasket.
Insufficient Fuel Vent in tank filler cap restricted. This (a) Install new cap, and inspect tank
Delivery will also cause collapsed fuel tank.) for leaks.
Leaks in fuel line or fittings. (b) Tighten the line fittings.
Dirt or restriction in fuel tank. (c) Install a new fuel filter and clean
out the tank.
Worn, ruptured, or torn diaphragm. (d) Install a new pump.
Frozen gas lines. (e) Thaw the lirles and drain the tank.
Improperly seating valves. (f) Install a new fuel pump.
Vapor lock. ( g ) Install heat shield where lines or
pump are near exhaust.
Weak main spring. (h) Install a new fuel pump.
Incorrect fuel pump. (i) Install correct fuel pump.
Restricted fuel filter. (j) Install a new filter.
Loose mounting bolts. (a) Tighten the mounting bolts.
Scored or worn rocker arm. (b) Install a new fuel pump.
Weak or broken rocker arm spring. (c) Install a new fuel pump.
PROPELLER SHAFT AND UNIVERSAL JOINTS 16-1
GROUP 16
PROPELLER SHAFT AND UNIVERSAL JOINTS
CONTENTS
Page Page
Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Propeller Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Ball and Trunnion Universal Joint.. . . . . . . . . . . . . . . . . 4
Special Tool Usage Chart.. ...................... 1 Cross and Roller Universal Joint. . . . . . . . . . . . . . . . . . . 5
Propeller Shaft Angularity. . . . . . . . . . . . . . . . . . . . . . . 3 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
Plymouth Plymouth Valiant

8 Cyl. (VP-2) 6 Cyl. (VP-1) All Models ( W - 1 )
PROPELLER SHAFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubular
Propeller Shaft Angularity. . . . . . . . . . . . . . . . . . . Approximate 2 Degrees
*Length-Standard Transmission. . . . . . . . . . . . . . . 55.7 6" 55.76" 53.40"
Automatic Transmission. . . . . . . . . . . . . . . 53.64" 53.64" 53.40"
Diameter-Standard Transmission. . . . . . . . . . . . . 3.00" 3.00" 2.75"
Automatic Transmission. . . . . . . . . . . . . 2.75" 2.75" 2.75"
Special Equipment. . . . . . . . . . . . . . . . 3.00" - 3.00"
UNIVERSAL JOINTS
Type-Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ball and Trunnion
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross and Roller
~~ ~~
*Front centerline of trunnion pin to centerline of rear yoke bearing bores.
SPECIAL TOOL USAGE CHART

Trunnion Pin Removing and Installing Jig
Plymouth 8 Cyl. Plymouth 6 Cyl. Valiant
Manual Transmission-Standard . . . . . . . . . . . . . . . . . . . C-33 13 C-552 C-552

Manual Transmission-225 Cubic Inch Engine. . . . . . . . - - C-33 13
Manual Transmission-Heavy Duty. . . . . . . . . . . . . . . . . C-3567 C-552 -
Automatic Transmission-Standard . . . . . . . . . . . . . . . . . C-3567 C-33 13 C-552
Automatic Transmission-225 Cubic Inch Engine. . . . . . - - C-3313
TORQUE REFERENCE
Foot-Pounds Inch-Pounds
Front-Companion Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear-Clamp Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Rebound Bumper Plate Bolts (Valiant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
(All other Plymouth Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Rear Spring U Bolt Nuts (Valiant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
(All other Plymouth Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
16-2 PROPELLER SHAFT AND UNIVERSAL JOINTS
BALL AND ROLLER
CLAMP
SHAFT
~~
BREATHER
63x572
Fig. 1-Ball and trunnion Universal Joint

(Disassembled)
SEAL
SHAFT
BUSHING
RETAINER
SEAL
,BUSHING
Fig. 2-Cross and Roller Universal Joint

(Disassembled)
PROPELLER SHAFT AND UNIVERSAL JOINTS

The propeller shaft has a ball and trunnion type lengthens the life of the boot by decreasing the
universal joint at its forward end (Fig. 1) and a cross flexing action due to variations of air pressure within
and roller type universal joint at the rear (Fig. 2). the assembly as the shaft moves back and forth in
When the vehicle is in motion, the propeller shaft the joint body.
is free to slide fore and aft inside the front universal The universal joints are permanently lubricated;
joint body. All working parts are sealed against road however, if the joints are disassembled for any rea-
splash, dust, mud and water. The front joint is son, they should be inspected and repacked with
equipped with a polished jute breather. The breather Mopar Multi-Mileage Lubricant, Part No. 2298947.
SERVICE PROCEDURES
1. PROPELLER SHAFT ANGULARITY NOTE: Each time the gauge is used, the level
must be on the same side of the propeller shaft.
The quiet smooth operation of the propeller shaft
(4) Hold the gauge on the underside of the pro-
and universal joints depends upon proper alignment. peller shaft near the rear universal joint (Fig. 4), and
The propeller shaft and rear axle housing angles may
look for the location of the bubble in the spirit level.
be measured by using an alignment measuring gauge, The entire bubble should be within three graduations
Tool 5-6485 with the vehicle in a level position and from center (Fig. 5 and 6).
no additional weight, except the fuel tank must be
full. (5) If the rear joint angle must be adjusted, tapered
shims should be added between the rear springs and
CAUTION: The vehicle must be supported by the differential housing spring plates, as shown in Figure
wheels, or front suspension lower control arms and 7.
rear axle housing. Do not use a frame contact hoist
(6) If the edge of the bubble is forward of the
for measuring propeller shaft angularity.
third graduation, the angle of the rear axle housing
(1) Use a twin post hoist or drive-on hoist, pit, should be changed. Loosen all “U” bolt nuts and
wheel or frame alignment rack. Level the vehicle. install two-degree tapered wedges between both rear
Measure the level at underside of the body sill at the springs and the axle housing pads with the thick end
center of the front door. of the wedge toward the front of the vehicle (Fig.
(2) Remove the rebound plate and bumper assem- 5). Tighten the rear spring “U” bolt nuts to 55 foot-
bly from the top of the differential carrier housing. pounds torque.
(3) Hold the gauge, Tool 5-6485 on the machined (7) Re-measure the rear joint angle, then install the
surfaces of the rebound plate bosses (Fig. 3). Adjust rebound bumper and plate assembly on the carrier
the gauge to center the bubble in the spirit level. housing. Tighten the retaining bolts to 200 inch-
pounds torque.
Fig. 3-Measuring the Angle of the Rear

Axle Housing Fig. 4-Measuring the Propeller Shaft Angularity
16-4 PROPELLER SHAFT AND UNIVERSAL JOINTS
ADD SHIMS
Fig. 5-Bubble location (Forward of Center)
2. PROPELLER SHAFT (Figs. 1 and 21

Removal
(1) Remove both rear universal roller and bushing
assembly clamps from the pinion yoke. (Do not dis- Fig. 7-Installing the Tapered Wedges
turb the retaining strap used to hold the roller as-
semblies on the universal joint cross).
(2) Disconnect the front universal joint from the (2) Push the body back and JY3"lOvethe parts from
transmission flange and remove the propeller shaft both ends Of the trunnion pin*
from the vehicle. (3) Remove the clamps and loosen the dust cover.
CAUTION: Do not allow the propeller shaft to Remove and save the breather (polished jute) located
drop or hang loose on the vehicle from either ioint between the shaft and rear end of the cover.
during the removal. Wire up to underbody. (4) Clean and examine the trunnion pin and the
raceways in the body for wear. If wear in the body
lnstallation can be felt, it should be replaced. If either part is
(1) Attach the front universal joint to the trans- to be replaced, use the "Special Tool Usage Chart"
mission flange. Tighten the attaching nuts to 32 foot- and a hydraulic press to push the pin out of the shaft.
pounds torque.
(2) Install the rear universal cross rollers into the Cleaning and lnspection
seats of the pinion yoke. (1) Clean the parts in kerosene, mineral spirits or
(3) Install the roller clamps and attaching bolts. other suitable solvents. If the pin, body and boot have
Tighten the attaching bolts to 110 inch-pounds torque. not been removed, make sure that the body and boot
are clean inside as well as outside.
3. BALL AND T R U N N I O N UNIVERSAL JOINT PROPELLER SHAFT

UNIVERSAL J O I N T CENTE
Disassembly
(1) Straighten the tabs and remove the grease
cover and gasket (Fig. 1).
SUBTRACT SHIMS - -r
UNIVERSAL JOINT UNIVERSAL JOINT BODY
DUST COVER OR
58x706 BOOT 49x910
Fig. 6-Bubble location (Rear of Center) Fig. 8-Sliding Cover Over Ball Head and Pin
59’1045
Fig. 9-Working Cover through Body
Fig. 10-Installing the Trunnion Pin
Ass embl y 4. CROSS AND ROLLER

UNIVERSAL J O I N T
When the trunnion pin and body have not been
removed, a new boot can be installed, after coating Disassembly
all parts with Multi-Mileage lubricant (Figs. 8 and 9). (1) Remove the retainer and press one roller and
Without using tools, stretch the boot over the pin bushing assembly out of the yoke by pressing the
and work it through the body into position on the opposite bushing in (Fig. 2).
shaft. (2) Press the remaining roller and bushing assem-
(1) The trunnion pin must be installed in the pro- bly out by pressing on the end of the cross assembly.
peller shaft by the use of a hydraulic press and the (3) Remove the cross from the yoke. The cross and
correct tool. The pin is properly centered when press seal retainers are serviced as an assembly. Do not
ram contacts the spacer portion of the tool (Fig. 10). remove seal retainers from the cross.
Refer to “Special Tool Usage Chart”.
(2) Install a thrust washer, rollers, ball, button Cleaning and Inspection
spring and thrust button on each end of the trunnion
pin and position the body over the pin assembly. (1) Clean the parts in kerosene, mineral spirits or
other suitable solvents and dry with compressed air.
(3) Position the boot on the propeller shaft, with
the breather (polished jute) parallel to the shaft. (2) Examine the bearing surfaces of the cross. The
Install and tighten the clamp. surfaces should be smooth, free from pits and ripples.
If the dust seal retainers are damaged, replace the
(4) Position the boot on the joint body and install
cross assembly.
the clamp.
(3) Examine the roller bearings in the bushings.
(5) Lubricate the universal joint with two ounces
Bearings that have operated on a worn cross should
Multi-Mileage lubricant applied evenly in both race- be replaced. Bearings should have a uniform appear-
ways, one-half back of the trunnion pin and one-half ance and should roll freely inside the bushings.
between the pin and cover. Two ounces of Multi-
Mileage Lubricant would be about 1/2 inch deep if
placed on the universal joint grease cover. Do not
Assembly
use more than the specified amount. Do not place (1) Force Multi-Mileage lubricant between the
grease inside the boot. rollers in all four bushings. Fill the reservoirs in the
(6) Install the gasket on the cover, and position ends of the cross.
the cover on the body with tabs at grooves in the (2) Place the cross in the propeller shaft yoke and
body. Bend the tabs to tighten cover in place. insert the roller bushing assemblies in the yoke.
166 PROPELLER SHAFT AND UNIVERSAL JOINTS
(3) Press the roller and bushing assemblies into the (5) Position the remaining two bushings on the
yoke while guiding the cross into both bushings. cross and install the retainer strap to hold the
(4) Press until both bushing retainers can be in- bushings on the cross during installation in the
stalled in the grooves in the bushings. vehicle.
SERVICE DIAGNOSIS
Propeller Shaft (a) Excessive grease in the (a) Remove all grease and pack a total 2
Vi bration universal joint dust boot. ounces of Multi-Milage Lubricant. Part
No. 2298947 evenly fore and aft of the
trunnion’ pin in both raceways.
(b) Undercoating or other foreign (b) Clean propeller shaft and wash with
material on shaft. solvent.
(c) Loose universal joint flange (c) Tighten the flange bolts.
bolts.
(d) Loose or bent universal joint (d) Install a new flange if worn or bent and
flange. tighten to specifications.
(e) Improper drive line angularity. (e) Correct the propeller shaft angularity.
(f) Rear suspension spring center (f) Loosen the spring clamps and reset the
bolt not in seat. spring center bolt.
(g) Worn trunnion pin. (g) Recondition the universal joint. Install a
new trunnion pin.
(h) Trunnion pin not centered. (h) Center trunnion pin correctly or replace,
using Special Tool.
(i) Worn universal joint bearings or (i) Recondition the universal joint.
missing needle bearings.
(j) Worn universal joint housing. (j) Recondition the universal joint. Install a
new housing.
(k) Propeller shaft damaged (bent (k) Install a new propeller shaft.
tube) or out of balance.
Universal Joint Nolse (a) Propeller shaft flange quts loose. (a) Tighten to specified torque.
(b) Lack of lubrication. (b) Inspect and replace worn parts and
lubricate with 2 ounces of Multi-Milage.
Lubricant, Part No. 2298947.
(c) Worn universal joint pin or (c) Replace worn parts.
housing.
SPRINGS AND SHOCK ABSORBERS 17-1
GROUP 17
SPRINGS AND SHOCK ABSORBERS
CONTENTS
Page Page
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 leaf Spring lnterliner Replacement. . . . . . . . . . . . . . . . 5
Tool list.. .................................... 1 Zinc lnterleaf Replacement. ...................... 6
Torque Reference. ............................. 2 Front Shock Absorbers. ......................... 6
Measuring Rear Spring Height. . . . . . . . . . . . . . . . . . . . 4 Rear Shock Absorbers Replacement. . . . . . . . . . . . . . -. 7
Rearsprings .................................. 4 Testing the Shock Absorber. ..................... 7
Rear Spring Front Pivot Bushing Replacement.. . . . . . . 4 Service Diagnosis. ............................. 7
SPECIFlCATlONS
Plymouth Valiant
VP-1, VP-2 w-1
REAR SPRINGS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi-Elliptic
Number of leaves
Sedan
(Standard). ....................................................... 5 4
(Heavy Duty)*. .................................................... 5 '/2 5
Station Wagon
(Standard). ....................................................... 6% 5
(Heavy Duty)*. .................................................... 6% 6
length (inches). ............................................................ 56 55
Width (inches). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2% 2%
Spring Mounting
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot, Rubber Bushed
Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "U" Bolts and Plate
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shackle, Rubber Bushed
SHOCK ABSORBERS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oriflow
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Bushing
"Zinc Interleaves used between all leaves.
TOOL LIST
C-3553. ................................................. .Front Shock Absorber lower Bushing Remover and Installer
C-3729.. ......................................................... .Rear Spring Pivot Bushing Remover and Installer
17-2 SPRINGS AND SHOCK ABSORBERS
TORQUE REFERENCE
Foot-Pounds
Front Pivot Nut-Plymouth. . . . . . ........................................................ 125
Valiant. . . . . . . . . . . . ..................................................... 60
Shackle Bolt Nut-Plymouth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Valiant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................... 40
“U” Bolt Nut (Plymouth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................. 45
(Va Iiant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front Spring Hanger to Body Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rear,Spring Hanger to Body Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front Shock Absorber Mounting Nuts
Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
lower. . . . . . . . . . . . ............................................................... 55
Rear Shock Absorber Mo
Upper (Plymouth).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
................................................................ 50
lower. . . . . . . . . . . . . . . . . . . . . . ...................................................... 50
Rear Shock Absorber Upper Stud to Body Nut (Valiant). . . . . . . . ............................. 50
REAR SPRINGS AND SHOCK ABSORBERS

The rear springs (Figs. 1 and 2) are of the semi- Zinc Interleaves - Zinc Interleaves are used
elliptic type with rubber bushings in the “eye” of between the spring leaves for heavy duty suspension
each end of the main leaf. equipped vehicles to help increase spring life. Zinc
The front ends of the springs are attached to interleaves are flat pieces of zinc or metal to help
mounting brackets bolted to the body. The rear ends cushion the spring leaves. They are used between
of the springs are attached to the body by flat plate each leaf for heavy duty suspension.
shackles (except Plymouth Station Wagons, which are Double acting “Oriflow” shock absorbers are used
equipped with offset plates) with rubber shackle with rubber mounting bushings at each end of the
bushings. The springs are attached to the rear axle shock absorber.
housing spring seats by “U” bolts. Shock absorbers should only be replaced when they
have lost their resistance in one or both directions,
if the DRIP or if they have been damaged. EVIDENCE
OF OIL MOISTURE IS NOT CAUSE TO REPLACE
/, e ..
THEM.
3;* --
y- -
I I
i 62x67A
62x66A
Fig. 1-Rear Springs-Hangers and Shackles Fig. 2-Rear Springs-Hangers and Shackles
(Plymouth) (Valiant)
- SPRINGS AND SHOCK ABSORBERS 17-3
62x68
Fig. 5-Rear Shock Absorbers (Plymouth)
The lower ends of the front shock absorber (Figs.
3 and 4) are attached to the lower control arm by
62x70A means of holes in the side plates of the lower control
arm. The top of the shock absorber extends through
Fig. 3-Front Shock Absorbers (Plymouth)
a bracket and fender shield and is disconnected
through the engine compartment.
The rear shock absorbers (Fig. 5 and 6) are mounted
with the lower end mounted to a stud, welded to the
rear spring plate. The upper end of the shock ab-
sorber is attached to a mounting stud, bolted to the
body over the rear axle housing on Valiant Models
and to a bracket welded to the 'body on Plymouth
Models.
49- @-
62 x 71B
62x69
Fig. 4-Front Shock Absorbers (Valiant) Fig. &Rear Shock Absorbers (Valiant)
REAR SPRING
SERVICE PROCEDURES
.
1 MEASURING REAR SPRING HEIGHT (3)Attach the rear spring rear hanger to the body
bracket and tighten the bolts to 30 foot-pounds
(1) Jounce the vehicle several times (front bumper
first). Release the bumpers at the same point in each torque.
cycle. (4) Attach the rear spring front hanger to the body
(2) Measure the sh.ortest distance from the highest bracket and tighten the nuts to 30 foot-pounds
point on the underside of the rear axle bumper strap torque.
(at rear of bumper) to the top of the axle housing. (5) Remove the rear axle housing support and
(3)Measure both right and left sides. place the center hole of the axle spring seat over the
If these measurements vary by more than ?4 inch head of the spring center bolt.
(from side to side) it is an indication that one of the (6) Place the spring plate under the spring and
rear springs may need replacing. It is normal for install the “U” bolts and tighten the nuts to 45
rear springs to show some reverse arch, even with no foot-pounds torque for Valiant and 50 foot-pounds for
load, so appearance alone should not be the reason Plymouth Models.
for spring replacement. (7)Raise the vehicle and connect the rear shock
absorbers. Remove the stands and lower the vehicle
2. REAR SPRING onto its wheels.
(8) Jounce the vehicle several times (front bumper
Removal first) and compare the spring heights. (It may be
(1) Raise the vehicle to a comfortable working necessary to replace the mating spring to insure the
level. position of the vehicle.)
(2) Disconnect the rear shock absorber at the lower (9)Tighten the front eye bolts and/or nuts to 125
mounting stud. foot-pounds (Plymouth) 60 foot-pounds (Valiant) and
(3)Support the vehicle at the lifting points, per- the shackle nuts to 40 foot-pounds torque (Plymouth)
mitting the rear springs to hang free. 30 foot-pounds torque (Valiant) with the full weight
of the vehicle on the wheels.
(4) Support the rear axle housing to this position.
(5) Remove the nuts attaching the rear spring front
pivot hanger to the body frame. 3. REAR SPRING FRONT PIVOT BUSHING
(6) Remove the “U” bolt nuts and spring plate. REPLACEMENT
(7)Remove the rear hanger bolts and remove the The spring front pivot and rear shackle bushings
spring from the vehicle. may be replaced with the spring still on the vehicle
(8) Remove the rear spring front pivot bolt and by the following method:
remove the hanger from the spring. (1) Raise the vehicle so the spring is relaxed with
(9) Remove the rear shackle and bushings from the rear wheels just touching the floor. Do not permit
the spring and hanger. weight of rear axle to be suspended on fully
extended shack absorbers.
Installat ton (2) To replace the front bushing, remove the rear
Inspect the rear spring front pivot bolt bushing and spring front hanger from the body bracket. Remove
if necessary replace the bushing using Tool C-3729 the pivot and hanger from the spring.
as outlined in Paragraph 3. (3)Place the new bushing on Tool (2-3729, as shown
(1) Attach the front hanger to the front end of in Figure 7. Arrange tool on spring eye, then press
spring and start the pivot bolt nut. Do not tighten. out the old bushing while pressing the new bushing
(2)Assemble the rear shackle and bushings (Figs. in the one operation.
1 and 2) in the spring rear eye and the rear spring (4) Assemble the front hanger to the spring, but
hanger. (Do not lubricate the rubber bushings.) Start do not tighten the pivot bolt nut until the full weight
the shackle bolt nuts. Do not tighten. of the vehicle is on the wheels.
c
SP-92
I /
SP-3179 SP-311
I
I SP-3242
I
I
‘-3” BUSHING I
SPRING SP-3178
Fig. 9-Positioning Spring Interliner
Fig. 7-Removing and Installing Spring Bushing (2) Remove the nut and washer of the spring align-
ment clips and remove the clips.
(5) Attach the spring hanger to the body bracket NOTE: On all Valiant models equipped with four
and tighten the mounting bolts to 30 foot-pounds. leaf springs, discard the alignment clips used after
(6) To replace the spring shackle bushing, remove they have been removed from the springs.
the rear hanger from the body bracket. Remove the (3) Separate the spring leaves (Fig. 8) with a
shackle, then slide the bushings out of the spring tapered pry bar or screw driver and using another
and hanger. screw driver, remove the interliner from the spring
(7) Insert the new bushings in the spring and leaf.
hanger, then assemble the shackle and hanger on the (4) Keeping the spring leaves separated, clean the
spring. Start the shackle bolt nuts. mating area of both spring leaves thoroughly. If any
(8) Attach the hanger to the body bracket and rust or corrosion is evident, wrap sandpaper around a
tighten the mounting bolt to 30 foot-pounds torque. flat file or putty knife and sand until area is smooth
and clean.
(9) With the full weight of the vehicle on the
wheels, tighten the rear spring front pivot bolt nut (5) With the spring leaves still separated, insert
125 foot-pounds (Plymouth) 60 foot-pounds (Valiant) the new interliner (Fig. 9) with the retaining buttons
and the shackle nuts to 40 foot-pounds (Plymouth) in alignment with the locating holes.
30 foot-pounds (Valiant). (6) Press the retaining buttons into the retainer
holes (Fig. 10) and remove the pry bar from the spring
4. LEAF SPRING INTERLINER REPLACEMENT leaves.
(1) Release the weight from the rear spring by (7) Repeat the above procedures for the balance
elevating the body at the closest lifting point of the of the interliners. (Do not lubricate the interlinerr.)
body. (8) Reinstall the aligning clips and replace re-
Fig. 8-Separating Spring leaves Fig. 10-Installing lnterliner Button

6 4 x 171
Fig. 12-Zinc Interleaf
5. Z I N C INTERLEAF REPLACEMENT
( Heavy Duty Suspension 1
(1) Remove the rear spring (See Paragraph 2).
Fig. 11-Installing Alignment Clip
(2) Remove the center bolt from the spring and
taining nuts and washers, as shown in Figure 11. On separate the leaves.
Valiant models equipped with the 4 leaf spring, install (3)Install the zinc interleaves between the spring
a new “bolt-on” type clip. leaves and install the centerbolt.
(9) Lower the vehicle onto its wheels. (4) Tighten the center bolt.
SHOCK
6. FRONT SHOCK ABSORBERS NOTE: New shock absorbers are furnished with
the lower bushing installed; however, bushings are
Removal furnished separately for service installation.
(1) Remove the nut and washer from the upper (6) Test the shock absorber as outlined in Para-
end of the piston rod. (Accessible from engine com- graph 8.
partment .)
(2) Raise the vehicle and remove the pivot bolt and
nut from the lower shock absorber eye and mounting
bracket.
(3) Compress the shock absorber and remove it
from the vehicle by pulling down out of the upper
shock absorber mounting bushing.
(4) If the upper bushing appears worn, damaged,
or deteriorated, remove it by first pressing out the
inner sleeve, then prying-out or cutting out the rub-
ber bushing. (This bushing will take some set after
it has been in service and should be replaced once it
has been removed.)
(5) If the lower bushing is to be replaced, remove
it from the shock absorber using Tool C-3553to press
on the outer sleeve of the bushing (Fig. 13). Pressing 57x71
on the inner sleeve will not remove the outer sleeve
from the shock absorber. Fig. 13-Installing Shock Absorber Bushing
installation (6) Position the shock absorber on the mounting

studs and install the remaining cupped washers and
(1) With the inner steel sleeve removed from the
nuts. Tighten the upper and lower stud nuts to 60
upper rubber bushing, immerse the bushing in water foot-pounds torque with the full weight of the vehicle
(do not use oil or soap) and with a twisting motion,
on the wheels.
start the bushing into the hole of the mounting
bracket, then tap into place with a hammer. Reinstall 8. TESTING THE SHOCK ABSORBER
the steel sleeve.
(1) With the shock absorber removed from the
(2) Install the lower mounting bushing in the eye vehicle, extend the shock absorber fully in an upright
of the shock absorber using Tool C-3553 (Fig. 13). position.
(3) Compress the shock absorber and install the (2) Inspect for evidence of fluid running from the
washer on the upper rod of the shock absorber and upper end of the reservoir. (Actual leakage will be
insert the rod through the upper bushing. a stream of fluid running down the side and dripping
(4) Install the upper compression washer and re- off the lower end of the unit. A slight amount of
taining nut and tighten to 25 foot-pounds torque. seepage is not unusual and does not affect perform-
(5) Align the lower mounting bracket and eye of ance.)
the shock absorber. Install the bolt and nut and (3) To test for low fluid level to trapped air in
tighten to 55 foot-pounds torque with the full weight the cylinder, hold the shock absorber in a vertical
of the vehicle on the wheels. position and alternately extend and compress the unit.
There should be no lost motion in either direction.
7. REAR SHOCK ABSORBER REPLACEMENT (4) Should lost motion be evident, hold the shock
absorber in its normal vertical position and fully
(1) Remove the nuts and washers attaching the extend it.
shock absorber to its mounting studs.
(5) Invert the unit and compress it. Do not extend
(2) Remove the shock absorber from the studs. the unit while inverted.
(3) Remove the remaining cupped washers from (6) Repeat steps 4 and 5 several times to expel any
the studs. air trapped in the cylinder.
(4) Inspect the bushings for deterioration or fa- (7) Should lost motion persist, replace the shock
tigue, and replace if necessary. Test and bleed the absorber. Repeat operation 4 and 5 prior to installa-
shock absorber, as outlined in Paragraph 8. tion of a new shock absorber. New shock absorbers
(5) Position the washers on the shock absorber may have a greater resistance than an old one due to
mounting studs. friction of the new seal.
Spring Sags or (a) Springs sagged or taken a set. (a) Replace the spring.
Bottoms (b) Broken, bent or weak spring (b) Replace the spring main leaf, or spring as
leaves. necessary.
Spring Noise (a) Loose “U” bolts. (4 Tighten the “U” bolt nut 50 foot-pounds
torque (Plymouth 45 foot-pounds
torque (Valiant).
(b) Loose or worn shackle bushings. (b) Replace the bushings and tighten shackle
bolt nuts 40 foot-pounds (Plymouth) 30
foot-pounds (Valiant).
(c) Worn or missing interliners. (c) Install new interliners.
Spring Breakage (a) Loose “U” bolts. (a) Tighten the “U” bolt nuts 50 foot-pounds
(Plymouth), 40 foot-pounds (Valiant).
(b) Shock absorber inoperative. (b) Replace the spring and the shock
absorber.
~~~~~ ~ ~
STEERING 19-1
GROUP 1 9
STEERING (MANUAL. POWER. PUMPS AND LINKAGE)
CONTENTS
PART 1-MANUAL STEERING GEAR
Page Page
Specifications ................................. 2 Steering Gear . Removal ........................ 5
Adjustments................................... 4 Cross Shaft Oil Seal Replacement................. 9
Testing Worm Bearing Pre-Load .................. 4 Ball Nut Rack and Sector Mesh Adjustment
Worm Bearing Pre-Load Adjustment ............... 5 (Out of Vehicle) ............................. 10
Ball Nut Rack and Sector Mesh Adiustment Steering Column Gearshift-Removal .............. 13
(In Vehicle) ................................. 5 Service Diagnosis .............................. 13
PART 2-STEERING LINKAGE
Steering Knuckles .............................. 20 Steering Linkage ............................... 20
PART 3-POWER STEERING GEAR
Specifications ................................. 2 Worm Shaft Oil Seal Replacement ................ 23

Gear Shaft Adiustment-Unit in Vehicle ............ 22 Power Steering Gear - Removal ..................24
Gear Shaft Oil Seal Replacement........... . . . . . . 22 Service Diagnosis .............................. 34
PART E P O W E R STEERING PUMP
Specifications ................................. 2 Power Steering Pump Discharge Fitting Ferrule

Operation., .................................. 38 Replacement ................................ 42
Measuring Fluid level ........................... 38 Flow Control Valve Replacement.................. 42
Pressure Test ................................... 38 Slipper Spring Replacement...................... 43
Pump Flow Test ................................ 39 Installing the Power Steering Pump ................ 46
Power Steering Pump-Removal .................. 40 Service Diagnosis .............................. 46
19-2 STEERING
SPECIFICATIONS
MANUAL STEERING
Type .................................................................. Recirculating Ball Nut

Ratio .................................................................. 24 to 1
Cross Shaft Bearings (Plymouth) ............................................. 3-Needle Bearings
Cross Shaft Bearings (Valiant). ............................................. 3-Bronze Bushings
Worm Shaft Bearings.. ................................................... 2-Caged Ball Bearings
Cross Shaft Adjusting Screw End Play.. ...................................... .OOO-.004 Inch
Worm Bearing Pre-Load (in car). ........................................... 1Y2 to 4!4 in. Ibs. to
Keep Wheel Moving
Worm Bearing Pre-Load (out of car). ........................................ 1!4 to 4% in. Ibs. to
Keep Wheel Moving
, y.
Sector Mesh Adjustment Pre-Load Torque-Includes worm bearing
Pre-Load (in car). ...................................................... 8% to 1 1 % in. Ibs.
Pull through high spot
Sector Mesh Adjustment Pre-Load Torque-Includes worm bearing
Pre-Load (out of car). ................................................... 7%to 1 1 % in. Ibs.
Pull through high spot
STEERING COLUMN
Column Bearing........................................................... 1 Ball Bearing

Wheel Turns-Steering Arm Removed. ....................................... 5%
Wheel Turns-Steering Arm and Linkage Attached............................. 5 J/s Approx.
Steering Shaft to Wormshaft Coupling. ...................................... Sealed U-Joint Type
POWER STEERING GEAR
Ratio .................................................................. 15.7 to 1

Gear Shaft Bearings.. .................................................... 3 Needle Bearings
Worm Shaft Thrust Bearing Pre-Load. ....................................... 16-24 Inch Ounces
.................................
Fluid Capacity of Steering Hydraulic System. 2Y2 Pints
Type of Fluid.. .......................................................... Use Only Part No. 2084329
Power Steering Fluid
POWER STEERING PUMP
Maximum Pump Pressure

.96 Displacement Pump (Valiant). ........................................... 650 to 750 psi Maximum
.96 Displacement Pump (Plymouth). ........................................ 850 to 950 psi Maximum
Maximum Fluid Flow at 3000 rpm.. ............................................. 2% Gal. per minute

STEERING 19-3
SPECIAL TOOLS
Tool Number Tool Name

C-760. ........................................... Pliers-Snap Ring
C-3 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pliers-Snap Ring
C-32 1 1 ........................................... Hose-High Pressure
C-3229.. ......................................... Pliers-Snap Ring
C-33098. ......................................... Gauge-Pressure Check
C-33 18. .......................................... Hose-Low Pressure
C-3323. .......................................... Fixture-Steering Gear Holding
C-3 388. .......................................... Hose-Cou pling
C-3428A. ........................................ Puller-Steering Wheel
C-3633.. ........................................ .Nut Wrench-Gear Shaft Retaining
C-3634. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nut Wrench-Power Train Retaining
C-3637. ......................................... .Nut (Splined)-Worm Shaft Turning
C-3638.. ......................................... Remover-Gear Worm Shaft Seal
C-3640. .......................................... Driver-Pump Shaft Seal
C-3642. .......................................... Remover-Pump Shaft Seal
C-3643. .......................................... Stand-Pump Shaft Supporting
C-3646. .......................................... Puller-Steering Arm (Replaces C-3402)
C-3649. ......................................... .Tool-Spacer to Housing Aligning
C-3650. .......................................... Driver-Gear Worm Shaft Seal
C-3676. .......................................... Remover and Installer-Power Train Piston Ring
C-3875. .......................................... Remover, Adapter, Installer and Arbor-Gearshaft Needle Bearings
C-3879. .......................................... Installer-Steering Column Shaft Bearing
C-3880.. ........................................ .Remover and Installer-Gear Shaft Oil Seal
C-3885A. ....................................... .Remover and Installer-Gear Shaft Oil Seal
C-3885A. ........................................ Gauge-Power Steering Pump Flow Test
C-389 1 ........................................... Puller-Steering Column Shaft Bearing
C-3894.. ........................................ .Puller-Tie Rod, Steering Arm and Idler Arm Ends
C-3929. .......................................... Arbor-Steering Gear Worm Shaft Bearing
C-3934. .......................................... Puller-Power Steering Pump Pulley
MTU-36: ........................................ .Ounce Pull Scale
TIGHTENING REFERENCE
Foot-Pounds
MANUAL STEERING
Cross Shaft Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Steering Arm Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Gear Assembly to Frame Bolt. ....................................................... 50
Steering Wheel Nut ................................................................ 24
Cross Shaft Adjusting Screw Lock Nut. ................................................. 35
POWER STEERING
Steering Wheel Nut ................................................................ 24
Steering Arm Nut .................................................................. 120
Steering Column Support Nut.. ....................................................... 110 to 200
Steering Gear Shaft Cover Nut ....................................................... 1 10 to 200
Steering Gear Shaft Adjusting Screw Lock Nut.. ......................................... 50
Pressure Control Valve Body Screws. .................................................. 10-15
Steering Gear Housing to Frame Bolt. ................................................. 50
Steering Valve End Plug ............................................................. 25
Steering Valve Body Attaching Bolts.. ................................................. 10-15
19-4 MANUAL STEERING GEAR
PART 1
M A N U A L STEERING GEAR
The manual steering gear (Fig. 1) is designed to pressed into the gear housing, and the upper bearing
Provide easy steering with a minkr~umof friction in cup is pressed into the wormshaft bearing adjuster.
the steering gear. A ball nut travels up or down on the
wormshaft, riding on recirculating balls acting as a The cross shaft is integral with the sector gear and
screw thread. the sector gear meshes with the rack teeth on the
The wormshaft and ball nut assembly is supported re-circulating ball nut. Adjustment at this point is
in the gear housing by an adjustable ball thrust type controlled by the cross shaft adjusting screw which
upper and lower bearing. The lower bearing cup is extends through the housing cover.
SERVICE PROCEDURES
1 ADJUSTMENTS 2. TESTING W O R M BEARING PRE-LOAD

( In Vehicle)
Two adjustments are provided in the steering gear
(Fig. 2). The worm bearing preload adjustment, and (1) Disconnect the steering gear arm from the
the ball nut rack sector gear mesh adjustment. sector shaft with Tool C-3646 (Fig. 3).
Before the correct adjustment can be made at the (2) Remove the horn button or horn ring (if so
ball nut rack and the sector gear, it must be deter- equipped).
mined that the worm bearing preload is properly (3) Loosen the cross shaft adjusting screw lock
adjusted. nut, and back out the adjusting screw approximately
The worm bearing preload adjustment is controlled two turns. This will relieve any friction load which
by the worm thrust bearing adjuster which threads may be present at the closely meshed ball nut rack
into the housing at the upper end of the wormshaft. and sector gear teeth.
(4) Turn the steering wheel two complete turns
/STEERING SHAFT
FILLER P L U G C R O S S SHAFT
DIE-CAST
/ A L U M I N U M HOUSING
A L L BEARINGS
UNIVERSA
COUPLl NG
CROSS SHAFT
GEAR CLEARANCE
ADJUSTING SCREW
V \ \WORM SHAFT
' RECIRCULATING-
BALL NUT
62x459
1
Fig. 1-Steering Gear Cross Section Fig. 2-Steering Gear Adjustment locations
MANUAL STEERING GEAR 19-5
wise to take out all lash between the ball nut rack
and sector gear teeth, then tighten the adjusting
screw lock nut to 35 foot-pounds torque.
(3)Turn the steering wheel about 34 turn away
from the center or “high spot” position. Then, using
torque wrench Tool C-3380,at the steering wheel nut,
measure the torque required to rotate the steering
wheel through the high spot at the center position.
The reading should be between 8% and 11% inch
pounds. This represents the total of the worm shaft
bearing preload and the ball nut rack and sector
gear mesh load. Readjust the cross shaft adjustment
screw if necessary, to obtain the proper torque read-
60x1218
ing.
(4)After the adjustments have been completed,
Fig. 3-Removing the Steering Gear Arm (Typical) place the front wheels in a straight ahead position,
and with the steering gear and steering wheel cen-
from the straight ahead position, and place the torque tered, install the steering arm on the cross shaft.
wrench Tool C-3380on the steering shaft nut. (5)Tighten the steering arm retaining nut to 120
(5) Rotate the steering shaft at least one turn to- foot-pounds torque.
ward the straight ahead position, while testing the
rotating torque with the torque wrench. 5. STEERING GEAR
The torque required to keep the wheel moving Removal
should be between 1Y2 and 4% inch pounds. If the NOTE: The manual steering gear can be removed
reading is not within these limits, adjustment of the without removing the steering column assembly.
worm bearing preload is necessary. (1) Remove the steering gear arm retaining nut.
Remove the arm with Tool (2-3646(Fig. 3).
3. W O R M BEARING PRE-LOAD (2) Remove the bolt from the coupling clamp at
ADJUSTMENT
the upper end of the steering gear wormshaft.
(1) Loosen the adjuster lock nut. (3)To provide sufficient clearance at the coupling,
(2) Use the adjuster wrench from Tool C-3884 set loosen the column jacket to instrument panel clamp
and turn the adjuster-clockwise to increase the pre- bolts (Fig. 4), sufficient to disengage the tab on the
load, or counter-clockwise to decrease the preload. clamp from the slot in the column jacket. Slide the
(3) While holding the adjuster from turning, tight- column assembly up far enough to disengage the
en the lock nut securely, then retest the worm bear- coupling from the wormshaft.
ing preload. CAUTION: Care is required to avoid scratching
the column jacket when sliding it up and down in the
4. BALL N U T RACK A N D SECTOR MESH clamp assemblies.
ADJUSTMENT ( In Vehicle 1
The cross shaft adjusting screw, located in the
housing cover, raises or lowers the shaft to provide
the proper mesh load between the tapered teeth of the
sector gear and the tapered teeth of the ball nut.
NOTE: This adiustment can be accurately made
only after the proper worm bearing preload has been
established.
(1) Turn the steering wheel gently from one stop
all the way to the other, carefully counting the num-
ber of turns. Turn the steering wheel back exactly
half way, to the center position.
(2) Turn the cross shaft adjusting screw clock- Fig. &Steering Column Assembly (Plymouth)
NOTE: It i s not necessary to disconnect t h e s h i f t
linkage o n Models equipped w i t h manual transmis-
sion, o r to remove the floor plate t o toe board bolts
when removing t h e steering gear. If the floor plate
bolts are loosened, it w i l l be necessary t o realign
t h e steering column when reinstalling the gear.
(4)Remove the three steering gear housing
mounting bolts and remove the steering gear from
the vehicle. On Models equipped with six cylinder
engines the steering gear can be removed through
the engine compartment. On 8 cylinder engines, re-
move steering gear from underneath the vehicle.
Disassembly
Thoroughly clean the entire outside surface of the
steering gear before disassembly to avoid contami- WORMSHAFT
BEARING
nating the wormshaft and ball nut assembly with
ADJUSTER
dirt or grit.
(1) Attach the steering gear to holding fixture, Tool
C-3323 and install the holding fixture in a vise (Fig.
2).
(2) Loosen the cross shaft adjusting screw lock
nut, and back out the screw about two turns to re- Fig. &Removing the Worm Shaft Adjuster
lieve the load caused by close mesh between the ball
nut rack and sector gear teeth. (7)Loosen the wormshaft bearing adjuster lock
nut with a soft drift and remove the lock nut. Hold
NOTE: Remove t h e cross shaft seal as outlined in
the wormshaft from turning while unscrewing the ad-
“Cross Shaft O i l Seal Replacement”.
juster, using tool wrench from Tool Set (2-3884.(Fig.
(3)Position the steering wormshaft in the 6).
straight-ahead position.
(8) Slide the worm shaft adjuster off the shaft
(4)Remove the bolts from the cross shaft cover,
then slowly remove the cross shaft while sliding the NOTE: The adjuster must be handled carefully to
arbor Tool C-3875into the housing (Fig. 5). avoid damage t o the aluminum threads.
NOTE: The arbor tool is not necessary on Valiant
Models.
(5) Remove the lock nut from the cross shaft ad-
justing screw and remove the screw from the cover
by turning the screw clockwise.
(6) Slide the adjustment screw and shim out of WORMSHAFT AND 1 4
the slot in the end of the cross shaft. BALL NUT
ASSEMBLY
62x468
Fig. 7-Removing the Worm Shaft and Ball Nut

Fig. 5-Removing the Cross Shaft ‘Assembly
~~ ~~
M A N U A L STEERING GEAR 19-7
CAUTION: Be careful that the ball nut does not PULLER
run down to either end of the wormshaft as the ball W 0RMSHAFT
guide ends can be damaged if the ball nut is allowed BEARING
to rotate until stopped at the end of the worm.
LOWER CUP
(9) Carefully remove the worm and ball nut as-
sembly (Fig. 7).
The ball nut and wormshaft are serviced as an
assembly only, and are not to be disassembled. Do
not remove or disturb the ball return guides.
NOTE: Place the ball nut and wormshaft assembly
in a clean place, and cover it to keep it clean.
(10) Remove the cross shaft needle bearing (if so
equipped) by placing the steering gear housing in an
arbor press; insert Tool C-3875with adapter ring in
lower end of housing (Fig. 8) and press both bearings
through the housing.
CAUTION. The adapter ring must be used with
remover and installer arbor, Tool C-3875 otherwise
the bearings will be crushed.
NOTE: Housings equipped with cross shaft bush-
Fig. 9-Removing the Lower Bearing Cup
ings are serviced in assembly only.
NOTE: The cross shaft cover assembly, including (12) Remove the wormshaft upper bearing cup in
a needle bearing or bushing, is serviced as an as- the same manner. However, this must be done care-
sembly. fully to avoid cocking the bearing cup and distorting
(11) Remove the wormshaft oil seal from the the adjuster counterbore.
wormshaft bearing adjuster, by inserting a blunt (13) Remove the lower cup if replacement is neces-
punch behind the seal and tap alternately on each sary by positioning the locking puller head jaws of
side of the seal until the seal is driven out of the puller Tool C-3868 (Fig. 9) behind the bearing cup
adjuster. and expanding the puller head by pressing down
on the center plunger of tool. Withdraw the bearing
cup by turning the puller screw nut in a clockwise
direction while holding the center screw.
PRESS Cleaning and Inspection
RAM
Wash all parts in clean solvent and blow dry with
C compressed air.
Test the operation of the ball nut assembly on the
wormshaft. If the ball nut does not travel smoothly
and freely on the wormshaft and there is roughness
or binding, the assembly must be replaced.
Extreme care is necessary when handling the
?
aluminum worm bearing adjuster to avoid damaging
the threads. It is equally important to avoid damaging
the mating threads in the gear housing. The worm-
shaft adjuster must Never be screwed into the
housing without lubrication, or when threads are dirty
or damaged. These precautions must be taken to
avoid “picking up” the threads and ruining the
62x462 housing and/or the wormshaft bearing adjuster.
Inspect the cross shaft for wear and check.fit of
Fig. 8-Removing the Cross Shaft Inner and the shaft in the housing bearings. Inspect the fit of
Outer Bearings the shaft pilot in its housing bearing in the cover.
adapter ring. Press the bearing into the housing to
5/ls inch below the end of the bore to provide space
for the oil seal.
CROSS SHAFT CAUTION: The adapter ring must be used with
RAM
remover and installer arbor Tool C-3875, otherwise
the bearings will be crushed.
(2) Install the inner needle bearing by placing
bearing on Tool C-3875 with the adapter ring (Fig.
10). Press the bearing into the inside end of the
housing bore flush with the inside end of the bore
surface.
(3) Install the wormshaft bearing cups, position
the cups in the housing and bearing adjuster nut.
Then press them in place with Tool C-3865 (Figs.
11and 12).
(4) Install the wormshaft oil seal by .positioning
the seal in the wormshaft adjuster with the lip of seal
up. Drive the seal into place with a suitable sleeve
so it is slightly below the end of the bore in the ad-
1. . v
* juster.
Fig. IO-Pressing the Inner Bearing into the Housing (5) Apply a.coating of steering gear lubricant to
all moving parts during assembly, also place lubricant
Make sure the wormshaft has not been bent or other- on and around oil seal lips.
wise damaged. (6) Clamp the holding fixture and housing in a
The cross shaft and wormshaft oil seals should be vise with the bearing adjuster opening upward.
replaced when the unit is reconditioned. (7) Place a thrust bearing in the lower cup in the
Assembly housing.
(1) Install the cross shaft outer needle bearing by (8) Hold the ball nut from turning (Fig. 7), and
placing the bearing on end of Tool C-3875 with the insert the wormshaft and ball nut assembly into the
Fig. 11-Installing the Worm Shaft lower Bearing Cup Fig. 12-installing the Worm Shaft Upper Bearing Cup
M A N U A L STEERING GEAR 19-9
housing with the end of the worm resting in the driver through the hole in the cover, turn the screw
thrust bearing. counter-clockwise to pull the shaft into the cover.
(9) Place the upper thrust bearing on the worm- (18) Install the adjusting screw lock nut, but do
shaft. not tighten at this time.
Thoroughly lubricate the threads on the adjuster (19) Rotate the wormshaft to centralize the ball
and the threads on the housing. nut.
(10) Place a protective sleeve of plastic tape over (20) Place a new cover gasket on the housing cover.
the wormshaft splines so that the splines do not (21) Carefully install the cross shaft and cover
damage the seal and slide the adjuster assembly over assembly into the steering gear housing (Fig. 5).
the shaft.
NOTE: The cross shaft and sector teeth should be
(11) Thread the adjuster into the steering housing, coated with the steering gear lubricant before instal-
and with Tool wrench C-3884 and splined nut set, ling the cross shaft in the housing.
tighten the adjuster to 50 foot pounds while rotating
the wormshaft. This is done to effectively seat the (22) Make certain some lash exists between the
bearings. cross shaft sector teeth and the ball nut rack then
install and tighten the cover bolts to 25 foot pounds
(12) Loosen the adjuster so no bearing preload
torque .
exists. Then, using torque wrench Tool C-3380, adjust
the wormshaft bearing preload from 1% to 4% inch
pounds. 6. CROSS SHAFT OIL SEAL REPLACEMENT
(13) After adjusting the preload, tighten the bear- The cross shaft oil seal may be replaced by this pro-
ing adjuster lock nut, and then retest t o be sure the cedure either on the bench, or without removing the
preload remains between 1% and 4% inch pounds. steering gear from the vehicle.
NOTE: When replacing the oil seal in the vehicle
(14) Before installing the cross shaft, pack the
worm shaft cavities in the housing above and below clean the exposed portion of the cross shaft to help
prolong oil seal life.
the ball nut with steering gear lubricant. Use steering
gear lubricant whenever possible, but if not available, Removal
a good grade of multi-purpose lubricant may be used. (1) Slide the threaded adapter of Tool C-3880
Do not use gear oil. When the gear is properly over the end of the cross shaft and install the nut
packed with steering gear lubricant it will contain portion of the tool on the shaft (Fig. 14). Maintain
eleven fluid ounces of lubricant, and the level of the pressure on the adapter with the tool nut while
lubricant will be at the top of the worm. screwing the adapter into the seal until it grips the
(15) Slide the cross shaft adjusting screw and oil seal firmly. Place the two half rings and retainer
shim into the slot in the end of the shaft.
(16) Test the end clearance shown in Figure 13.
The screw must be free to turn with no perceptible \
end play to .004 inch loose. Three different thickness

shims are available to obtain the specified clearance.
(17) Start the cross shaft and adjuster screw into
bearing in the housing cover. Then, using a screw
--
I*%
\ SHIM
ADJUSTING SCREW
- 60x1231
Fig. 13-Checking the Cross Shaft Adjusting Screw

End Clearance Fig. lrl-Removing the Cross Shaft Oil Seal
" ." (2) Place the seal and protector sleve assembly
onto the splines on the cross shaft with the lip of
the seal facing the gear housing (Fig. 15).
(3) Slide the seal down off the protector sleeve onto
the cross shaft and remove the sleeve.
NOTE: A piece of tape can be wrapped around the
end of the sleeve, opposite the tapered end, to provide
CROSS SHAFT a better grip when removing the sleeve.
(4) Place the installing adapter from Tool C-3880
against the seal with the short step end toward the
seal (Fig. 16).
(5) Place the nut down from Tool set C-3880 on
the cross shaft, and turn it down against the adapt-
er, pressing the seal into the housing until the step
on the adapter contacts the end of the housing.
a%* 7. BALL N U T RACK A N D SECTOR MESH

ADJUSTMENT (Out of Vehicle 1
Fig. 15-Cross Shaft Oil Seal Protector
The ball nut rack and sector mesh adjustment can
be accurately made only after proper worm bearing
over both portions of the tool. Turn the tool nut preload has been established.
counter-clockwise to withdraw the seal from the (1) Turn the wormshaft to the midpoint of its
travel. When the gear is exactly centered, the master
housing.
spline on the wormshaft will be at the 12 o'clock
Instullution position when viewed with the gear positioned as it
would be when installed in the vehicle.
(1) Place the cross shaft seal on the seal protector
(2) Turn the cross shaft adjusting screw clockwise
sleeve from Tool Set C-3880 by carefully sliding the to take out all lash between the ball nut rack and
seal over the tapered end of the sleeve so the lip sector gear teeth, then tighten the adjusting screw
of the seal faces the tapered end of the sleeve. lock nut (Fig. 17).
HOLDING
FIXTURE -SEAL TOOL
Fig. 16-Installing the Cross Shaft Oil Seal Fig. 17-Cross Shaft Adjustment
M A N U A L STEERING GEAR 19-1 1
TORQUE\
lnstalling the Steering Gear
( I n the Vehicle)
SPLINED NUT (1) Slide the steering column assembly upward
TOOL to where the column coupling will clear the end of
the wormshaft and permit installation of the steering
gear. Also make sure the clamp is in place on the
d- ’Y CROSS SHAFT steering shaft coupling.
4DJUSTMENT
SCREW NOTE: On models equipped with six cylinder en-
gines the steering gear can be entered through the
hood opening. However, when installing the steering
gear in models equipped with eight cylinder engines,
limited clearance makes it necessary to place the
gear in position from underneath the vehicle.
#
62x469 (2) Position the steering gear in position and install
the three mounting bolts.
,Fig. 18-Testing the Ball Nut Rack and
Cross Shaft Sector Mesh (3) Tighten mounting bolts to 50 foot pounds tor-
que.
(3) Turn the worm shaft about % turn away from (4) With the master serration on the wormshaft
the center or “high-spot” position. Again using aligned with the notch mark on the coupling housing
splined adapter from Tool Set C-3884 and Tool C- slide the steering column assembly down far enough
3380 torque wrench (Fig. 18) rotate the wormshaft to engage the column coupling with the wormshaft.
through the center or “high spot” position, observing (5) Align the groove on the steering column
the rotating torque required to turn the gear through coupling with the groove in the wormshaft and install
the high spot. The reading should be between 7% the coupling bolt, washer and nut.
and 11% inch pounds. This represents the total of (6) Tighten the nut to 30 foot pounds torque.
the worm bearing preload and the sector gear mesh (7) While the jacket clafip bolts are loose, position
load. the jacket assembly so the steering shaft coupling
(4) Readjust the cross shaft adjustment screw is centered at the midpoint of its travel.
if necessary to obtain the proper ,torque reading. Be The coupling travel midpoint can be determined
sure the adjusting screw lock nut is tight whenever by a X6” diameter gauge hole which-is provided in
a preload torque reading is taken. the steering shaft (Fig. 19).
(5) With the steering gear positioned in a vise at When the dimension from the top of the coupling
its operating angle, fill the gear housing with ap- to the center of the gauge hole is inch the cou-
proved steering gear lubricant so level of lubricant pling is centered in its travel.
covers top of worm.
Fig. 19-Positioning the Steering Shaft Coupling Fig. 20-Positioning the Steering Shaft Coupling
(Manual Steering and Standard Transmission) ‘(Power Steering and Standard Transmission)
NOTE: On Valiant models with both power steer- (9) Turn the steering gear and steering wheel to
ing and standard transmission, the column jacket the midpoint of its travel.
should be positioned so the dimension between the
(10) Place the front wheels in the straight ahead
top of the coupling and the column jacket seal is
position so the master serrations in the steering gear
3/ls inch (Fig. 20).
arm align with those on the steering cross shaft.
( 8 ) After centering the coupling, tighten the col-
umn jacket to instrument panel clamp bolts to 95 (11) Install the steering gear arm, lock washer
inch pounds torque. and nut on the cross shaft and tighten the nut to
120 foot pounds torque.
NOTE: On vehicles equipped with manual trans-
mission and concentric shift linkage, it will be neces- (12) After the steering gear has been completely
sary to readjust the length of the 1st and reverse installed, test the steering wheel to be sure it is
shift rod and the 2nd and 3rd shift rod after the centered in the straight ahead position. If it is found
steering column assembly has been secured in posi- to be off center with the wheels straight ahead, adjust
tion. See ”Manual Transmission Linkage Adiust- the tie rods to center the wheel. See Group 2, “Front
ments”. Suspension”.
M A N U A L STEERING
Hard Steering (a) Low or uneven tire pressure. (a) Inflate the tires to recommended
pressures.
(b) Insufficient lubricant in the steering (b) Lubricate as necessary.
gear housing or in steering linkage.
(c) Steering gear shaft adjusted too tight. (c) Adjust according to instructions.
(d) Front wheels out of line. (d) Align the wheels. See “Front
Suspension”.
(e) Steering column misaligned. (e) See “Steering Gear Alignment”.
Pull t o One Side (a) Incorrect tire pressure. (a) Inflate the tires to recommended
(Tendency of t h e pressures.
Vehicle t o veer in (b) Wheel bearings improperly adjusted. (b) See “Front Wheel Bearing
one direction only) Adjustment”.
(c) Dragging brakes. (c) Inspect for weak, or broken brake
shoe spring, binding pedal.
(d) Improper caster and camber. (d) See “Front Wheel Alignment
Group”.
(e) Incorrect toe-in. (e) See “Front Wheel Alignment
Group”.
(f) Grease, dirt, oil or brake fluid on brake (f) Inspect, replace and adjust as
linings. necessary.
(g) Front and rear wheels out of alignment. (g) Align the front wheels. See “Front
Suspension Group”.
(h) Broken or sagging rear springs. (h) Replace the rear springs.
(i) Bent suspension parts. (i) Replace the parts necessary.
STEERING COLUMN GEARSHIFT 19-13
SERVICE DIAGNOSIS--- ( Continued 1
M A N U A L STEERING
Wheel T r a m p (a) Incorrect tire pressure. Inflate the tires to recommended

(Excessive Vertical pressures.
Motion of Wheels) (b) Improper baIance of wheels, tires and Balance as necessary. See “Wheels
brake drums. and Tires”.
(c) Loose tie rod ends or steering Inspect and repair as necessary.
connections.
(d1 Worn or inoperative shock absorbers. Replace the shock absorbers as
necessary.
Excessive Play or Steering gear shaft adjusted too loose Replace worn parts and adjust
Looseness in t h e or badly worn. according to instructions.
Steering Wheel Steering linkage loose or worn. Replace worn parts. See “Front
Wheel Alignment”.
Front wheel bearings improperly Adjust according to instructions.
adjusted .
Steering arm loose on steering gear Inspect for damage to the gear
shaft. shaft and steering arm, replace
parts as necessary.
Steering gear housing attaching bolts Tighten the attaching bolts to 50
loose. foot-pounds torque.
Steering arms loose a t steering Tighten according to torque
knuckles. specifications.
Worn ball joints. Replace the ball joints as neces-
sary. See “Front Suspension”.
STEERING C O L U M N GEARSHIFT
The new concentric gear shift utilizes a hollow- 1).The shift mechanism is supported by resin bearings
tube inside the steering column jacket to transmit and requires very little maintenance. Lubrication is
shift lever motions to the lower shift linkage (Fig. required at 32,000 mile intervals.
SERVICE PROCEDURES
1. STEERING C O L U M N A N D GEARSHIFT shift tube levers at the bottom of the steering column
assembly.
Removal (From the VehicleI (3) Remove the steering shaft coupling to worm-
(1) Disconnect the battery cable at the battery shaft clamp bolt.
negative terminal. NOTE: The bolt must be completely removed since
(2) Disconnect the shift linkage rods from the it engages a groove in the wormshaft.
19-14 STEERING COLUMN GEARSHIFT
SWITCH RETAINING
SCREWS (31
BEARING HOUSING
BOLT (2)
ARSHlFT
TUBE
Fig. 2-View of the Steering Column-Upper End
Disassembly
(1) Remove the turn signal lever retaining screw
REVERSE LEVER 62x544 and remove the lever.
NOTE: Disassemble, repair and assemble the
Fig. 1-Steering Column with the Concentric Gearshift
steering column assembly on a clean, padded bench
to protect the finish on the column jacket and related
(4) Disconnect the directional signal, and horn
parts.
wires.
(2)Remove the three recessed head switch re-
(5) Remove the horn button on Valiant models
taining screws (Fig. 2) and pull the turn signal switch
by inserting a small screw driver into the slot in
and switch plate up and out, feeding the wires and
the steering wheel at the edge of the horn button,
connectors through the steering column jacket.
and pry the horn button and retaining “0”ring out
of the steering wheel. (3) Disengage the column jacket lower seal from
the lip on the jacket, and slide the seal down toward
NOTE: To remove the Plymouth horn button, turn the coupling.
the horn button 1/4 turn counterelockwise, and lift
it out of the steering wheel. To remove the extra
equipment horn ring ornament from Plymouth mod-
els, remove the 2 screws from the underside of the
steering wheel.
(6) Remove the horn switch retaining screws.
(7) Disconnect the horn wire clip and remove the
horn switch assembly.
(8)Remove the steering wheel retaining nut and
washer.
(9) Remove the steering wheel, using puller Tool
C-3428.
(10) Disconnect the steering column at the instru-
ment panel bracket by removing the retaining screws
and clamp.
(11) Remove the floor plate to toe board attaching
screws.
(12) Lift the steering column assembly up and off
the end of the wormshaft, and remove the assembly
out through the passenger compartment being care-
ful not to soil or damage the headlining. Fig. 3-Removing the Steering Shaft Bearing
WASHER \
LOWER SUPPORT CUP
(4) Exert an upward force on the steering shaft SPACER
to force the steering column jacket upper bearing
and insulator up and out of the counterbore in the
bearing housing. Remove the insulator from the bear-
ing.
NOTE: Due to t h e limited space between the
joint and jacket tube o n vehicles equipped with
power steering and manual transmission, install the
wheel nut o n t h e column tube, then tap the column
tube o n a wood block t o release the jacket tube,
bearing and seal f r o m the jacket tube.
(5) Using snap ring pliers Tool C-3128, remove the
bearing upper snap ring from the upper groove in
the steering shaft.
(6) Using bearing puller Tool C-3891, remove the II 62x451
steering column upper bearing (Fig. 3).
Fig. 5-lower End of the Steering Column
(7) Remove the lower snap ring and slide the Tube Assembly
steering shaft and coupling assembly down, and out
of the steering column jacket assembly. (10) Remove the three lower support cup to jacket
(8) Remove the column jacket lower seal from the attaching screws (,Fig.5) and remove the cup.
steering shaft. (11) Remove the nylon thrust washer, the low and
NOTE: The steering shaft and coupling assembly reverse lever, and the spacer.
i s serviced as an assembly, and is not to be dis-
(12) Remove the two lower shift tube bushing re-
assembled.
taining screws at the slotted holes in the jacket.
(9) While supporting the gearshaft housing in the (13) Slide the shift tube with the 2nd and direct
area around the shift lever pivot pin, drive out the lever, nylon bushing, spring and spring retainer out
pivot pin, using a 3/16'' punch, and remove the shift of the jacket (Fig. 6).
lever (Fig. 4).
NOTE: A Y'" drive, 3h" hex socket may b e used t o NOTE: The shift tube assembly with 2nd and
support t h e gearshift housing. direct lever, spring, retainer and nylon bushing are
serviced as an assembly, and are not to be disassem-
bled.
(14) Remove the floor plate from the column jacket.
(15) Remove the hexagon nuts from the two bear-
ing housing retaining bolts, and lift the steering
SELECTOR S P R I N G SHIFT TUBE AND

7 LEVER A S S E M B L Y
[I ~ 3/16" PUNCH
SHIFT LEVER
/'
\
C O L U M N JACKET
N Y L O N BUSPING
' i
62x530A
Fig. &Removing the Shift lever Pivot Pin Fig. &Removing the Shift Tube Assembly
19-16 STEERING COLUMN GEARSHIFT
eter of the isolator with a soap solution or rubber
lubricant. This will make it easier to slide the column
up or down for proper positioning in the car when
centering the steering shaft coupling.
(6) The floor plate assembly must be installed be-
fore installing the shift tube and levers, since this
cannot be done after the shift tube and levers are
in place in the steering column.
NOTE: Metal to metal working surfaces should be
lubricated with Multi-Purpose Chassis Lubricant to
facilitate installation.
(7) Turn the nylon bushing on the shift tube, as
shown in Figure 6, so the two holes in the bushing
are aligned with the centerline of the 2nd and 3rd
Fig. 7-Jacket lube (Disassembled) speed shift lever, then slide the shift tube and lever
assembly through the jacket tube and into the bear-
column upper bearing housing off the jacket assem- ing housing.
bly, as shown in Figure 7. (8) Install the spacer around the selector lever so
(16) Lift the gearshift housing and spring washer it rests against the 2nd and 3rd speed shift lever.
off the steering column jacket. (9) Install the low and reverse lever. Then install
the nylon washer, centering it over the end of the
lnspection shift tube.
After cleaning, inspect all parts for wear or dam-
(10) Install the lower support cup in the jacket
age. Note the condition of the pins in the two lower
(Fig. 5), while holding pressure against the cup to
shift levers, the shift lever socket at the top end of
overcome the selector spring load, start the three
the shift tube, and the inner end of the shift lever.
support cup retaining screws, and tighten to 30 inch
Inspect the steering shaft upper bearing for
pounds.
smooth operation, and lubricate with Multi-Purpose
Chassis Lubricant or similar lubricant. If the bearing (11) Loosely enter the lower bushing retaining
has any signs of roughness or wear, it should be re- screws through the slots in the jacket, and into the
placed. Replacement bearings are pre-lubricated. nylon bushings (Figs. 6 and 7).
(12) Rotate the nylon bushing to where all play
Assembly at the shift levers and spacers is eliminated, but
(1) Position the spring washer on the ledge pro- no binding occurs. With the bushing in this position,
vided in the top end of the steering column jacket tighten the two bushings to jacket screws to 30 inch
(refer to Figure 71, and place the shift lever housing pounds torque.
in position at the top end of the column jacket, NOTE: The shift tube must be free to slide up and
(2) Place the two bearing housing retaining bolts down in its bushings. No binding i s permissible.
in position in the housing, and just start the nuts on (13) The gearshift lever insulator (Fig. 1) should
them. be examined, and if any wear or damage is evident,
(3) Stand the column assembly upright, and lower it should be pulled off the lever and replaced.
the bearing housing into position, engaging the bolt NOTE: A worm gearshift lever insulator will
heads in the slots in the column jacket. result in a “thumping” or rattling sound in the steer-
(4) Tighten the two retainer bolt nuts alternately ing column.
and evenly in steps to prevent unseating the bolt (14) Place a screw driver blade between the 2nd
heads from the slots. Tighten to 50 inch pounds. and 3rd speed shift lever and the selector lever, so
(5) Position the isolator (refer to Figure 4) in the it will hold the selector lever at neutral position
inside diameter of the floor plate, and install the floor half way between the two shift levers (Fig. 8).
plate on the steering column with the insulated side (15) Position the gearshift lever in the shift lever
down. housing so it engages the hole in the shift tube plate
NOTE: Before installing the floor plate and iso- with the pin hole aligned.
lator on the column jacket, lubricate the inside diam- (16) Support the jacket tube housing in the area
steering wheel retaining washer and nut, on the top

of the steering shaft in that order (Fig. 9).
NOTE: Never press the bearing into position with
SELECTOR LEVER
a sleeve that exerts pressure against the outer race,
COLUMN LOWER since this would damage the bearing. Do not drive
the bearing into place with a hammer, since damage
to the bearing and steering shaft coupling will oc-
cur.
(21)Turn the steering wheel retaining nut to exert
pressure on the installing sleeve, upper snap ring,
and bearing, pressing the bearing down onto the
knurled section of the steering tube and against the
lower snap ring.
62x454
NOTE: The steering column upper bearing has
approximately .001” interference fit at knurled section
Fig. 8-Holding the Selector lever in the
of steering shaft.
Neutral Position
(22)Exert sufficient pressure against the upper
around the pin hole (Fig. 4) and drive the pivot pin snap ring to flatten it against the bearing so it can
in flush with the housing. enter the groove in the steering tube. Be sure the
NOTE: Before sliding the column jacket lower seal
snap ring is firmly seated in the groove.
onto the steering shaft, the seal should be lubricated. (23)Place the bearing insulator over the bearing
Fill the cavity in the inside diameter of the seal, column upper bearing, and position the bearing and
between the two moulded in seal bushings with short insulator in the counterbore provided in the bearing
fibre wheel bearing lubricant. housing.
(17)Slide the seal onto the steering shaft, and (24)Position the directional switch assembly in
down against the coupling, with the lip at the out- the bearing housing, while feeding the turn signal
side diameter facing upward, so the seal can be and horn wires through the steering colunin and out
positioned on the lower end of the column jacket through the opening provided in the column
during assembly. jacket.
(18)Slide the steering shaft into the column as- (25)Place the switch plate over the switch, and
sembly, and install the horseshoe shaped lower snap install the three switch retaining screws (Fig. 22).
ring in the lower groove on the steering shaft. Tighten screws to 24 inch pounds torque.
(19)Place the steering column upper bearing on (26)Position the turn signal lever in the assembly,
the steering shaft. sighting down through the hole in the switch to
align the screw hole, and install the lever attaching
(20)Position the wavy upper snap ring against the
screw. Tighten screws to 24 inch pounds torque.
top of the bearing.
Place bearing installing sleeve Tool (2-3879and the installation (In the Vehicle 1
(1) Insert the column and jacket tube assembly
through the floor pan opening, being careful not to
soil or damage the headlining.
(2)Position the clamp on the coupling and with
the master splines on the worn shaft and coupling
aligned, engage the column coupling with the steer-
ing gear worn shaft.
(3)Loosely fasten the steering column jacket to
the instrument panel bracket with the clamp and
the two attaching screws. Be sure the tab on the
1;T *,I L,bJL
clamp is entered in the locating slot in the column
( ;r -24
- I
jacket.
Fig. 9-Installing the Steering Column Upper Bearing NOTE: The column jacket clamp must be installed
19-1 8 STEERING COLUMN GEARSHIFT
w i t h the tab edge up o n Plymouth models and tab (9) Push the floor plate down to contact the toe
edge down o n Valiant Models. board, and start the floor plate to toe board attach-
(4) With the steering shaft coupling clamp in ing bolts, leaving them just loose enough so the floor
position on the coupling assembly, install the clamp plate can be shifted to align the lower end of the col-
bolt so that it engages the groove in the wormshaft. umn jacket.
Tighten clamp bolt nut to 30 foot pounds torque. (10) Visually inspect to be sure the lower end of
(5) On Plymouth Models, the clearance between the the column jacket and shifter tube assembly is con-
column jacket and the edge of the instrument panel centric with the steering shaft. If they are not con-
should be ?4 inch on the left, % 6 inch on the top and centric, shift the floor plate to a position where it
%6 inch on the right. To adjust this clearance, also holds the column jacket and shift tube assembly
loosen the adjustment spacer to instrument attaching concentric with the steering shaft and tighten the
bolts. The spacer has elongated holes to allow for floor plate to toe board attaching screws to 90 inch
adjustment up or down on the steering column to pounds.
provide the desired clearance. Do not tighten the NOTE: If the column jacket and shift tube assem-
clamp bolts at this time, however, the adjustment bly are not concentric it i s possible f o r t h e steering
spacer to instrument panel attaching bolts should shaft t o rub o n the inside surface of the shifter tube
be tightened to 90 inch pounds torque. at the lower end.
(6) Position the steering jacket assembly so the (11) Recheck the lower end of the column jacket
steering shaft coupling is centered at the midpoint of and shift tube assembly, to assure that they have re-
its travel. mained concentric with the steering shaft after
NOTE: With the steering column jacket clamp tightening the attaching screws.
bolts loose, "free travel" in the steering shaft coupling (12) Slide the steering column lower seal up to
along w i t h the slotted bolt holes in the column the bottom end of the column jacket, and force the
clamp; permits the jacket and steering shaft assembly outer lip of the seal into position around the flanged
t o move up and down (axially). lower end of the column jacket and shift tube as-
(7) A :%(; inch gauge hole is provided in the steer- sembly (Fig. 8).
ing column shaft. When the dimension from the top
(13) With the master splines in the steering wheel
of the coupling to the centerline of the gauge hole
hub and steering shaft aligned, place the steering
is inch (refer to Figure 19 "Manual Steering
wheel on the steering shaft.
Gear") the coupling is centered in its travel.
(14) Install the steering wheel retaining washer and
NOTE: On Valiant Models equipped w i t h both
nut. Tighten the steering wheel nut to 24 foot pounds
power steering and standard transmission, the gauge
torque.
hole in the steering column shaft is concealed b y the
column jacket seal. On these models, the column (15) Install any horn switch parts previously re-
jacket should be positioned so the dimension between moved from the steering wheel, and install the horn
t h e top of the coupling and the column jacket seal is button or horn ring.
.?/1,; inch (refer t o Figure 20 "Manual Steering Gear"). NOTE: On Valiant models equipped wi* a h o r n
(8) With the coupling centered, tighten the col- button, place the "0" ring in t h e groove in the horn
umn jacket to instrument panel clamp bolts to 95 button, and snap it i n t o place in the steering wheel
inch pounds torque. (or h o r n ring, if so equipped).
STEERING LINKAGE 19-19
62 x 2828
Fig. 1-Steering linkage (Plymouth)
62 x 2908
Fig. 2-Steering linkage (Valiant)

19-20 STEERING LINKAGE
PART 2
STEERING LINKAGE
SERVICE PROCEDURES
1. STEERING KNUCKLES 2. STEERING LINKAGE (Figures 1 and 2 )
Removal The tie rod end seals and covers should be inspected
(1) Remove the upper control arm rebound bum- at all oil change periods.
per.
(2) Raise the vehicle so the front suspension is in Removal
full rebound (under no load). CAUTION: Removal of the tie rod ends from the
steering knuckle arm or the center link by methods
other than using Tool C-3894 will damage the tie rod
(4) Remove all load from the torsion bar by backing end seal.
off the adjusting bolt.
(5)Remove the upper ball joint stud from the Damaged seals require removal of the seals and
steering knuckle using Tool C-3711. inspection of the tie rod assembly end at the throat
opening. If the parts have not lost all the grease or
(6) Remove the two upper bolts attaching the steer- are not contaminated, worn or rusted, use new seals
knuckle to the brake support. and reinstall, otherwise, a new complete tie rod end
(7)Remove the two lower bolts attaching the steer- assembly should be installed. Lubricate the tie rod
ing arm to the steering knuckle and remove the end assembly.
steering knuckle.
When removing the tie rod ends, idler arm or steer-
NOTE: Support the brake assembly during this ing gear arm, all seals should be closely inspected
operation to prevent damage to the brake hose when for wear or damage. The tie rod ends are of the semi-
the lower bolts are removed. permanently lubricated type.
lnstallatlon (1) Remove the tie rod ends from the steering
(1) Position the steering knuckle on the brake sup- knuckle arms using Tool C-3894 (Fig. 3). Use care
port and install the upper mounting bolts and nuts. not to damage the seals.
Tighten the nut finger tight only. (2) Using Tool (2-3894, remove the inner tie rod
(2) Position the steering knuckle arm on the steer- ends from the link.
ing knuckle and install the mounting bolts and nuts.
(3) Remove the idler arm stud from the link using
Tighten the nuts finger tight only.
To01 C-3894.
(3) Install the upper ball joint stud in the steering
knuckle and tighten the ball joint stud nut 55 foot- (4) Remove the idler arm stud from the “K” mem-
pounds torque on Valiant and 100 foot-pounds torque ber, using Tool C-3894.
on Plymouth. Install the cotter pin.
(4) Tighten the steering knuckle upper bolt nuts
55 foot-pounds torque. Tighten the lower bolt nuts
to 100 foot-pounds torque on Valiant and 120 foot-
pounds torque on Plymouth.
(5) Place a load on the torsion bar by turning in
the adjusting bolt. See “Front Suspension”, Group 2.
(6) Install the wheel and drum assembly.
(7) Adjust the front wheel bearings. Refer to
“Wheels, Bearings and Tires”, Group 22.
(8) Lower the vehicle to the floor.
(9) Install the upper control arm rebound bumper
and tighten the nut 200 inch-pounds torque.
.IJ 62x329
(10) Measure and adjust the front wheel alignment
as necessary. Fig. 3-Removing Tie Rod End Stud
POWER STEERING GEAR 19-2 1
(5) Remove the steering gear arm stud from the (2) Place the link over the idler arm stud and the
link, using Tool C-3894. steering gear arm stud and tighten the nuts to 40
foot-pounds torque. Install the cotter pins.
lnst allat ion (3) Connect the tie rod ends to the steering knuckle
Replace all tie rod and steering arm assemblies arms. Tighten the nuts to 40 foot-pounds torque, slide
that are damaged or worn. the stone protector into position and install the cotter
(1) Position the idler arm stud in the bracket and pins.
install the washer and nut. Tighten nut to 45 foot- (4) Measure and adjust the front end toe. See
pounds maximum torque and install the cotter pin. “Front Suspension” Group 2.
RIGHT TURN POWER CHAMBER SPOOL VALVE
PIVOT LEVER
RECIRCULATING BALL GUIDE
REACTION SPRINGS
STEERING COLUMN
CONNECTION
WORirl SHAFT BALANCING RING
LEFT TURN POWER CHAMBER

RIGHT TURN REACTION RING
POWER PISTON
ENTER THRUST BEARING RACE
EFT TURN REACTION RING,
PITMAN ARM YLINDER HEAD
64x717
Fig. 1-Power Steering Gear (Sectional View- Typical)

19-22 POWER STEERING GEAR
PART 3
POWER STEERING GEAR

The power steering gear (Figs. 1 and 2) consists of the steering wheel to the power piston through a
a gear housing containing a gear shaft with sector U-joint type coupling. The wormshaft is geared to
gear, a power piston with gear teeth milled into the the piston through recirculating ball contact. The
side of the piston which is in constant mesh with steering valve, mounted on top of the steering gear,
the gear shaft sector, and a wormshaft connecting directs the flow of fluid in the system.
SERVICE PROCEDURES
1. GEAR SHAFT ADJUSTMENT-Unit in tool nut SP-3610 on the gear shaft. Maintain pressure
Vehicle on the threaded adapter with the tool nut while
screwing the adapter far enough to engage the metal
(1) Start the engine and run at idle speed.
portion of the outer seal. Place the two half rings
(2) Turn the steering wheel gently from one stop SP 1932, and Tool retainer ring over both portions
all the way to the other, counting the number of of the tool, as shown in Figure 4. Turn the tool nut
turns. Then turn the wheel back exactly half way,
to the center position.
(3) Loosen the adjusting screw until backlash is
STEERING
evident, then retighten adjusting screw until back- GEAR
lash just disappears. Continue to tighten to % to Y2
turn from this position and tighten lock nut to 50
STEERING
foot-pounds torque to maintain this setting.
2. GEAR SHAFT OIL SEAL ARM \

REPLACEMENT
The gear shaft oil seal may be replaced without re-
moving the steering gear from the vehicle.
Removal
(1)Remove the steering arm nut.
(2) Disconnect the steering gear arm from the gear Fig. 3-Removing Steering Gear Arm
shaft with Tool C-3646 (Fig. 3).
(3) Slide the threaded adapter SP-3609 of Tool C-
3880 over the end of the gear shaft and thread the
, 1'
Fig. 2-Steering Gear Housing (Sectional View) Fig. L R e m o v i n g Gear Shaft Oil Seal
POWER STEERING GEAR 19-23
'TOOL
,SEAL
64 x 634 64 x 632
Fig. 5-Gear Shaft Oil Seal Protector Fig. 7-Installing Gear Shaft Grease Retainer
counter-clockwise to withdraw the outer seal from the (4)Position the outer seal in the housing bore;
housing. place tool adapter SP-3828 with short step of lip
(4) Remove the oil snap ring with pliers Tool C- against the seal (Fig. 7). Install tool nut on the gear-
3229 and remove the seal back-up washer. shaft and tighten the tool nut until the shoulder of the
tool adapter contacts the gear housing.
(5) Use Tool C-3880 in the same manner as out-
lined in step (3) to remove the inner seal. (5) Place the steering gear and front wheels in the
straight ahead position and install the steering gear
lnstallat ion arm and nut.
(1) Place the seal protector SP 3613 of Tool C-3880 (6) Tighten the steering gear arm nut to 120 foot-
over the splines of the gear shaft and slide the inner pounds torque.
seal over the protector with the lip of the seal down,
as shown in Figure 5. 3. W O R M SHAFT O I L SEAL
(2) Remove the seal protector SP 3613 and place REPLACEMENT
tool adapter SP-3828 with the long step of adapter
against the seal, as shown in Figure 6. Install tool nut The worm shaft oil seal replacement requires re-
moval of the steering gear assembly from the vehicle.
on the gear shaft and tighten the tool nut until the
Refer to Paragraph 4.
shoulder of the tool adapter contacts the gear housing.
(3) Remove the tool nut and adapter and install (1) Remove the oil seal with Tool C-3638 (Fig. 8).
the seal back-up washer and oil snap ring. (2) Slide the new oil seal over the protector (lip
TOOL
64 x 633
Fig. 6-Installing Gear Shaft Inner Oil Seal 'Fig. 8-Removing Worm Shaft Oil Seal
-
TOOL \ \\’
E@
SPRING
%
Fig. 9-Installing Worm Shaft Oil Seal Fig. 10-Removing Steering Valve Assembly
of seal toward housing), then remove the seal pro- Disassembly

tector. Prior to disassembly, clean the gear assembly
(3) Drive the oil seal in place with Tool (2-3650 thoroughly in a suitable solvent and install unit in
(Fig. 9). holding fixture Tool C-3323. Remove and discard all
“0”seal rings and seals, using new ones lubricated
4. POWER STEERING GEAR with petrolatum when reassembling. To disassemble
Removal the power steering unit for repair or overhaul, refer
(1) Disconnect the battery ziegative ground cable to Figure 1 then proceed as follows:
at battery negative post. (1) Drain the steering gear through the pressure
(2) Remove the steering column coupling to worm and return connections by turning the steering worm
shaft clamp bolt. shaft from one extreme of travel to the other.
(3) Loosen the jacket tube clamp screw at the in- (2) Remove the valve body attaching screws, and
strument panel. remove the valve body and the three “0”rings (Fig.
10).
(4) Tap the coupling assembly upward and carefully
lift the steering column end jacket assembly up and (3) Remove the pivot lever and spring. Pry under
off the end of the worm shaft. the spherical head with a screw driver (Fig. 11).
NOTE: Tie the jacket tube to protect it against NOTE: Use care not to collapse slotted end of the
damage during the steering gear removal. valve lever as this will destroy the bearing toler-
ances of the spherical head.
(5) Disconnect the pressure and return hoses at
the steering gear valve. Fasten the ends of the hoses PIVOT LEVER
above oil level in the pump reservoir and cap ends
of hoses and fittings of the steering valve.
-l
(6) Raise the vehicle.
(7) Remove the gear shaft nut and washer and
remove the steering arm from the gear shaft with
Tool C-3646 (Fig. 3).
(8) Remove the bolts attaching the steering gear to
frame and remove the steering gear assembly.
NOTE: On 6 cylinder engines, remove the steering
gear through the engine compartment. On 8 cylinder
engines, remove the unit from underneath the vehicle.
h
On 318 cubic inch engines, remove the starting 64 x 628 7
motor. Do not damage oil cooler lines on units so
1
equipped. Fig. 1 1-Removing the Pivot lever
64 x 625
A 81
Fig. 1’2-Removing the Gear Shaft Cover Fig. 14-Removing the Power Train (Typical)
Retaining Nut
(9) While holding the power train firmly com-
(4) Remove the gear shaft oil seal inner and outer pressed, pry on the piston teeth with a screw driver
as outlined in Paragraph 2, “Gear Shaft Oil Seal Re- using the gear shaft as a fulcrum and remove the com-
placement”. plete power train (Fig. 14).
(5) Loosen the gear shaft adjusting screw locknut NOTE: It i s important that the cylinder, center
to facilitate removal and remove the gear shaft cover race and spacer assembly and the jacket support be
nut with Tool C-3633 (Fig. 12). maintained in close contact with each other. This will
prohibit the teflon sealing ring on the worm shaft
(6) Rotate the worm shaft to position the gear shaft from becoming disengaged from its retainer in the
sector teeth at the center of the piston travel then cylinder head, It will also eliminate the possibility of
loosen the steering power train retaining nut with the reaction rings becoming disengaged from their
Tool (2-3634 (Fig. 13). grooves in both the cylinder head and worm shaft
CAUTION: Oil will drain out when the gear support.
shaft and cover are withdrawn from the gear housing. (10) Place Tool (2-3875 on the threaded end of the
(7) Withdraw the gear shaft just enough so that gear shaft, then slowly remove the shaft while slid-
the sector gear teeth clear the housing, then rotate the ing the tool into the housing. The tool will prevent
shaft 180 degrees and allow the ends of the gear the needle bearings from falling out of the cage.
teeth to rest on the housing (Fig. 14). Cleaning and inspection
(8) Turn the worm shaft to the full left turn posi- When disassembling, each part should be placed in
tion to compress the power train parts, then remove a suitable solvent, washed, then dried by compressed
the power train retaining nut and washer. air. Careful handling of parts must be exercised to
avoid the occurrence of nicks and burrs. Crocus cloth
TOOL may be used to remove small nicks or burrs provided
it is used carefully. When used on the steering gear
valve, use extreme care not to round off the sharp
edge portions of the two lands located between the
valve drilled holes. The sharp edge portion of these
two lands is vitally important to this type of valve.
Power Train Disassembly
(Figs. 7 and 751
(1) Place the power train in a vise equipped with
soft jaws to avoid damaging the piston assembly.
64x6
CAUTION: Do not turn the worm shaft mere than
Fig. 13-Removing the Power Train Retaining Nut one-half turn during disassembly.
i
ii
( 5 ) Remove the reaction seal from the groove in
the face of the support with air pressure directed into
i the ferrule chamber (Fig. 17).

(6) Inspect all grooves for burrs. Make sure the pas-
sage from the ferrule chamber to the upper reaction
chamber is unobstructed.
TRAIN (7) Remove the reaction spring, reaction ring,
worm balancing ring and spacer, ferrule “0” ring
d and center bearing spacer.
(8) Hold the worm shaft from turning, then turn
the nut with sufficient force to release the staked
portions from the knurled section and remove the
T
-*OOL 64 x 624
nut.
NOTE: W i r e brush t h e knurled section to remove
Fig. 1 G R e t a i n i n g the Bearing Rollers with Arbor Tool the chips, then blow o u t the nut and w o r m shaft to ret-
move any metal particles.
(2) Remove the worm shaft support tang washer. (9) Remove the upper thrust bearing race (thin)
NOTE: The 33 support bearing rollers may f a l l and upper thrust bearing.
out when the column support i s removed f r o m the (10) Remove the center bearing race.
w o r m shaft. Use arbor Tool C-3929 (Fig. 161, t o hold (11) Remove the lower thrust bearing and lower
rollers in position when t h e support is removed. thrust bearing race (thick).
(3) Raise the column support until the worm shaft (12) Remove the lower reaction ring and reaction
oil seal just clears the top of the worm shaft and spring.
position the arbor Tool C-3929 on top of the worm (13) Remove the cylinder head assembly.
shaft and into the oil seal. With the arbor in posi- (14) Remove the two “0” rings in the two outer
tion pull up on the jacket support until the arbor is grooves in the cylinder head.
positioned in the support bearing then remove sup-
port and arbor. (15) Remove the reaction “0”ring from the groove
in the face of the cylinder head with air pressure
NOTE: T o install new rollers, retain the rollers in directed into the oil hole located between the two “0”
the cage with wheel bearing lubricant. ring grooves (Fig. 18).
NOTE: If the w o r m shaft o i l seal is t o be re- (16) Remove the retainer, back-up ring and oil seal
placed, p e r f o r m the operation with t h e w o r m shaft from the cylinder head counterbore (Fig. 19). Inspect
support assembled in the steering gear housing (Figs. the seal for possible damage and replace the seal if
8 and 9). necessary.
(4) Remove the large “0” ring from the groove in “0” RINGS IiEAD
the shaft support.
/ - ,,’
“Lr..
RING
“0’
REACTION “o**
RING ” FERRULE
/
SUPPORl 60x1 245 58x46
Fig. 17-Removing the Reaction Seal from the Fig. 18-Removing the Reaction Ring from the
Worm Shaft Support Cylinder Head
19-28 POWER STEERING GEAR ~~~ ~
(b) Press down on the piston to bottom the ring

in the piston groove, forcing the open ends of the
CYLINDER HEAD
ring out for ease of locking the ring. Ring should be
positioned with the ring hooks in line with the ball
guide plug.
(2) Place the piston assembly in a vertical position
(worm shaft up) in a vise equipped with soft jaws.
(3) Inspect the cylinder head ferrule oil passage for
obstructions and the lands for burrs, then lubricate
the two large “0”rings and install them in the cylin-
der head grooves, (Fig. 19).
(4) Install the cylinder head oil seal, back-up ring
and retainer (if removed). Make sure the retainer is
seated in the groove.
RETAINER L REACTION “ 0 RING 58x47
(5) Install the lower reaction seal in the cylinder
Fig. 19-Removing the Cylinder Head Oil Seal head groove.
(17) Test the operation of the worm shaft. The NOTE: The small “0” ring for the ferrule groove
torque required to rotate the wormshaft throughout should be installed after the worm shaft bearing pre-
its travel in or out the piston must not exceed 2 load has been established; otherwise, the small ” 0
inch pounds. ring will be damaged by the reaction springs and
center bearing spacer.
NOTE: The worm and piston is serviced as a com-
(6) Slide the cylinder head assembly (ferrule up) on
plete assembly and should not be disassembled.
the worm shaft, test the worm shaft seal ring making
Assembling the Power Train sure the gap is closed to avoid damaging the ring as
the cylinder head moves against the piston flange.
Discard all “0”seal rings and seals, using new ones
lubricated with petrolatum when reassembling. Re- (7) Lubricate with MoPar Power Steering Fluid,
fer to Figures 1 and 15 for parts identification. Part No. 2084329 and install the parts in the following
order:
(1) If the power piston ring was removed, inspect
(a) Lower thrust bearing race (thick).
the condition of the rubber sealing ring located under
the cast iron ring and replace it if necessary. Install (b) Lower thrust bearing.
the cast iron piston ring as follows: (c) Lower reaction spring (with the small hole over
(a) Slide a new piston ring into place in the piston the ferrule).
groove, then place the piston and ring assembly in (d) Lower reaction ring (flange up so ring protrudes
Tool C-3676 with the lower part of the piston and ring through reaction spring and contacts the reaction “0”
resting on the land of the Tool (Fig. 20). ring in the cylinder head).
(e) Center bearing race.
;
N PISTON RING
/ PISTON
(f) Upper thrust bearing.
(g) Upper thrust bearing race (thin).
(h) Start the worm shaft thrust bearing adjusting
WORM SHAFT \ I nut (do not tighten).
(8) Turn the worm shaft counter-clockwise one-
half turn. Hold the worm shaft in this position with
the splined nut, Tool C-3637 and socket wrench, then
tighten the nut to 50 foot-pounds torque to pre-
stretch the worm shaft threads.
CAUTION: If the worm shaft i s turned more than
one-half turn, the cylinder head oil seal retainer
will clear the oil seal ring on the worm shaft. Al-
ways position the worm shaft oil seal ring before
bottoming the cylinder head against the piston top
Fig. 20-Installing the Piston Ring flange to avoid damaging the oil seal ring.
s- (b) Strike the punch a sharp blow with a hammer
HlORM SHAFT and test pre-load.
-%t
NOTE: If the adjusting nut moved during the stak-
ing operation, it can be corrected by striking the
CENTER BEARING
-*/
nut a glancing blow in the direction required to re-
gain proper preload.
(c) After retesting for proper pre-load, stake the
nut at three more locations 90° apart around the
upper part of the nut.
/ (d) To test the total staking, torque the nut to 28
FERRULE ' A foot-pounds torque in either direction. If the nut
does not move the staking operation is satisfactory.
58x65 IMPORTANT: Retest the pre-load adjustment, the
torque of 16 to 24 inch ounces must remain after the
Fig. 21-Checking the Center Bearing Pre-load
adjusting nut i s securely locked.
(9) Loosen the adjusting nut. Place several rounds (11) Position the center bearing spacer assembly
of cord around the center bearing race (Fig. 21). over the center bearing race, engaging the dowel pin
Make a loop in one end of the cord and hook the of the center bearing spacer in the slot of the race, and
loop of a distributor breaker arm spring scale Tool the slot of the center spacer entered over the cylin-
MTU-36 in the cord loop. Pulling the cord will cause der head ferrule.
the bearing race to rotate. Retighten the worm bear- NOTE: This will align the valve pivot lever hole in
ing adjusting nut while pulling on the cord with the center bearing race with the valve pivot lever
the scale. If the adjusting nut is tightened properly, hole in the center bearing spacer assembly.
the reading on the scale should be 16 to 24 ounces (20
(12) Install the upper reaction ring on the center
ounces preferred while the race is turning).
bearing spacer with the flange down against the
(10) Stake the upper part of the worm shaft ad- spacer.
justing nut into the knurled area of the shaft.
(13) Install the upper reaction pressure spring over
CAUTION: Place a support under the adiust- the reaction ring with the cylinder head ferrule
ing nut during the staking operation to avoid brin- through the hole in the reaction spring.
neling the piston and worm bearings. (14)Install the worm balancing ring (without flange)
(a) Hold a Vi inch flat end punch on the center line inside the upper reaction ring.
of the worm shaft end at a slight angle to the nut
'
I
flange (Fig. 22).
a h *' SUPPORT
ADJUSTING NUT
CENTER THRUST BEARING RACE
CYLINDER HEAD
PISTON
ORM SHAFT
/
REACTION RING
59xl41A 60x1 246
Fig. 22-Staking the Worm Shaft Bearing Fig. 23-Installing the Reaction Seal Ring in
Adjusting Nut Worm Shaft Support
(15) Lubricate the ferrule “0”ring with petrolatum cloth if extreme care is used not to round off the
and install it in the groove on the cylinder ferrule. sharp edge portion of the valve. The sharp edge por-
(16) If the oil seal was removed from the worm tion is vitally important to the operation of this
shaft support, install a new seal with Tool C-3650 valve.
(Fig. 9). With the lip of the seal toward the bearing, Clean the valve bodies and valve pistons thor-
drive in the seal until the tool bottoms on the support. oughly in clean solvent. Blow out all passages and
(17) Lubricate and install the reaction seal ring in blow parts dry with compressed air. Lubricate pis-
the groove in the face of the worm shaft support tons and bores with Power Steering Fluid Part Num-
with the flat side of seal out (Fig. 23). Install the “0” ber 2084329.
ring in the groove on the support. Assembling the Steering Valve
(18) Slide the worm shaft support and arbor, Tool (1) Install the steering spool valve into the valve
C-3929 over the worm shaft, carefully engaging the body so that the valve lever hole is aligned with the
cylinder head ferrule and “0”ring and making sure lever opening in the valve body. Valve must be per-
the reaction rings enter the circular groove in the fectly free in the valve body without sticking or
support. Remove the tool arbor when the support is binding (Fig. 24).
positioned. (2) Install a new gasket on the end plug (if re-
(19) Align the parts on the power train so the valve moved). Tighten the plug to 25 foot-pounds torque.
pivot lever hole in the center of the bearing spacer (3) Install the piston cushion spring in the control
assembly is 90 degrees counter-clockwise from the valve body. Lubricate the piston and insert the nose
piston rack teeth in the “up” position to index with end of piston into the body bore. Test for smooth op-
the steering valve assembly. eration. Be sure the cushion spring is not cocked.
Steering Valve Disassembly
(4) Install the spring on top of the piston, compress
the spring and install the retaining pin.
(1) Remove the two screws attaching the control
( 5 ) Position the two new “0”rings on the control
valve body to the steering valve body and separate
valve body and attach the control valve body to the
the two bodies (Fig. 24).
steering valve body. Tighten the two attaching screws
(2) Compress the control valve spring and remove to 10 foot-pounds torque.
the retainer pin, spring, valve piston and cushion (6) If the pressure inlet fitting has been removed,
spring. replace the copper gasket and retighten the fitting
(3) Carefully shake out the spool valve and inspect to 30 foot-pounds torque.
the valve for nicks, burrs and scores. Do not remove
the valve body end plug unless inspection indicates Gear Shaft and Needle Bearlngs
a leak at the gasket. Removal
NOTE: If the spool valve or valve body is damaged, Refer to Figure 15 for parts identification.
replace the valve and body assembly. (1) Remove the lock nut from the gear shaft ad-
justing screw and remove the screw from the cover
Small burrs and nicks may be removed with crocus
by turning the screw clockwise. Slide the adjustment
“ 0RINGS screw and shim out of the slot in the end of the gear
shaft.
NOTE: The gear shaft cover aswmbly, including
the needle bearing, i s serviced as a unit and should be
replaced when bearing replacement is necessary.
(2) To remove the gear shaft needle bearings, re-
move oil seal snap ring with pliers, Tool (2-3229 and
remove the seal back-up washer.
(3) Insert tool (2-3875 in the steering housing; place
the housing in a press then press out the bearings
SCREW and the oil seal.
58x48A lnstallaflon
Fig. 24-Valve Body Assembly (Disassembled) (1) To install the gear shaft outer needle bearing,
POWER STEERING GEAR 19-3 1
THIS CAVITY MUST “0”RING

BE FILLED WITH
WHEEL BEARING
RET~INER \
OIL ?EAL
~ ~ 7 2 0
Fig. 25-Steering Gear Housing (Sectional View)
place the bearing on the end of Tool C-3875. Press the of the housing with petrolatum and carefully install
bearing into the steering gear housing Vi inch below the power train assembly, with the center bearing
the end of the bore to provide space for the oil seal, spacer valve lever hole in the “UP” position to line
back-up washer and snap ring and cross shaft grease up with the control valve lever clearance hole in the
retainer. See “Gear Shaft Oil Seal Replacement”, Par- steering gear housing.
agraph 2. CAUTION: Make sure the cylinder head is bot-
CAUTION: The arbor adapter ring must be used tomed on the housing shoulder (Figs. 1 and 2).
with the C-3875 Remover and Installer arbor, other- (2) Align the valve lever hole in the center bearing
wise the bearings would be crushed. spacer exactly with the steering valve hole in the
(2) To install the inner needle bearing, place the
gear housing, using the spacer to housing Aligning
Tool C-3649. (Fig. 26)
bearing on the end of Tool C-3875. Press the bearing
into housing flush with the end surface of the bore.
(3) Insert the gear shaft and adjusting screw into
the cover and using a screw driver through the thread-
ed hole in the cover, turn the screw counter-
clockwise to pull the shaft into the cover. Lubricate
a new seal ring and slide it over the adjusting screw
into position on top of the cover. Install the adjust-
ing screw lock nut, but do not tighten at this time.
(4) Lubricate the “0”ring and gear shaft cover
with petrolatum and place the “0”ring in the cover
groove (Fig. 25).
Assembling the Steering Gear
(1) With the steering gear housing in the holding Fig. 26-Aligning the Center Bearing Spacer with the
fixture in approximate car position; lubricate the bore Steering Valve
(2) Connect the test hoses C-3211 and C-3318with
proper adaptors to the hydraulic pump on the vehicle
with the pressure gauge C-3309B installed between
the pump and the steering gear to register pressures.
(3)Start the engine and operate at idle to bring the
steering gear to normal operating temperature.
(4) Centralize the steering valve on the gear hous-
ing by tapping it up or down, then expel all air from
the unit by turning the worm shaft several times to
the right and then to the left.
(5) Refill the reservoir before preceeding with the
following tests and adjustments on the bench.
(a) Tighten the steering valve body attaching screws
Fig. 27-Installing the Valve Pivot lever
(b) With the gear shaft on center, tighten the gear
NOTE: The aligning tool should not be removed
shaft adjusting screw until backlash just disappears.
until the spanner nut is securely tightened.
If the power train has been disassembled, tighten
1%turns from this position and while holding the ad-
(3)Install the power train and worm shaft sup- justing screw in this position, tighten the lock nut
porting tang washer and retainer nut. Tighten the (Fig. 28).
nut 110 to 200 foot-pounds torque with Tool C-3634.
NOTE: This i s a temporary adjustment to bring
(4) Set the power piston at the center of travel and
the piston rack and sector teeth in full alignment.
install the gear shaft and cover assembly so that the
sector teeth index with the piston rack teeth. Make (c) Turn off the hydraulic power to the unit. Op-
sure the “0”ring is positioned in the face of the erate the unit manually for a minimum of 180° from
cover (Fig. 25). center in each direction, measured at the worm shaft.
(5) Install the cover spanner nut and tighten 110 (d) With the hydraulic power to the gear unit and
to 200 foot-pounds torque with Tool C-3633. with the gear shaft on center, readjust the gear shaft
(6) Install the valve pivot lever (double bearing backlash. This will require loosening the adjusting
end first) (Fig. 27), into the center bearing spacer screw until backlash is evident. Then retighten the
through the hole in the steering housing so that the adjusting screw until the backlash just disappears.
slots in the valve lever are parallel to the worm shaft Continue to tighten for % to Y2 turn from this position
in order to engage the anti-rotation pin in the center and tighten the lock nut to 50 foot-pounds torque to
bearing race. Install the valve pivot lever spring. maintain this setting.
NOTE: Turn the worm until the piston bottoms (e) Starting from a point at least one full turn of
in both directions and observe the action of the lev- the worm shaft either side of center, the torque
at the gear shaft required to turn the unit through
er. It must return snappily to its center position when
the worm torque is relieved.
1 ..-
(7) Install the valve body on the housing making
sure the valve pivot lever enters the hole in the valve
spool (Fig. 1).Be sure the “0”ring seals are in place.
Tighten the valve mounting screws to 7 foot-pounds
torque.
( 8 ) Install the new gear shaft inner seal followed
by the seal back-up washer and snap ring and a new
grease retainer as outlined under “Gear Shaft Oil
Seal Replacement”, Paragraph 2.
Bench Test and Adjustments
(1)Remove the oil reservoir cover and fill the res-
ervoir Power Steering Fluid 2084329 to the lever
mark. Fig. 28-Adjusting the Steering Gear Mesh
P O W E R STEERING G E A R 19-33
center at 2 rpm in each direction shall not exceed between the frame and the engine. DO NOT damage
25 foot-pounds or vary more than 5 foot-pounds from the automatic transmission oil cooler lines on vehicles
left to right. Perform this operation carefully to pre- so equipped.
vent a lockup in the steering gear. (2) Install the steering gear housing retaining bolts
(f) Adjust the torque evenly by moving the steer- and tighten to 50 foot-pounds torque.
ing valve assembly by tapping on the back pressure (3) Install the starting motor.
valve body attaching screws to move the valve body (4) Position the steering gear in center of high
up on the steering housing, and tap on the end plug spot and install the steering gear arm, washer and
to move the valve body down on the housing. nut. Tighten nut to 120 foot-pounds torque.
NOTE: If the torque is greater to the left, move (5) Connect the hydraulic hoses to the steering
the control valve body down. If the torque is greatest valve.
to the right, move the valve body up. After position- (6) Place the front wheels and steering wheel in
ing the valve to obtain equal torque, tighten valve the straight-ahead position.
body attaching screws to 15 foot-pounds torque to
maintain this setting.
(7)Position the clamp on the steering shaft coup-
ling and with the master splines on the worm shaft
(g) With the gear at or near the full turn in either and notch on the body of the coupling aligned, engage
direction, attempt to return the unit to center by the column coupling with the steering gear worm
applying a torque wrench at the steering gear shaft. shaft.
Hold the worm shaft until the cross shaft torque
(8) Install the coupling clamp bolt and tighten the
builds up to 50 foot-pounds. Release the worm shaft
bolt to 30 foot-pounds torque.
and maintain a constant steady pull on the gear shaft
(turning cross shaft slowly). If the cross shaft torque (9) Position the steering jacket assembly so the
does not drop to 25 foot-pounds torque maximum steering shaft is centered at the midpoint of up and
as the unit passes through center, check for too much down travel.
interior drag; binding valve lever, binding spool NOTE: A 3/16” gauge hole i s provided in the
valve, or cross shaft adjustment that is too tight. steering column shaft, when the dimension from the
(6) With the unit under power, but with no load, top of the coupling to the centerline of the gauge
the torque required to rotate the worm shaft through hole is 13/16 inch, the coupling i s centered in its
an included angle of 180° (90’ either side of center) travel.
shall be 6-10 inch pounds. Disconnect the test equip- (10) With the coupling centered, tighten the col-
ment and mounting fixture and install the unit in the umn jacket to the instrument panel clamp bolts to
vehicle. 95 inch-pounds torque.
Installation of Steering Gear in Vehicle (11) Connect the negative cable to the battery.
(1) On vehicles equipped with six cylinder engines, (12) Start the engine, turn the steering wheel to
enter the steering gear at the engine compartment. right and left several times to expel1 the air from the
On eight cylinder equipped vehicles, enter the steer- system.
ing gear from below with the gear shaft end of the (13) Inspect the power steering pump reservoir
steering gear first, then roll the gear up into position level, replenish as necessary.
POWER STEERING GEAR
Tires not properly inflated. (a) Inflate the tires to recommended

pressures.
Low oil level in pump reservoir (usually (b) See “Fluid Level”, Power Steering
accompanied by pump noise). Pump.
Loose pump belt. See “Belt Adjustment”.
Improper caster and camber. See “Front Wheel Alignment”.
Front Suspension Section.
Power steering output low. Perform the “Pump Pressure and
Flow Tests”. NOTE: When the
power steering pump fails to
give proper steering assist, the
trouble is usually caused by
fouling of the flow control valve
causing it to stick in the open or
“by-pass” position. This fouling
can be caused by gum deposits,
pieces of broken slipper springs,
burrs, or foreign material (pieces
of rubber, dirt or matching chips).
If no fouling of the flow control
valve is evident, or if the flow
control valve contains pieces of
coiled wire (broken slipper spring),
the pump should be disassembled
for possible slipper spring
replacement.
Steering linkage binding. Repair and lubricate as necessary.
Steering gear malfunctions. Adjust or repair as follows:
1. Gear shaft adjustment too tight. 1. See “Gear Shaft Adjustment”.
2. Faulty or damaged valve lever. 2. Remove steering gear, repair as
necessary.
3. External leakage. 3. Inspect for leakage a t the lower
sector shaft oil seal; the sector
shaft cover “0”.
4. Excessive internal leakage. 4. Remove the steering gear and
repair as necessary.
Poor Recovery from (a) Tires not properly inflated. Inflate the tires to recommended
Turns pressures.
(b) Steering linkage binding. Repair and lubricate as necessary.
(c) Improper wheel alignment. See “Front Wheel Alignment”,
Front Suspension Section.
Damaged steering tube bearing. Remove the jacket tube and
replace bearings.
Steering wheel column jacket and See “Installation of Steering
steering nut improperly aligned. Gear”.
SERVICE DIAGNOSIS--- (Continued 1
POWER STEERING GEAR
Poor Recovery from (f) Steering gear malfunctions. Adjust or repair as follows:
Turns Continued 1. Improper gear shaft adjustment. 1. See “Gear Shaft Adjustment”.
2. Column support spanner nut loose. 2. Remove the steering gear, disas-
semble, inspect and reassemble as
outlined in this section.
3. Damaged valve lever. 3. Remove the steering gear and
4. Improper worm thrust bearing 4. Remove the steering gear, dis-
adjustment. assemble, inspect and reassemble.
See “Center Bearing Preload”,
Assembly of Power Train.
5. Worn or damaged cylinder head 5. See “Steering Gear Removal,
worm seal ring or faulty worm piston Disassembly and Inspection”,
ring. replace parts as necessary. See
“Disassembly and Assembly of
Power Train”.
6. Burrs or nicks in the reaction ring 6. Remove the steering gear and
grooves in the cylinder head or column repair as necessary.
support .
7. Dirt or chips in the steering gear 7. Remove the steering gear,
unit. disassemble completely, clean in a
clean solvent, inspect and make
repairs as necessary.
8. Rough or catchy worm in the piston 8. Replace the worm and piston
assembly. assembly. See “Steering Gear
Removal, Disassembly, Inspection
and Reassembly”.
Car Leads t o Either (a) Tires not properly inflated. Inflate the tires to recommended
Side pressures; See “Wheels and Tires”.
(b) Improper wheel alignment. See “Front Suspension, Front
Wheel Alignment”.
Valve body out of adjustment. If vehicle leads to the left, move
the steering valve housing down
on the steering housing. If vehicle
leads to the right, move the
steering valve housing up on the
steering housing.
Valve lever damaged. Remove the steering gear and
replace or repair as necessary.
Column support spanner nut loose. Remove the steering gear and
Excessive Steering Improper gear shaft adjustment. See “Gear Shaft Adjustment”.
Wheel Free-Play Column support spanner nut loose. Remove the steering gear, disas-
semble, inspect, and reassemble.
Improper worm thrust bearing Remove the steering gear, disas-
adjustment. semble, inspect and reassemble,
see “Center Bearing Preload
Assembly of Power Train”.
Coupling loose on the worm shaft. Inspect the wormshaft splines for
wear.
SERVICE D I A G N O S I 6 (Continued 1
P O W E R STEERING GEAR
Lack of Assist (a) Oil leaking past worm shaft oil seal (a) Remove the steering gear,
1. (One Direction) ring. disassemble, inspect and replace
the parts as necessary.
(b) Broken or worn ring on worm piston. (b) See “Assembly of the Power
Train”.
(c) Piston end plug loose. (c) Replace the worm and piston
assembly.
(d) Reaction seal missing. (d) Remove the steering gear and
Lack of Assist (a) Pump belt slipping. (a) See “Pump Belt Adjustment”.
(Both Directions) (b) Pump output low. (b) Perform the “Pump Pressure and
Flow Tests”, also refer to
correction (e) in Diagnosis under
“Hard Steering”.
(c) Broken or worn ring on worm piston. (c) See “Assembly of Power Train”.
(d) Piston end plug loose. (d) Replace the worm and piston
assembly.
(e) Internal leakage in the steering gear (e) Replace the steering gear valve
valve body. body assembly.
Temporary (a) Oil level low in pump reservoir. (a) See “Fluid Level”.
Increases in Effort (b) Loose pump belts. (b) See “Pump Belt Adjustment”.
When Turning (c) Oil on pump belt. (c) Replace the belt and adjust.
Steering Wheel (d) Binding steering linkage. (d) Lubricate and repair as necessary.
t o t h e Right or Left (e) Engine idle too slow. (e) See “Fuel Specifications”.
(f) Air in the system. (f) Work the steering wheel from
right to left until the air is
expelled.
(g) Power steering pump output low. (g) See Diagnosis “Hard Steering”
correction (e).
(h) Gear malfunction. (h) Adjust and repair as outlined
under “Hard Steering”-
condition and correction (g).
Noises (a) Buzzing noise in neutral and stops when (a) Noisy pump, make pressure test
the steering wheel is turned. and repair as necessary. Damaged
hydraulic lines or interference of
the hoses with components
attached to the fender shield. Air
in system; work steering wheel
from right to left until the air is
expelled.
POWER STEERING GEAR
Noises-Conti nued (b) Chuckling noise. Causes as follows: (b) Correct as follows:
1. Improper gear shaft adjustment. 1. See “Gear Shaft Adjustment”.
2. Improper worm shaft thrust bearing 2. Remove steering gear, tlisas-
adjustment. semble, inspect and reassemble.
See “Center Bearing Preloatl”.
3. Coupling loose on the worm shaft. 3. Inspect worm shaft splines for
wear. Also inspect retaining pin
for tightness.
4. Worn worm and piston assembly. 4. Replace worm and piston
assembly.
(c) Metallic clatter or tapping noise. (c) Replace the back pressure valve
cushion.
(d) Knocking condition a t the bracket stop (d) Rubber stop worn or missing from
when the engine is running. pump bracket.
(e) Loose pump belt. (e) Belt not properly adjusted or worn
to the extent that belt tension
cannot be properly adjusted.
19-38 POWER STEERING PUMP
PART 4
POWER STEERING PUMP

1. OPERATION pump to the flow control valve. Orifices in the meter-
ing insert permit a flow of approximately two gal-
The ’lipper type power steering pump is a lons per minute to the gear before the valve moves
driven constant displacement pump. to the lift to allow the excess to flow back to the
In operation (Fig. 1) the spring-loaded sli9pers in inlet side of the pump. Maximum pressure in the
the pump rotor are in contact wlth the eccentric, in- system is limited by the pressure relief valve. The
side diameter of the housing. As the rotor revolves valve opens into the reservoir when the pressure
the slippers forces the oil from the inlet side of the exceeds the maximum pressure specified.
SERVICE PROCEDURES
2. MEASURING FLUID LEVEL 3. PRESSURE TEST
(1) Start the engine, turn the steering wheel back (1) Test pump belt tension. See “Cooling System”,
and forth several times to expel the air from the sys- Group 7.
tem, then shut off engine. (2) Disconnect the pump to the steering gear pres-
sure hose at the power steering pump. Connect the
(2) Remove the filler cap and visually check the
test hose (2-3388 with the proper adapter between
oil level in the reservoir:
power steering pump and pressure gauge C-3309B
Engine Cold-Oil level should be at the bottom of with the shut-off valve between the pressure gauge
filler neck. and the pressure hose that you disconnected from the
Engine Hot-Oil level should be one-half way up pump. (Fig. 2). Make sure all connections are tight
in fill neck. and that the shut-off valve is fully opened.
If necessary, add only 2084329 Power Steering NOTE: The pressure gauge must be installed be-
Fluid to the required level. Do not overfill. tween the pump and the shut-off valve, all connec-
RELIEF VALVE
RETAINER RING (2)
FLOW CONTROL VALVE
DISCHARGE FERRULE 63x664
Fig. 1-Power Steering Pump (Schematic)

POWER STEERING PUMP 19-39
with a thermometer in reservoir, as shown in Figure

3; the pressure gauge should show a pressure of less
than 100 psi. If the pressure is higher, inspect the
hoses and connections for kinks and obstructions, or
restrictions in the steering gear.
(7) Increase the engine speed to 1000 rpm, then
slowly close the gauge shut-off valve. With the gauge
shut-off valve fully closed the pump pressure should
be as shown in “Specifications”.
CAUTION: Do not close the valve for more than a
few seconds, as this would abnormally increase the
oil temperature and cause undue oil pump wear.
(8) If the pressure exceeds the maximum shown in
the “Specifications”, the relief valve is faulty or the
pump is equipped with the wrong relief valve.
Fig. 2-Pressure Test (Typical)
(9) If the pressure is less than the minimum shown
in “Specifications”, the relief valve is defective. Re-
tions must be tight and shut-off valve full open. place the relief valve with the correct relief valve
known to be in working order and repeat test. Now
(3) Remove the pump reservoir filler cap. if the pressures are below the minimum shown in the
(4) Connect one lead of the tachometer to the dis- pressure chart, disassemble the pump and inspect the
tributor terminal of coil, the other lead to a good flow control valve for evidence of fouling, or slipper
ground, start the engine and operate at 500 rpm and spring breakage.
fill pump reservoir to the proper level. (10) With the gauge shut-off valve fully open, op-
(5) Expel all air from the unit by turning the steer- erate the steering unit through another cycle, this
ing wheel to the full right turn and back to the full time holding the unit at extreme travel in each direc-
left turn several times and recheck oil level. tion while watching the oil pressure gauge. The gauge
NOTE: To assist in heating the pump oil: slowly reading should be equal in each direction. If not, it
turn the pressure gauge valve towards the closed posi- indicates excessive internal leakage in the steering
tion until gauge reads 400 psi and open valve fully gear unit.
when oil temperature reached 150 degrees F. NOTE: Do not hold the worm shaft at either ex-
(6) With the engine operating at idle speed (500 treme position for more than a few seconds.
rpm) and no steering effort applied, and oil tempera- (11) If the pressures are within the ranges speci-
ture between 150 degrees F. and 170 degrees F. test fied under “Specifications,” make a flow test as out-
lined in Paragraph 4,
4. PUMP FLOW TEST

(1) Test the pump belt tension. See “Cooling Sys-
tem”, Group 7.
(2) Disconnect the pump pressure hose at the
power steering pump and connect the test hose
adapter tube and pressure gauge C-3309B with the
proper adapters between the power steering pump
and the hose disconnected from the pump (refer to
Fig. 1).
NOTE: The pressure gauge must be installed be-
tween the pump and the shutsff valve, all connec-
tions must be tight and the s h u t 4 valve fully open.
(3) Disconnect the return hose at the power steer-
Fig. 3-Testing the Oil Temperature in the ing pump. Remove return hose screen, be sure screen
Pump Reservoir i s cleaned and reinstalled after tests.
I (9) Decrease the engine speed to 500 rpm, then

slowly turn the pressure gauge shut-off valve to-
wards the closed position to obtain the following
pressure readings on pressure gauge at the pump dis-
charge without fully closing shut-off valve.
CAUTION: Do not close valve completely.
Valiant 170-225 Cu. In. Engines 600 psi
Plymouth 6 and 8 Cylinder Engines 750 psi
With the above values registered on the pressure
II
i gauge the flow checking gauge should show a mini-
mum pressure of 10 psi. If the flow pressure reading
a is less than 10 psi; test the flow valve operation for
d
sticking; if the valve operation is satisfactory the
pump is worn and should be replaced.
If the flow pressure reading is 10 psi or greater,
and the relief valve is operating properly; the pump
is good.
When removing the test equipment, make sure the
pressure and return hoses are reinstalled properly.
There should be no interference of the hoses with
components attached to the fender shield or dash
panel.
NOTE: The return hose screen should be cleaned
Fig. +Flow Test Gauge Connection; and reinstalled in the end of the return hose before
rei nsta Iling the return hose.
(4) Install the flow checking gauge set Tool C-3885
with special hose between the power steering pump 5. POWER STEERING PUMP
and the return hose disconnected from the pump, as Removal
shown in Figure 4. (1) Loosen the pump lower mounting bolt and re-
NOTE: The fitting that has the restriction; and the move the belt from the pulley.
arrow on the “tee” connector (Fig. 4) must be towards (2) Place a container under the pump and discon-
the power steering pump. nect both hoses at the pump. Cap ends of hoses and
(5) Remove the oil reservoir cover and fill reservoir secure hoses high enough to prevent loss of fluid.
to the proper level. (3) Remove the bolts attaching the bracket to the
(6) Start the engine and operate at 500 engine rpm. engine and remove the pump and bracket assembly.
(7) Expel all air from the unit by turning the Oil Seal Replacement
steering wheel to the full right turn and back to the Removal
full left turn several times. (1) Remove the power steering pump from the en-
(8) Increase the engine speed 1000 to 1200 rpm gine.
and with no steering effort applied, oil temperature (2) Clean the exterior of the pump before dis-
between 150 degrees F. and 170 degrees F. (check the assembly.
thermometer in reservoir), the flow pressure gauge in (3) Remove the filler cap and drain the reservoir.
the pump return line should read between 14 psi
(4) Remove the brackets, reservoir screws gasl?et
and 25 psi. If the correct checking orifice is used for
the test and the flow pressure gauge registers less than and “0”ring.
14 psi, inspect to see if the restrictor is installed (5) Using spacer washers between the front
properly, and if it is installed properly, dirt may be bracket and the pump, reinstall the front-bracket for
restricting control valve movement or blocking the use as a holding‘fixture. Clamp the bracket in a vise
orifice or flow valve spring may be weak. If the re- (Fig. 5).
turn pressure is greater than 25 psi, the flow valve (6) Remove the pulley with Tool (3-3934 or C-3615
may be stuck in the closed position. as follows:
FLOW CoNlRoL VALVE

PLUG AND SNAP RING
58x224
Fig. 5-Removing the Pump Pulley
(a) Engage one half-collar under the flange of the

Fig. 7-Installing the Pump Oil Seal
pulley hub.
(b) Position the screw shaft and nut with the flange with a stone or fine emery cloth. This will prevent
section inside the half-collar. seal damage when the new seal is installed. Do not
(c) Engage the other half-collar under the pulley stone or emery the area on the shaft that the lip seal
hub and over the flange of the screw shaft nut and contacts.
install the retainer sleeve over both half-collars. (1) Install the new seal with the lip of the seal
(d) Hold the nut from turning and' turn the tool toward the pump. Use Tool C-3640 to drive the seal
screw. flush with the insert (Fig. 7).
(2) Support the pump body on the holding fixture,
(e) If there is evidence of an oil leak, remove pump Tool C-3643, with the tool dowel pins in the pump
shaft oil seal by threading Tool C-3642 far enough bolt holes so that the pressure will be absorbed by
into seal to engage the metal portion of the seal, as
the lower end of the pump shaft (Fig. 8).
shown in Figure 6. Turning puller center screw while
holding tool body will withdraw the seal assembly CAUTION: The pump must be supported in a man-
from the pump. ner in which a l l pressing force will be applied to the
shaft only; otherwise, the pump body and rotor will
installation be damaged.
CAUTION: The pulley end of the shaft should be (3) Install the pulley with a heavy duty arbor press.
examined for sharp burrs or corners and smosthed Press on the pulley hub only until the hub is flush
with the end of the pump shaft.
RAM
LLEY
4 63x665
Fig. &Removing Pump Shaft Oil Seal Fig. 8-Installing the Pump Pulley
(4) Lubricate the large “0”ring and the reservoir

cap screw gasket and install both on the pump body.
(5) Install the reservoir and the pump brackets.
Tighten the screws to 16 foot-pounds torque. FRONT INSERT
(6) Install the pump steering pump and test belt

adjustment as outlined under “Cooling System,” FERRULE
Group 7. METERING INSERT
6. POWER STEERING PUMP DISCHARGE

FITTING FERRULE REPLACEMENT
(1) Wipe away all dirt around the discharge fitting LSP
and tighten the high pressure hose tube nut to 24
fcot-pounds torque. “0“RING
(2) Restart the engine and turn steering gear from / /RELIEF VALVE
stop to stop to build up pressure.
If the discharge fitting is leaking, disconnect the
high pressure hose at the pump and examine the
tubing flare for nicks, scratches, or other damage. If 63x668
the tubing flare or nut is damaged, replace the high
pressure hose. Fig. IO-Pump Cut-Away View (Typical)
(3) Examine the pump housing in the discharge
area to be sure that the housing has not been dam- opening in the down position, this will prevent any
aged by cross-threading or over-tightening the flare chips from falling into the pump.
nut. If the housing is cracked or if the threads are
damaged; the pump must be replaced. (c) Use a No. 4 screw-extractor (EZ Out). Turn the
extractor into the ferrule (Fig. 9). Then rock the
(4) Examine the brass ferrule in the pump dis- extractor slightly to remove the ferrulz. Perform this
charge fitting for nicks and scratches. The hose tub- operation carefully so as not to damage the threads
ing flare should make an indentation in the ferrule on the housing.
which is concentric with the center hole and of ap-
proximate uniform depth all the way around. If the (d) Clean out the discharge bore of any foreign
ferrule is damaged or not seated properly, replace it material (brass chips, dirt etc.).
as follows: (e) Center the new ferrule with the tapered end up
(a) Remove the pump from the vehicle. in the housing bore. The ferrule is pressed into
place by the high pressure hose and tightening the
flare nut to 24 foot-pounds torque. Figure 10 is a
cutaway view to show the ferrule properly seated in
the housing.
CAUTION: Be sure that the ferrule is centered in
the housing bore before reinstalling the high pressure
hose flare nut.
7. FLOW CONTROL VALVE REPLACEMENT

(1) With the pump reservoir removed, remove one
of the flow control valve end plug retaining rings and
end plug (Fig. 11).
(2) Depress the control valve against spring pres-
sure and allow it to spring back. The valve should
pop out of the bore to a point where it can be re-
moved. If the valve should stick, do not force it, but
Fig. %Installing Ferrule Extractor repeat the spring back procedure several times.
SPANNER NUT
UNCH MARKS
63x670
Fig. 11-Removing Flow Control Valve Retaining Ring Fig. 12-Center Punch Marks on the Pump Body,
Spanner Nut and the Front Insert
NOTE: Gum deposits will cause the control valve
to stick in one position and it will be necessary to 8. SLIPPER SPRING REPLACEMENT
break the valve free by light tapping and repeat step
(1) Remove the pump and bracket from the vehicle.
2. If the control valve and bore were fouled by gum-
ming, foreign material, or burrs, the valve and (2) Remove the bracket and reservoir.
valve bore should be thoroughly cleaned and flushed (3) Remove the pump pulley (Fig. 5).
and reassembled. (4) Use a center punch to mark the position of the
front insert and spanner nut in the pump housing
NOTE: Inspect the flow control valve and valve
(Fig. 12), to insure that the front insert and spanner
bore. If the valve or valve bore in pump body are nut are returned to the exact same position at re-
badly scored, replace the pump assembly less pulley assembly.
and reservoir. (5) Use a ?4 inch drift to loosen and remove the
(3) Install the control valve spring, seating the spanner nut (Fig. 13).
spring in the spring socket.
(4) Remove any burrs with a fine hone or crocus
cloth but Do Not round the valve land corners.
(5) Lubricate with Mopar power steering fluid Part
No. 2084329, and install the control valve over the
control valve spring and into the bore. When all
valve lands have cleared the retaining ring groove
area, work the control valve back and forth against
spring pressure until the valve operates smooth and
freely .
(6) Install a new “0”ring on the end plug.
(7)Lubricate the end plug and “0”ring and install
the end plug with the machined projection out.
(8) Install the plug retainer ring with the sharp
edge of ring up.
(9) Install the relief valve.
(10) Install the pulley (Fig. 8).
(11) Install a new pump body “0”ring, new reser-
voir gasket and reservoir and brackets. Fig. 1 L R e m o v i n g the Spanner Nut
---.
+‘%PRESS RAM
63x677
Fig. 16-4nstalling the Slipper Springs (Typical)
of the pump shaft, this will prevent shaft oil seal

damage when a new seal is installed.
CAUTION: Do not stone o r emery t h e area o n
63x074
t h e shaft that the seal lip contacts.
Fig. 1LRemoving the Shaft, Rotor and the Front Insert

(9) If all parts are in a serviceable condition, dis-
card all eight slipper springs even if they appear to
(6) Support the pump housing so that the front in- be in good condition.
sert is clear of press and using a smooth V2 inch diam- (10) Thoroughly flush and clean all parts with
eter bar (Fig. 14), press the shaft, rotor and front in- clean solvent.
sert out of the pump housing. NOTE: It is essential that cleanliness be observed
CAUTION: Be careful not to damage t h e pump throughout t h e pump assembly.
rear bearing. (11) Using a piece of wire 25 inches long, make
(7) Examine the parts for broken edges or deep three turns around the center of the rotor and fasten
scoring, especially on the rotor and slippers. If the wire as shown in Figure 15. Bend the ends of the
either of these conditions are present, then the pump wire towards the pulley end of shaft. Do not make the
assembly less relief valve, pulley, and reservoir must wire coils too tight or the wire will be difficult to
be replaced. Small nicks or burrs may be smoothed remove.
with a fine hone.
CAUTION: Use care when handling the rotor and
NOTE: The cam insert has two machined notches shaft since t h e corners of the r o t o r are extremely
(one large and one small) on the inside surface; sharp and must remain sharp for good pump opera-
these are not to be interpreted as deep ecoring. tion. The o i l seal and bearing surfaces of t h e shaft
( 8 ) Smooth off burrs or corners on the pulley end must remain free o f any nicks and burrs.
(12) Use an ordinary wood pencil with the point
broken to install the new springs. Enter the blunt
tapered end of the pencil in the spring and snap the
springs into the pockets in the rotor by turning the
pencil clockwise (Fig. 16). Install the springs and
slippers in one rotor slot at a time. Remove the pen-
cil from the spring with a counter-clockwise rotation.
Either end of the spring may be inserted into the
rotor pocket.
NOTE: Make sure the proper springs are installed.
(13) Install each slipper by sliding the slipper be-
Fig. 15-Slipper Retainer Wire Retainer Tool tween the two springs and the wire tool so that the
Installed on Rotor ends are flush with the rotor. The notched portion
POWER STEERING P U M P 19-45
3/4”
v --
SLIPPERS (4)
W I R i TOOL 63x678
Fig. 17-Slippers Installed on the Rotor

I
S M A L L PUMP
of the slipper must be installed, as shown in Figure (.96 CU. IN. D I S P L A C E M E N T ) 63x681
17.
Fig 19-Slipper Retainer Washer Tool
NOTE: Inspect the springs to make sure they are
in the pockets and i n an upright position under the
slipper (Fig. 18). (16)Hold the washer against the rotor with a screw
driver while removing the wire retaining tool, making
(14)Using a washer of the dimensions shown in sure that the slippers remain flush with the end of
Figure 19 drop it over the pulley end of the shaft. the rotor.
This washer is used to keep the slippers flush with
the end of the rotor. (17) Line the pump shaft with the lower bearing
and push the shaft, rotor and slippers all the way into
NOTE: It is important that the slippers remain the cam insert.
flush with the end of the rotor throughout the as-
sembly operation. NOTE: The slipper ends may hang up on the
center openings in the cam insert. I f this should oc-
(15) Insert the shaft and rotor assembly with the cur, rotate the shaft while installing to overcome this
flat washer tool and slipper retaining wire tool into condition.
the pump cam insert so that the slippers and rotor
are inside the cam with the end of the shaft resting (18)Remove the special flat washer tool. Make sure
against the back f x e in the housing (Fig. 20). that the springs are in place by rotating the pump
shaft and looking through the notch in each slipper.
CAUTION: Do not attempt to insert the pump
shaft into the bearing a t this time. (19)Lubricate the rotor and slippers with clean
power steering fluid and rotate the shaft to make
sure the slippers do not bind.
SLIPPER S P R I N G S 181
63x679
Fig. 1’8iSlippers & Springs Installed in the Rotor Fig. 2(1--lnstalling the Shaft & Rotor Assembly
19-46 PdWER STEERING PUMP
(20) Replace the shaft seal and “0”ring seal on

the front insert. Lubricate the shaft seal, “0”ring PRESS RAM
and shaft with power steering fluid.
(21) After making sure the inner face on the front ---.
insert is smooth and free of burrs, place the insert
assembly on the shaft with care so that the shaft
seal is not damaged by the end of the Shaft.
(22) Support the pump housing in an arbor press
(Fig. 21), and using a 1% inch socket with a V2 inch
drive, align the center punch marks on the front in-
sert and the pump body, and press the insert into
the pump housing.
(23) Install the spanner nut and use a 34 inch drift
to tighten to the exact original position in the hous-
ing as indicated by the pin punch marks placed on the
pump body and spanner nut at disassembly.
(24) Install the flow control valve as outlined under 63x684
“Flow Control Valve Installation”, Paragraph 7.
(25) Install the pump pulley (Fig. 8). Fig. 21-Pressing the Front Insert into Pump Housing
(26)Install a new “0”ring on the pump body and
install the reservoir and pump brackets. (3) Connect the pressure and return hoses.
(4) Fill the pump reservoir with Number 2084329
9. INSTALLING THE POWER Power Steering Fluid, see “Checking Fluid Level”.
STEERING PUMP
(1) Position the pump and bracket on the engine (5) Start the engine, turn the steering wheel all
and install the attaching bolts. the way to the left and back all the way to the right
(2) Install the drive belts and adjust. See “Belt several times to expel the air from the system, then
Adjustment”, “Cooling System” Group 7. Tighten the turn off the ignition switch to stop engine and re-
pump bracket bolts to 30 foot-pounds torque. check fluid level in reservoir.
SERVICE DIAGNOSIS
POWER STEERING PUMP
Low Oil Pump (a) Pump belt loose. See “Pump Belt Adjustment”.
Pressure (b) Pump pulley loose. Replace the pulley, measure the
pump diameters as follows: Shaft
diameter .8120-.8125 Pulley inside
diameter .8095-.8105. If shaft is
damaged, replace pump.
Oil level low in pump reservoir. (c) See “Fluid Level”.
Pressure relief valve spring weak, or (d) Replace the relief valve and
relief valve stuck in open position. perform “Pump Pressure Test”.
Flow control valve stuck. (e) Repair as necessary. Refer to
“Flow Control Valve Removal and
Installation”.
Worn pump rotor, slippers, or broken (f) Repair as necessary. See “Hard
and distorted springs. Steering” Correction (e).
SERVICE DIAGNOSIS---(Continued1
POWER STEERING PUMP
High Pump Pressure (a) Wrong relief valve. (a) Replace relief valve and perform
“Pump Pressure Test”.
(b) Relief valve clogged with foreign (b) Replace relief valve and perform
matter (dirt, metal chips, etc.). “Pump Pressure Test”.
Leakr (a) Reservoir over-filled. NOTE : Operating (a) See “Fluid Level”.
the steering gear manually when the
engine is not running will cause the
steering gear to displace the fluid from
the steering gear housing which will
then be forced out of the pump filler
cap vent, giving a false indication of
fluid leakage.
(b) Pressure and return hose connections (b) Tighten all fittings, check hose for
and fittings. deterioration: replace any faulty
hoses. If the discharge fitting is
leaking; See “Power Steering
Pump Discharge Fitting Ferrule
Replacement”.
(c) Reservoir to-pump-body “0”ring or (c) Replace the reservoir “0”ring
mounting screws. and tighten reservoir mounting
screws.
(d) Pump shaft oil seal. (d) Replace oil seal.
TRANSMISSION 2 1- T
GROUP 21
TRANSMISSION
-
PART 1 M A N U A L TRANSMISSION
CONTENTS
1 -A-3-SPEED M A N U A L TRANSMISSION
Page Page
.......... ........ 2
.............................. 10
Gearshift Interlock Adjustment. . . . . . . . ... 11
Gearshift Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Speedometer Pinion Usage Chart. ............. 11
1 B-4 FORWARD SPEED M A N U A L TRANSMISSION
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transmission-Disassembly ............... 17
Special Tools.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transmission-Assembly . . . . . . . . . . .
Shift Linkage-Adjustment . . . . . . . . . . . . . . . . . . . . . . . 14 Transmission-Installation i
Transmission-Remova 1. . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
IC-SERVICE D I A G N O S I S
Manual Transmission. . . . . . 24
-
PART 2 TORQUEFLITE (TORQUE CONVERTER)
CONTENTS
2A-Specifications. ... 25 Aluminum Thread Repair. . , , . . . . . . . . . . . . . . . . . . . . 66
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Front Pump Oil Seal.. . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removal of Sub-Assemblies . ................ 67
Hydraulic Control System. . . . . . . . . . . 31 Recondition Sub-Assemblies . . . . . . . . . . . . . . . . . . . . . . 69
Gearshift and Porking Lock Controls. . . . . . . . . . . . . . . 31 Valve Body Assembly .................... 70
Operating Instructions. . . 41 Accumulator Piston an pring . . . . . . . . . . . . . . . . 73
2B-Service-Maintenance, Adjustments and Tests. . . 41 Extension Housing Bushing and Oil Seal
Lubrication. . . . . . . . . . . . . . . . 41 (Six Cylinder Vehicles). . . . . . . . . . . . . . . . . . 74
Push Button Control Unit. . . . . . . . . . . . . . . . . . . . . 43 Extension Housing Bearing and Oil Seal
Console Gearshift Unit. . . . . . 44 (Eight Cylinder Vehicles). . . . . . . . . . . . . . . . . 74
Back-up Lamp Switch Replace 45
Parking Sprag and Lever.. . . . . . . . . . . . . . . . . . . 74
Push Button and Console Shift 45
Governor and Support. . . . . . . . . . . . . . . . . . . . . . 74
Gearshift Control Cable (Transmission End). . . . . . 45
Rear Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Parking Lock Cable (Transmission End). . . . . . . . . 46
Neutral Starting Switch. . ................ 47 Front Oil Pump and Reaction Shaft Support
48 (Six Cylinder Vehicles). . . . . . . . . . . . . . . . . . 75
Band Adjustment
Throttle Linkage .................. 53 Front Oil Pump and Reaction Shaft Support
Hydraulic Control Pressure Tests. . . . . . . . . . . . . . 53 (Eight Cylinder Vehicles). . . . . . . . . . . . . . . . . 78
Hydraulic Control Pressure Adjustments. . . . . . . . . 54 Front Clutch (Six Cylinder Vehicles). . . . . . . . . . . . 7 9
Air Pressure Tests. . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Operations with Transmission in Vehicle. . . . .
Speedometer Pinion .....................
56
57
57
Front Clutch (Eight Cylinder Vehicles). . . . . . . . . . .
Rear Clutch (Six Cylinder Vehicles) . . . . . . . . . . . .
Rear Clutch (Eight Cylinder Vehicles). . . . . . . . . . . 84
::
Output Shaft Oil Se 57 Planetary Gear Assemblies, Sun Gear and
Extension Housing. . . . . . . . . . . . . . . . . . . . . . . . . . 58 Driving Shell (Six Cylinder Vehicles). . . . . . . . . 87
Governor ........................... 59 Planetary Gear Assemblies, Sun Gear and
Rear Oil ....................... 40 Driving Shell (Eight Cylinder Vehicles). . . . . . . . 88
Parking Lock Components. . . . . . . . . . . . . . . . . . . . 61 Overrunning Clutch. . , , . . . . . . . . . . . . . . . . . . . . . 89
Neutral Starting Switch.. . . . . . . . . . . . . . . . . . . . . 62 Kickdown Servo and Band.. . . . . . . . . . . . . . . . . . 91
Valve Body Assembly and Accumulator Piston. . . 62 low-Reverse Servo and Band. . . . . . . . . . . . . . . . 91
Transmission and Converter Removal and Installation. . 62 lnstallation of Sub-Assemblies . . . . . . . . . . . . . . . 92
Recondition Transmission Unit Out of Vehicle. . . . . . . . . 66 Starter Ring Gear Replacement. . . . . . . . . . . . . . . . . . . 95
Flushing the Torque Converter. . . . . . . . . . . . . . . . . . . . 66 2C- Service Diagnosis. . . . . . , . . . . , . . , . . . . . . . . . 97 .
21-2 TRANSMlSSlON4-SPEED M A N U A L
SPEC1FlCATlONS
3-SPEED MANUAL TRANSMISSION
Plymouth VP-1
Model Application. .................. Valiant W-1 Taxi/Poliee Plymouth VP-2
Engine Displacement (Cu. In.). ......... 170-225 225 318 361-383
H.D. H.D. H.D.
RATIO
First. ......................... 3.22 2.95 2.95 3.02 3.02 2.55
Second, ....................... 1.84 1.83 1.83 1.76 1.76 1.49
Direct.. ....................... 1.00 1.oo 1.oo 1.oo 1.oo 1.oo
Reverse. ...................... 4.14 3.80 3.80 3.95 3.95 3.34
LUBRICANT
Capacity ...................... Refer to Group 0 "Lubrication"
Type ......................... Auto. Transmission Fluid
Type "A" Suffix "A"
Gears.. . . . . . . . . . . . . . . . .:. .... Helical
TOLERANCES
Second Speed Gear End Play. . . . . .002 to .014"
Countershaft End Play.. .......... ,0045 to .028"
Clutch Housing Face Run-Out . . . . . . .006" Max.
Clutch Housing Bore Run-Out . . . . . . .008" Max.
SPECIAL TOOLS
DD- 10 14. . . . . . .Repair Stand C-464. . . . . . . . .Arbor (idler gearshaft)

C-3281 . . . . . . . .Holding Tool C-3789. . . . . . . .Installer (seal)
C-452. . . . . . . . .Puller C-375 1 . . . . . . . .Installer (bushing)
C-3755. . . . . . . . Driver C-3754. ...... .Installer (oil seal)
C-578. . . . . . . . .Arbor (countershaft) C-3767. . . . . . . .Protector (shift shaft oil seal)
C-3766. . . . . . . . Installer (seal) C-3753 . . . . . . . .Puller (extension seal)
C-3765. . . . . . . .Installer (detent ball) C-3806. . . . . . . .Fixture (engine support)
TORQUE REFERENCE
Front Bearing Retainer Bolts .................................................. - 360

Extension Housing Bolts.. .................................................... 50 -
Nuts ...................................................... 50 -
Gearshift Operating Lever Nuts. .............................................. - 180
Mainshaft Flange Nut.. ..................................................... 175 -
Transmission to Clutch Housing Bolts.. .......................................... 50 -
TRANSMISSION“-SPEED MANUAL 21-3
1A-34PEED MANUAL TRANSMISSION

The three speed Manual Transmission used on 6- The three speed manual transmission (Fig. 1) is
cylinder vehicles is referred to as Model A-903 and of the synchromesh type with helical cut gears to
the three speed Heavy Duty Manual Transmission provide silent operation. The countershaft gear is in
used on 8-cylinder vehicles is referred to as Model constant mesh and is supported by two rows of the
A-745. The Model A-745 with modifications is also roller bearings at each end. The mainshaft is support-
used on 6-cylinder Plymouth Models for Taxi and ed by ball bearings at each end of the extension
Police car operations. The service procedures are the housing. The speedometer drive gear is integral with
same except where noted. the mainshaft.
SERVICE PROCEDURES
1. TRANSMISSION (2) If necessary, attach puller Tool C-452, and re-

Removal (From the Vehicle 1 move the flange assembly.
(1) Drain the lubricant from the transmission. (3) Remove the bolts that attach the cover to the
case. Remove the cover and discard the gasket.
(2) Disconnect the propeller shaft, speedometer
cable, housing and the gearshift control rods. Dis- (4) Using a pair of feeler gauges, measure the syn-
connect parking brake control cable, and interlock chronizer float. The measurement of the “float”
rod (if so equipped). should be taken before any further disassembly of
the transmission is attempted.
CAUTION: Remove the speedometer cable (pin- (5) The synchronizer “float” should be between
ion comes out with the cable) with the hand so that .050 and .090 inch, when measured between the syn-
the housing is not crushed. chronizer outer ring pin and the opposite synchronizer
(3) Remove the back-up light switch leads (if so outer ring. This measurement must be made on two
equipped). pins, 180° degrees apart with equal gap on both ends
for “float” determination, as shown in Figure 3.
(4) Install engine support fixture C-3806, mounting
hooks firmly into the holes in the side of the frame (6) There should be a snug fit between the pins
members with the support ends up against the un- and the outer rings, similar to that obtained when
derside of the oil pan flange. measuring with a micrometer.
(5) Adjust the fixture to support the weight of Extension Housing
the engine, then raise engine slightly and remove the
(1) Remove the bolts and one nut that attaches
rear support attaching bolts. Remove the crossmem-
ber. the extension housing to the transmission case. Slide
the extension off the mainshaft. Discard the gasket.
(6) Support the transmission, using a suitable jack,
then remove the bolts that attach the transmission BACK-UP LIGHT
to the clutch housing. SWITCH PLUG
(7) Slide the transmission rearward until the pin-

ion shaft clears the clutch disc before lowering the R
A#->- -+--
\
-r
-7
transmission. (This precaution will avoid damaging IE-
the clutch disc). 1
(8) Lower the transmission and remove from under
the vehicle.
(9) Mount the transmission in repair stand, DD-
1014.
Disassembly (Figs. 7 and 21 / 60x852
DRAIN PLUG
(1) Using flange holding Tool C-3281, remove the
flange retaining nut and washer. Fig. 1-Transmission Assembly (6-Cylinder)
.-c
0
.-E
In
n
In
E
!!
c
TRANSMlSSlON4-SPEED MANUAL 2 1-5
moval.) Be careful not to bind the inner synchronizer
ring on the drive pinion clutch teeth.
(3) Remove the snap ring which locks the main

drive pinion bearing on the pinion shaft, using snap
pliers. Remove the pinion bearing washer, then care-
fully press the pinion shaft out of the bearing, using
an arbor press. Remove the oil slinger. (Refer to
Fig. 5.)
(4) Remove the 14 bearing rollers from the cavity
in the end of the drive pinion (15 bearing rollers 8-
Cyl) using a hook or a flat blade.
Mainshaft
!I’ UL +
(1) With the transmission in reverse, remove the
outer center bearing snap ring, using a hook or a flat
Fig. 3-Measuring the Synchronizer “Float”
blade, then partially remove the mainshaft.
Remove the oil seal, using Tool C-748, (6 cyl.) C-3753 (2) Cock the mainshaft, then remove the clutch
(8 cyl.). sleeve, the outer synchronizer rings, the front inner
(2) Remove the extension housing and mainshaft ring and the 2-3 shift fork. (Refer to Figs. 6 and 7.)
bearing, (8 cyl.), (6 cyl.) bushing (Tool C-3755). (3) Remove the clutch gear retaining snap ring,
Drive Pinion using snap ring pliers. Slide the clutch gear off the
(1) Remove the bolts that attach the main drive end of the mainshaft.
pinion bearing retainer, then slide the retainer off the (4) Slide the second speed gear, stop ring and the
pinion. Discard the gasket and drive the seal out of synchronizer spring off the mainshaft.
the retainer, using a suitable drift.
( 5 ) Remove the low and reverse sliding gear and
(2) On the 8 cylinder, when removing the drive
pinion and bearing assembly from the transmission shift fork as the mainshaft is completely withdrawn
case, slide the synchronizer front inner stop ring from from the case.
the short splines on the pinion as the assembly is (6) Remove the countershaft gear, and the thrust
being removed from the case, as shown in Figure 4. washers from the case.
On the 6 cylinder, grasp the pinion shaft with the
hand and pull the assembly out of the case. (It may (7) Remove the bearing rollers (88) spacer rings
be necessary to tap the shaft lightly to aid jn its re- (4) and the center spacer from the countershaft gear.
t.
BEARING
OIL SLINGER
AB
61x121 DRIVE PINION

57x1728
Fig. &Removing Drive Pinion Assembly Fig. 5-Drive Pinion Assembly

2 1-6 TRANSMISSION-3-SPEED MANUAL
CLUTCH GEAR SYNCHRONIZER (4) Remove the bearing rollers, (4) washers and
SLEEVE STOP INNER RING the center spacer from the cluster gear.
Reverse Idler Gear

(1) Using a suitable drift, drive the reverse idler
gear shaft towards the rear and out of the case. Re-
move the woodruff key from the end of the shaft.
(2) Lift out the reverse idler gear, thrust washers
SPREADER
and bearing rollers (22) out of the case. Remove the
bearing rollers from the gear.
OUTER RING ASSY’S. 61x120A
Gearshift Mechanism ( 6 Cylinder)
Synchronizer Unit (8 -Cylinder) (This operation need only be done if the seals are
SECOND SPEED GEAR SPREADER SPRING-...
leaking).
INNER STOP RING
(1) Remove the operating levers from their re-
spective shafts.
THIRD SPEED GEAR
OUTER STOP RING (2) Drive out the tapered retaining pin (shown in
Figure 1) from either of the two lever shafts, then
withdraw levershaft from inside the transmission.
CLUTCH GEAR (The detent balls are spring loaded; as the shaft is
being withdrawn, the ball will drop to the bottom of
the case.)
ND SPEED GEAR (3) Remove the interlock sleeve, spring, pin and
both balls from the case. (Refer to Fig. 7.) Drive out
the remaining tapered pin, then slide the lever shaft
out of the transmission.
THIRD SPEED GEAR
INNER STOP RING 59x4436
(4) Using a suitable drift, drive out the lever shaft
oil seals and discard.
Fig. &Synchronizer Unit (6-Cylinder)
Gearshift Mechanism t 8 Cylinder 1
Countershaft Gear t 6 Cylinder 1
(This operation need only be done if seals are
(1) Using a feeler gauge measure the end play of leaking.)
the cluster gear. The end play should be from .0045
‘to .028 inch. This measurement will determine if new (1) If necessary, remove both the lever shaft seals,
thrust washers are to be installed at reassembly. using Tool C-3638.
(2) Using Tool C-578, drive the countershaft rear-
ward and out of the case. Remove the woodruff key
from the end of the shaft.
Countershaft Gear t 8 Cylinder 1
CAUTION: Do not drive the countershaft toward
the front of the transmission case.
(I) Using countershaft bearing arbor Tool C-3834,
drive the countershaft toward the rear of the case
until the small key can be removed from the counter-
shaft.
(2) Drive the countershaft the remaining way out
of the case, keeping the arbor tight against the end
of the countershaft to prevent loss of the bearing
rollers. 6011853-A
(3) Remove the cluster gear, thrust washers and

the thrust plate from the case. Fig. 7-Synchronizer Assembly (&Cylinder)
~
TRANSMlSSlON4-SPEED MANUAL 21-7
(2) Using a small punch, remove the low and re- gear, install a new lever and shaft. Inspect the shift
verse gear lever shaft tapered lock pin by driving it forks for wear on the shanks and pads.
toward the top of the transmission case. Assembly
(3) Remove the second and third gear lever shaft (1) Place two new shift lever shaft seals centered
in the same manner. over their bores in the case. Using Tool (2-3766,
(4) Remove the lever shafts from the transmission (C-3650 8 cyl.) drive both seals into the case, until the
case, taking care not to lose the spring loaded detent tool bottoms.
balls. (2) Install Tool C-3767, then slide the low and
(5) Remove the interlock sleeve, spring, pin and reverse lever shaft into the rear boss of the case.
the detent balls. through the seal and into position. Lock in position
with the tapered pin. Turn the lever until the center
Cleaning and lnspection (neutral) detent is in line with the interlock bores.
Clean all the parts (including the case) in a suitable (Use sealer on the pins.)
solvent and blow dry with compressed air.
(3) Slide the interlock sleeve in .its bore in thc
CAUTION: Do not spin the bearings with com-
pressed air. The bearings should be immersed in clean
solvent and rotated by hand until clean. A bearing
that is spun by air pressure is likely to score due to
the absence of lubrication.
Lubricate the cleaned bearings with light oil, then
turn by hand to test for roughness, looseness or wear.
Test the fit of the bearings on their respective shafts
and in the bores. Inspect the second speed gear and
the reverse idler gear needle bearings for scoring or
wear. Inspect the mainshaft splines for galling or
scoring. Inspect bearing mounting surfaces and snap
ring grooves. Slight nicks or burrs can be stoned off.
Inspect the gear teeth on the synchronizer clutch gear
LOW L REVERSE
and sleeve. If there is evidence of chipping or exces- /e
\ i
sively worn teeth, install a new part at reassembly.
Be sure the clutch sleeve slides freely on the clutch 60x 858
gear.
levers (6-Cylinder)
Install a new gear, if any of the gear teeth are
broken, chipped or excessively worn. Small nicks or
burrs can be stoned smooth. SECOND AND DIRECT
Inspect the clutch teeth in the drive pinion. If ex-
cessively worn, broken or chipped, install a new pin-
ion. Inspect the mainshaft pilot bearings (drive pin-
ion) for pitting or scoring. If either of these conditions
exist, install a complete new set of bearings.
Inspect the bearing rollers removed fom the gear
for pitting or scoring. If necessary, install a new set
as required.
Inspect the general condition of the transmission
case and extension housing and all the threaded holes
and plugs for stripped or pulled threads.
Inspect all mating and gasket surfaces for rough-
ness and scratches. Inspect the castings for small
cracks and sand holes.
Inspect the interlock sleeve and pin for free move-
ment in their bores. Examine the detent balls and
pins for brinneling. If the lever detents show signs 61 x 3
of excessive wear to the extent of not locking in the Fig. 8-Gearshift Forks and Shafts (8-Cylinder)
21-8 TRANSMISSION?-SPEED MANUAL
case followed by one of the interlock balls. Install
the interlock spring and pin (Refer to Fig. 8). Mainshaf t
(1) Install the low and reverse fork, (with the off-
(4) Place the remaining interlock ball on top of
the interlock spring, using Tool C-3765. (A good set to the rear) and engage the fork in the low and
method of installing the second ball is to stick the reverse sliding gear, then positiion in the case by
ball in the tool recess by means of lubricant, then use shifting into reverse.
the tool to position the ball on the detent spring.) (2) Slide the mainshaft into the case and through
(5) Install seal protector Tool C-3767, on the sec-
the low and reverse gear.
ond and high lever shaft, depress the interlock (3) Install the second and third shift fork with the
ball, using Tool C-3765 and at the same time install offset toward the rear of the case.
the second and high lever into the fully seated posi- In cases where the synchronizer “float” measure-
tion, with the center detent (neutral) aligned with ment was above .090 inch, synchronizer shims Part
the detent ball. Remove the tool. Secure the lever Number 2464724 should be installed to reduce the
shaft with the remaining tapered pin. “float” to .090 inch or less. Install the shim on the
shoulder of the second speed gear, before the spread-
Reverse Idler Gear er spring is installed, as shown in Figure 9.
(1) Coat the bore of the gear with lubricant, then If the synchronizer “float” is below .050 inch,
slide arbor Tool C-464 into the bore. Lubricate the 22 material should be ,removed from the ends of all six
bearing rollers, then install in the area around the synchronizer pins (an equal amount) until the syn-
arbor. chronizer “float” is above the .050 inch dimension.
(2) Install a new thrustwasher at each end of the (4) Install the second speed gear and spreader
gear and over the arbor. (Use enough lubricant to spring and/or shims, if required on the mainshaft.
hold the washers in position.) Install the second gear inner stop bronze ring and
the second gear outer stop ring assembly (Refer to
(3) With the bevelled ends of the teeth forward, Fig. 6). Engage the synchronizer clutch sleeve with
slide the gear down into position in the case. Install the second and high shift fork.
the gear shift in its opening at the rear of the case.
Install woodruff key then position the shaft with the (5) Slide the clutch gear over the end of the
keyway. mainshaft and down against the second speed gear.
Select a snap ring of the correct thickness and install.
(4) Raise the idler gear slightly to align with the (This snap ring eliminates end play and must be a
shaft, then drive the shaft into the case through the snug fit.) Install the synchronizer clutch gear snap
thrust washer and gear, until the end of the ahaft is ring in the mainshaft groove. Make certain the ring is
approximately l/cc inch below the surface of the case. bottomed all the way around in the groove.
Remove Tool C-464 from the case. Measure the clearance between the clutch gear and
Countershaft Gear second speed gear. The clearanc’e should be from
.004 to .014 inch. (The end play in excess of .014
(1) Slide the countershaft gear needle bearing
inch will permit gear to “jump out”.)
spacer over Tool C-578, then coat the bore of gear
with lubricant. Slide the tool and spacer in the gear 2 N D SPEED
bore. GEAR
(2) Six Cylinder Cars: Lubricate the bearing rollers
and install 22 rollers in each end of the gear in the
area around the arbor.
Eight Cylinder Cars: Lubricate the bearing roll-
ers and install 22 rollers, the spacer washer, and an-
other 22 rollers in each end of the gear around the
arbor.
Install the bearing washers at each end of the gear
covering the bearings. (Add a small amount of grease
to hold the washers in place).
(3) Install the thrustwashers at each end of the
countershaft gear and over the arbor. (Use lubricant
I to hold the washers.) Install the counterdhaft gear in AGAINST THIS FACE
the case, making sure the tabs on the thrustwashers
slide into the grooves in the case. Fig. 9-Synchronizer “Float” Shim location
TRANSMISSION--%SPEED MANUAL 2 1 -9
(6) Position the mainshaft further in the case Extension Housing
by tapping on the outer bearing race; bottoming the (1) Install a new rear mainshaft bushing, using
bearing (alternate from one side to the other). Install Tool C-3751.(As the tool is being removed, it bur-
the bearing snap ring in the case. This snap ring i s a nishes the bushing.) (8 cyl. uses a bearing.)
select fit.
(2) Install the extension housing oil seal using
Drive Pinion To01 C-3754.
(1)Slide the oil slinger (if removed) over the Place seal protector Tool C-3768 in position on the
pinion shaft and down against the rear. (Refer to mainshaft splines to protect the oil seal while in-
Fig. 5). stalling extension housing.
CAUTION: Damage to the oil seal will result if
(2) Slide the bearing over the pinion shaft (snap
the tool is not used.
ring groove away from the gear end), then seat on
the shaft, using an arbor press. (3)Lightly lubricate the gasket surface of the case
and the seal protector tool. Install the extension hous-
NOTE: Be sure the slinger does not "hang up" in
ing gasket.
the snap ring groove during the pressing operation.
(4)Slide the extension housing over the mainshaft
(3) Secure the bearing and washer with the selected and down against the case, at the same time guiding
thickness snap ring. Four snap rings are available to the shaft into the oil seal. Install attaching bolts and
eliminate end play (same thickness as clutch gear and tighten to 50 foot-pounds torque.
mainshaft snap rings). (5)Install the flange assembly, and secure with a
Be sure the snap ring is properly seated. If the new washer and nut. Tighten the nut to 175 foot
large snap ring around the bearing was removed, in- pounds torque while holding the flange with Tool
stall at this time. C-3281.
(4)Place the pinion shaft in a vise (with soft (6) Lightly lubricate the cover gasket surface,
jaws). then install the 14 rollers for 6-cylinder, or 15 then install gasket and cover. Install the attaching
for 8-cylinder, using lubricant to hold them in place. bolts and tighten to 144 inch-pounds torque.
Install the bearing retaining ring in its groove.
(7)Install the drain plug and back-up light switch
(5)Refer to Figure 6, then install the third gear (if so equipped) and tighten securely.
outer stop ring and the third gear inner stop ring. (8) Refill the transmission with Automatic Trans-
Guide the drive pinion through the front of the case mission Fluid, Type "A", Sufix "A". Install filler
and engage the inner stop ring with the clutch teeth, plug and tighten securely.
then seat the bearing.
The pinion shaft bearing is fully seated when the lnstallatton t In the Vehicle I
snap ring is in full contact with the case. (1)Remove the transmission from the repair
(6)Install a new seal in the pinion bearing re- stand. Install rear crossmember and support, then
tainer, using Tool (2-3789. slide under vehicle.
(2) Raise the transmission, using a suitable jack,
(7)Slide the pinion bearing retainer (less gas- until the main drive pinion is centered in the clutch
ket) over the shaft and down against the case. housing bore.
(8)Hold the retainer against the case, using hand (3)Roll the transmission slowly forward until the
pressure, then measure the clearance between the pinion shaft enters the clutch disc. Turn the pinion
retainer and case, using a feeler gauge. shaft until the splines are aligned, then push trans-
Select a gasket from .003to .004inch thicker than mission forward until seated against clutch housing.
the clearance. (This is done to eliminate bearing end NOTE: Do not allow the transmission to "hang"
play .I after the pinion has entered the clutch disc.
(9)Install gasket of correct thickness, then re- (4)Install the transmission attaching bolts and
install pinion retainer. Install attaching bolts and tighten to 50 foot-pounds. Remove the jack.
tighten to 360 inch pounds torque. (5)Using a pointed drift, align the crossmem-
(10) Use the countershaft and drive the arbor Tool ber bolt holes, then install attaching bolts. Tighten
C-578forward and out of the countershaft gear until to 50 foot-pounds torque.
the woodruft key can be inserted in the countershaft. (6)Remove the engine support fixture and dis-
Continue to drive shaft into case, until approximately engage the hooks from the holes in the frame side
%4 inch below the surface of the case. rails.
21-10 TRANSMlSSlON4-SPEED MANUAL
(7) Install the speedometer drive pinion and cable inch-pounds torque. (Refer to Fig. 10.) During the
assembly. above setting, the 2nd and 3rd control rod should
(8) Reconnect the gearshift rods, propeller shaft, be adjusted to also position the selector lever (on
and back-up light switch leads (if so equipped). the column) 5 degrees above horizontal level on the(
Plymouth Models and 10 degrees on the Valiant
(9) Road test the vehicle, making sure the trans-
Models (transmission in neutral).
mission shifts smoothly and operates quietly.
(5) Slide the clamp and swivel (on the end of the
(10) If the shift linkage requires adjustment, refer
1st and reverse control rod) either in or out, until
to Paragraph 2.
the swivel stub shaft enters the hole in the trans-
mission lever. Install washers and clip to secure. De-
2. GEARSHIFT LINKAGE termine the mid back-lash position in the linkage,
Adiustments then tighten the clamp bolt to 100 inch-pounds torque.
(1) With the 2nd and 3rd control rod disconnected (6) Remoye the positioning wedge or tool from
from the lever on the column and the 1st and reverse the cross-over blade and lever, then move the selec-
control rod disconnected from the transmission lever, tor lever through all positions to test the adjustments
position both transmission levers in neutral. (The to insure cross-over smoothness.
neutral detent balls must be engaged to make this
adjustment correctly.) To test, start the engine (with 3. REAR OIL SEAL
clutch disengaged) then release the clutch slowly. Removal
(2) Inspect the axial freedom of the shift levers in (1) Disconnect propeller shaft at the transmission
the column assembly. If the outer end of the levers flange and secure shaft to frame member for clear-
move axially over $i6 inch, loosen the two upper ance.
bushing screws and rotate the plastic bushing (down- (2) Hold the mainshaft flange with Tool C-3281 and
ward), until all free play of the levers has been re- remove flange nut and washer.
moved. Retighten the bushing screws securely. (Refer (3) Remove the transmission flange, use Tool C-
to Fig. 9.) 452 if necessary.
(3) Install a wedge or suitable tool between the (4) Remove the oil seal with Tool C-748.
cross-over blade and the 2nd and 3rd lever, so that
the cross-over blade is engaged with both lever cross- Installation
over pins, as shown in Figure 10. (5) Drive the new seal into the extension housing
(4) Adjust the swivel on the end of the 2nd and with To01 C-3837.
3rd control rod until the stub shaft of the swivel en-
4 /TRANSYSSION
ters the hole in the column lever. Install the washers
and clip to secure. Tighten the swivel lock nut to 70 I! r-
'\ '! k; r 1ST AND REVERSE LEVER
2ND AND 3RD I
2ND AND 3RD

1ST AND REVERSE
LEVER PIN ASSEMBLED VIEW
CROSSOVER B U D
SPRING WASHER
PLAIN WASHER
INTERLOCK LEVER
63 X 781
Fig. 1-earshift lever Adjustment Fig. 1 1 4 e a r s h i f t Interlock

TRANSMlSSlON4-SPEED MANUAL 2 1-1 1
(6) Install the transmission flange, washer and nut. position. Shift the transmission into neutral.
Tighten the nut to 175 foot-pounds. (2) Install the interlock rod with anti-rattle wash-
(7) Reconnect the propeller shaft and tighten flange ers and clips leaving the sliding adjustment bolt
nuts to 30 foot-pounds. loose.
(3) Rotate the pawl lever forward to bottom the
4. GEARSHIFT INTERLOCK ADJUSTMENT pawl in the transmission 1st-rev. lever pawl slot. Then
( If so Equipped 1 (Taxi Only) tighten the sliding clamp bolt to 100 inch-pounds
Pawl Adjustment (Refer t o Fig. 7 7 J torque.
(1) After installation of the transmission levers, CAUTION: Do not pull the interlock rod back-
shift the transmission into neutral. wards against the fork pull back spring load during
(2) Install the pawl lever with the anti-rattle this adjustment.
washers and retaining clip. To determine if the linkage has been properly
(3) Assemble the pawl to the pawl lever, leaving adjusted, perform the following two tests with the
the attaching bolts loose. engine not running.
(4) Rotate the pawl forward into full engagement (1) Shift the transmission in the normal manner
with the 1st-rev. lever pawl slot. with the clutch disengaged from neutral to first, and
(5) Position the pawl to provide equal clearance from neutral to reverse engaging the clutch when in
with the pawl slot on both sides of the pawl. gear. If operation is not normal, readjust the pawl
and linkage as described above.
(6) Tighten the two pawl bolts to 200 inch-pounds
torque. (2) Disengage the clutch. Shift the transmission
half-way between neutral and first. Let out the clutch
Linkage Adjustment pedal. The interlock, when properly adjusted should
(1) With the clutch linkage installed and adjusted, allow the pedal to return to about 5” from the fully
make sure the clutch pedal is in the fully returned returned position.
SPEEDOMETER PINION USAGE CHART
(Manual Transmission 1
Tire Axle Manual output Pinion

Model Size Ratio Trans. Shaft Teeth Teeth Color
Valiant 650-13 3.23:1 Std. 7 19 Dark Blue

w-1 3.55:l Std. 7 20 Green
3.91:l Std. 7 20* Green
Plymouth 650- 14 3.31:l Std. 7 ia Dark Purple
VP- 1 3.5a:i Std. 7 20 Green
3.23:l H.D.** 7 ia Natural
3.58:1 H.D.** 7 20 Black
Plymouth 700-14 3.31:l Std. 7 ia Dark Purple
v P-2 3.58:1 Std. 7 19 Dark Blue
3.23:l H.D. ** 7 ia Natural
3.5a:i H.D. ** 7 20 Black
*Use .909:1 Ratio Adapter
**Heavy Duty
21-1 2 TRANSMlSSlON4-SPEED MANUAL
-
1B 4 FORWARD SPEED MANUAL TRANSMISSION
SPECIFICATIONS
Engine Displacement (Cu. In.) 170-225 361,383,413
TRANSMISSION MAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chrysler
Gear Ratio
First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.09 2.66
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.92 1.91
Third . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 1.39
Fourth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.oo 1.oo
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00 2.58
Rear Axle Ratios

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 3.23
*Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 3.23
Sure-Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 3.23
lubricant
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7% Pints 7% Pints
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Transmission Fluid,
Type "A", Suffix "A"
Gear Type
All Gears (except Reverse). ........................................ Helical
Tolerances
Clutch Housing Face Runout.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006"
Clutch Housing Bore Runout.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008"
Countershaft Gear (cluster) End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0045 to .028"
*Gear Sets available through MoPar 2.93, 3.55, 3.91, 4.1, 4.3, 4.56, 4.89.
SPECIAL TOOLS
C-452. . . . . . . . .Flange Holder C-3789. . . . . . . .Seal Installer

C-748. . . . . . . . .Oil Seal Remover C-3837. . . . . . . .Oil Seal Installer
C-3787. . . . . . . .Fixture, l e g C-3938. . . . . . . . Countershaft Arbor
C-3806. . . . . . . .Fixture, Engine Support C-3591 . . . . . . . .lever Aligning Tool
TORQUE RERFERENCE
Extension Housing to Case Bolts. . . . . . . . ................ 35-45 -

Main Drive Pinion Bearing Retainer Bolts.. .............................. 15-20
Transmission to Clutch Housing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Crossmember Attaching Bolts. . . . . . . . . . . . . . . . . ........... .... 50
Shift Mechanism Pivot Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Shift Lever Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Companion Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Gearshift Housing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Gearshift Operating Lever Nuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Transmission Drain Plug.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
TRANSMISSION4-SPEED M A N U A L 27 -7 3
4 FORWARD SPEED MANUAL TRANSMISSION

The A-833 four forward speed synchromesh trans- duty ball bearing at the rear, and an Oilite bushing
mission shown in Figure 1, consists of a series of pressed into the end of the crankshaft. The main shaft
helical gears designed for high torque capacity and front end is piloted in 16 needle type roller bearings,
with teeth so proportioned as to operate at high located in a cavity in the end of the main drive
speeds without excessive friction loss or heat genera- pinion (Fig. 2) and is supported by a heavy duty
tion. The shafts, bearings, synchronizers and other ball bearing in the center of the case. The rear end
precision parts are held to close tolerances to provide of the mainshaft is supported by a ball bearing
durability during extended heavy operation. pressed on the end of the mainshaft and a snug fit in
the end of t,he extension housing, as shown in Fig-
The main drive pinion is supported by a heavy ure 2.
1ST A N D 2 N D SHIFT ROD
3RD A N D 4TH SHIFT R O D \

I B
JUSTING SCREW
3RD A N D 4TH SHIFT
LOCK NUT
OPERATING LEVER
iHlFT HOUSING
4 1ST A N D 2 N D SHIFT
REVERSE SHIFT B OPERATING LEVER
OPERATING LEVER 4
REVERSE SHIFT
ROD
6 4 x 734
Fig. 1-Four Forward Speed Transmission Assembly
J-"
64x73 5
Fig. 2-Four Forward Speed Transmission (Sectional View)

21-14 TRANSMlSSlON4-SPEED MANUAL
The countershaft gear (cluster) is supported by ward gear may be engaged while the vehicle is in
a double row of needle type roller bearings (38) at motion through the use of synchronizing clutches
each end and the thrust is taken on thrustwashers (Fig. 2).
between the ends of the gear and the transmission
case. The alignment of the needle type roller bearings The transmission may be used as an aid to decel-
within the gear are maintained by 4 thrust washers eration by downshifting in sequence without double
(one being used between the rows of rcller bearings clutching or gear clashing, due to the fact that all
and one at each end. (Fig. 2). forward speeds are synchronized. (The reverse speed
The reverse idler gear is supported on a bronze gear is not synchronized). The service procedures
bushing, pressed into the gear. covering the Valiant four forward speed transmis-
The gearshifting is manually operated through shift sion is identical to the following service procedures
control rods to the transmission (Fig. 1). Any for- except where noted.
SERVICE PROCEDURES
1. ADJUSTING THE SHIFT LINKAGE center pin through the first two levers. Tighten set
(1) Remove the shift boot attaching screws and screw securely. (This aligns the 3 levers in the gear
shift control assembly, and holds them in the neutral
slide the boot up on the shift lever (Fig. 3). Test to be
sure the pivot bolt is tightened securely (55 foot- position, as shown in Figure 3.)
pounds). Test to be sure shift lever bolts are tight- (4)Adjust the length of the three shift rods, by
ened securely (30 foot-pounds). turning the swivels either in or out until the swivel
stub shafts match the control rod lever holes (Trans-
(2) Disconnect all the shift rods from the levers
mission shift operating levers must be in the neutral
at the adjusting by removing the spring clip detent position during this Adjustment.) Install the
retainers and flatwashers.
swivel stub shafts and secure the flat washers and
(3) Slide Tool C-3591 over the levers, inserting spring clip retainers.
LEVER STOP ADJUSTING SCREW

(REAR)
3RD A N D 4TH ROD
ALL SHIFT OPERATING I -

7 \
REVERSE ROD
SPRING CLIP
'
3RD A N D 4TH ADJUSTING SWIVEL
LEVERS MUST BE IN NEUTRAL REVERSE ADJUSTING SWIVEL 64x736
Fig. 3-Gearshift linkage Adjustments

TRANSMlSSlON4-SPEED MANUAL 21-1 5
M A I N DRIVE PINION ,GEiRSHIFT HOUSING
\ PINION BEARING RETAINER

\ I CASE
/ GASKET ,BREATHER
1 EXTENSION HOUSING
COMPANION
FLANGE
BACK-UP LIGHT SWITCH
REPAIR STAND REVERSE OPERATING LEVER

1
Fig. 4-Four Forward Speed Transmission in

Repair Stand
(5) Remove the lever aligning tool. cable, care should be used, so as not to crush the
(6)With the transmission hand shift lever in the housing. Remove by hand.
third or fourth speed detent position, adjust the lever (4) Disconnect the left hand exhaust pipe (dual
stop screw (front and rear) to provide from .020 to exhaust) from the exhaust manifold.
.040 inch clearance between the lever and the stops. (5) Disconnect the parking brake control cable.
When this adjustment has been made, tighten the (6)Disconnect the back-up light switch leads at
adjusting screw locknuts securely.
the connector. (If so equipped.)
(7)Inspect the linkage for ease of shifting into all
gears and for smoothness of crossover and handshift (7)Install the engine support fixture C-3487 (or
C-3487 and (2-3806depending on Model,) (or a suit-
lever clearances.
able jack) engaging the hooks in the holes in the
CAUTION: Because there is no reverse gear in-
terlock, it is very important that the transmission 3RD AND 4TH SPEED LEVERS IN 1ST AND 2ND SPEED
GEAR SHIFTER SHAFT NEUTRAL GEAR SHIFTER SHAFT
linkage adjustments are correctly performed in order AND DETENT PLATE POSITION AND DETENT PLATE
to prevent the possibility of engagement into two /
gears at the same time.
(8)Slide the boot down the shift lever shaft to
the floor pan and secure with attaching screws.
2. TRANSMISSION
-i
Removal from the Vehicle
(1) Remove the shift lever boot attaching screws
and slide the boot up on the shift lever. Remove the
lever attaching bolts and remove the shift lever and DETENl
'
boot from the stub lever of the shift housing. On all BALL
Valiant Models, disconnect the transmission shift rods. <
(2) Drain the lubricant from the transmission.
3RD AND----, -r
4TH SPEED
GEARSHIFT FORK
INTERLOCK
SLEEVE
\ 1ST AND 2ND
GEARSHIFT FORK
DETENT BALL 64x739
(3)Disconnect the propeller shaft, speedometer
cable, and pinion. When removing the speedometer Fig. 5-Transmission Shift Housing Assembly
2 1-1 6 TRANSMlSSlON4-SPEED MANUAL
64 x 740
Fig. 6-Transmission Assembly (Disassembled View)

TRANSMlSSlON4-SPEED M A N U A L 2 1-1 7
1. Bearing Retainer 49. Countershaft 3. DISASSEMBLING THE TRANSMISSION
2. Bearing Retainer Gasket 50. Thrustwasher, Geor (1)
3. Bearing Retainer Oil Seal 51. Thrustwasher, Needle Roller Bea To disassemble the transmission for repair or over-
4. Snap Ring, 'Bearing (Inner) haul, refer to Figures 1, 3, 4, 5 and 6.
5. Snap Ring, Bearing (Outer) 52. Needle Bearing Rorlers
6. Pinion Bearing 53. Bearing Spacer (1) Mount the transmission in repair stand DD-
7. Transmission Case 54. Countershaft Gear (Cluster)
8. Filler Plug 55. Needle Bearing Rdlerr
1014, then disconnect the gearshift control rods from
9. Gear, 2nd Speed 56. Thrustwarher, Needle Roller Beat the shift control levers and the transmission operating
10. Stop Ring levers, by removing the spring retainer clips and the
11. Shift Plate Springs 57. Thrustwasher, Gear ( I )
12. Clutch Gear 58. Wockup light Switch flatwashers.
13. Shift Plates (3) 59. Backup light Switch Gasket
14. Shift Plate Spring 60. Plug (2) Remove the two gearshift control housing
15. Snap Ring 61. Retainer, Reverse Detent Ball Sp mounting bolts, then remove the gearshift control
16. 1st and 2nd Clutch Sleeve Gear
62. Gasket housing from the transmission extension housing or
17. Stop Ring 63. Spring, Reverse Detent Ball mounting bracket (if so equipped). Remove the gear-
18. 1st Speed Gear 64. Ball, Revers* Detent
19. Bearing Retaining Ring 65. Woodruff Key
shift control housing mounting bracket bolts and re-
20. Center Bearing 66. Reverse Slider Gear Shaft move bracket. (If so equipped.)
21. Snap Ring 67. Bushing, Reverse Slider Gear
22. Gasket, Case to Extension Housi68. Gear, Reverse Slider (3) Remove the back-up light switch. (If so
69. Fork, Reverse Shifter equipped.)
23. lackwasher 70. Reverse lever
24. Bolt 71. Oil Seal, Reverse Lever Shaft (4) Using a suitable holding tool, remove the
25. Extension Housing 72. Reverse Operating lever companion flange attaching nut and washer, then
26. Mainshaft Rear Bearing 73. Flatwasher
27. Rear Bearing Oil Seal 74. lockwasher slide the flange from the end of the mainshaft (out-
28. Companion Flange 75. Nut
29. Washer 76. Gearshift Control Housing put).
30. Nut 77. 1st and 2nd Operating Lever (5) Remove the bolts that attach the gearshift
31. Main Drive Pinion 78. Flatwasher
32. Oil Slinger 79. Lockwasher, lever housing to the transmission case. With all the levers
33. Needle Bearing Rollers 80. Nut, lever in the neutral detent position, pull the housing out
34. Snap Ring 81. lockwasher, lever
35. Stop Ring 82 Fla8twasher, lever and away from the case. (The first and second, third
36. Snap Ring 83. 3rd and 4th Operating lever and fourth shift fork may remain in engagement with
37. Shift Plate Spring 84. Detent Ball
38. Clutch Gear 05. Detent Ball Spring the synchronizer sleeves.) Work the forks out of the
39. Shift Plate Spring 86. Detent Ball Sleeve sleeves and remove from the case. Discard the hous-
40. Clutch Sleeve 87. Detent Ball Spring
41. Stop Ring 88. Detent Ball ing gasket.
42. 3rd Speed Gear 89. O i l Seal (2) The following three steps need only be done, if
43. Speedometer Drive Pinion 90, 3rd and 4th lever
44. Speedometer Drive Clip 91, 1st and 2d lever oil leakage i s visible around the gearshift lever shafts.
45. Speedometer Drive Pinion Seal 92, 3rd and 4th Speed Fork
46. Mainshaft (Output) 93. 1st and 2nd Speed Fork (6) Remove the nuts, lockwashers and flatwash-
47. Shift Plates (3) 94. Drain Plug ers that attach the first and second, third and 4th
48. Woodruff Key 95. Gasket, Shift Control Housing
speed shift operating levers to the shafts. Disengage
64x740 the shift levers from the flats on the shafts and re-
Fig. &Transmission Assembly (Diassembled View) move.
(7) Carefully push the gearshift lever shafts out of
frame side members. Be sure the support ends are the housing, allowing the detent balls to fall free.
up against the underside of the oil pan flange. Remove the seals and discard.
(8) Adjust the fixture (or jack) to support the GASKET EXTENSION HOUSING
weight of the engine, then raise the engine slightly
and remove the rear crossmember attaching bolts.
Remove the crossmember.
(9) Support the transmission, then remove the
transmission attaching bolts.
(10) Rotate the transmission until the shift hous-
ing and stub lever clear, then slide the transmission
toward the rear until the main drive pinion shaft
clears the clutch disc, before lowering the transmis-
sion. (This will avoid damaging the clutch disc.)
'4 '
(11) Lower the transmission and remove from 64x741 7
under the vehicle. Clean the outside of the case be- Fig. 7-Removing or Installing the Extension
fore disassembling. Housing and Mainshaft Assy.
21-1 8 TRANSMISSIONA-SPEED M A N U A L
1ST AND 2ND CLUTCH 1ST SPEED GEAR EXTENSION CLUTCH GEAR SHIFT PLATES (3) 1ST SPEED GEAR
SLEEVE GEAR (34 TEETH) --
(35 TEETH) HOUSING
SECOND SPEED
GEAR (34 TEETH); \-*A 1ST AND 2ND CLUTCH \STOP RING/ ^*
1ST AND 2ND SYNCHRONIZER SNAP RING

_ - _ - GEAR
CLUTCH --
EXTENSION HOUSING /v, PLIERS
3RD AND 4TH I 64x744
CLUTCH SLEEVE 3RD SPEED GEAR (29 TEETH) '' 64x742
Fig. 8-Mainshaft Gear Identification Fig. 1O-Removing or Installing Center Bearing

Snap Ring
(8) Slide the gearshift interlock sleeve, interlock
pin and spring out of the housing (Fig. 5). (2) Slide the 3rd speed gear and stop ring off the
(9) Remove the main drive pinion bearing re- mainshaft. (Do not separate the 3rd and 4th speed
tainer attaching bolts, then slide the retainer and synchronizer clutch gear, sleeve, shift plates or
gasket from the main drive pinion shaft. Remove the springs unless inspection reveals a replacement part
pinion oil seal. is required.)
(10) Remove the bolts that attach the extension (3) Using a suitable pair of long nose pliers, com-
housing to the transmission case. press the snap ring that retains the mainshaft center
(11) Slide the third and fourth synchronizer bearing in the extension houisng, as shown in Figure
sleeve slightly forward, then using a soft hammer, 10.
tap on the extension housing (in a rearward direc- (4) Holding the snap ring compressed, pull the
tion). Slide the housing and mainshaft assembly out mainshaft assembly and bearing out of the extension
and away from the case, as shown in Figure 7. housing, as shown in Figure 11. Remove the rear oil
(12) Refer to Figure 8 for location of the various seal from the extension housing. Discard the seal.
gears, synchronizer sleeves and clutches before dis-
( 5 ) Remove the rear bearing from the mainshaft
assembling the mainshaft.
by inserting steel plates on the front side of the 1st
Disassembling the Malnshaft (Fig. 9 J speed gear, then using an arbor or hammer, press or
(1) Using a pair of snap ring pliers, remove the drive the rear bearing off the mainshaft. (Be careful
snap ring that retains the 3rd and 4th synchronizer not to damage the gear teeth.)
clutch gear and sleeve, slide 3rd and 4th synchronizer
assembly off the end of the mainshaft.
3RD AND 4TH SPEED SYNCHRONIZER CLUTCH GEAR
\ 3RD SPEED GEAR

- (6) Using snap ring pliers, remove the snap ring
SNAP RING GROOVE
b -
MAINSHAFT / 1
64x743 64x745 EXTENSION HOUSING I

Fig. 9-Disassembling the Transmission Mainshaft Fig. 1 1-Removing or Installing the Mainshaft
TRANSMlSSlON4-SPEED MANUAL 21-1 9
SNAP RING SNAP R I N G

GROOVE GRYOVE
SNAP R I N G 64 x 748
GROOVE
BEARING
RETAINING RING
Fig. 1 A M a i n s h a f t Bearing Surfaces
64x746
Fig. 12iRemoving or Installing the Center (9) Using a suitable drift, drive the reverse slider
Bearing Snap Ring gear shaft (from front to rear) far enough out of the
that retains the mainshaft bearing on the shaft, as case to remove the reverse slider gear, as shown in
shown in Figure 12. Remove the bearing, bearing Figure 17. Remove the woodruff key from the shaft.
retainer ring, 1st speed gear, and first speed stop ring. Remove the shaft from the case.
(7) Again using snap ring pliers, remove the snap (10) Remove the reverse gearshift lever detent
ring that retains the 1st and 2nd clutch sleeve gear
and clutch to the mainshaft, as shown in Figure 13. REVERSE SLIDING
REVERSE SHIFTER
Slide the 1st and 2nd clutch sleeve gear and clutch SHAFT A N D DETENT
from the mainshaft. (Do not separate the clutch
sleeve gear and the clutch, unless inspection reveals a
replacement part is required.)
Figure 14 shows the various mainshaft bearing
surfaces of the gears. Inspect these surfaces for signs
of wear, scoring, or any condition that would not
allow the shaft to be used at reassembly. (See Clean-
ing and Inspection.)
Figure 15 shows the reverse gear shift fork, the REVERSE LEVER
reverse sliding gear, the reverse sliding gear shaft and DETENT SPRING
the cluster gear.
REVERSE SPEED
(8) Using a shim stock feeler gauge, measure the GEARSHIFT FORK
SHIFTER SHAFT
end play of the countershaft gear, by inserting the
gauge between the thrust washer and the gear, as 64 x 749
shown in Figure 16. This measurement should not Fig. lii-Gear, Shaft and Lever Identificdion
exceed .0045 to .028". If measurement is greater than
that specified, new thrust washers must be installed at
reassembly.
FEELER GAUGE
THRUST WASHER
I
1ST A N D 2 N D CLUTCH SLEEVE GEAR
BEARING
' Y 64 x 750
64x747
Fig. 1'3-Removing or Installing Clutch Gear Fig. 1 &Measuring the Cluster (Countershaft)
Snap Ring Gear End Play
press, remove the bearing from the main drive pin-
ion.
(15) Remove the countershaft gear (cluster) from
the bottom of the case, as shown in Figure 19.
(16) Remove the arbor and the 76 needle type
bearings, thrust washers and spacer, from the center
of the countershaft gear.
Cleaning and hspection
Transmission Case
Clean the transmission case thoroughly, using a
suitable solvent, dry with compressed air. Inspect the
case for cracks, stripped threads in the various bolt
Fig. 17-Removing or Installing the Reverse holes and the machined mating surfaces for burrs,
Slider Gear nicks or any condition that would render the case
unfit for further service. The front mating surface
spring retainer, gasket, plug and detent ball spring should be smooth; if any burrs are present, dress
from the rear of the case (Fig. 15). them off with a fine mill file. If threads are stripped,
The following step need only be done if oil leak- install Helicoil inserts.
age is visible around the reverse gearshift lever shaft.
Ball Bearings
(11) Carefully push the reverse gearshift lever Wash the ball bearing, using a clean solvent and
shaft into the case, and remove from the case, as blow dry with compressed air.
shown in Figure 18. Lift out the detent ball from the CAUTION: Do not spin the bearings with air
ljottom of the case. Remove the shift fork from the pressure; turn slowly by hand. Spinning unlubricated
shaft and detent plate. bearings may cause damage to the races and the balls.
(12) Using countershaft arbor C-3938, and a Be sure the ball bearings are clean, then lubricate
plastic hammer, drive the countershaft out of the them with light grade engine oil. Inspect the bearings
case, allowing the countershaft gear to be lowered to for roughness. This can best be determined by slowly
the bottom of the case. (This will permit the removal turning the outer race by hand. Measure the fit of
of the main drive pinion.) the bearings on their respective shafts.
(13) Using a pair of snap ring pliers, remove the
Needle Type Bearing Rollers and Spacers
main drive pinion bearing outer snap ring, using a
plastic hammer, drive the main drive pinion into the Inspect the main drive pinion and countershaft
case and remove. gear bearing rollers for flat spots or brinelling. In-
spect the countershaft bearing roller spacers for signs
(14) Using snap ring pliers, remove the main of wear or galling. Install new parts as required.
drive pinion bearing inner snap ring. Using an arbor
Gears
Inspect the gear teeth on the synchronizer clutch
gears and stop rings. If there is evidence of chipping
or excessively worn teeth, install new parts at reas-
sembly. Be sure the clutch sleeve slides easily on the
clutch gear. Inspect the teeth on the second and third
speed gears and the first speed gear for chipped or
broken teeth, or showing signs of excessive wear.
Small nicks or burrs must be stoned off.
Inspect the teeth on the main drive pinion. If ex-
cessively worn, broken or chipped, a new pinion
should be installed.
Test the interlock sleeve and pin for free move-
ment in the bore of the shift housing. Examine the
detent balls for signs of brinelling. If the lever detents
show signs of excessive wear to the extent of not
Fig. 18-Removing or Installing the Reverse locking in gear, install a new part. Inspect the shift
Shift Fork and lever forks for wear on the shanks and pads.
TRANSMISSIONA-SPEED MANUAL 2 1-2 1
Synchronizer Stop Rings THRUST WASHER COUNTER SHAFT

TANG GEAR
Inspect the stop rings for cracks at the corners of
the shift plate indexing slots. If the rings are cracked
or show signs of extreme wear on the threaded bore,
install new rings at reassembly.
Mainshaft (Output I
Refer to Figure 14 and inspect the mainshaft gear
and bearing mating surfaces. If the gear contact sur-
faces show signs of galling or excessively worn, a
new mainshaft should be installed.
Inspect the snap ring grooves for burred edges. If
\THRUST WASHER
rough or burred, remoge the condition using a fine TANG
64 x 754
file or crocus cloth. Inspect the synchronizer clutch Fig. PO-Cluster Gear and Arbor Assembly
gear teeth on the shaft for burrs.
Mainshaf t
4. ASSEMBLING THE TRANSMISSION
To reassemble the transmission, refer to Figures (1) Slide the second speed gear over the mainshaft
1,4 and 6. (synchronizer cone toward the rear) and down into
position against the shoulder on the shaft (See Figure
Countershaft Gear ( Cluster I ( Fig. 6 I 13).
(1) Using heavy grease, coat the inside of the bore (2) Slide the first and second clutch sleeve gear
of the gear at each end, then install the roller bearing assembly including 2nd gear stop ring) over the
spacer; centered. Insert arbor Tool C-3938, into the mainshaft (with the shift fork slot toward the front)
gear and through the spacer. Center the arbor. and down into position against the second speed gear.
(2) Coat the needle type roller bearings with (Be sure the stop ring is indexed with the shift plates.)
heavy grease, then at each end of the gear, install 19 Install a new snap ring to secure. (Fig. 13).
rollers, followed by a spacer ring and 19 more roller
(3) Slide the low gear stop ring over the shaft
bearings and 1spacer ring. (Refer to Fig. 2.)
and down into position and index with the shift plates.
(3) Coat the thrustwasher with heavy grease and
install them over the arbor with the tang side toward (4) Slide the first speed gear (synchronizer cone
the case boss, as shown in Figure 20. toward the clutch sleeve gear just installed) over the
mainshaft and down into position against the clutch
(4) Install the countershaft gear assembly into the sleeve gear.
case, as shown in Figure 19. Allow the gear assembly
to rest on the bottom of the case. (Be sure the thrust- ( 5 ) Install the mainshaft bearing retaining ring,
washers stay in position.) followed by the mainshaft center bearing. Using an
arbor and a suitable tool, drive or press the bearing
down into position. Install a new snap ring to secure
(refer to Figure 12).
(6) Slide the rear bearing over the mainshaft and
drive or press into position.
(7) Install the partially assembled mainshaft into
the extension housing far enough to engage the re-
taining ring in the slot in the extension housing (See
Figure 11). Compress the retaining ring and at the
same time seat the mainshaft in the extension hous-
ing. (Refer to Figure 10.) (Be sure retaining ring is
seated all around its slot.)
(8) Slide the third speed gear over the mainshaft
(with the synchronizer cone toward the front) fol-
64 x 753
lowed by the third gear stop ring.
Fig. 19-Removing or Installing the Cluster Gear (9) Install the third and fourth speed synchronizer
and Arbor clutch gear assembly (including sleeve, shift plates
2 1-22 TRANSMlSSlON4-SPEED MANUAL
and springs) on the mainshaft (shift fork slot toward with the rear face of the case. Remove arbor Tool
the rear) down against the third speed gear. Be sure (2-3938.
and index the rear stop ring with the clutch gear
shift plates (Refer to Figure 9). resting the Countershaft Gear End Play
Using a shim stock feeler gauge, measure the end
(10) Install the retaining snap ring as shown in
play of the countershaft by inserting the feeler gauge
Figure 9, then, using heavy grease, position the front
between the thrust washer and the gear (Fig. 16).
stop ring over the clutch gear, again indexing the
This measurement should not exceed .0045 to .028
ring slots with the shift plates. (Refer to Fig. 8.)
inch.
CAUTION: It is very important that the index- The following step need only be done if the reverse
ing of all stop rings and the positioning of the gears shaft was removed because of oil leak.
and clutches on the mainshaft be correct, or the mrt-
(1) Install a new oil seal on the reverse gearshift
ing of the extension housing to the case will not be
possible without damage.
lever shaft and coat with Lubriplate. Carefully install
the lever shaft into the bore in the case and position
Main Drive Pinion (Fig. 2 I 1 (Fig. 18). Install the reverse fork in the lever.
(1) Slide the bearing oil slinger over the main (2) Install the reverse shift detent ball and spring.
drive pinion shaft, then press the main drive pinion Install the reverse detent ball spring retainer gasket
bearing on the pinion shaft. (Be sure the outer snap and retainer Tighten securely.
ring groove is toward the front.) Seat the bearing (3) Position the reverse slider gearshaft in posi-
fully against the shoulder on the gear. tion in the end of the case, and drive in far enough
(2) Install a new inner snap ring into the groove to position the reverse slider gear on the protruding
to retain the bearing. Be sure the snap ring is seated. end of the shaft with the shift slot toward the rear
(Fig. 17). At the same time, engage the slot with the
(3) Install the main drive pinion and bearing in
reverse shift fork.
the case and into position in the front bore. Tap light-
ly into place, using a plastic hammer. Install the outer (4) With the reverse slider gear correctly posi-
snap ring in the bearing groove. tioned, drive the reverse gear shift into the case far
enough to be able to install the woodruff key. Drive
(4) Start the countershaft in its bore at the rear the shaft into position, flush with the end of the case
of the case. Raise the countershaft gear until the (Fig. 15).
teeth mesh with the main drive pinion gear. (Be sure
(5) Install the back-up light switch and gasket
the thrust washers remain in position on the ends of
the arbor and the tangs aligned with the slots in the (if so equipped), and tighten securely.
case.) Installing the Extension Housing and
(5) Align the countershaft arbor with the bores in Mainshaft Assembly
the case, then drive or press the countershaft into the (1) Coat a new extension housing to case gasket
gear. Install the woodruff key. Continue to press the with grease (both sides) then place in position on the
shaft into the case until the end of the shaft is flush case.
(2) Center the reverse slider gear on its shaft,
BEARING then carefully insert the mainshaft assembly into the
SNAP RING (OUTER)
TOWARD THE FRONT
\ I MAIN DRIVE
PINION
case (Fig. 7). Be sure the third and fourth speed
stop ring is indexed with the shifter plates.
(3) Move the third and fourth speed clutch sleeve
slightly toward the front and at the same time align
the end of the mainshaft with the main drive pinion.
Push in on the extension housing and bottom against
the case and gasket.
(4) Install the attaching bolts and tighten securely.
(5) Move the reverse slider gear ahead to the
neutral position.
Transmission Oearshift Housing
ROLLER BEARINGS ( 1 6 )/ .*-
The following 4 steps need only be done if the
64 x 755
gearshift housing was disassembled previously be-
Fig. 21-Main Drive Pinion and Bearing Assembly cause of leaking seals.
TRANSMISSIONA-SPEED MANUAL 21-23
(1) Slide the interlock sleeve into position in the roll under the vehicle, using a suitable transmission
housing. Coat a new seal with Lubriplate, then slide jack.
over a shift shaft and down into its groove. (2) Raise the transmission until the main drive
(2) Install the gearshift lever shaft in position pinion is centered in the clutch housing bore.
in the housing, then install the gearshift operating (3) Roll the transmission slowly forward until the
lever on the flats of the shaft (lever pointing upward, pinion shaft enters the clutch disc, then drop the jack.
refer to Figure 1). Install a flatwasher, lockwasher Turn the pinion shaft until the splines are aligned,
and nut. Tighten securely. then work the transmission forward until seated
(3 Place a detent ball in the sleeve, followed by against the clutch housing.
the poppet spring and interlock pin. Start the remain- NOTE: Do not allow the transmission to “hang“
ing lever shaft into the housing, after installing the after the pinion shaft has entered the clutch disc.
shaft seal as mentioned previously. Install the operat- (4) Install the transmission attaching bolts and
ing lever on the flats of the shaft (lever pointing tighten to 50 foot-pounds torque.
upward) and secure with flatwasher, lockwasher and (5) Using a pointed drift, align the crossmember
nut. Tighten the nut securely. bolt holes and then install the attaching bolts. Tight-
(4) Place the remaining detent ball on the poppet en to 50 foot-pounds torque.
spring, then compress the ball and the spring, using (6) Remove the engine support fixture and dis-
a small screwdriver. Push the shafts in until seated. engage the hooks from the holes in the frame side
Turn the shafts until the balls drop into the neutral
rails.
position detent. (See Fig. 5.)
(7) Install the speedometer drive pinion and cable.
(5) Place the transmission assembly on its side
Connect the back-up light switch wires (if so equip-
with the gearshift housing cover opening up. Install
a shift fork in each synchronizer sleeve collar, and ped).
with both sleeves in the neutral position, install the (8) Reconnect the parking brake cable and pro-
shift housing and a new gasket. (Line up the shift peller shaft.
fork ends with the shaft in the housing.) (9) Reconnect the exhaust pipes (if removed).
(6) Install the attaching bolts and tighten evenly Tighten bolts securely. Reconnect the transmission
to avoid distortion of the housing (center bolt on shift rods (on Valiant Models only.)
each side are pilot bolts and should be installed first). (10) Fill the transmission with 7% pints of Type
(7) Using Tool C-3789, install a new oil seal in “A” Suffix “A” lubricant or until the oil just dribbles
the retainer bore. Install the main drive pinion bear- out of the filler hole.
ing retainer and gasket. Install the attaching bolts and (11) Install the gearshift lever (and boot) to the
tighten from 30 to 35 foot-pounds torque. stub lever on the shift housing and secure with bolts.
(8) Install the gearshift control assembly and the Tighten securely.
shift rods (Fig. 3), in correct position and secure with (12) Slide the boot down the shift lever to the
washers and clips on Valiant Models only. floor pan and secure with screws.
(9) Install the propeller shaft companion flange (13) Road test the vehicle to make sure the trans-
on end of mainshaft. Install washer and nut and mission shifts smoothly and operates quietly.
tighten to 175 foot-pounds torque. 6. SERVICING THE REAR OIL SEAL
5. INSTALLING THE TRANSMISSION (1) Disconnect the propeller shaft at the trans-
Before installing the transmission, a test of the mission flange *ndsecure the shaft to the frame mem-
clutch housing bore and face alignment should be ber for working clearance.
made. (Refer to the “Clutch” Group 6 for the ser- (2) Hold the mainshaft with Tool (2-3281, then
vice procedure.) remove the flange nut and washer.
Place a small amount of short fibre wheel bearing (3) Remove the transmission flange, using Tool
lubricant around the inner end of the main drive C-452 if necessary.
pinion shaft pilot bushing in the flywheel and on the (4) Remove the oil seal, using Tool C-748.
pinion bearing retainer release bearing sleeve area. (5) Drive a new seal into the extension housing,
NOTE: Do not lubricate the end of the pinion using Tool C-3837.
shaft, the clutch disc splines or the clutch release (6) Install the transmission flange, washer and
levers. nut. Tighten nut to 175 foot-pounds torque.
(1) Remove the transmission from the repair stand (7) Reconnect the propeller shaft and tighten the
and install the rear crossmember and support, then flange nuts to 30 foot-pounds torque.
2 1-24 TRANSMISSION-MANUAL-DIAGNOSIS

( 4 Forward Speed Manual Transmission1
Output Shaft Pinion
Tire Size Axle Ratio Teeth Teeth Color
650x1 3 2.93 8 19 Dark Blue*

3.23 8 21 Gray
3.55 8 19 Dark Blue
3.9 1 8 21 Gray
7.00~14 2.93 8 18 Dark Purple
3.23 8 20 Green
3.55 8 18 Dark Purple
14
7.50~ 2.93 8 18 Dark Purple
3.23 8 19 Dark Blue
3.55 8 21 Gray
3.9 1 8 19 Dark Blue*
*Use .9058: 1 Adaptor.
1C-SERVICE DIAGNOSIS
Hard S h i f t i n g Incorrect clutch adjustment. (a) Refer to the Clutch Group for corrections.
Improper cross-over adjustment. (b) Perform the cross-over adjustment
as outlined in Paragraph “Gearshift
Linkage Adjustments”.
Synchronizer clutch sleeve (e-d-e) Causes noted can only be corrected
damaged. by disassembling the transmission and
replacing damaged or worn parts.
Synchronizer spring improperly
installed.
Broken or worn synchronizer stop
rings.
Transmission Slips Linkage interference. (a) Inspect and remove all linkage
Out of Gear interferences.
Gearshift rods out of adjustment. (b) Adjust the gearshift rods as outlined in
Paragraph “Gearshift Linkage
Adjustments”.
Second or direct speed gear (e) Disassemble the transmission and replace
synchronizer clutch teeth worn. parts as‘necessary.
Clutch housing bore or face out of (d) Refer to the Clutch Group for correction
alignment. procedures.
Transmission Noises Excessive end play in the cluster (a) Replace the worn gear.
Backlash Noise gear.
Loose synchronizer hub spline fit (b) Inspect the mainshaft and synchronizer
on mainshaft. hub and replace parts as necessary.
Loose spline fit on low speed (c) Inspect the low speed sliding gear and
sliding gear to mainshaft spline. mainshaft. Replace parts as necessary.
Loose spline fit of rear mainshaft (d) Inspect the mainshaft and flange splines.
flange. Replace parts as necessary.
Damaged, broken or excessively (e) Replace the worn gears.
worn gear teeth.
Drive pinion bearing worn. (f) Replace the worn bearing.
TRANSMISSION-TORQUEFLITE -
2 1-25
PART 2 - TORQUEFLITE TRANSMISSION (TORQUE CONVERTER) 2A-S PECIFICAT10 NS
Torqueflite For Six Torqueflite For Eight

Cylinder Models Cylinder Models
TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Three Speed with Torque Converter

TORQUE CONVERTER DIAMETER. . . . . . . . . . . . . . . . . . . . . 10J/4 inches 1 1 J/4 inches
OIL CAPACITY-TRANSMISSION AND
TORQUE CONVERTER (Dry Fill). . . . . . . . . . . . . . . . . 18 pints 20 pints
Automatic Transmission Fluid Type “A”, Suffix “A“
COOLING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-Heat Exchanger
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump (Rotor Type)
CLUTCHES
Number of Front Clutch Plates. . . . . . . . . . . . . . . . . . . . 3 (170 Cu. In. Eng.) 4
4 (225 Cu. In. Eng.)
Number of Front Clutch Discs. . . . . . . . . . . . . . . . . . . . . 3 (170 Cu. In. Eng.) 4
4 (225 Cu. In. Eng.) -
Number of Rear Clutch Plates. . . . . . . 2 2 (6 Cyl. Police Cars & Taxi Cabs)
- 2 (318 Cu. In. Eng.)
3 (361-383-426-Cu. In. Eng.)
Number of Rear Clutch Discs. . . . . . . . . . . . . . . . . . . 3 (6 Cyl. Police Cars & Taxi Cabs)
3 (3 18 Cu. In. Eng.)
4 (361-383-426-Cu. In. Eng.)
GEAR RATIOS
1-Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45 to 1
2-Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 to 1
D-Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 to 1
R-Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 to 1
N-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
FRONT-REAR PUMPS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear (Rotary)
End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front- .001 to .0025”
Rear-.OO 1 5 to .003”
DRIVE TRAIN END PLAY., . . . . . . . . . . . . . . . . . . . . . . . . . . .024 to .068 inch .030 to .069 inch
CLUTCH PLATE CLEARANCE
Front Clutch.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .042 to .087” (3 Disc Clutch) .024 to .123 inch
.056 to .104” (4 Disc Clutch) -
Rear Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .018 to .036 inch .022 to .042“ (3 Disc Clutch)
- .026 to .054” (4 Disc Clutch)
SNAP RINGS
Front and Rear Clutches
Rear Snap Ring (Selective). ...................... .060 to .062 inch .060 to .062 inch
.068 to .070 inch .074 to .076 inch
.076 to .078 inch .088 to .090 inch
Output Shaft Bearing. .......................... .086 to .088 inch
THRUST WASHERS
Output Shaft to Input Shaft (Selective). . . . . . . . . . . . . .052 to .054 inch
(Natural)
.068 to .070 inch
(Red)
.083 to .085 inch
(Black)
2 1-26 TRANSMISSION-TORQUEFLITE
SPECIFICATION& ( Continued 1
Torqueflite For Six Torqueflite For Eighl

Cylinder Models Cylinder Models
THRUST WASHERS
Reaction Shaft Support to Front Clutch Retainer
(Selective) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .043 to .045 inch
(Natural)
.061 to .063 inch
- (Green)
- .084 to .086 inch
- (Red)
Sun Gear Driving Shell.. . . . . . . . . . . . . . . . . . . . . . . . . .060 to .062 inch -
Driving Shell (Steel). . . . . . . . . . . . . . . . . . . . . . . . . . . . .034 to .036 inch
Overrunning Clutch Race. . . . . . . . . . . . . . . . . . . . . . . . . .060 to .062 inch
Kickdown Annulus Support. . . . . . . . . . . . . . . . . . . . . . . .121 to .125 inch
Front Clutch to Rear Clutch.. . . . . . . . . . . . . . . . . . . . . . .043 to .045 inch
Front Clutch to Reaction Shaft Support. . . . . . . . . . . . . .043 to .045 inch -
Output Shaft to Input Shaft. . . . . . . . . . . . . . . . . . . . . . - .062 to .064 inch
Sun Gear Driving Shell Thrust Plate (Steel) . . . . . . . . . . .034 to .036 inch
Rear Planetary Gear to Driving Shell. . . . . . . . . . . . . . .062 to .064 inch
Front Planetary Gear to Annulus Gear Support. . . . . . .062 to .064 inch
Front Annulus Gear Support to Driving Shell. . . . . . . . . .062 to .064 inch
Front Clutch Piston Retainer to Rear Clutch
Piston Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .061 to .063 inch
(Green)
SPECIAL TOOLS
6 and 8 Cyl. Vehicles
C-452 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller-Companion Flange
C-484 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pliers-Snap Ring
C-763. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch-Remote Control Starter
C-3203A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jack-Transmission
C-3229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pliers-Snap Ring
C-328 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wrench-Companion Flange Holding
C-3288. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Studs-Pilot
C-3292. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge-Low Pressure
C-3293. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge-High Pressure
c-3335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Straight Edge
c - 3339. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dial Indicator
C-3422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor-Engine Valve Spring
C-3705 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter-Transmission Band Adjuster
(Use with C-3380 Torque Wrench)
C-3749. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand-Valve Body
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remover-Front Oil Pump and Reaction Shaft Support
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge-Throttle Pressure Setting
C-3765. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer-Shifter Shaft Detent Ball
C-3887. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit-Service Bushing Removing and Installing
6 Cyl. Vehicles
C-3283 .................................................. Studs-Pilot
C-3575. ................................................. Compressor-Front Clutch Piston Spring
C-3750 .................................................. Stand-Transmission
C-375 1 .................................................. Installer and Bumisher-Extension Housing Bushing
............................................... Remover-Output Shaft Oil Seal
TRANSMISSION-TORQUEFLITE 2 1-27
SPECIAL TOOLCContinued
C-3754. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver-Output Shaft Oil Seal
c-3755 . . . . . . . . . . . . . . . . . . . . . . ...................... Remover-Extension Housing Bushing
.................. ..................... .Aligning Tool-Front Oil Pump
c-3757. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer-Front Pump Oil Seal
C-3758. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover-Front Pump Oil Seal
c-3759. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly Tool-Front Oil Pump to Reaction Shaft Support
C-3760 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor-Rear Clutch Piston Spring
C-3762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning Sleeve-Rear Oil Pump Cover
C-3768. . . ..... . . . . . . . . . . . . . . . . .Protector-Output Shaft Oil Seal
C-3809. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixture-Engine Lifting
C-3899. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remover-Output Shaft Oil Seal Rubber Lip
8 Cyl. Vehicles
C-748. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover-Output Shaft Oil Seal
C-3204. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver-Output Shaft Bearing
C-3275. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover-Output Shaft Bearing
. . . . . . . . . . . . . . . . .Fixture-Engine Support
. . . . . . . . . . . . . . . . .Stand-Transmission
C-3837. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver-Output Shaft Oil Seal
C-3860. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver-Front Pump Oil Seal
C-386 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover-Front Pump Oil Seal
C-3863. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor-Front Clutch Piston Spring
Installer-Overrunning Clutch Cam
C-3864 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aligning Sleeve-Rear Oil Pump Cover
C-3881 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aligning Tool-Front Oil Pump Rotor
C-3882. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adapter Kit-Use with C-3750 Transmission Stand
TORQUE REFERENCE-TORQUEFLITE
Foot-Pounds I n c h-Pounds
Kickdown Band Adjusting Screw Lock Nut (Eight Cylinder Cars). . . . . . . . . . 29 -
Kickdown Band Adjusting Screw Lock Nut (Six Cylinder Cars). . . . . . . . . . . . . . . 25 -
Kickdown Lever Shaft Plug.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 150
Reverse Band Adjusting Screw Lock Nut (Eight Cylinder Cars). . . . . . . . . . . . . . . 35 -
Reverse Band Adjusting Screw Lock Nut (Six Cylinder Cars). . . . . . . . . . . . . . . . 20 -
Cooler Line Fitting.. . . . . . . . . . . . . . . . . . . . . ......................... - 75
Control Cable Adlusting Wheel Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . ... - 40
Converter Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 -
Converter Drive Plate to Crankshaft Bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 -
Converter Drive Plate to Torque Converter Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . - 270
Extension Housing to Transmission Case Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 -
Extension Housing to Insulator Mounting Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 -
Extension Housing-Crossmember to Frame Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . 75 -
Front Oil Pump Housing to Transmission Case Bolt.. ....................... - 150
Governor Body to Parking Sprag Bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 100
'/I
Neutral Starter Switch-Initial Contact 4- to J/s turn. . . . . . . . . . . . . . . . . . . . 60 Maximum -
Neutral Starter Switch (Console Shift only) . . . . . . . . . . . ._.. . . . . . 25-30 --
Oil Filler Tube Bracket Bolt.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 150
Oil Pan Bolt.. . . . . . . . . . . . ................................... - 150
Output Shaft Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 -
Overrunning Clutch Cam Set Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 40
Parking Lock Cable Locking Bolt. . . .............................. - 10
Parking Sprag Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 150
Pressure Test Take-off Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 75
Reaction Shaft Support to Front Oil Pump Bolt. .......................... - 150
Rear Oil Pump Cover Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 140
Transmission to Engine Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-30 -
Valve Body Screw.. . . ............................. - 28
Valve Body to Transmission Case Bolt. ................................. - 100
Speedometer Cable Clamp Screw.. ................................... - 150
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TORQUEFLITE TRANSMISSION
GENERAL INFORMATION The transmission combines a torque converter with
a fully-automatic 3-speed gear system (Figs. 1 and 2).
The (A-904) TorqueFlite Transmission is used in all
The torque converter housing and transmission case
vehicles equipped with six cylinder engines except
are an integral aluminum casting. The transmission
Police Cars and Taxi Cabs. The number of front
consists of two multiple disc clutches, an overrunning
clutch plates, extension housing length and mounting
clutch, two servos and bands, and two planetary gear
pad location are different, depending on the engine
sets to provide three forward ratios and a reverse
usage. Refer to Specifications for front clutch plate
ratio. The common sun gear of the planetary gear sets
information.
is connected to the front clutch by a driving shell
The (A-727) TorqueFlite Transmission is used in all which is splined to the sun gear and to the front
vehicles equipped with eight cylinder engines, and is clutch retainer. The hydraulic system consists of a
available for the six cylinder engine Police Cars and front and rear pump, and a single valve body which
Taxi Cabs. The number of rear clutch plates, exten- contains all of the valves except the governor valve.
sion housing length and mounting pad location, and Venting of the transmission is accomplished by a
transmission case front mounting flange are differ- drilled passage through the upper part of the front
ent, depending on the engine usage. Refer to Specifi- oil pump housing.
cations for rear clutch plate information. The torque converter is attached to the crankshaft
CLUTCH ENGAGEMENT AND BAND APPLICATION CHART

BUTTON
POSITION FRONT REAR FRONT REAR OVERRUNNING
AND DRIVE CLUTCH CLUTCH (KICKDOWN) (LOW-REV.) CLUTCH
CONDITION BAND BAND
N
NEUTRAL DISENGAGED DISENGAGED RELEASED RELEASED NO MOVEMENT
D-DRIVE
(DIRECT) ENGAGED ENGAGED RELEASED RELEASED OVER RUNS
1.00 to 1
D-DRIVE
(BREAKAWAY) DISENGAGED ENGAGED RELEASED RELEASED HOLDS
2.45 to 1
~~~
D-DRIVE
KICKDOWN
(TO SECOND) DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS
1.45 to 1
2-SECOND DISENGAGED ENGAGED APPLIED RELEASED OVER RUNS
1.45 to 1
2-SECOND
KlCKDOW N
(TO LOW) DISENGAGED ENGAGED RELEASED RELEASED HOLDS
2.45 to 1
1-LOW DISENGAGED ENGAGED RELEASED APPLIED PARTIAL HOLD
2.45 to 1
1-LOW
(RETARDING) DISENGAGED ENGAGED RELEASED APPLIED NO MOVEMENT
2.45 to 1
R-REVERSE ENGAGED DISENGAGED RELEASED APPLIED NO MOVEMENT
2.20 to 1
TRANSMISSION-TORQUEFLITE 21-31
through a flexible driving plate. Cooling of the con- reverse operation. The front pump check valve pre-
verter is accomplished by circulating the transmission vents loss of rear pump pressure through the front
fluid through an oil-to-water type cooler, located in pump circuit when the front pump flow is recirculat-
the radiator lower tank. The torque converter assem- ing.
bly is a sealed unit which cannot be disassembled. A check valve is incorporated in the rear oil pump
The transmission fluid is filtered by an internal cover to prevent air from entering the system during
“Dacron Type” filter attached to the lower side of the reverse operation.
valve body assembly. The manual valve obtains the different transmis-
Engine torque is transmitted to the torque con- sion drive ranges as selected by the vehicle operator.
verter then, through the input shaft to the multiple The reverse blocker valve mechanically blocks the
disc clutches in the transmission. The power flow manual valve from moving into reverse position above
depends on the application of the clutches and bands. approximately 20 mph.
Refer to “Clutch Engagement and Band Application The 1-2 shift valve automatically shifts the trans-
Chart”. mission from low to second or from second to low
depending on the vehicle operation.
1. HYDRAULIC CONTROL SYSTEM The 2-3 shift valve automatically shifts the trans-
Figures 3 through 10 show the position of the mission from second to direct or from direct to
various valves with color coded passages to indicate second depending on the vehicle operation.
those under hydraulic pressure for all operations of The kickdown valve makes possible a forced down-
the transmission. shift from direct to second-second to breakaway or
The hydraulic control system makes the transmis- direct to breakaway (depending on vehicle speed) by
sion fully automatic, and has four important functions depressing the accelerator pedal past the detent
to perform. In a general way, the components of any “feel” near wide open throttle.
automatic control system may be grouped into the The shuttle valve has two separate functions and
following basic groups: performs each independently of each other. The first
The pressure supply system, the clutches and band is that of providing fast release of the kickdown
servos, the pressure regulating valves and the flow band, and smooth front clutch engagement when the
control valves. driver makes a “lift-foot” upshift from second to
Taking each of these basic groups or systems in direct. The second function of the shuttle valve is to
turn, the control system may be described as fol- regulate the application of the kickdown servo and
lows: band when making direct to second kickdowns.
Pressure Supply System Clutches, Band Servos and Accumulator
The pressure supply system consists of a front The front and rear clutch pistons, and both servo
pump driven by the engine through the torque con- pistons are moved hydraulically to engage the
verter, and a rear pump driven by the transmission clutches and apply the bands. The pistons are released
output shaft. by spring tension when hydraulic pressure is released.
Pressure Regulating Valves On the 2-3 upshift, the kickdown servo piston is
The pressure regulating valves consist of a regu- released by spring tension and hydraulic pressure.
lator valve which controls line pressure at a value The accumulator controls the hydraulic pressure
dependent on throttle opening. on the apply side of the kickdown servo during the
The torque converter control valve maintains 1-2 shift; thereby, cushioning the kickdown band
torque converter operating pressure and transmission application at any throttle position.
lubricating pressure.
2. GEARSHIFT AND P A R K I N G LOCK
The governor valve transmits regulated pressure to CONTROLS
the transmission (in conjunction with throttle pres-
sure) to control upshift and downshift speeds. The push button gearshift control unit is essentially
The throttle valve transmits regulated pressure to the same on all vehicles. The parking lock lever is
the transmission (in conjunction with governor pres- attached to the left side of the push button unit.
sure) to control upshift and downshift speeds. When the parking lock is applied, the transmission is
automatically shifted to the neutral position by the
Flow Control Valves control unit.
The rear pump check valve prevents loss of front Some vehicles are equipped with a “lever type”
pump pressure through the rear pump circuit during console gearshift control. The transmission and park-
ing lock control cables are the same type as used quires heavy throttle for ‘/2 mile or more. Lower
with the push button control. The parking lock is ratios reduces possibility of overheating the transmis-
applied by moving the selector lever past a gate to sion and converter under these conditions. 1 (low)
the PARK position. position is for severe operation or to obtain better
CAUTION: Never apply the parking lock until the control.
vehicle has stopped; otherwise, a severe ratcheting
noise will occur. Push Starting
If the engine fails to start in the normal manner, it
3. OPERATING INSTRUCTIONS may be started by pushing. Towing the vehicle to
start i s not recommended due to the sudden surge o f
The transmission will automatically upshift and power when the engine starts.
downshift at approximately the speeds shown, in the Turn the ignition on, then push the 1 (low) button
“Shift Pattern Summary Chart”. (See page14 1) in, or move the selector lever to the low position and
NOTE: All shift speeds given in the ”Shift Pattern depress the accelerator pedal slightly. After the vehi-
Summary Chart“ may vary somewhat due to produc- cle has been pushed to a speed of 15 to 25 mph (ap-
tion tolerances and rear axle ratios. This is not too proximately), the transmission will drive the engine.
important; however, the quality of the shifts i s very
important. All shifts should be smooth, responsive, Towing Vehicle
and with no noticeable engine runaway. Transmission Inoperative: Tow the vehicle with a
rear end pickup or remove the propeller shaft.
Mountain Driving Transmission Operating Properly: The vehicle may
When driving in the mountains with either heavy be towed safely in N (neutral) at moderate speeds.
loads or when pulling trailers, the 2 (second) or 1 (low) For long distance towing (over 100 miles), the pro-
position should be selected on upgrades which re- peller shaft should be removed.
- -
2B SERVICE MAINTENANCE, ADJUSTMENTS AND TESTS
While in the process of making adjustments and
tests, do not stall test the torque converter. For sion may Occur, wide open throttle stall operation
safety reasons and because damage to the transmis- should be avoided.
SERVICE PROCEDURES
4. LUBRICATION Fluid Level
The transmission fluid and the oil filter should Inspect the fluid level every 6 months (more often
provide satisfactory lubrication and protection to the if conditions warrant) with the engine and transmis-
automatic transmission and no change is recommend- sion at normal operating temperature. Refer to “Lu-
ed in vehicles used in normal service. Regularly brication and Maintenance”, Group 0.
scheduled oil and filter changes, therefore will not be
required in these vehicles, except when the opera- brain and Refill
tion of the vehicle is classified as severe.
(1) Raise the vehicle on a hoist. Place a drain con-
If the regular operation of the vehicle is classified
tainer with a large opening, under the transmission
as severe, the transmission should be adjusted and the oil pan.
fluid and the oil filter changed approximately every
32,000 miles, according to any of the following: (2) Loosen the pan bolts at one corner, tap the
pan to break it loose allowing the fluid to drain, then
Police or taxicab operation
remove the oil pan.
Frequent towing of trailers
(3) Remove the access plate from in front of the
Continuous operation at higher than normal loading converter, remove the drain plug allowing the fluid to
and/or temperature. drain (Fig. 11). Install and tighten the converter drain
The transmission should not be idled in gear for plug to 14 inch-pounds torque, and install the access
long periods. plate.
AMI Sucllon ............

CONVERlEl ....... .30-75 p i
LUIIIUTION ...... .5-30 pi
CONTROL SYSTEM IN
NEUTRAL
ENGINE RUNNING
62x2308
OIL FILTER
Fig. ?Neutral Hydraulic Circuits

ACCUMULATOR
CONVERTER ~
LINE ............... 7 i psi

PUMP SUCTION ............
THROTTLE ...........40 psi
GOVERNOR ........ .0.75 psi
CONVERTER ........30-75 psi

LUBRICAIION .......5-30 psi
CONTROL SYSTEM IN
BREAKAWAY
HALF THROTTLE
62x23 1 u
OIL FILTER
Fig. 4-Drive-Breakaway Hydraulic Circuits

KD F~SERVO
-
ACCUMULATOR
I II = I
TORQUE '
CONVERTER 1
TI
c
F-RONT CLUTCH
I I I MANUAL VA.
d $ COOLER -T
TOR VA.
OIL PRESSURES
LINE ............... i
PUMP SUCTION
THROTTLE
COVERNOR
............
.......... .40 psi
.........6-71 psi
CONVERTtR ....... .30-71 psi
LUBRlCAllON ...... ,140 psi I

..
TO LUB. CONTROL SYSTEM IN
DRIVE (SECOND)
HALF THROTTLE
62x2320
'Fig. 5-Drive-Second Hydraulic Circuits

4-t- SERVO
-7
7
SHUTTLE VA.
- 1
ACCUMULATOR
A-
TORQUE
CONVERTER
OIL PRESSURES
LINE.............55.90 pi '
PUMP SUCllON ............
THROITLt ..........O-90 psi

GOVERNOR ........, 6 9 0 pi
CONVERTER ........30-11 psi
LUBRICATION ......,140 p i
W
TO LUB. CONTROL SYSTEM IN
I DRIVE (DIRECT)
62x2338
OIL FlLT
Fig. &Drive-Direct Hydraulic Circuits

TRANSMISSION-TORQUEFLITE -
2 1-37
~
-
I
L J
r
ACCUMULATOR
TORQUE
CONVERTER
OIL PRESSURES
LlNt ...............90 pu
WMI SUCTION ............
THROlTtf .......... .90 psi
GOVfRNOR ....... .60-65 psi
CONVtRlER ........30-75 psi
LUIRICITION .......!
CONTROL SYSTEM IN
DRIVE (KICKDOWN)
- - AT 50 M.P.H.
62x2348
OIL FILTER
Fig. 7-Drive-Kickdown Hydraulic Circuits

21-38 TRANSMISSION-TORQUEFLITE
TORQUE
CONVERTER
OIL PRESSURES
LlNl ...............55 pi
WIW SUCTION ............
GOVERNOR .........(-I5 pd
CONVtRTtR ........30-75 pd
LUIRICAIION ...... .5-30 pd
CONTROL SYSTEM IN
MANUAL SECOND
CLOSED THROTTLE
62x2358
1111
OIL FILTER
U I
Fig. 8-Manual Second Hydraulic Circuits

TORQUE
CONVERTER
LINE . . . . . . . . . . . . . . , I S psi
PUMP SUCTION ............
GOVERNOR ........ , 0 3 0 psi
CONVERTER . . . . . . . .30-75 psi
LUBRICATION . . . . . . .5.30 psi
TO LUB.
CONTROL SYSTEM IN
MANUAL LOW
CLOSED THROTTLE
62r23-58
OIL FILTER
'Fig. 9-Manual l o w Hydraulic Circuits

TORQUE
CONVERTER I
LUB.
6
OIL PRESSURES
LlNf ...........210-260 p i
W W SUCTION ............
CONVtRTtl ........30-75 psl
LUIRICATION ........
CONTROL SYSTEM IN
REVERSE
62x2378
OIL FILTER
Fig. 1 "Reverse Hydraulic Circuits

TRANSMISSION-TORQUEFLITE 2 1-4T
SHIFT PATTERN S U M M A R Y CHART

(Valiant with 650-1 3 Tires 1
CAR SPEED-170 CU. IN. ENG. CAR SPEED-225 CU. IN. ENG.
(Axle Ratio) (Axle Ratio)
Condition 3.23-1 3.55-1 2.93-1 3.23-1 3.55-1
Closed Throttle 1-2 Upshift.. . . . . . . 6-1 1 6-10 7-13 6-12 6-10
Closed Throttle 2-3 Upshift. . . . . . . . 10-14 9-13 11-16 10-14 9-13
Wide Open Throttle 1-2 Upshift. . . . . . . . 25-4 1 23-36 28-40 25-36 23-33
Wide Open Throttle 2-3 Upshift.. . . . . . . 58-69 52-63 59-72 53-65 49-59
3-2 Kickdown Limit.. . . . . . . . . . . . . . . . . . 46-62 42-56 46-63 42-57 38-53
3-1 Kickdown Limit. . . . . . . . . . . . . . . . . . . 24-35 22-32 27-33 24-30 22-28
Closed Throttle Downshift. . . . . . . . . . . . . . 4-10 4-9 5-12 4-10 4-10

( Plymouth 6 with 700-14 Tires 1
CAR SPEED-225 CU. IN. ENG.

(Axle Ratio)
Condition 2.93-1 3.23-1 3.31-1 3.55-1
Closed Throttle 1-2 Upshift., . . . . . . . . . . . . . . . . . . . . 7-14 6-1 3 6-12 6-1 2
Closed Throttle 2-3 Upshift.. . . . . . . . . . . . . . . . . . . . . 11-17 10-15 10-15 9-14
Wide Open Throttle 1-2 Upshift. . . . . . . . . . . . . . . . . . . . . . 29-42 26-38 26-37 24-35
Wide Open Throttle 2-3 Upshift. . . . . . . . . . . . . . . . . . . . . . 62-76 56-69 55-67 51-63
3-2 Kickdown Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-67 43-62 42-59 40-55
3-1 Kickdown Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-35 25-32 25-3 1 23-29
Closed Throttle Downshift. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 3 5-1 2 4-1 2 4-1 1

( Plymouth 8 with 700-14 Tires 1
CAR SPEED TO AXLE RATIOS

318 Cu. In. Eng. 361, 383 Cu. In. Eng. 426 Cu. In. Eng.
8 Cylinder Std. 8 Cylinder (Hi Per.)
Condition 2.76-1 3.23-1 2.93-1 3.23-1 3.23-1 3.91 -1
Closed Throttle 1-2 Upshift. . . . . . 8-14 7-12 6-1 3 6-12 6-12 5-10
Closed Throttle 2-3 Upshift. . . . . . 13-18 11-15 12-18 11-16 11-17 9-14
Wide Open Throttle 1-2 Upshift. . . . . . 32-45 27-38 30-43 27-39 44-59 37-49
Wide Open Throttle 2-3 Upshift. . . . . . 69-80 58-69 65-76 59-69 82-93 68-77
3-2 Kickdown Limit. . . . . . . . . . . . . . . . . 60-74 5 1-63 56-70 51-63 73-87 6 1-72
3-1 Kickdown Limit. . . . . . . . . . . . . . . . . 30-38 25-33 27-35 25-32 28-53 23-44
Closed Throttle Downshift. . . . . . . . . . . . 5-13 4-1 1 4-12 4-1 1 4-1 1 3-9
2 1-42 TRANMlSSlON-TORQUEFLITE
Fig. 11-Converter Drain Plug
(4) If necessary, adjust the reverse band (Refer to

Paragraph 12).
Fig. 12-Dip Stick Markings
(5)Install a new oil filter on the bottom of the
valve body. Be sure to use a new gasket and tighten
(8) Start the engine and allow to idle for at least
the retaining screws to 28 inch-pounds torque.
two minutes. Then, with the parking brake on, de-
(6) Clean the oil pan, and reinstall using a new press each button momentarily, ending with the N
gasket. Tighten the oil pan bolts to 150 inch-pounds (neutral) button pushed in or move the selector lever
torque. to each position, ending in the neutral position.
(7) Six Cylinder Cars: Pour five quarts of Auto- (9) Add sufficient fluid to bring the fluid level to
matic Transmission Fluid Type “A” Suffix “A” the “ADD ONE PINT” mark.
through the filler tube. Recheck the fluid level after the transmission is
Eight Cylinder Cars: Pour eight quarts of Auto- at normal operating temperature. The level should be
matic Transmission Fluid Type “A” Suffix “A” between the ”FULL” mark and the ”ADD ONE
through the filler tube. PINT” mark (Fig. 12).
NOTE: PUSHBUTTON BEZEL

NOT SHOWN
GEARSHIFT CONTRO
AND WASHER (3)
PARKING LOCK ARM
LOCK NUT AND WASHER (2)

CABLE 63x362
Fig. 13-Removing or Installing Gearshift Control Unit (Valiant)

CAUTION: To prevent dirt from entering the (4) Valiant Models: Remove the windshield wiper,
transmission, make certain that the dip stick cap i s headlamp switch knobs, switch bezels, then remove
fully seated onto the filler tube. the switches. Remove two screws from the push but-
ton bezel, then remove the bezel and seal.
Periodic Adjustments
NOTE: Models with the narrow push button bezel
The following adjustments should be performed at
do not require remoyal of the switches.
32,000 mile intervals or more frequent under abnor-
mal operating conditions. Plymouth Models: Remove three screws from the
push button bezel, then remove the bezel and seal.
(1) Adjust the kickdown band. Refer to Paragraph
12. (5) Remove all push buttons (except neutral but-
ton) by pulling them off the control actuator slides.
(2) Adjust the gearshift control cable (Refer to
Paragraph 9). (6) Using a socket and long extension through the
push button opening, remove two nuts securing the
(3) Adjust the engine idle in neutral. Refer to the
“Fuel System”, Group 14. control assembly to the mounting bracket (Fig. 13
or 14). Carefully work the assembly rearward out of
(4) Adjust the transmission and carburetor throttle the cluster.
linkage to obtain the proper shift pattern (Refer to
(7)Remove the neutral push button, and disconnect
Paragraph 13).
the push button gearshift and parking lock cables
from the control unit.
5. PUSH BUTTON CONTROL U N I T
Control Unit Adjustment
Removal
(1) Disconnect the negative (ground) cable from the
The following procedures describe the gearshift
battery. control unit adjustments. If the transmission fails to
shift into NEUTRAL when the parking lock is applied,
(2) Disconnect the back-up lamp switch wire con- inspect the parking lock lever travel in the instru-
nectors (if so equipped). ment panel slot and the parking lock cable adjust-
(3) Remove the parking lock handle from the arm ment at the transmission before adjusting the control
(Fig. 13 or 14). unit (Refer to Paragraph 10).
SCREW (3)
INSTRUMENT CLUSTER PANEL

1
>vL[ -\PARKING LOCK ARM
1 PARKING LOCK CABLE -,

GEARSHIFT CONTROL CABLE 64 x 470
Fig. 1LRemoving or Installing Gearshift Control Unit (Plymouth)

center spring.
(4) Adjust the lever stop screw to obtain .010 inch
clearance between the neutral slide pin and the lever
heel (Fig. 16). Tighten the lever stop screw lock nut
securely.
Installation
(1) Connect the push button gearshift and parking
lock cables to the control unit. Secure the cable hous-
ings by clamping them in the control brackets.
(2) Install the neutral push button on the neutral
actuator slide. Carefully guide the control unit into
position from the rear of the instrument cluster. In-
stall the two retaining nuts and tighten securely.
(3) Install the other push buttons in proper order
62x193 on the control actuator slides.
\ (4) Valiant Models: Install the push button seal and
Fig. 1LAdjusting lever Nose Contact rrt Neutral bezel. Install and tighten the bezel retaining screws.
Slide Pin Install the windshield wiper and headlamp switches if
removed.
(1) Remove the overcenter spring and back off the Plymouth Models: Install the push button seal and
lever stop screw (Fig. 15). Make sure no binding bezel. Install and tighten the bezel retaining screws.
exists in the neutral slide, neutral slide pin and (5) Operate the push buttons and correct any
bushing, cam pivot, and that they are adequately lu- binding that might exist.
bricated.
(6) Install the parking lock control handle. Connect
(2) Hold the neutral slide in against the rocker the back-up switch wires (if so equipped).
bar with about a 5 to 10 pound load.
(7) Connect the battery ground cable.
(3) Loosen the lock nut and rotate the cam so the
lever nose just touches the neutral slide pin as it 6. CONSOLE GEARSHIFT UNIT (Fig 17)
passes over the pin when moving the parking lock
lever from the OFF to ON position. Only light contact Removal
should occur so the lever does not hang up on the (1) Remove the gearshift and parking lock cables
pin. Hold the cam in this position and tighten the
lock nut to 95 inch-pounds torque. Install the over-
LEVER STOP SCREW
BACK-UP LAMP
MOUNTING LEGS
SLIDE PIN
.
62xl92A
Fig. 16-Adjusting lever Heel to Neutral Slide GEAR SHIFT CONTROL CABLE-
Pin Clearance Fig. 17-Console Gemshift Unit
from the transmission. Refer to Paragraphs 9 and 10.
Remove the adjusting wheel from the gearshift cable. 7. BACK-UP L A M P S W I T C H REPLACEMENT
(2) Remove the set screw from the gearshift lever ( If So Equipped1
knob and remove the knob. (1) Push Button Type: Remove the push button
(3) Remove the two screws from the top rear end gearshift and parking lock control unit. Straighten
of the console upper finish plate. Raise the rear end the four tabs that hold the switch to the switch
of the finish plate and work it rearward to disengage bracket, and separate the switch from the bracket.
it from the front of the console. Lift the finish plate To install, place the switch in position on the
upward far enough to remove the dial lamp and switch bracket and bend over the four tabs. Reinstall
socket, then lift off the plate. the push button gearshift and parking lock control
unit.
(4) Remove the four inner bolts securing the gear-
(2) Console Lever Type: Refer to Paragraph 6 and
shift unit to the console.
perform steps 2 through 6 under “Removal”
(5) Carefully raise the lower edge of the console Disconnect the switch wires and remove the screw
side trim to obtain access to the console-to-floor attaching the switch to the side of the gearshift unit.
bracket mounting bolts (three bolts on each side of To install, attach the switch to the side of the
the console). Loosen the bolts several turns, but do gearshift unit and tighten the retaining screw. Con-
not remove. nect the wires and test the back-up light for proper
(6) Disconnect the courtesy lamp wires, then lift operation. Refer to Paragraph 6 and perform steps
off the console assembly. 2 through 5 under “installation”.
(7) Carefully pull the gearshift and parking lock 8. PUSH BUTTON AND CONSOLE SHIFT
cables through the grommets in the floor pan and L A M P REPLACEMENT
remove the gearshift control unit assembly.
The Valiant push button lamp is located approx-
imately in the center of the push button cluster. To
lnstallation replace the bulb, remove the push button bezel and
(1) Insert the gearshift and parking lock cables necessary push buttons. Slide a short place of tight
through the openings in the floor pan. Place the gear- fitting rubber hose over the bulb to remove it from
shift control unit on the temporary floor pan support the socket.
to hold it in place while installing the console. The Plymouth push button lamp is located on the
(2) Lower the console down over the shift lever back side of the instrument cluster, next to the inner
and connect the courtesy lamp wires, then position side of the push button control unit mounting bracket.
the console on the floor mounting brackets. Making The bulb can be replaced by removing the bulb
sure the retaining bolt flat washers are outside of socket from the rear of the instrument cluster.
the console flange, tighten the six bolts securely. The console selector lever dial lamp is located
directly under the dial. To replace the bulb, remove
(3) Lift the gearshift control unit off the temporary the console upper the finish plate and remove the
support. Align the control unit in the console, install socket and bulb. Refer to Paragraph 6. Steps 2 and
and tighten the four retaining bolts. 3 under “Removal”.
(4) Slide the three tabs on the front end of the
console finish plate under the finish moulding at the 9. GEARSHIFT CONTROL CABLE
front, and lower the finish plate far enough to install (Transmission End 1
the dial lamp and socket. Then lower the rear of the Removal
finish plate into position and install the two retaining (1) Raise the vehicle on a hoist.
screws.
(2) Remove the gearshift control cable to trans-
(5) Install the gearshift lever knob and secure with mission adjusting wheel lock screw. Pull the cable
the set screw. outward just enough to allow the fluid to drain into
(6) Inspect the cables for proper routing. Make sure a container.
there are no sharp kinks or interference with other (3) Pull the cable out of the transmission case
parts. as far as possible, back off the adjusting wheel a few
(7) Install the adjusting wheel on the gearshift turns if necessary.
cable. Install the cables in the transmission and adjust (4) Insert a small screw driver above and slightly
as outlined in Paragraphs 9 and 10. to the right of the cable (Fig. 18). Disengage the
I.
TUIROllLE SHAFT
KICKDOWN BAND
ADJUSTING SCRE
P CK
t K U M LVULtb!
a 4
63x578A ‘29B
‘Fig. 1’8-Removing Gearshift Control Cable Fig. 19-Removing Parking Lock Cablo
cable adapter lock spring by pushing the screw driver While holding the cable outward, rotate the adjust-
handle to the right while pulling outward on the cable. ment wheel clockwise until it just contacts the case
squarely.
lnstallat ion Turn the wheel counter-clockwlw just enough to
(1) Push Button Type: With the parking lock lever make the next adjustment hole in the wheel line up
in the OFF position, have an assistant engage the (R) with the screw hole in the case. Counting this
button and hold it firmly engaged until the cable hole as number one, continue turning the wheel coun-
attachment operation is completed. ter-clockwise until the fifth hole lines up with the
(2) Console Lever Type: Place the selector lever screw hole in the case.
in the PARK position. (7) Push the cable and adjusting wheel tight against
(3) Back the adjustment wheel off on the cable the case then install the lock screw and tighten to
housing (counter-clockwise) until two or three threads 75 inch-pounds torque.
are showing on the guide behind the wheel. (8) Refill the transmission with Automatic Trans-
(4) Lubricate the cable housing with transmission mission Fluid Type “A” Suffix “A” to the proper level.
fluid, insert the cable in the transmission case, push Refer to Paragraph 4.
inward on the cable making sure the lock-spring en-
gages the cable. 10. PARKING LOCK CABLE
(Transmission End1
Adjust menf
(5) Push Button Type: Have an assistant hold the Removal
(R) button firmly depressed. Hold the control cable (1) Loosen the parking lock cable clamp bolt where
guide centered in the hole of the transmission case the cable enters the housing cover (Fig. 19). Tap the
and apply only enough inward force (approximately end of the clamp bolt lightly to release its hold on
two pounds) to bottom the assembly in the reverse the cable. Remove the housing cover lower plug.
detent. While holding the cable bottomed, rotate the (2) With a screw driver inserted through the plug
adjustment wheel clockwise until it just contacts the opening, push gently against the projecting portion
case squarely. of the cable lock-spring, then withdraw the lock cable.
Turn the wheel clockwise just enough to make the CAUTION: Do not use pliers or similar tool to
next adjustment hole in the wheel line up with the withdraw the cable from the adaptor cover as the
screw hole in the case. Counting this hole as number cable cover might be damaged c a w i n g an oil leak.
one, continue turning the wheel clockwise until the
fifth hole lines up with the screw hole in the case. lnst allation
(6) Console Lever Type: Have an assistant hold the (1) Place the push button parking lock lever in the
selector lever firmly in the 1 (low) position. Hold the OFF position, or place the console selector lever in
control cable centered in the hole of the transmission the NEUTRAL position.
case and pull the cable outward (approximately two (2) Insert a screw driver through the plug opening
pounds) to bottom the assembly in the low detent. and position it behind the cable adapter stop washer
(6) Gently pull outward on the cable housing to
its limit of travel, release and then tighten the clamp
bolt to 10 inch-pounds torque.
CAUTION: DO not use pliers or similar tool to puir
outward on the cable as the cable cover might be dam-
aged causing an oil leak.
(7) Test the adjustments by allowing the vehicle to
roll slowly on a slight incline. The parking sprag
should fully engage the gear with the lever in the
ON position, and there should be no ratcheting noise
“L“ ~ .,- with the lever in the OFF position.
Fig. 20-Installing Parking lock Cable 1 1. NEUTRAL STARTING SWITCH

(Fig. 20). Hold the adapter outward while pushing Adjustment and Test
the cable in as far as possible, making sure the lock- Push Button Control O n l y )
spring engages the cable. (1) With the proper control cable adjustment as-
sured, depress the N (neutral) push button.
(3) Gently pull outward on the cable housing to its
limit of travel, release and then tighten the clamp (2) Raise the vehicle on a hoist, loosen the neutral
bolt to 10 inch-pounds torque. Reinstall the plug in starting switch allowing the fluid to drain into a
the cover and tighten to 75 inch-pounds torque. container.
(3) Unscrew the neutral starting switch from the
Adjustment-Parking Lock Lever transmission case and inspect to see that the switch
(Push Button Control O n l y ) operating lever finger is aligned in the center of
(1) Operate the parking lock lever from one end of switch opening in the case.
the slot in the instrument panel to the other. *The (4) Place the cupped washer and “0” ring over the
lever should have clearance at both ends. One hole in threads of the switch (Fig. 21), then screw the switch
the parking lock arm is slotted to permit the parking into the transmission case a few turns.
lock lever adjustment (Fig. 13 or 14). If adjustment (5) Connect one lead of a test lamp to the battery
of the lever is required, first loosen the cable clamp current and the other lead to the switch terminal.
bolt on the transmission, making sure the cable Screw the switch into the transmission case until the
housing is free to move in the parking sprag cover lamp lights, then tighten the switch an additional ?La
hole. to 9’’turn.
(2) To adjust, move the lever to the fully OFF NOTE: The switch must be tight enough to prevent
position. Loosen the two nuts attaching the lock arm oil leakage. If not, add a thin washer and readiust
to the pushbutton housing. Loosen the nuts just the switch. Do not tighten over 60 foot-pounds torque.
enough to free up the lock arm.
(6) Remove the test lamp and connect the wire to
(3) Block the locking level l/le inch from the OFF the switch.
end of the lever slot, then tighten the two nuts on
the pushbutton housing. Recheck lever travel to be
certain that clearance exists at both ends of the lever
travel.
(4) Place the parking lock lever (on the instrument
panel) in the OFF position.
Adjustment--Transmission Cable End
(Push Buffon and Console Shift)
(5) If not performed in Step 1, loosen clamp bolt
securing the cable housing in the parking sprag lever 56x228
cover on the bottom of the transmission extension
housing. Tap the end of clamp bolt lightly to release
its hold on the cable. Fig. 21-Neutral Starting Switch
SEAL ASSEMBLY the left side of the transmission case near the throt-
tle lever shaft (Fig. 18).
(1) Loosen the lock nut and back off approximately
five turns. Test the adjusting screw for free turning
in the tranmsission case.
(2) Using wrench, Tool C-3380 with adapter C-3705,
tighten the band adjusting screw 47 to 50 inch-pounds
torque. If adapter (2-3705 is not used, tighten the
adjusting screw t o ' 7 2 inch-pounds which is the true
tor que.
(3) Six Cylinder Cars: Back off the adjusting screw
2 turns. (225 cu. in. engine) and 2% turns (170 cu.
in. engine). Hold the adjusting screw in this posi-
SWITCi 64x4 tion and tighten the lock nut to 25 foot-pounds torque.
Fig. 22-Neutral Starting Switch Eight Cylinder Cars: Back off the adjusting screw
2 turns. Hold the adjusting screw in this position and
(7) Add fluid to the transmission to bring it up to tighten the lock nut to 29 foot-pounds torque.
proper level. Refer to Paragraph 4.
Low and Reverse Band
Adjustment and Test (1) Raise the vehicle, drain the transmission fluid
t Console Shift Only J and remove the oil pan.
The neutral starting switch (Fig. 22) should operate (2) Loosen the adjusting screw lock nut and back
in both the PARK and NEUTRAL selector lever off nut approximately five turns (Fig. 23). Test the
positions. adjusting screw for free turning in the lever.
(1) To test the switch, disconnect the wire from (3) Using wrench, Tool C-3380 with adapter C-3705,
the switch. tighten the band adjusting screw 47 to 50 inch-
(2) Connect one lead of a test lamp to battery cur- pounds torque. If adapter C-3705 is not used, tighten
rent and the other lead to the switch terminal. If the the adjusting screw to 72 inch-pounds which is the
test lamp does not light, the switch may be faulty, true torque.
out of adjustment, or the gearshift control cable may (4) Six Cylinder Cars: Back off the adjusting screw
be improperly adjusted. 5% turns. Hold adjusting screw in this position and
(3) Unscrew the switch from the transmission case tighten the lock nut to 20 foot-pounds torque.
allowing the fluid to drain into a container. Move the
LOW AND REVERSE BAND ADJUSTING
selector lever to the PARK and then to the NEUTRAL
positions, and inspect to see that the switch operating
lever is centered in the switch opening in the case.
(4) Screw the switch into the transmission case and
tighten to 25-35 foot-pounds torque. Retest the switch
with the test lamp.
(5) Add fluid to the transmission to bring up to
the proper level. Refer to Paragraph 4.
NOTE: Test the starter for operating in all push
button or selector lever positions. If it should oper-
ate in any position other than push button neutral
or selector lever park and neutral, readjust the gear-
shift control cable. Refer to Paragraph 9. In some
cases, it may be necessary to align the valve body
neutral and/or park fingers with the switch plunger.
PRESSURE
Refer to Paragraph 24. JSTING SCREW
I
12. BAND ADJUSTMENTS 1-2 , v
I
CABLE ADAPTER N v 0
Klckdown Band
The kickdown band adjusting screw is located on Fig. 23-Bottom View of Transmission (Pan Removed)
z
8
z?
4
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.
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K
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4
z
3
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X
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S
i
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W
E
- 4 ri
Eight Cylinder Cars: Back off the adjusting screw 3
turns. Hold adjusting screw in this position and tight-
en the lock nut to 35 foot-pounds torque.
GOVERNOR PRESSURE
(5) Reinstall the oil pan using a new gasket. Tight-
en the oil pan bolts to 150 inch-pounds torque. E
(6) Fill the transmission with Automatic Transmis-
sion Fluid Type “A” Suffix “A”. Refer to Paragraph
4.
13. THROTTLE LINKAGE- ADJUSTMENT

(1) With the engine at operating temperature and
the carburetor off the fast idle cam, adjust the idle
speed to 500 rpm, (use tachometer).
(2) Adjust the throttle linkage, as outlined and
illustrated in Figures 24,25,26 or 27. Fig. 29-Pressure Test locations (Rear End of Case)
14. HYDRAULIC CONTROL PRESSURE direct.) Reduce the engine speed slowly to 1,000rpm.
TESTS Line pressure at this time (1,000rpm) must be 54-60
psi, and the front servo release pressure must not be
Line Pressure and Front Servo more than 3 psi below the line pressure.
Release Pressure
(4)Disconnect the throttle linkage from the trans-
Line pressure and front servo release pressure mission throttle lever and move the throttle lever
tests must be made in D (drive) position with the rear gradually to the full throttle position. Line pressure
wheels free to turn. The transmission fluid must be at must rise to a maximum of 90-96psi just before or
operating temperature (150to 200° F). at kickdown into low gear. Front servo release pres-
(1) Install an engine tachometer, raise the vehicle sure must follow the line pressure up to the kickdown
on a hoist and position the tachometer so it can be point and should not be more than 3 psi below the
read under the vehicle. line pressure.
(2) Connect two 0-100 psi pressure gauges, Tool If the pressure is not 54-60psi at 1,000 rpm, ad-
(2-3292to the pressure take-off-points at the side of just the pressure, as outlined in Paragraph 15.
the accumulator and at the front servo release (Fig. If the front servo release pressures are less than
28). the pressures specified and line pressures are within
(3) With the control in D (drive) position, speed up limits, there is excessive leakage in the front clutch
the engine slightly until the transmission shifts into and/or front servo circuits. Always inspect the ex-
ternal transmission throttle lever for looseness on the
direct. (Front servo release will be pressurized in
valve body shaft when making the pressure tests.
Lubrication Pressures
The lubrication pressure test should be made at
the same time that line pressure and front servo re-
:RONT SERVO RELEAS lease pressure are tested.
(1)Install a “tee” fitting between the cooler return
line fitting and the fitting hole in the transmission
case at the rear of left side of the transmission
(Fig. 29). Connect a 0-100psi pressure gauge, Tool C-
3292 to the “tee” fitting.
(2)At 1,000 engine rpm, with the throttle closed
and transmission in direct, lubrication pressure
should be 5-15 psi. Lubrication pressure will be ap-
proximately doubled as the throttle is opened to max-
imum line pressure.
Rear Servo Apply Pressure
Fig. 28-Pressure lest locations (Right Side of Case) (1) Connect a 0-300 psi pressure gauge, Tool C-3293
to the apply pressure take-off point at the rear servo GOVERNOR PRESSURE CHART
(Fig. 29). (318,361,383 Cu. In. Engine-Plymouth 8 )
(2) With the transmission control in R (reverse)
position and the engine speed set at 1600 rpm, the Car Speed (Axle Ratio) Pressure
reverse servo apply pressure should be 240-280 psi. Standard Hi Performance limits
Governor Pressure 2.76-1 3.23-1 2.93-1 3.23-1 ....... PSI

(1) Connect a 0-100 psi pressure gauge, Tool C-3292
19-21 16-18 17-20 16-18 ....... 15
to the governor pressure take-off point, located at 41-51 35-44 38-48 35-43 ....... 50
the lower left side of the extension near the mount-
69-76 59-65 65-72 59-65 ....... 75
ing flange (Fig. 29).
(2) Governor pressures should fall within the limits
given in the “Governor Pressure Chart”. GOVERNOR PRESSURE CHART
If the governor pressures are incorrect at the given (426 Cubic Inch Engin-Plymouth 8)
vehicle speeds, the governor valve and/or weights are
probably sticking. Car Speed Pressure
(Axle Ratio) limits
3.23-1 3.91-1 ......................... PSI
GOVERNOR PRESSURE CHART 15-18 12-15 ......................... 15
( 170 Cubic Inch Engine--.Valiant) 56-63 46-52 ......................... 50
82-90 68-74 ......................... 75
Car Speed Pressure
(Axle Ratio) limits
NOTE: The governor pressure should respond
smoothly to changes in mph and should r e t u r n t o 0
3.23-1 3.55-1 ... . . . . . . . . . . . . . . . . . . . . . . PSI
t o 11/2 psi when the vehicle is stopped. High pres-
16-17 14-15 ......................... 15
sure at stand still (above 2 psi) will prevent t h e trans-
29-39 27-35 ......................... 45
mission f r o m downshifting.
59-66 54-60 ......................... 75
Throttle Pressure
No provisions are made to test the throttle pres-
sure. Incorrect throttle pressure should only be sus-
GOVERNOR PRESSURE CHART pected if the part throttle shift speeds are either
(225 Cubic Inch Engin-Valiant) very delayed or occur too early in relation to vehicle
speeds. In which case, the throttle linkage should be
Car Speed Pressure adjusted before throttle pressure setting is adjusted.
(Axle Ratio) limits Refer to Paragraphs 13 and 15.
2.93-1 3.23-1 3.55-1 ................ PSI 15. HYDRAULIC CONTROL PRESSURE

17-19 15-17 14-15 ................ 15 ADJUSTMENTS
29-38 26-34 24-31 ................ 45
60-69 55-63 50-57 ................ 75 Line Pressure
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though the line
pressure adjustment is correct. Always inspect and
GOVERNOR PRESSURE CHART
correct the throttle pressure adjustment before ad-
justing the line pressure.
( 225 Cubic Inch Engine--.Plymouth 6 1
NOTE: Before adjusting t h e line pressure, m e a t
Car Speed Pressure u r e the distance between the manual valve (valve in
(Axle Ratio) limits 1-low position) and line pressure adjusting screw
(Fig. 30). This measurement must be 17’” inches; cor-
2.93-1 3.23-1 3.31-1 3.55-1 ....... PSI rect by loosening the spring retainer screws and re-
18-20 16-18 16-18 15-17 ....... 15 ositioning the spring retainer. The regulator valve
30-40 27-36 25-35 25-33 ....... 45 may cock and hang up in i t s bore if t h e spring re-
63-73 57-67 56-65 53-61 ....... 75 tainer is out o f position.
THROTTLE LEVER
STOP SCREW
60x376 B
Fig. 32-Throttle Pressure Adjustment
therefore, the adjustment should be tested if a mal-

function is evident.
9ig. --Measuring Spring Retainer Location
(1)Remove the valve body assembly from the trans-
mission to perform the adjustment. (Refer to Para-
If the line pressure is not correct, it will be neces- graph 24.)
sary to remove the valve body assembly to perform (2) Loosen the throttle lever stop screw lock nut
the adjustment. (Refer to Paragraph 24.) and back off approximately five turns (Fig. 32).
The approximate adjustment is 1-5/lsinches, meas-
ured from the valve body to the inner edge of the ad- (3)Insert gauge pin of Tool C-3763 between the
justing nut (Fig. 31). However, due to manufacturing throttle lever cam and the kickdown valve.
tolerances, the adjustment can be varied to obtain (4) By pushing in on the tool, compress the kick-
the specified line pressure. down valve against its spring so the throttle valve is
The adjusting screw may be turned with an Allen completely bottomed inside the valve body.
wrench. One complete turn of the adjusting screw (5) As force is being exerted to compress the
changes closed throttle line pressure approximately spring, tighten the throttle lever stop screw finger
1% psi. Turning the adjusting screw counter-clock- tight against the throttle lever tang with the throttle
wise increases pressure, and clockvise decreases the
pressure.
Throttle Pressure
Throttle pressures cannot be tested accurately;
FRONT PUMP
I-+\ ADJUSTING
Fig. 31-Line Pressure Adjustment Fig. 33-Air Pressure Tests

lever cam touching the tool and the throttle valve Rear Clutch
bottomed. Apply air pressure to the rear clutch “apply” pas-
NOTE: Be sure the adjustment is made with the sage and listen for a dull “thud” which indicates that
spring fully compressed and the valve bottomed in the rear clutch is operating. Also inspect for exces-
the valve body. sive oil leaks.
(6) Remove the tool and tighten the stop screw NOTE: If a dull ”thud” cannot be heard in the
lock nut securely. clutches, place the finger tips on the clutch housing
fnd again apply air pressure. Movement of the pis-
16. AIR PRESSURE TESTS tan can be felt as the clutch i s applied.
A ’,’NO DRIVE” condition might exist even with Ktckdown Servo
tlorrdet h i d pressure, because of inoperative clutches Direct air pressure into the front servo “apply”
or bands. The inoperative units, clutches, bands and passage. Operation of the servo is indicated by a
servos can be located through a series of tests by tightening of the front band. Spring tension on the
substituting air pressure for the fluid pressure (Fig. servo piston should release the band.
33). The front atid rear clutches, kickhow3 servo, and
low-reverse servo may be tested by applying air pres- Low and Reverse Servo
sure to their respective passages after the valve boay Ditect air pressure into the rear servo “apply”
assembly has been removed. (Refer to Paragraph 24.) passage. Operation of the servo is indicated by a
To make the air pressure tests, proceed as follows: tightening of the rear band. Spring tension on the
CAUTION: Compressed a i r supply must be free of servo piston should release the band.
all dirt or moisture. Use a pressure of 30 to 100 psi. If the clutches and servos operate properly, no
unshift or erratic shift conditions indicate that the
Front Clutch malfunctions exist in the control valve body assem-
bly.
Apply air pressure to the front clutch “apply” pas-
sage and listen for a dull “thud” which indicates that Governor
the front clutch is operating. Hold the air pressure Governor operating failures can generally be diag-
on for a few seconds and inspect the system for ex- nosed by a road test or hydraulic pressure test.
cessive oil leaks. (Refer to Paragraph 14.)
TORQUEFLITE
Tire Axle Engine output Pinion

Modd Size Ratio No. Cyl. Shaft Teeth Teeth Color
Valiant
w-1 650- 13 2.93:l 6 7 17 Orange
3.23:l 6 7 19 Dark Blue
3.55: 1 6 7 20 Green
Plymouth 700-14 2.76: 1 6 7 16 Brown
VP- 1 2.93:l 6 7 16 Brown
3.23:l 6 7 18 Dark Purple
3.31:l 6 7 18 Dark Purple
Plymouth 700- 14 2.76: 1 8 8 17 Orange
VP-2 2.93:l 8 8 18 Dark Purple
3.23:l 8 8 20 Green
3.55:l 8 8 20 Green
SERVICING OPERATIONS WITH TRANSMISSION IN VEHICLE

Various transmission components can be removed described in Paragraph 31.
for repairs without removing the transmission from Heli-Coil inserts are recommended for repairing
the vehicle. The removal, reconditioning and installa- damaged, stripped or worn threads in the aluminum
tion procedures for these components are covered parts. (Refer to Paragraph 27.)
.here, except the valve body reconditioning, which is
SERVICE PROCEDURES
17. SPEEDOMETER PINION sion flange.
Removal a h i Instalbtlkm (2) Hold the transmission flange with Tool C-3281
and remove the retaining nut and washer (Fig. 36).
(1) Remove the screw and retainer securing the Slide the flange off the output shaft. (Use puller, Tool
speedometer cable to the extension housing. Carefully C-452 if necessary.)
work the pinion and sleeve assembly out of the hous-
(3) Six Cylinder Vehicles: Drive Tool (2-3899
ing (Fig. 34).
through the output shaft oil seal to remove the rubber
(2) To replate sth8 fjifiibn dntl/or oil seal, pry the lips from the seal (Fig. 37). Screw taper threaded end
clip off the pinion and slide the pinion assembly off
the cable. Install a new seal on thecable housing.
(3) If transmission fluid is found in the cable hous- INNER
ing, replace the seal inside the pinion bore (Fig. 35). PINION [L /C3FiFR
Pry the old seal out of the pinion bore. Place a new
seal on the end of the cable with the lip toward the
cable, then slide the pinion over the seal and cable. CABLE
Secure with the spring clip.
o::T&
??L-.,. /
(4) To install, push the pinion and sleeve assembly
into the extension housing so the sleeve flange is
tight against the housing, then install the retainer
and screw. Tighten the screw to 150 inch-pounds
torque.
F
CLIP
./
RETAINER
4%u
4-4
BOLT l
-**
-?
18. OUTPUT SHAFT OIL SEAL 6 1 X359
Replacement Fig. 3LSpeedometer Pinion (Disassembled)

(1) Disconnect the propeller shaft at the transmis-
RI
1
60 x 182
\
60 x 186
Fig. 3LRemoving or Installing Output Shaft
Fig. 3LRemoving or Installing Speedometer Pinion Flange Nut
PROTECTOR
I 1
SEAL DRIVER
60x389
Fig. 39-Installing Output Shaft Oil Seal

(Six Cylinder Cars)
63x577 19. EXTENSION HOUSING

Fig. 37-Removing Rubber l i p from Output Shaft Seal
Removal
(Six Cylinder Can) (1)Remove the speedometer drive pinion and
sleeve assembly. (See Paragraph 17.)
of the Tool C-3753into the seal (Fig. 38),then tighten (2) Remove the transmission flange. (See Paragraph
the screw of the tool to remove the seal. Blow loose 18.)
particles of the old seal out of the extension hous- (3)Drain approximately two quarts of fluid from
ing. the transmission.
Eight Cylinder Vehicles: Screw taper threaded end
(4)Loosen the parking lock cable clamp bolt where
of Tool C-748into the seal (Fig. 38),then tighten the
the cable enters the housing cover. Refer to Fig. 19.
screw of tool to remove the seal.
Tap the end of clamp bolt lightly to release its hold
(4) Six Cylinder Vehicles: To install a new seal, on the cable. Remove the housing cover lower plug.
slide protector sleeve Tool C-3768 over the output Insert a screw driver through the hole, then while
shaft splines, then drive in the seal (lip side facing exerting pressure against the projecting portion of
inward) with Tool C-3754(Fig. 39). the cable lock-spring, withdraw the lock cable.
Eight Cylinder Vehicles: To install a new seal, posi-
(5) Remove the two bolts securing the extension
tion the seal in opening of extension housing with
housing to the crossmember insulator.
lip of the seal facing inward. Drive the seal into
housing with Tool C-3837(Fig. 40). (6)Raise the transmission slightly to clear the
crossmember with service jack, Tool C-3203A. Re-
(5) Install the transmission output shaft flange. In-
move the crossmember attaching bolts and remove
stall the washer with its three projections toward
the crossmember, insulator and spring assembly.
the flange and the nut with its convoluted surface
contacting the washer. Hold the flange with Tool C- (7)Remove the extension housing to transmission
3281,and tighten the nut to 175 foot-pounds torque. bolts, tap the housing lightly with a soft mallet to
break it loose from the transmission, then remove
(6)Connect the propeller shaft to the transmission
the housing.
flange.
62x178
Fig. 40--lnstalling Output Shaft Oil Seal
Fig. 38-Removing Output Shaft Oil Seal (Eight Cylinder Cars)
(4)Place a new seal in the opening of the extension
housing (lip of seal facing inward). Using Tool C-
3837, drive the seal into the housing until tool bot-
toms (Fig. 40).
lnsf allation
(1) Using a new gasket, carefully slide the exten-
sion housing into place, install the retaining bolts and
washers, tighten bolts to 24 foot-pounds torque.
(2) Install the crossmember, insulator and spring
assembly. Tighten the crossmember attaching bolts
to 75 foot-pounds torque. Lower the transmission so
the extension housing rests on, and is aligned with
the insulator. Install the insulator to extension hous-
ing bolts and tighten to 35 foot-pounds torque.
Fig. 41-Removing Output Shaft Bearing (3) Install and adjust the parking lock cable. (Refer
(Eight Cylinder Cars) to Paragraph 10.)
(4)Install the transmission flange and connect the
Bearing Replacement [Eight Cylinder propeller shaft. Refer to Paragraph 18,(Step 5.)
Vehicles I
(5)Install the speedometer drive pinion and sleeve.
Note: To replace the bushing in the transmission
(6) Add fluid to the transmission to bring it up to
extension housing, (Six Cylinder vehicles) refer to
”Recondition Sub-Assem bl ied‘, Paragraph 33.
the proper level. (Refer to Paragraph 4.)
(1) Pry or drive the oil seal out of the extension 20. GOVERNOR
housing with a long blunt drift. Be sure not to mar
the oil seal surface in the housing. Removal
(2)Remove the bearing snap ring from the exten- (1) Remove the extension housing. (See Paragraph
sion housing. Drive the bearing rearward out of the 19.)
housing with Tool C-3275(Fig. 41). (2)Using a screw driver carefully pry the snap
(3) Place a new bearing in the opening of the ex- ring from the weight end of the governor valve shaft
tension housing. Using Tool C-3204,drive the bearing (Fig. 43). Slide the valve and shaft assembly out of
into housing (Fig. 42). Install the bearing retaining governor body.
snap ring. (3) Remove the large snap ring from weight end
of the governor body, lift out the governor weight
assembly.
(4)Remove the snap ring from inside the governor
SNAP RING
62x179 Ls-’’’y’ GOVERNORBODY’ F q

GOVERNOR SUPPORT AND-
PARKING GEAR 6Ox18OB
Fig. 42-Installing Output Shaft Bearing
(Eight Cylinder Cars) Fig. 43-Governor Shaft and Weight Snap Rings
27 - 6 0 TRANSMISSION-TORQUEFLITE
weight, remove inner weight and spring from the

outer weight. Figure 44 shows a disassembled view of
the governor assembly.
(5) Remove the snap ring from behind the gover-
nor body, then slide the governor and support as-
sembly off the output shaft. If necessary remove the
four bolts and separate governor body from the sup-
port.
Cleaning and Inspection
The primary cause of the governor operating fail-
ure is due to a sticking governor valve or weights.
Rough surfaces may be removed with crocus cloth.
Thoroughly clean all parts in clean solvent and in-
spect for free movement before assembly.
Fig. 4+Removing or Installing Rear Oil Pump
/nstallation
Inner Rotor
(1) Assemble the governor body to the support (if
disassembled) and tighten bolts finger tight. Make
free movement after installation.
sure oil passage of the governor body aligns with
passage in the support. (5) Install the extension housing, transmission
flange and connect the propeller shaft.
(2) Position the support and governor assembly on
the output shaft. Align the assembly so the governor (6) Connect and adjust the parking lock cable. (Re-
valve shaft hole in the governor body aligns with fer to Paragraph 10).
the hole in the output shaft, then slide the assembly
into place. Install snap ring behind the governor body 21. REAR OIL PUMP
(Fig. 43). Tighten the body to support bolts to 100 Removal
inch-pounds torque. Bend ends of lock straps over the
bolt heads. (1) Remove the extension housing. See Paragraph
19.
(3) Assemble the governor weights and spring, and
secure with snap ring inside of the large governor (2) Remove the governor and support. See Para-
weight. Place the weight assembly in the governor graph 20.
body and install snap ring. (3) Unscrew the rear oil pump cover retaining bolts
(4)Place the governor valve on the valve shaft, and remove the cover.
insert the assembly into the body and through the (4)The oil pump inner rotor is keyed to the output
governor weights. Install the valve shaft retaining shaft by a small ball, therefore, use care in sliding
snap ring. Inspect the valve and weight assembly for out the inner rotor so as not to lose the ball (Fig. 45).
Remove the outer rotor from the pump body.
NOTE: If the rear oil pump body requires replace
SPRING
ment, it will be necessary to disassemble the trans-
mission as the pump body must be driven rearward
out of the case with a wood block.
VALVE inspection
Inspect the oil pump body and cover machined
SNAP surfaces for nicks and burrs. Inspect the rotors for
RINGS
scoring or pitting. With the gears cleaned and install-
ed in the pump body, place a straight edge across the
face of rotors and pump body. Using a feeler gauge,
measure the clearance between the straight edge and
face of the rotors. Clearance limits are from .0015
61x358
to .003inch.
installation
:Fig. 4AGovernor Assembly (Disassembled) (1) Place the outer rotor in the pump body.
w 1 LEVER AND ADAPTER
REAR OIL PUMP CHECK
!I A1
-
TOOL’
OIL PUMP COVER AG

p
64x18
Fig. 46-Aligning Rear Oil Pump Cover Fig. 47-Removing or Installing Parking Lock lever
and Cable Adapter
(2) Turn the output shaft so the inner rotor driving
ball pocket is up. Install the ball and slide the inner port gear and the spring is positioned so as to lift
rotor on the output shaft in alignment with the ball the sprag away from the gear.
(Fig. 45).
(2) Position the lock lever, spacer and cable adapt-
(3) Install the oil pump cover with the retaining er assembly in the extension housing and install the
bolts threaded in a few turns. Slide the aligning fix- lever shaft (Fig. 47). The lever roller must be on top
ture Tool C-3864 (8-cylinder vehicles) or Tool C-3762 of the sprag so as to push it into engagement with
(6- cylinder vehicles) all the way in until it bottoms the support gear. Install and tighten the plug to 150
against the rotors (Fig. 46), then retighten the cover inch-pounds torque.
bolts evenly to 140 inch-pounds torque. (3) Insert a small punch through the cable open-
(4) Install the governor and support. (See Para- ing in the adapter cover and into end of the adapter.
graph 20.) Carefully lower the cover into position, feeding the
(5)Install the extension housing, transmission adapter into the cable opening in the cover. Install
flange and connect the propeller shaft. the cover retaining screws and tighten to 150 inch-
(6) Connect the parking lock cable. pounds torque.
(4) Install the extension housing, transmission
22. PARKING LOCK COMPONENTS flange and connect the propeller shaft.
Removal (5) Connect the parking lock cable. (See Paragraph
10.)
(1) Remove the extension housing. See Paragraph
19.
(2) To replace the parking lock support gear, refer
to Paragraph 20.
(3) Remove the parking lock cable adapter cover
from the bottom of the extension housing.
(4) Remove the plug from the extension housing,
slide out the shaft to remove the parking lock lever,
spacer and cable adapter (Fig. 47). Replace the adapt-
er spring if it is distorted.
(5)Slide the bushing sleeve out of the housing to
remove the parking sprag and spring (Fig. 48).
I nstallafion
(1) Position the parking sprag and spring in the
housing and insert the bushing sleeve (Fig. 48). Make
sure the square lug on the sprag is toward the sup- Fig. 48-Removing or Installing Parking Sprag
23. NEUTRAL STARTING S W I T C H lnst allatton

Replacem ent (1) Clean the mating surfaces and inspect for burrs
(1) Disconnect the wire from the switch, unscrew on both the transmission case and valve body steel
the switch allowing the fluid to drain into a container. plate.
(2) Push Button Control: Place the cupped washer (2) Install the accumulator piston in the transmis-
and “0”ring over the threads of the switch (Fig. sion case.
21), then screw the switch into the transmission case (3) Position the accumulator spring on the valve
a few turns. Refer to Paragraph 11 for complete Ad- body.
justment and Test. (4) Carefully position the valve body assembly in
(3) Console Shift: Place the seal assembly over the the transmission case, install the retaining bolts and
threads of the switch (Fig. 22), then install and tight- tighten finger tight. With the neutral starting switch
en the switch 25 to 35 foot-pounds torque. Refer to installed, place the manual valve in the neutral posi-
Paragraph 11for complete adjustment and test. tion. Shift the valve body if necessary to center the
(4) Add fluid to the transmission to bring it up to neutral finger over the neutral switch plunger. Snug
proper level. Refer to Paragraph 4. the bolts down evenly, then tighten to 100 inch-pounds
NOTE: Test the starter for operating in all push
torque.
button or selecter lever positions. If it should oper- (5) Connect the control cable adapter to the valve
at& in any position other than push button neutral or body manual lever and install the retaining nut. Con-
selector lever park and neutral, readjust the gearshift nect the gearshift control cable. Refer to Paragraph 9.
control cable. Refer to Paragraph 9. In some cases, it (6) Install the seal, flat washer and throttle lever
may be necessary to align the valve body neutral on the throttle shaft. Tighten the clamping bolt. In-
and/or park fingers with the switch plunger. Refer to spect the throttle lever for looseness by forcing it in
Paragraph 24. both directions.
(7) Install the oil pan, using a new gasket.
24. VALVE B O D Y ASSEMBLY AND
ACCUMULATOR PISTON (8) Add fluid to the transmission to bring it up to
proper level. (Refer to Paragraph 4.)
Removal
(1) Raise the vehicle on a hoist. 25. TRANSMISSION AND CONVERTER
(2) Loosen the oil pan bolts, tap the pan to break REMOVAL AND INSTALLATION
it loose allowing the fluid to drain, then remove the
CAUTION: The transmission and converter must
oil pan.
be removed and installed as an assembly; otherwise,
(3) Loosen the clamp bolt and lift the throttle the converter drive plate, front pump bushing, and
lever and washer off the transmission throttle lever oil seal will be damaged. The drive plate will not
shaft. support a load; therefore, none of the weight of the
(4) Disconnect the gearshift control cable. Refer to transmission should be allowed to rest on the plate
Paragraph 9. Shift the valve body manual lever to the during removal or installation.
1 (low) position to expose the nut securing the cable
adapter to the lever (Fig. 23). Remove the nut and Removal
disengage the cable adapter from the manual lever. (1) Connect a remote control starter switch, Tool
(5) Place a drain pan under the transmission, then C-763 to the starter solenoid and position the switch.
remove the ten hex-head valve body to transmission so the engine can be rotated from under the vehicle.
case bolts. Hold the valve body in position while re- (2) Disconnect the high tension wire from the dis-
moving the bolts. tributor cap.
(6) Lower the valve body assembly down out of the (3) Place the parking lock lever (if so equipped) in
transmission, being careful not to cock the throttle the OFF position, then raise the vehicle on a hoist
lever shaft in the case hole or lose the accumulator or support with stands.
spring. (4) Remove the cover plate from in front of the
(7) Withdraw the accumulator piston from the converter assembly to provide access to the converter
transmission case. Inspect the piston for scoring, and drain plug and mounting bolts.
the rings for wear or breakage. Replace as required. (5) Rotate the engine with the remote control
NOTE: Servicing the valve body assembly is out- switch to bring the drain plug to “6 o’clock” position.
lined in Paragraph 31. Drain the torque converter and transmission.
TRANSMISSION-TORQUEFLITE TORQUE CONVERTER 2 1-63
(6)Mark the converter and drive plate to aid in
reassembly. The crankshaft flange bolt circle, the
inner and outer circle of holes in the drive plate, and
the four tapped holes in the front face of the con-
verter all have one hole offset so these parts will
be installed in the original position. This maintains
the balance of the engine and converter.
(7) Rotate the engine with the remote control
switch to locate two converter to drive plate bolts at
“5 and 7 o’clock” positions. Remove the two bolts
rotate the engine with switch and remove the other
two bolts.
CAUTION: Do not rotate the converter or drive
plate by prying with a screw driver or similar tool
as the drive plate might become distorted. Also, the
starter should never be engaged if the drive plate is
not attached to the converter with at least one bolt
or if the transmission case to engine bolts have been Fig. 49-Engine lifting Fixture (6 Cyl. Engine)
loosened.
(8)Disconnect the negative (ground) cable from the (19)Install an engine support fixture, Tool C-3487
battery. (8 cyl. engine) or Tool C-3809 (6 cyl. engine) and
(9)Remove the starting motor assembly. raise the engine slightly (Fig. 49 or 50).
(10) Disconnect the wire from the neutral starting (20)Remove the crossmember attaching bolts and
switch. remove the crossmember, insulator and spring assem-
(11)Remove the push button gearshift control ca- bly.
ble to transmission adjusting wheel lock screw. Pull (21)Place a transmission service jack under the
the control cable out of the transmission case as far transmission to support the assembly.
as possible, back off the adjusting wheel a few turns (22)Attach a small “C” clamp to edge of the bell
if necessary. housing to hold the converter in place during remov-
(12)Insert a small screw driver above and slightly al of the transmission.
to the right of the control cable (Fig. 18). Disengage (23)Remove the bell housing retaining bolts. Care-
the cable adapter lock spring by pushing the screw fully work the transmission rearward off the engine
dr,ver handle to the right while pulling outward on block dowels and disengage the converter hub from
the cable. the end of the crankshaft.
(13) Disconnect the throttle rod from the throttle (24) Lower the transmission jack and remove the
lever on the transmission. transmission and converter assembly.
(14)Disconnect the oil cooler lines at the transmis- (25)To remove the converter assembly, remove the
sion and remove the oil filler tube.
(15)Remove the speedometer pinion and sleeve as-
sembly from the transmission (Fig. 34).
(16) Loosen the transmission parking lock cable
clamp bolt where the cable enters the cover (Fig. 19).
Tap the end of the clamp bolt lightly to release its
hold on the cable. Remove the housing cover lower
plug. Insert a screw driver through the hole, then
gently exert pressure against the projecting portion of
the cable lock-spring and withdraw the lock cable.
(17) Disconnect the front universal joint and se-
cure the propeller shaft out of the way.
(18)Remove the two bolts securing the extension
housing to the crossmember insulator. Fig. 5GEngine lifting Fixture (8 Cyl. Engine)
2 1-64 TRANSMISSION-TORQUEFLITE TORQUE CONVERTER
OOL
.I
I
-1
I
’21I
NMENT
S
4
Fig. 51-Aligning Front Pump Rotors Fig. 52-Measuring Converter for Full Engagement
in Transmission
“C” clamp from the edge of the bell housing, then
carefully slide the assembly out of the transmission. of the plate. A stamped V mark identifies the offset
hole in the converter front cover (Fig. 53). Carefully
Converter lnsfallation work the transmission assembly forward over the en-
(1) Rotate the front pump rotors with Tool (3-3756 gine block dowels with the converter hub entering
(Six Cylinder Vehicles) or Tool C-3881 (Eight Cylinder the crankshaft opening.
Vehicles) until the two small holes in the handle are (4) After the transmission is in position, install the
vertical (Fig. 51). bell housing bolts and tighten 25 to 30 foot-pounds
(2) Carefully slide the converter assembly over torque.
the input shaft and reaction shaft. Make sure the (5) Install and tighten the two lower drive plate
converter impeller shaft slots are also vertical and to converter bolts to 270 inch-pounds torque.
fully engage the front pump inner rotor lugs.
Test for full engagement by placing a straight edge
on the face of the case (Fig. 52). The surface of the
converter front cover lug should be at least $5 inch
to the rear of the straight edge when the converter is
pushed all the way into the transmission.
(3) Attach a small “C” clamp to the edge of the bell
housing to hold the converter in place during the
transmission installation.
lnstaNation
(1) Inspect the converter drive plate for distortion
or cracks and replace if necessary.
(2) Coat the converter hub hole in the crankshaft
with wheel bearing grease. Place the transmission
and converter assembly on a service jack and position
the assembly under the vehicle for installation. Raise
or tilt as necessary until the transmission is aligned
with the engine.
(3) Rotate the converter so the mark on the con-
verter (made during removal) will align with the ‘* MARK
mark on the drive plate. The offset holes in the plate - - - -. .. . --

are located next to the 9’s inch hole in the inner circle Fig. 513-Converter and Drive Plate Markings
TRANSMISSION-TORQUEFLITE TORQUE CONVERTER 2 1-65
(6) Install the starting motor and connect the bat- (13) Connect the throttle rod to the transmission
tery ground cable. throttle lever.
(7)Rotate the engine with the remove control (14)Have an assistant engage and hold in firmly,
switch and install the other two drive plate to con- the R (reverse) button or place the console selector
verter bolts. Tighten the bolts to 270 inch-pounds lever in the park position. Insert the control cable in
torque. the transmission case, push inward on the cable
(8)Install the crossmember, insulator and spring making sure the lock spring engages the cable. In-
assembly. Tighten the crossmember attaching bolts stall the control cable adjusting wheel lock screw.
to 75 foot-pounds torque. Lower the transmission so (15)Connect the wire to the neutral starting swtich.
the extension housing rests on, and is aligned with (16)Install the cover plate in front of the conver-
the insulator. Install the insulator to extension hous- ter assembly.
ing bolts and tighten to 35 foot-pounds torque.
(17).Install the transmission case to cylinder block
(9) Insert a screw driver through the parking lock brace.
cover plug opening and position it behind the cable
adapter stop washer (Fig. 20). Hold the adapter out- NOTE: The converter cover plate must be between
ward while pushing the cable in as far as possible, the case and the brace. The oil line bracket is at-
making sure the lock-spring engages the cable. Gently tached in front of the brace. Tighten the bolts holding
pull outward on the cable housing to its limit of travel, the brace to the case‘before attaching brace to
release, then tighten the clamp bolt to 10 inch-pounds the cylinder block.
torque. Remove the screw driver and reinstall the plug (18)Refill the transmission with Automatic Trans-
in the cover. mission Fluid Type “A” Suffix “A”. Refer to Para-
(10) Connect the propeller shaft to the front com- graph 4 for complete transmission filling instruc-
panion flange. tions.
(11)Install the speedometer drive pinion and NOTE: To completely adjust the throttle linkage,
sleeve. gearshift control cable; and neutral starting switch,
(12) Connect the oil cooler lines to the transmis- refer to “Maintenance, Adjustments and Tests”, Par-
sion and install the oil filler tube. agraphs 9 , l l and 13.
RECONDITION THE TRANSMISSION U N I T O U T OF THE VEHICLE

The following reconditioning paragraphs cover the In the event that any part has failed in the trans-
removal, disassembly, inspection, repair, assembly mission, the torque converter should be flushed to
and installation procedures for each sub-assembly in insure that fine metal particles are not later trans-
detail. ferred back into the reconditioned transmission.
SERVICE PROCEDURES
26. FLUSHING THE TORQUE CONVERTER 27. ALUMINUM THREAD REPAIR
The torque converter must be removed from the Damaged or worn threads in the aluminum trans-
vehicle for flushing, as the converter should never be mission case and valve body can be repaired by the
rotated by the starter with the transmission removed. use of Heli-Coils. Essentially, this repair consists of
drilling out the worn or damaged threads, tapping the
(1) Place the torque converter in an upright posi-
hole with a special Heli-Coil Tap, and installing a
tion and pour two quarts of new clean solvent or
Heli-Coil insert into the tapped hole. This brings the
kerosene into the converter through the impeller
hole back to its original thread size.
hub.
The chart lists the threaded hole sizes which are
(2) Turn and shake the converter so as to swirl the used in the aluminum case and valve body, and the
solvent through the internal parts. Turning the tur- necessary tools and inserts for the repair of damaged
bine and stator with the transmission input and reac- or worn threads. Heli-Coil tools and inserts are read-
tion shafts will aid in dislodging foreign material. ily available from most automotive parts jobbers.
(3) Position the converter in its normal operating NOTE: Some thread drag may occur in screwing a
position with the drain plug at the lowest point. Re- bolt into the installed Heti-Coil insert. Therefore, a
move the drain plug and drain the solvent. Rotate the torque reading should be taken of the thread drag
turbine and stator, and shake the converter while with an inch-pound torque wrench and added to the
draining to prevent dirt particles from settling. specified bolt torque, so that all bolts securing a
(4) Repeat the flushing operation at least once, or particular part will be tightened to the same torque.
as many times as required until the solvent or kero-
sene drained out is clear. 28. FRONT PUMP OIL SEAL
( 5 ) After flushing, shake and rotate the converter Replacement
several times with the drain plug out to remove any The front pump oil seal can be replaced without re-
residual solvent and dirt. Flush any remaining solvent moving the front pump and reaction shaft support
from the converter with two quarts of new transmis- assembly from the transmission case.
sion fluid. This will prevent any adverse effect the NOTE: The vent shield is not used or required on
solvent may have on the transmission seals. Reinstall the (Six Cylinder Vehicles) front pump. See Figures
the drain plug and tighten to 14 foot-pounds torque. 54 and 55.
HEM-COIL CHART
~~
INSERTING EXTRACT-
Thread Part Insert Part Part Part
~~~~
10-24 1 185-2 .285" '%" (.203") 3 CPB 528-3N 1227-6

'/4 -20 1 185-4 %" l%" (.265") 4 CPB 528-4N 1227-6
%-I 8 1 185-5 1%" Q (.332") 5 CPB 528-5N 1227-6
34-16 1 185-6 %6" x (.397") 6 CPB 528-6N 1227-6
%6- 1 4 1 185-7 'lh" ' 9 h " (.453") 7 CPB 528-7N 1227-16
the exterior of the unit, preferably by steam. Clean-
liness through the entire disassembly and assembly
cannot be over-emphasized. When disassembling, each
part should be washed in a suitable solvent, then
dried by compressed air. Do not wipe parts with shop
towels. All of the mating surfaces in the transmis-
sion are accurately machined; therefore, careful han-
dling of parts must be exercised to avoid nicks or
burrs.
Oil Pan
(1) Place the transmission assembly in a repair
stand, Tool C-3750 with adapter C-3882 (Fig. 56). The
adapter is not used with the Six Cylinder Vehicle
transmission.
(2) Unscrew the oil pan bolts and remove the oil
2d pan and gasket.
62x1 83
Fig. S&Removing Front Pump Oil Seal

Valve Body Assembly
(1) Unscrew the nut and remove the control cable
adapter from the valve body manual lever (Fig. 23).
(1) Screw seal remover Tool C-3758 (Six Cylinder
Vehicles) or Tool C-3861 (Eight Cylinder Vehicles) into (2) Remove the ten hex-head valve body asssembly
the seal (Fig. 54). Tighten screw portion of the tool to transmission case bolts (Fig. 23). Hold the valve
to withdraw the seal. body in position while removing the bolts.
(2) To install a new seal, place the seal in the open- (3) Lift the valve body asssembly out of the trans-
ing of the pump housing (lip side facing inward). Us- mission case, being careful not to cock the throttle
ing Tool C-3757 (Six Cylinder Vehicles) or Tool C-3860 lever shaft.
(Eight Cylinder Vehicles), drive seal into housing until Accumulator Piston and Spring
the tool bottoms (Fig. 55).
(1) Lift the spring off the accumulator piston and
withdraw the piston from the case.
29. REMOVAL OF SUB-ASSEMBLIES
Prior to removing any of the transmission sub-as-
semblies, plug all the openings and thoroughly clean
62x184
Fig. 55--.lnrtalling Front Pump Oil Seal Fig, 56-Transmission Installed in Repair Stand
the transmission bell housing with its plunger seated

against the end of the input shaft (Fig. 58). Chuck the
input shaft in and out to obtain end play reading. End
play specifications are .030 to .069 inch.
(2) Record the indicator reading for reference
when reassembling the transmission (Refer to Para-
graph 49).
Extension Housing
(1) Hold the transmission flange with Tool C-3281,
and remove the retaining nut and washer (Fig. 36).
Slide the flange off the output shaft (Use puller, Tool
C-452 if necessary).
(2) Remove the extension housing to transmission
bolts, tap the housing lightly with a soft mallet to
Fig. 57-Measuring Drive Train End Play (Six Cyl. Cars) break it loose from the transmission, then carefully
remove the housing.
Measuring Drive Train End Play
Governor and Support
Measure the drive train end play before removal of (1) Using a Screw driver, carefully pry the snap
the output shaft universal joint flange. This will usu- ring from the weight end of the governor valveshaft
indicate when a change in the thrust washer is (Fig. 43). Slide the valve and shaft assembly out of the
required to properly adjust end play during assembly governor body.
(except when major parts are replaced). The thrust
washer is located between the reaction shaft support (2) Remove the snap ring from behind the governor
and the front clutch retainer on Eight Cylinder body, then slide the governor body and support as-
vehicles. The thrust washer i s located between the sembly off the output shaft.
input and output shafts on Six Cylinder Vehicles. Rear Oil Pump
(1) Six Cylinder Vehicles: Attach a dial indicator to (1) Unscrew the rear oil pump cover retaining
the extension housing with its plunger seated against bolts and remove the cover.
the companion flange (Fig. 57). Chuck the output (2) The oil pump inner rotor is keyed to the output
shaft in and out to obtain end play reading. End play shaft by a small ball. Use care in sliding out the inner
specifications are .024 to .069 inch. rotor so as not to lose the ball (Fig. 45). Remove the
Eight Cylinder Vehicles: Attach a dial indicator to
outer rotor from the pump body.
TRANSMISSION
NOTE: If replacement of the rear oil pump body
L ,. VENT SHIELD is required, drive it rearward out of the case with a
wood block after the transmission has been disassem-
bled.
Front Oil Pump and Reaction

Shaft Support
Ai ( 1 ) Remove the front oil pump housing retaining

bolts.
(2) Tighten the front band adjusting screw until
the band is tight on the front clutch retainer. This
prevents the clutch retainer from coming out with
the pump which might cause unnecessary damage to
the clutches.
(3) Attach Tool C-3752 to the pump housing flange,
as shown in Figure 59, install the tool in the threaded
holes in the pump flange.
01
1 (4) Bump outward evenly on the two “knocker
Fig. 58-Measuring Drive Train End Play weights” to withdraw the oii pump and reaction shaft
(Eight Cyl. Cars) support assembly from the case.
TRANSMISSION-TORQUERITE 2 1-69
TRANSMISSION VENT ,% NOTE: If the overrunning clutch cam and/or rol-

ler spring retainer are found damaged or worn, refer
to Paragraph 46 for replacement procedures.
Kickdown Servo
(1) Compress the kickdown servo spring by using
engine valve spring compressor, Tool C-3422, then
remove the snap ring (Fig. 60).
(2) Remove the rod guide, springs and piston rod
from the case. Be careful not to damage the piston
rod or guide during removal.
(3) Insert Tool (2-484 inside the piston and with-
draw the piston from the transmission case.
Low and Reverse Servo
62x19
v TOOL
(1) Compress the low and reverse servo piston
spring by using engine valve spring compressor, Tool
C-3422, then remove the snap ring.
‘Fig. 59-Removing Front Oil Pump and Reaction (2) Remove the spring retainer, spring, and servo
Shaft Support Assembly piston and plug assembly from the case.
Front Band and Front Clutch 30. RECONDITION SUB-ASSEMBLIES

(1) Loosen the front band adjuster, remove the The following procedures cover the disassembly,
band strut and slide the band out of the case. inspection, repair, and assembly of each sub-assembly
(2) Slide the front clutch assembly out of the case. as removed from the transmission.
Pre-sized service bushings are available for replace-
lnput Shaft and Rear Clutch ment for most all bushings in the TorqueFlite trans-
(1) Grasp the input shaft, and slide the input shaft mission. The two bushings in the sun gear are not
and rear clutch assembly out of the case. serviced because of the low cost of the sun gear as-
sembly. If the bushings are found worn or scored,
NOTE: Be careful not to lose the thrust washer they should be replaced as outlined in the following
located between the rear end of input shaft and for-
ward end of the output shaft.
Planetary Gear ssemblies, Sun Gear,

Driving Shell
(1) While supporting the output shaft and driving
shell, carefully slide the assembly forward and out
through the case.
NOTE: Be very careful not to damage the ground
surfaces on the output shaft during removal.
Rear Band and Low-Reverse Drum

(1) Remove the low-reverse drum, then loosen the
rear band adjuster, remove the band strut and remove
the band from the case.
Overrunning Clutch
(1) Note the position of the overrunning clutch
rollers and spring before disassembly to assist in
reassembly.
(2) Carefully slide out the clutch hub and remove
the rollers and springs. Remove the low and reverse 173
drum thrust washer (Six Cylinder Vehicle) from in-
side the overrunning clutch case. ‘Fig. 6GCompressing Kickdown Servo Spring
Y _
>,
9
T. C. CONTROL
b VALVE SPRING
I
,
3
64x19
Fig. 61-Removing or Installing Oil Filter Fia. 62-Regulator and Converter Control Valves
(Assembled View)
reconditioning procedures.
The bushing replacement tools listed by “SP” num- 31. VALVE B O D Y ASSEMBLY
bers are part of Tool Kit C-3887. Disassembly
The use of crocus cloth is permissible where neces- CAUTION: Never clamp any portion of t h e valve
sary, providing it is used carefully. When used on the body o r transfer plate in a vise. Any slight distortion
valves, use extreme care to avoid rounding off the of t h e aluminum body o r t h e transfer plate will result
sharp edges. The sharp edge is vitally important to in sticking valves, excessive leakage o r both. When
this type valve. Sharp edges prevent dirt and foreign removing o r installing valves or plugs, slide them in
matter from getting between the valve and body, thus or out carefully. Do not use force.
reducing the posssibilities of sticking. When it be-
(1) Place the valve body assembly on repair stand,
comes necessary to recondition the transmission, and
Tool C-3749(Fig. 61). Remove three screws from the
the vehicle has accumulated considerable mileage,
oil filter and lift off the filter and gasket.
install new seal rings on parts requiring their usage.
(2) While holding the spring retainer bracket firm-
NOTE: Coat each p a r t with Automatic Transmis- ly against the spring force, remove the three bracket
sion Fluid Type ”A” Suffix “ A during assembly. retaining screws (Fig. 62).
STEEL PLATE STIFFENER PLATE
REVERSE BLOCKER
TRANSFER PLATE VALVE AND COVER 60x368 A
Fig. 63-Transfer and Steel Separator Plate Assembly (Disassembled)

TRANSMISSION-TORQUEHITE 2 1-71
/
Fig. L A F r o n t Pump Check Valve and Steel 62x32A
THROTTLE LEVER
STOP SCREW ' \MANUAL LEVER
THROTTLEVALVE
GOVERNOR
END PLATE
PLUG
Ball location
'Fig. 65-Valve Body Controls (Assembled View)
(3) Remove the spring bracket, torque converter
control valve spring, and the regulator valve spring (6) Invert the transfer plate assembly and remove
with line pressure adjusting screw assembly. the stiffener plate. Remove remaining screws securing
NOTE: Do not alter the setting of the line pressure the steel plate to transfer plate, and carefully lift off
adjusting screw and nut. The nut has an interference the steel plate (Fig. 63). Remove the rear pump check
thread and does not turn easily on the screw. valve and spring.
(4) Slide the regulator valve out of the valve body. (7) Remove the reverse blocker valve cover and lift
Slide the torque converter control valve out of the out the spring and valve.
valve body. (8) Note location of the six steel balls in the valve
(5) Remove the 14 transfer plate retaining screws. body, one is larger than the other five and is in the
Carefully lift the transfer plate and steel plate as- larger chamber (Fig 64). Remove the steel balls,
sembly off the valve body. front pump check valve and spring.
SPRING
RETAINER
REGULATOR VALVE RACKET
MANUAL VALVE-
TORQUE CONVERTER
CONTROL VALVE \
CONSOLE SHIFT ONLY /
KICKDOWN VALVE LINE PRESSURE

Y+
ADJUSTING SCREW
ASSEMBLY
THROTTLE LEVER
STOP SCREW
l\GOVERNOR PLUG
c
L!#
\t, Ehin
LI*Y
DI A T E
I L n I L
1-2 SHIFT VALVE

:4 \
GOVERNOR PLUG
\
2-3 SHIFT VALVE SHUTTLE VALVE
60x3608
GOVERNOR PLUG THROTTLE PLUG
Fig. &Valve Body-lever Side (Disassembled)

(9) Invert the valve body and lay it on a clean cloth clean solvent. Wash thoroughly and blow dry with
or paper. Remove E-clip from the throttle lever shaft compressed air. Make sure all the passages are clean
(Fig. 65).Remove any burrs from the shaft, then while and free from obstructions.
holding the manual lever detent ball and spring in Inspect the manual and throttle valve operating
their bore with Tool C-3765 or similar tool, slide the levers and shafts for being bent, worn or loose. If
manual lever off the throttle shaft. Remove the detent a lever is loose on its shaft, it may be silver soldered
ball and spring. only, or the lever and shaft assembly should be re-
(10)Remove the manual valve, carefully slide it placed. Do not attempt to straighten bent levers.
out of valve body with a rotating motion. Inspect all mating surfaces for burrs, nicks and
scratches. Minor blemishes may be removed with
(11) Remove the throttle lever and shaft from the
mocus cloth, using only a very light pressure. Using a
valve body.
straight edge, Tool C-3335,inspect all mating surfaces
(12) Remove the shuttle valve cover plate (Fig. 65). for warpage or distortion. Slight distortion may be
Remove the E-clip from the exposed end of the corrected, using a surface plate. Make sure all
shuttle valve. metering hales in the steel plate are open. Using a
(13)Remove the throttle lever stop screw assembly pen light, inspect bores in the valve body for scores,
(Fig. 66), be careful not to disturb the setting any scratches, pits and irregularities.
more than is necessary. Inspect all valve springs for distortion and col-
(14) Remove the kickdown detent, kickdown valve, lapsed coils. Inspect all valves and plugs for burrs,
throttle valve spring and the throttle valve (Fig. 66). nicks and scores. Small nicks and scores may be re-
moved with crocus cloth, providing extreme care is
(15)Remove the governor plug end plate (Fig. 66).
taken not to round off the sharp edges. The sharpness
Tip up the valve body to allow the shuttle valve throt-
of these edges is vitally important because it prevents
tle plug, spring, shuttle valve, and the shift valve
foreign matter from lodging between the valve and
governor plugs to slide out into your hand.
the valve body, thus reducing the possibility of stick-
Note the longer stem on the 1-2 shift valve plug
ing. Inspect all valves and plugs for freedom of oper-
as a means for identification.
ation in the valve body bores. When bores, valves and
(16) Remove the shift valve end plate (Fig. 67)and plugs are clean and dry, the valves and plugs should
slide out the two springs and valves. fall freely in the bores.
(17)Remove the regulator valve end plate. Slide
NOTE: The valve body bores do not change dimen-
the regulator valve line pressure plug, sleeve, and the
sionally with use. Therefore, a vatve body that was
regulator valve throttle pressure plug out of the valve
functioning properly when the vehicle was new, will
body. operate correctly if it is properly and thoroughly
Cleaning and lnspection cleaned. There is no need to replace the valve body
Allow all parts to soak a few minutes in a suitable unless it is damaged in handling.
Assembly
(1)Place the rear pump check valve and-spring in
the transfer plate (Fig. 63).Position the steel plate on
the transfer plate, hold the rear pump check valve
in its bore with a thin steel scale, and install four
steel plate to transfer plate retaining screws. Make
T VALVE sure the bolt holes in the steel plate and transfer
;.”” plate are aligned, then tighten screws evenly to 28
inch-pounds torque. Inspect the rear pump check
valve for free movement in the transfer plate. Install
the stiffener plate and tighten the retaining screws
1-2 SHIFT VALVE to 28 inch-pounds torque.
REGULATOR (2) Turn the transfer plate over and install the
VALVE LINE reverse blocker valve spring and valve (Fig. 63).Ro-
PRESSURE PLUG
/
9
“
-.
.. -. tate the valve until it seats through the steel plate.

REGULATORVALVE SHIFT VALVE/ Hold the valve down and install the blocker valve
END PLATE END PLATE 60x3598
cover plate. Tighten the two remaining screws to 28
Fig. 67-Valve Body-Shift Valve Side (Disassembled) inch-pounds torque.
TRANSMISSl ON-TORQUEFLITE' 2 1-73
(3) Place the 1-2 and 2-3 shift valve governor plugs
in their respective bores (Fig. 66). Install the shuttle
valve, spring and shuttle valve throttle plug. Install
the governor plug end plate and tighten the five
retaining screws to 28 inch-pounds torque.
(4) Install E-clip on end of the shuttle valve (Fig.
66). Install the shuttle valve cover plate and tighten
the four retaining screws to 28 inch-pounds torque. THROlTLE
(5) Install the 1-2 and 2-3 shift valves and springs ' &: LEVER
AND
(Fig. 67). Install the shift valve end plate and tighten
the three retaining screws to 28 inch-pounds torque.
60x382
(6) Install the regulator valve throttle pressure
'Fig. 68-Installing Detent Ball, Spring and
plug, sleeve, and the line pressure plug (Fig. 67). In- Manual Lever
stall the regulator valve end plate and tighten the two
long dimension of nut at right angles to the valve
retaining screws to 28 inch-pounds torque.
body (Fig. 62).
(7) Install the throttle valve and spring (Fig. 66).
(16) Install the spring retainer bracket, making
Slide the kickdown detent and the kickdown valve
sure the converter valve spring is engaged on the
(counterbore side of detent toward valve), then in-
stall the assembly in the valve body. tang and position squarely in the bracket. Tighten the
three bracket retaining screws to 28 inch-pounds
(8) Install the throttle lever stop screw (Fig. 66), torque (Fig. 62).
and tighten the lock nut finger tight.
NOTE: Measure and if necessary, align the spring
(9) Install the manual valve in the valve body (Fig. retainer bracket, as described in Paragraph 15.
66).
(17) Install the oil filter and tighten the three
NOTE: The insert in Figure 66 shows the manual retaining screws to 28 inch-pounds torque. After the
valve used i n transmissions with the console shift. valve M y has been serviced and completely assem-
(10) Install the throttle lever and shaft on the valve bled, adjust the throttle and line pressures, as out-
body (Fig. 68). Insert the detent spring and ball in its lined in Paragraph 15. However, if pressures were
bore in the valve body. Depress the ball and spring satisfactory prior to disassembly, use the original
with Tool C-3765 or similar tool and slide the manual settings.
lever over the throttle shaft so that it engages the
manual valve and detent ball. Install the retaining 32. ACCUMULATOR PISTON AND SPRING
E-clip on the throttle shaft. Inspection
NOTE: The insert in Figure 65 shows the manual Inspect the two seal rings for wear and,make sure
lever used in transmissions with the console shift.
(11) Position the valve body assembly on the hold-
ing stand.
' SCREW
(12) Place the six steel balls in the valve body
chambers with the large ball in the large chamber
(Fig. 64). Place the front pump check valve and spring NUT
in the valve body.

(13) Position the transfer plate assembly on the CUP
valve body. Hold the front pump check valve in its
bore with a thin steel scale. Install the 14 retaining
screws, starting at the center and working outward,
tighten the screws to 28 inch-pounds torque.
(14) Install the torque converter valve and the
regulator valve (Fig. 66).
(15) Position the torque converter valve spring and 62x342A
regulator valve spring over the ends of their respec-
tive valves. Place the line pressure adjusting screw Fig. 69-Replacing Extension Housing Bushing
assembly on the end of the regulator valve spring with (Six Cylinder Cars)
they turn freely in the piston grooves. It is not neces- (3) Slide the bushing sleeve out of the housing to
sary to remove the rings unless conditions warrant. remove the parking sprag and spring (Fig. 48).
Inspect the piston for nicks, burrs, scores and wear.
inspection
Inspect the piston bore in the case for scores or other
damage. Inspect the piston spring for distortion. Re- Figure 70 shows the parking sprag and lever dis-
place parts as required. assembled.
Inspect the bushing sleeve and shaft for scores and
33. EXTENSION HOUSING BUSHING AND free movement in the housing, and in sprag and lever.
OIL SEAL ( S i x Cylinder Vetaiclesl Inspect the roller for nicks, burrs, and free turning.
Inspect the square lug on parking sprag for broken
Replacement edges or other damage. Replace parts as required.
(1) Drive the oil seal out of the extension housing
with a long blunt drift. Assembly
(2) Drive out the bushing with Tool C-3755 (Fig. (1) Position the parking sprag and spring in the
69). housing and insert the bushing sleeve (Fig. 48). Make
sure the square lug on the sprag is toward the sup-
(3) Slide a new bushing over the ground end of port gear and the spring is positioned so as to lift the
Tool C-3751, then drive the bushing into the housing sprag away from the gear.
with the tool (Fig. 69). Make sure the oil hole of the
bushing aligns with the slot in the housing. (2) Position the lock lever, adapter and spacer in
the housing and install the lever shaft (Fig. 47). The
(4) While holding the screw from turning, tighten lever roller must be on top of the sprag so as to push
the tool nut to draw the burnisher through the bush- it into engagement with the gear.
ing.
(3) Place a new adapter cover gasket on the exten
(5) Place a new oil seal in the opening of the ex- sion housing, then insert a small punch through cable
tension housing (lip of seal facing inward). Using Tool opening in the adapter cover and into the end of
(2-3754, drive the seal into the housing until tool bot- the adapter. Carefully lower the cover into position,
toms (Fig. 39). feeding the adapter into the cable opening in the
cover. Install the cover retaining screws and tighten
34. EXTENSION HOUSING BEARING AND
to 150 inch-pounds torque.
OIL SEAL ( Eight Cylinder Vehicles)
Replacement 36. GOVERNOR AND SUPPORT
(1) Pry or drive the oil seal out of the extension Disassembly
housing with a long blunt drift. Be sure not to mar (1) Remove the large snap ring from the weight
the oil seal surface in the extension housing. end of the governor body, lift out the weight assem-
(2) Remove the bearing snap, ring from the exten- bly.
sion housing. (2) Remove the snap ring from inside the governor
(3) Drive the bearing rearward out of the exten- weight, remove the inner weight and spring from the
sion housing with Tool C-3275 (Fig. 41). outer weight.
(4) Place a new bearing in opening of the exten-
sion housing. Using Tool .C-3204, drive the bearing
into the housing (Fig. 42). Install the bearing retaining
snap ring.
(5) Place a new oil seal in opening of the extension
housing (lip of seal facing inward). Using Tool C-3837,
drive the seal into housing until tool bottoms (Fig.
40).
35. PARKING SPRAG AND LEVER
Disassembly
(1) Remove the parking lock cable adapter cover
the bottom of the extension housing.
(2) Remove the plug and slide the shaft out of the 63x579
extension housing to remove the parking lock lever, Fig. 7GParking Lock Lever, Sprag and Cablo
adapter and spacer (Fig. 47). adapter IDirassembled)
(3) If the lugs on the support gear are damaged, remeasure the clearance between the straight edge and
move the four bolts and separate the support from face of the rotors. Clearance limits are from .0015 to
the governor body. .003 inch.
Cleaning and Inspection Rear Oil Pump Body Replacement
Figure 44 shows a disassembled view of the gover- If replacement of the rear oil pump body is re-
nor assembly. quired, drive it rearward out of the case with a wood
Inspect all parts for burrs and wear. Inspect the block and hammer. The following procedures must
inner weight for free movement in the outer weight, be followed when installing a new rear oil pump body
and outer weight for free movement in the governor or reinstalling the original pump body to prevent
body. Inspect the valve for free movement in the pump body distortion.
governor body. The weights and valve should fall (1) Screw two pilot studs, Tool C-3288 into the
freely in the bores when clean and dry. Rough sur- case to guide the pump body during installation.
faces may be removed with crocus cloth. (2) Chill the pump body in cold water or with ice.
Inspect the governor weight spring for distortion. Quickly position the body over the pilot studs, and
Inspect the lugs on the parking sprag and support drive it firmly into the case with a wood block and
gear for broken edges or other damage. Thoroughly hammer. Remove the pilot studs.
clean all the governor parts in clean solvent and test
for free movement before assembly. 38. FRONT OIL PUMP AND REACTION
SHAFT SUPPORT ( S i x C y l i n d e r Cars 1
Assembly
Disussem bly
(1) If the support was separated from the governor
Figure 71 shows the front oil pump and reaction
body, assemble and tighten the bolts finger tight.
Make sure the oil passage of the governor body aligns shaft support disassembled.
with the passage in the support. (1) Remove the bolts from the rear side of the
(2) Assemble the governor weights and spring, and reaction shaft support and lift the support off the oil
secure with the snap ring inside of the large governor Pump.
weight. Place the weight assembly in the governor (2) Remove the rubber seal ring from the front
body and install the snap ring. pump body flange.
(3) Drive out the oil seal with a blunt punch.
37. REAR OIL PUMP
lnspeetion
Inspection Inspect interlocking seal rings (Fig. 71) on the reac-
Inspect the oil pump body and cover machined sur- tion shaft support for wear or broken locks, make
faces for nicks and burrs. Inspect the rotors for scor- sure they turn freely in the grooves. Do not remove
ing or pitting. With the rotors cleaned and installed rings unless conditions warrant. Inspect the front
in the pump body, place a straight edge across the clutch piston retainer to reaction shaft support thrust
face of rotors and pump body. Use a feeler gauge to washer for wear. Washer thickness should be .043 to
OIL PUMP BODY

/ BOLT AND WASHER
*.\J
i A. REACTION SHAFT SUPPORT --e-,-
I
I
"0' RING
INNER
OUTER ROTOR
THRUST WASHER' r'
Fig. 71-Front Oil Pump and Reaction Shaft Support (Six Cylinder Cars)
.045 inch, replace if necessary. Inspect machined sur-
faces on the oil pump body and reaction shaft s u p
port for nicks and burrs. Inspect the pump body and
reaction shaft support bushings for wear or scores.
Inspect the oil pump rotors for scoring or pitting.
With the rotors cleaned and installed in the pump
body, place a straight edge across face of the rotors
and pump body. Use a feeler gauge to measure the
clearance between the straight edge and face of the
rotors. Clearance limits are from .001 to .0025 inch.
Also, with a feeler gauge, measure the rotor tip clear-
ance between the inner and outer rotor teeth. Clear-
ance limits are from .007 to .012 inch.
Front Pump Bushing Replacement
(1) Place the front pump housing (seal face down)
on a smooth firm surface. Fig. 73-Staking Front Pump Bushing (Six Cyl. Cars)
(2) Place the removing head, Tool SP-3551 in the (6) Drive the bushing into the housing until the
bushing and install the handle, Tool SP-3549 in the tool bottoms in the pump cavity. Be careful not to
removing head (Fig. 72). cock the tool during installation.
(3) Drive the bushing straight down and out of the (7) Stake the bushing in place by using a blunt
pump housing bore. Be careful not to cock the tool punch or similar tool (Fig. 73). A gently tap at each
in the bore. stake slot location will suffice.
(4) Position the new bushing on the installing head, (8) Using a narrow-bladed knife or similar tool,
To01 SP-3624. remove the high points or burrs around the staked
(5) With the pump housing on a smooth clean sur- area (Fig. 73). Do not use a file or similar tool that
face, start the bushing and installing head in the will remove more metal than is necessary.
bushing bore. Install the handle, Tool SP-3549 in the
installing head (Fig. 72). Reaction Shaft Bushing Replacement
In case of a reaction shaft bushing failure, always
inspect the support for wear from the input shaft seal
TOOL HANDLE ring lands. If worn or grooved, replace the support
SP-3549 REMOVING assembly.
HEAD
SP-3551 (1) Assemble the remover Tool SP-3631, the cup
FRONT PUMP / Tool SP-3633, and the hex nut Tool SP-1191.
CAUTION: Do not clamp any part of the reaction
shaft or support in a vise.
TOOL HANDLE
62x343A
Fig. 72-Replacing Front Pump Bushing (Six Cyl. Cars) Fig. 7LReplacing Reaction Shaft Bushing (Six Cyl. Cars)
(2) With the cup held firmly against the reaction ALIGNING TOOL
shaft, thread the remover into the bushing as far as
possible by hand (Fig. 74).
(3) Using a wrench, screw the remover into the
bushing 3 to 4 additional turns to firmly engage the
threads in the bushing.
(4) Turn the hex nut down against the cup to pull
the bushing from the reaction shaft. Thoroughly clean
the reaction shaft to remove the chips made by the
remover threads.
(5) Lightly grip the bushing in a vise or with pliers
and back the tool out of the bushing. Be careful not
to damage the threads on the bushing remover. , .A*
-- PUMP ROTORS 60x37

(6) Slide a new bushing on the installing head Tool
SP-3635, and start them in the bore of the reaction Fig. 75-Assembling Front Pump and Reaction Shaft
shaft. Support (Six Cylinder Cars)
(7) Support the reaction shaft upright on a clean (2) Assemble and place the rotors in center of the
smooth surface and install the handle Tool SP-3549 support (Fig. 75).
in the installing head (Fig. 74). Drive the bushing into (3) Lower the pump body over the pilot studs, in-
the shaft until the tool bottoms. sert Tool (2-3756 through the pump body and engage
(8) Thoroughly clean the reaction shaft support as-
with the pump inner rotor. Rotate the rotors with the
sembly before installation. tool to enter the rotors in the pump body, then with
Assembly the pump body firmly against the reaction shaft sup-
(1) Place the reaction shaft support in assembling port, tighten the clamping tool securely.
Tool (2-3759 with hub of the support resting on a (4) Invert the front pump and reaction shaft sup-
bench (Fig. 75). Screw two pilot studs, Tool C-3283 port assembly with the clamping tool intact. Install
into threaded holes of the reaction shaft support the support to pump body bolts and tighten to 125
flqnge. inch-pounds torque. Remove the clamping tool, pilot
VENT BAFFLE
THRUST WASHER (SELECTIVE)

62x22 A /
BOLTS ( 6 )
Fig. ir&-Front Oil Pump and Reaction Shaft Support (Eight Cylinder Cars)
studs and the rotor alignment tool. pitting. With the rotors cleaned and installed in the
(5) Place a new oil seal in opening of the front oil pump body, place a straight edge across the face of
pump housing (lip of seal facing inward). Using Tool the rotors and the pump body. Use a feeler gauge to
(2-3757, drive the seal into the housing until tool bot- measure the clearance between straight edge and
toms. face of the rotors. Clearance limits are from .001 to
.0025 inch. Also, with a feeler gauge, measure the
39. FRONT OIL PUMP AND REACTION rotor tip clearance between the inner and outer rotor
SHAFT SUPPORT (Eight Cylinder teeth. Clearance limits are from .007 to .012 inch.
Vehicles1
Front Pump Bushing Replacement
Disassembly
Figure 76 shows the front oil pump and reaction (1) Place the front pump housing on a clean smooth
shaft support disassembled. surface with the rotor cavity down.
(1) Remove the bolts from 'the rear side of the re- (2) Place the removing head Tool SP-3550 in the
action shaft support, and remove the vent baffle and bushing, and install the handle Tool SP-3549 in the
lift the support off the oil pump. removing head (Fig. 77).
(2) Remove the rubber seal ring from the front (3) Drive the bushing straight down and out of the
pump body flange. bore. Be careful not to cock the tool in the bore.
(3) Drive out the oil seal with a blunt punch. (4) Position a new bushing on the installing head
To01 SP-3625.
lnspecfion (5) With the pump housing on a smooth clean sur-
Inspect the interlocking seal rings (Fig. 76) on the face (hub end down), start the bushing and installing
reaction shaft support for wear or broken locks, head in the bushing bore. Install the handle Tool
make sure they turn freely in the grooves. Do not re- SP-3549 in the installing head (Fig. 77).
move the rings unless conditions warrant. Inspect the
(6) Drive the bushing into the housing until the
machined surfaces on the oil pump body and reaction
tool bottoms in the pump cavity. Be careful not to
shaft support for nicks and burrs. Inspect the pump
cock the tool during installation.
body and reaction shaft support bushings for wear or
scores. Inspect the oil pump rotors for scoring or (7) Stake the bushing in place by using a blunt
punch or similar tool (Fig. 78). A gentle tap at each
stake slot location will suffice.
REMOVING (8) Using a narrow-bladed knife .or similar tool,
HEAD remove the high points or burrs around the staked
SP-3550
area (Fig. 78). Do not use a file or similar tool that
FRONT PUMP will remove more metal than is necessary.
HOUSING
(9) Thoroughly clean the pump housing before in-
stallation.
INSTALLING
HEAD
SP-3625
6 2 X 347
Fig. 77-Replacing Front Pump Bushing
{Eight Cylinder Cars) Fig. 78-Staking Front Pump Bushing (Eight Cyl. Cars)
HEX NUT (5) Lightly grip the bushing in a vise or with pliers
and back the tool out of the bushing. Be careful not
to damage the threads on the bushing remover.
INSTALLING
HEAD SP-3634
(6) Slide a new bushing (chamfered end first) on
/ the installing head Tool SP-3634,and start them in
the bore of the reaction shaft.
REMOVER SP-3632
(7)Support the reaction shaft upright on a clean
f
BUSHING
smooth surface and install handle Tool SP-3549in the
installing head (Fig. 79). Drive the bushing into the
I I shaft until the tool bottoms.
(8)Thoroughly clean the reaction shaft support
assembly before installation.
W II II
W Assembly
62x349A (1)Assemble the pump rotors in the pump housing
Fig. 79-Replacing Reaction Shaft Bushing (Fig. 76).
(Eight Cylinder Cars) (2) Install the reaction shaft support and position
the vent baffle over the vent opening.. Install the re-
Reaction Shaft Bushing Replacement taining bolts and tighten to 150 inch-pounds torque.
(1) Assemble the remover Tool SP-3632,the cup (3) Place a new oil seal in opening of the front
Tool SP-3633,and the hex nut Tool SP-1191. oil pump housing (lip of seal facing inward) using
CAUTION: Do not clamp any part of the reaction Tool C-3860drive the seal into the housing until the
shaft or support in a vise. tool bottoms.
(2) With the cup held firmly against the reaction
shaft, thread the remover into the bushing as far as 40. FRONT CLUTCH ( S i x Cylinder
possible by hand (Fig. 79). Vehicles 1
(3)Use a wrench to screw the remover into the Disassembly
bushing 3 to 4 additional turns to firmly engage the Figure 80 shows a disassembled view of the front
threads in the bushings. clutch assembly.
(4) Turn the hex nut down against the cup to pull (1) Use a screw driver to remove the large snap
the bushing from the reaction shaft. Thoroughly clean ring that secures the pressure plate in the clutch pis-
the reaction shaft to remove the chips made by the ton retainer. Lift the pressure plate and clutch plates
remover threads. out of the retainer.
PISTON SEAL RING (INNER)
DRIVING DISCS
ASSEMBLY
CLUTCHPLATES 60 x 173A
Fig. 80-Front Clutch Assembly-Disassembled (Six Cylinder Cars)

TOOL HANDLE
TOOL
REMOVING
HEAD
FRONT CLUTCH SP-3627
Fig. 82-Replacing Front Clutch Retainer Bushing

(Six Cylinder Cars)
Fig. 81-Removing or Installing Front Clutch
Retainer Snap Ring (Six Cylinder Cars) Front Clutch Retainer Bushing
Replacement
(2) Install compressor, Tool C-3575 over the piston (1) Lay the clutch retainer (open end down) on a
spring retainer, as shown in Figure 81. Compress the clean smooth surface and place the removing head
spring and remove the snap ring, then slowly release Tool SP-3627 in the bushing (Fig. 82). Install the han-
the tool until the spring retainer is free of the hub. dle Tool SP-3549 in the removing head.
Remove the tool, retainer and spring. (2) Drive the bushing straight down and out of the
(3) Invert the clutch retainer assembly and bump clutch retainer bore. Be careful not to cock the tool
it on a wood block to remove the piston. Remove the in the bore.
seal rings from the piston and clutch retainer hub. (3) Lay the clutch retainer (open end up) on a
clean smooth surface. Slide a new bushing on the in-
Inspection stalling head Tool SP-3626, and start them in the
Inspect the facing material on all the driving discs. clutch retainer bore (Fig. 82).
Replace discs that are charred, glazed or heavily pit-
(4) Install handle Tool SP-3549 in the installing
ted. Discs should also be replaced if they show evi-
dence of material flaking off or if the facing material head. Drive the bushing into the clutch retainer un-
can be scraped off easily. Inspect the driving disc til the tool bottoms.
splines for wear or other damage. Inspect the steel (5) Thoroughly clean the clutch retainer before
plate and pressure plate surfaces for burning, scoring assembly and installation.
or damaged driving lugs. Replace if necessary. Assembly
Inspect the steel plate lug grooves in the clutch re- (1) Lubricate and install the inner seal ring on
tainer for smooth surfaces, plates must travel freely
in grooves. Inspect the band contacting surface on the
clutch retainer for scores, the contact surface should
be protected from damage during disassembly and
handling. Note the ball check in the clutch retainer,
make sure the ball moves freely. Inspect the piston
seal ring surfaces in the clutch retainer for nicks or
deep scratches, light scratches will not interfere with
the sealing of neoprene rings. Inspect the clutch
retainer inner bore surface for wear from the reac-
tion shaft support seal rings. Inspect the clutch re-
tainer bushing for wear or scores.
Inspect the inside bore of the piston for score
marks, if light, remove with crocus cloth. Inspect the
seal ring grooves for nicks and burrs. Inspect the
neoprene seal rings for deterioration, wear, and hard- 60x363
ness. Inspect the piston spring, retainer and snap Fig. 83-Measuring Front Clutch Plate Clearance
ring for distortion. '(Six Cylinder Cars)
PISTON SEAL RING
(INNER)
I PIST,ON
\ SPRING RETAINER
I
CLUTCH PLATES SNAP RING
(SELECTIVE)
I
PISTON RETAINER PISTON SEAL RING

f
ASSEMBLY SPRINGS(l0)
(OUTER1
SNAP RING
DRIVING DISCS /
PRESSURE PLATE 62x,
Fig. 8 6 F r o n t Clutch Assembly-Disassembled (Eight Cylinder Cars)
hub of the clutch retainer. Make sure lip of the seal 41. FRONT CLUTCH (Eight Cylinder
faces down and is properly seated in the groove. Vehicles)
(2) Lubricate and install the outer seal ring on the Disassembly
clutch piston, with lip of the seal toward bottom of Figure 84 shows a disassembled view of the front
the clutch retainer. Place piston assembly in the re- clutch assembly.
tainer and, with a twisting motion, seat the piston in (1) Using a screw driver, remove the large snap
the bottom of the retainer. ring that secures the pressure plate in the clutch pis-
(3) Place the spring on the piston hub and posi- ton retainer. Lift the pressure plate and clutch plates
tion the spring out of the retainer.
- - retainer and snap ring on the spring.
Compress the spring with Tool C-3575 (Fig. 81), and
seat the snap ring in the hub groove. Remove the com-
pressor tool.
(4) Lubricate all the clutch plates, install one steel
plate followed by a lined plate until all the plates are
installed. Install the pressure plate and snap ring.
Make sure the snap ring is properly seated.
NOTE: The 170 cubic inch engine transmission
uses three plates and discs in the front clutch and the
225 cubic inch engine uses four steel plates and
discs.
(5) With the front clutch completely assembled, in-
sert a feeler gauge between the pressure plate and
snap ring (Fig. 83). The clearance should be .056 to
.lo4 inch for the four plate clutch, and .042 to .087
inch for the three plate clutch. If not, install a snap
ring of proper thickness to obtain the specified clear-
ance.
NOTE: Snap rings are the same as those used in
the rear clutch and are available in .060-.062; .068- Fig. 85-Removing or Installing Front Clutch Spring
.070 and .076-.078 inch thickness. Retainer Snap Ring (Eight Cylinder Cars)
21-82 TRANSMlSSlONTORQUEnlTE
(2) Install compressor, Tool C-3863 over the pis- seal grooves for nicks and burrs. Inspect the neoprene
ton spring retainer, as shown in Figure 85. Compress seals for deterioration, wear, and hardness. Inspect
the springs and remove the snap ring, then slowly re- the piston springs, retainer and snap ring for distor-
lease the tool until the spring retainer is free of the tion.
hub. Remove the tool, retainer and springs.
Front Clutch Retainer Bushing Replacement
(3)Invert the clutch retainer assembly and bump
it on a wood block to remove the piston. Remove the (1) Lay the clutch retainer (open end down) on a
seals from the piston and clutch retainer hub. clean smooth surface and place the removing head
Tool SP-3629in the bushing. Install the handle Tool
Inspection SP-3549in the removing head (Fig. 86).
Inspect the facing material on all the driving discs. (2) Drive the bushing straight down and out of the
Replace discs that are charred, glazed or heavily clutch retainer bore. Be careful not to cock the tool
pitted. Discs should also be replaced if they show in the bore.
evidence of material flaking off or if the facing
material can be scraped off easily. Inspect the driving (3)Lay @e clutch retainer (open end up) on a
disc splines for wear or other damage. Inspect the clean smooth surface. Slide a new bushing on the in-
steel plate and pressure plate surfaces for burning, stalling head Tool SP-3628,and start them in the
scoring or damaged driving lugs. Replace if necessary. clutch retainer bore.
Inspect the steel plate lug grooves in the clutch re- (4) Install handle Tool SP-3549 in the installer
tainer for smooth surfaces, plates must travel freely (Fig. 86). Drive the bushing into the clutch retainer
in the grooves. Inspect the band contacting surface on until the tool bottoms.
the clutch retainer for scores. Note the’ball check in (5)Thoroughly clean the clutch retainer before as-
the clutch retainer, make sure the ball moves freely. sembly and installation.
Inspect the seal surfaces in the clutch retainer for
nicks or deep scratches, light scratches will not in- Assembly
terfere with sealing of the neoprene rings. Inspect (1) Lubricate and install the inner seal on hub of
the clutch retainer bushing for wear or scores. the clutch retainer. Make sure the lip of the seal
Inspect the inside bore of the piston for score faces down and is properly seated in the groove.
marks, if light, remove with crocus cloth. Inspect the (2)Install the outer seal on the clutch piston, with
the lip of seal toward the bottom of the clutch re-
TOOL HAN
tainer. Apply a coating of “Door Ease” to the outer
SP-3549 REMOVER HEAD
SP-3629 edge of the seal for easier installation of the piston
FRONT CLUTCH
RETAINER
\ /
BUSHING
TOOL HAN
SP-3549
INSTALLING
HEAD SP-3628
Y-
2 t
2 x 4
6 2 X 350
Fig. 86-Replacing Front Clutch Retainer Bushing Fig. 87-Front Clutch Piston Return Spring-location
(Eight Cylinder Cars) YEight Cylinder Cars)
installed. Install the pressure plate and snap ring.
Make sure the snap ring is properly seated.
(5) With the front clutch completely assembled, in-
snap ring (Fig. 88). The clearance should be .024 to
.123 inch. If not, install a snap ring of the proper
thickness to obtain the specified clearance.
NOTE: Snap rings are the same as those used in
the rear clutch and are available in .060-.062, ,074-
,076 and .088-.090 inch thickness.
42. REAR CLUTCH ( S i x Cylinder Vehicles 1

Disassembly
Figure 89 shows a disassembled view of the rear
clutch assembly.
(1) Using a screw driver, remove the large snap
TlVE
RING ring that secures the pressure plate in the clutch
\
piston retainer. Lift the pressure plate, clutch plates,
62 X 2 and inner pressure plate out of the retainer.
Fig. 88-Measuring Front Clutch Plate Clearance (2) Install compressor Tool C-3760 over the piston
(Eight Cylinder Cars) spring, as shown in Figure 90. Compress the spring
just enough to clear snap ring, then remove the snap
assembly. Place the piston assembly in the retainer ring.
and carefully seat the piston in the bottom of the re-
(3) Remove the compressor tool and piston spring.
tainer.
Invert the clutch retainer assembly and bump it on
(3) Place the 10 springs on the piston hub exactly a wood block to remove the piston. Remove the seal
as shown in Figure 87. Position the spring retainer rings from the piston.
and snap ring on the springs. Compress the springs
(4) If necessary, remove the snap ring and press
with Tool C-3863 (Fig. 85), and seat the snap ring in
the input shaft from the piston retainer.
the hub groove. Remove the compressor tool.
(4) Lubricate all the clutch plates, install one steel inspection
A
plate followed by a lined plate until all the plates are Inspect the facing material on all the driving discs.
DRIVING SNAP RING
PISTON SEAL RING (OUTER) SNAP RING
~ (SELEVIVE)
PISTON RETAINER
THRUST WAS
SEAL RINGS(2) SNAP RING PISTON SEAL SPRING PRESSURE PLATES

RING (INNER) PLATE
60x385 A
Fig. 89-Rear Clutch Assembly-Disassembled (Six Cylinder Cars)
groove. Install compressor, Tool (2-3760 over the

spring (Fig. go), compress the spring just enough to
install the snap ring. Remove the compressor tool.
(5) Install the inner pressure plate in the clutch
retainer with raised portion of plate resting on the
spring.
(6) Lubricate all clutch plates, install one lined
plate followed by a steel plate until all the plates are
installed. Install the outer pressure plate and snap
ring.
(7) With the rear clutch completely assembled, in-
snap ring (Fig. 91). The clearance should be between
.018 to .036 inch. If not, install a snap ring of proper
Fig. %Removing or Installing Rear Clutch Spring thickness to obtain the specified clearance.
Retainer Snap Ring (Six Cylinder Carsl NOTE: Rear clutch plate clearance is very im-
portant in obtaining the proper clutch operation. The
Replace discs that are charred, glazed or heavily clearance can be adjusted by the use of various
pitted. Discs should also be replaced if they show evi- thickness outer snap rings. Snap rings are available in
dence of material flaking off or if the facing material ,060-.062, .068-.070 and .076-.078 inch thickness.
can be scraped off easily. Inspect the driving disc
splines for wear or other damage. Inspect the steel 43. REAR CLUTCH (Eight Cylinder
plate and pressure plate surface for burning, scoring Vehicles 1
or damaged driving lugs. Replace if necessary. In-
spect the plates and discs for flatness, they must not Disassembly
be warped or cone-shaped. Figure 92 shows a disassembled view of the rear
Inspect the steel plate lug grooves in the clutch re- clutch assembly.
tainer for smooth surfaces, plates must travel freely (1) Use a screw driver to remove the large snap
in the grooves. Note the ball check in the clutch re- ring that secures the pressure plate in the clutch
tainer, make sure the ball moves freely. Inspect the retainer. Lift the pressure plate, clutch plates, and
seal ring surfaces in the clutch retainer for nicks or inner pressure plate out of the retainer.
deep scratches, light scratches will not interfere with
(2) Remove the piston spring snap ring and remove
sealing of the neoprene rings. Inspect the neoprene
the spring.
seal rings for deterioration, wear and hardness. In-
spect the piston spring and snap rings for distortion. (3) Invert the clutch piston retainer assembly and
Inspect the interlocking seal rings (Fig. 89) on the bump it on a wood block to remove the piston. Re-
input shaft for wear or broken locks, make sure they move the seals from the piston.
turn freely in the grooves. Do not remove the rings
unless conditions warrant. Inspect the rear clutch to a
FEELER GAUGE
front clutch thrust washer for wear. Washer thickness
should be .043 to .045 inch, replace if necessary.
Assembly
(1) If removed, press the input shaft into the pis-
ton retainer and install the snap ring.
(2) Lubricate and install the inner and outer seal
rings on the clutch piston. Make sure the lip of the
seals face toward head of the clutch retainer, and are
properly seated in the piston grooves.
(3) Place piston assembly in the retainer and, with
a twisting motion, seat the piston in the bottom of the SELECTlVt
SNAP RING’
retainer. 60 x 183
(4) Place the spring over the piston with the outer Fig. 91-Measuring Rear Clutch Plate Clearance
edge of the spring positioned below the snap ring (Six Cylinder Cars)
DRIVING SNAP RING

DISCS ..
(SELECTIVE)
CLUTCH RETAINER PISTON

PISTON SEAL
INPUT SHAFT
PISTON
I1 PLATES
I SNAP' RING
PISTON SEAL
(OUTER)
62x1 65
Fig. 92-Rear Clutch Assembly-Disassembled !Eight Cylinder Cars)
(4)If necessary, remove the snap ring and press being careful not to clamp on the seal ring lands or
the input shaft from the clutch piston retainer. bearing journals.
lnspection (2) Assemble the remover Tool SP-3630, the kup
Tool SP-3633, and the hex nut Tool SP-1191.
Inspect the facing material on all the driving discs.
Replace the discs that are charred, glazed or heavily (3) With the cup held firmly against the clutch
pitted. Discs should also be replaced if they show evi- piston retainer, thread the remover into the bushing
dence of material flaking off or if the facing material as far as possible by hand (Fig. 93).
can be scraped off easily. Inspect the driving disc (4)Using a wrench, screw the remover into the
splines for wear or other damage. Inspect the steel bushing 3 to 4 additional turns to firmly engage the
plate and pressure plate surfaces for burning, scor- threads in the bushing.
ing or damaged driving lugs. Replace if necessary. (5) Turn the hex nut down against the cup to pull
Inspect the steel plate lug grooves in the clutch the bushing from the input shaft.
retainer for smooth surfaces, plates must travel
freely in the grooves. Note the ball check in the pis-
ton, make sure the ball moves freely. Inspect the seal TOOL
surfaces in the clutch retainer for nicks or deep HANDL
SP-354
scratches, light scratches will not interfere with seal- CUP
ing of the neoprene seals. Inspect the neoprene seals P-3633
for deterioration, wear, and hardness. Inspect the REAR CLUTCH
piston spring and snap rings for distortion.

Inspect the interlocking seal rings (Fig. 92) on the
input shaft for wear or broken locks, make sure they.
turn freely in the grooves. Do not remove the rings
unless conditions warrant. Inspect the bushing in the
input shaft for wear or scores. Inspect the rear clutch
to front clutch thrust washer for wear. Washer thick- SHAFT
ness should be .061 to .063 inch, replace if necessary. L-J

lnput Shaft Bushing Replacement m' ' 62x351
(1) Clamp the input shaft in a vise with soft jaws, Fig. 93-Replacing lnput Shaft Bushing (Eight Cyl. Cars)
(6)Thoroughly clean the input shaft to remove SELECTIVE
**. SNAP RING
the chips made by the remover threads. Make certain
the small lubrication hole next to the ball in the end
of the shaft is not plugged with chips. Be sure no
chips are lodged next to the steel ball.
(7) Slide a new bushing on the installing head Tool
SP-3636, and start them in the bore of the input
shaft.
(8) Stand the input shaft upright on a clean smooth
surface and install handle Tool SP-3549 in the in-
stalling head (Fig. 93).Drive the bushing into the shaft
until the tool bottoms.
(9) Thoroughly clean the input shaft and clutch
piston retainer before assembly and installation.
Assembly
(1) If removed, press the input shaft into the dutch
piston retainer and install the snap ring.
(2) Lubricate and install the inner and outer seal
rings on the clutch piston. Make sure the lip of the
seals face toward the head of the clutch retainer, Fig. %-measuring Rear Clutch Plate Clearance
and are properly seated in the piston grooves. (Eight Cylinder Cars)
(3) Place the piston assembly in the retainer and,
with a twisting motion, seat the piston in bottom of retainer splines and support the assembly so the
the retainer. clutch retainer remains in place.
(41 Position the clutch retainer over the piston (5)Place the spring over the piston with outer edge
of spring positioned below the snap ring groove. Start
one end of the snap ring in the groove, make sure
the spring is exactly centered on the piston, then
progressively tap the snap ring into the groove (Fig.
94). Be sure the snap ring is fully seated in the
groove.
(6)Install the inner pressure plate in the clutch
retainer with raised portion of the plate resting on
the spring.
SPRING (7) Lubricate all the clutch plates, install one lined
1; I SNAP RING
plate followed by a steel plate until all the plates are
installed. Install the outer pressure plate and snap
ring.
NOTE: The 318 cubic inch engine transmission
uses three discs and two steel plates in the rear
clutch, and the other V-8 engines use four discs and
three steel plates.
(8) With the rear clutch completely assembled, in-
snap ring (Fig. 95).The clearance should be .022-.042
inch for the three-disc clutch and .026-.054inch for
the four-disc clutch. If not, install a snap ring of
proper thickness to obtain the specified clearance.
Low limit clearances are desirable.
Fig. 94-Installing Rear Clutch Spring and Snap Ring NOTE: Rear clutch plate clearance is very impor-
IEight Cylinder Cars) tant in obtaining proper clutch operation. The clear-
FRONT PLANETARY GEAR ASSEMBLY

SNAP RINGS
F\I\. THRUST
I
WASHER I1 THRUST WASHER (STEEL)
DRIVING SHELL
SNAP I / RING SUN GEA

/
REAR PLANETARY GEAR ASSEMBLY
AR ANNULUS GEAR
REAR ANNULUS
FRONT ANNULUS / 7- -
FRONT ANNULIJS GEAR LOW AND
REVERSE DRUM
THRUST WASHER
'p
THRUST WASHER (SELECTIVE)
1
60 x 176A
Fig. 96-Planetary Gear A,ssemblies, Sun Gear, Driving Shell, l o w and Reverse Drum and Output Shaft-
-Disassembled (Six Cylinder Cars)
ance can be adjusted by the use of various thickness remove the snap ring from front of the annulus
outer snap rings. Snap rings are available in .060-.062, gear to separate the support from the annulus gear.
.074-.076 and .088-.090 inch thickness. (4) Slide the sun gear, driving shell and rear plan-
etary assembly off the output shaft.
44. PLANETARY GEAR ASSEMBLIES, S U N (5) Lift the sun gear and driving shell off the rear
GEAR, D R I V I N G SHELL
( S i x Cylinder Vehicles)
Measure the end play of the planetary gear as-
semblies, sun gear and driving shell before re-
moving these parts from the output shaft. With the
assemblies in an upright position, push the rear an-
nulus gear support downward on the output shaft.
Insert a feeler gauge between the rear annulus gear
support hub and the shoulder on the output shaft. FEELER GAUGE
(Refer to Figure 97). The clearance should be .006 to
.046 inch. REAR PLANETARY
Disassembly
(1) Remove the thrust washer from the forward
end of the output shaft (Fig. 96).
(2) Remove the snap ring from the forward end of
the output shaft, then slide the front planetary as-
sembly off the shaft.
(3) Remove the snap ring and thrust washer from
forward hub of the front planetary gear assembly,
slide the front annulus gear and support off the I
planetary gear set (Fig. 96). Remove the thrust washer Fig. 97-Measuring End Play of Planetary Gear
from rear side of the planetary gear set. If necessary, Assembly, Sun Gear and Driving Shell
planetary assembly. Remove the snap ring and steel Position the thrust washer on the rear side of the
washer from the sun gear (rear side of driving shell). planetary gear assembly.
Slide the sun gear out of the driving shell, and (8) Carefully work the front planetary and annulus
remove the snap ring and steel washer from the op- gear assembly on the output shaft, meshing the plan-
posite end of the sun gear if necessary. etary pinions with the sun gear teeth.
(6) Remove the thrust washer from the forward (9) With all the components properly positioned,
side of the rear planetary assembly and remove the install the retaining snap ring on the front end of
planetary gear set from the rear annulus gear. If the output shaft. Re-measure the end play of the
necessary, remove the snap ring from the rear of the assembly.
annulus gear to separate the support from the an-
nulus gear. 45. PLANETARY GEAR ASSEMBLIES,
inspection SUN GEAR, DRIVING SHELL
( Eight Cylinder Vehicles 1
Inspect the bearing surfaces on the output shaft for
nicks, burrs, scores or other damage. Light scratches, Measure the end play of the planetary gear as-
small nicks or burrs can be removed with crocus semblies, sun gear and driving shell before removing
cloth or a fine stone. Inspect the speedometer drive these parts from the output shaft. With the assembly
gear for any nicks or burrs, and remove with a sharp in an upright position, push the rear annulus gear
edged stone. Make sure all oil passages in the shaft support downward on the output shaft. Insert a feeler
are open and clean. gauge between the rear annulus gear support hub and
Inspect the bushings in the sun gear for wear or the shoulder on the output shaft (Fig. 97). The clear-
scores, replace the sun gear assembly if the bushings ance should be .010 to .039 inch.
are damaged. Inspect all the thrust washers for wear Dtsassembly
and scores, replace as required. Inspect all the lock
rings for distortion. Inspect annulus gear and driving (1) Remove the thrust washer from the forward
gear teeth for damage. Inspect the planetary gear end of the output shaft (Fig. 98).
carrier for cracks and pinions for broken or worn (2) Remove the snap ring from the forward end of
gear teeth and for broken pinion shaft lock pins. the output shaft, then slide the front planetary as-
sembly off the shaft.
Assembly (3) Slide the front annulus gear off the planetary
Refer to Figure 96 for parts reference. gear set (Fig. 98). Remove the thrust washer from the
(1) Place the rear annulus gear support in the rear side of the planetary.gear set.
annulus gear and install the snap ring. (4) Slide the sun gear, driving shell and the rear
(2) Position the rear planetary gear assembly in planetary assembly off the output shaft.
the rear annulus gear and place the thrust washer (5) Lift the sun gear and driving shell off the rear
on the front side of the planetary gear assembly. planetary gear assembly. Remove the thrust washer
(3) Insert the output shaft in the rear opening of from inside the driving shell. Remove snap ring and
the rear annulus gear. Carefully work the shaft steel washer from the sun gear (rear side of driving
through the annulus gear support and planetary gear shell) and slide the sun gear out of the shell. Remove
assembly. Make sure the shaft splines are fully en- the front snap ring from the sun gear if necessary.
gaged in splines of the annulus gear support. Note that the front end of the sun gear is longer than
(4) Install the steel washer and snap ring on one the rear.
end of the sun gear. Insert the sun gear through the (6) Remove the thrust washer from the forward
front side of the driving shell, install the rear steel side of the rear planetary gear assembly, remove the
washer and snap ring. planetary gear set from the rear annulus gear.
(5) Carefully slide the driving shell and sun gear h s p e c t ion
assembly on the output shaft, engaging the sun gear
Inspect the bearing surfaces on the output shaft
teeth with the rear planetary pinion teeth.
for nicks, burrs, scores or other damage. Light
(6) Place the front annulus gear support in the an- scratches, small nicks or burrs can be removed with
nulus gear and install the snap ring. crocus cloth or a fine stone. Inspect the speedometer
(7) Position the front planetary gear assembly in drive gear for any nicks or burrs, and remove with
the front annulus gear, place thrust washer over the a sharp edged stone. Make sure all oil passages in
planetary gear assembly hub and install the snap ring. the shaft are open and clean.
/ / 62x15
OUTPUT SHAFl LOW AND REVERSE DRUM
Fig. 98-Planetary Gear Assemblies, Sun Gear, Driving Shell, l o w and Reverse Drum and Output Shaft-
'Disassembled (Eight Cylinder Cars)
Inspect bushings in the sun gear for wear or scores, the front annulus gear.
replace the sun gear assembly if bushings are dam- (6) Carefully work the front planetary and annulus
aged. Inspect the thrust for wear and gear assembly on the output shaft, meshing the plan-
Scores, replace if damaged O r Worn below SpeCifiCa- etary pinions with the sun gear teeth.
tions. Inspect the thrust faces of the planetary gear
carriers for wear, scores or other damage, replace (7) With all components properly positioned, in-
as required. Inspect the planetary gear carrier for stall the retaining snap ring on the front end of the
output shaft. Re-measure the end play of the assem-
cracks and pinions for broken or worn gear teeth
and for broken pinion shaft lock pins. Inspect the bly.
annulus gear a n d driving gear teeth for damage. Re-
place distorted lock rings. 46. OVERRUNNING CLUTCH
Assern bly Inspection
Refer to Figure 98 for parts reference. Inspect the clutch rollers for smooth round sur-
faces, they must be free of flat spots and chipped
(l)Position the rear gear in edges. Inspect the roller contacting surfaces in the
the rear annulus gear. Place the thrust washer on
the front side of the planetary gear assembly.
(2) Insert the output shaft in the rear opening of
the rear annulus gear. Carefully work the shaft
through t h e annulus gear and planetary gear assem-
bly. Make sure the shaft splines are fully engaged in
splines of the annulus gear.
(3) Install the snap ring in the front groove of the BOLT AND
sun gear (long end of gear). Insert the sun gear WASHER (5)
through the front side of the driving shell, install the i
i
rear steel washer and snap ring. I
(4) Carefully slide the driving shell and sun gear
assembly on the output shaft, engaging the sun gear
%
teeth with the rear planetary pinion teeth. Place the / SPRING
CAM RETAINER 62x28
thrust washer inside the front driving shell.
(5) Place the thrust washer on the rear hub of the Fig. 99-Overrunning Clutch Service Replacement Cam
front planetary gear set, then slide the assembly into (Six Cylinder Cars)
Fig. 101-Cam Retaining Bolts Installed (Six Cyl. Can)

Fig. 100-Center Punch Rivet Heads ( S i r Cyl. Cars)
(6) Tap the cam firmly into the case if necessary.
cam and race for brinelling. Inspect the roller springs Draw the retaining bolts down evenly, then tighten
for distortion, wear or other damage. Eight Cylinder to 100 inch-pounds torque.
Vehicles: Inspect the cam set screw for tightness. If (7) To install the rear oil pump body, refer to
loose, tighten and restake the case around the screw. Paragraph 37.
Six Cylinder Vehicles: Inspect the low and reverse
drum thrust washer (behind the overrunning clutch Overrunning Clutch Cam Replacement
hub) for wear or scores. I Eight Cylinder Vehicles I
If the overrunning clutch cam and/or the roller
Overrunning Clutch Cam Replacement spring retainer are found damaged, replace the cam
[Six Cylinder Vehicles I and spring retainer in the following manner:
If the overrunning clutch cam or spring retainer (1) Remove the set screw from the case below the
are found damaged, they can be replaced with a clutch cam.
service replacement cam, spring retainer, and retain-
(2) Insert a punch through the pump body bolt
ing bolts (Fig. 99). The service parts are retained in
the case with bolts instead of rivets. To install, pro- holes and drive the cam from the case (Fig. 102).
ceed as follows: Alternate the punch from one bolt hole to another
so the cam will be driven evenly from the case.
(1) Drive the rear oil pump body rearward out of
43) Clean all burrs and chips from the cam area
the case with a wood block and hammer.
in the case.
(2) Center punch the rivets exactly in the center
of each rivet head (Fig. 100).
(3) Drill through each rivet head with a 3 ? inch
drill. Be very careful not to drill into the tranrmir-
sion case. Chip off the rivet heads with a small
chisel, then drive the rivets and cam from the case
with a blunt punch of proper size.
(4) Carefully enlarge the rivet holes in the case
with a inch drill. Remove all chips and foreign
matter from the case, make sure the cam area is free
of chips and burrs.
(5) To install, position the cam and roller spring
retainer in the case. Align the cam bolt holes with
the holes in the case, then thread all five retaining 62x181
bolt and washer assemblies into the cam a few turns.
The belleville washers must be installed so its inner Fig. 102-Removing Overrunning Clutch Cam
diameter is coned toward the bolt head (Fig. 101). (Eight Cylinder Can)
TRANSMISSION-TORQUERITE 2 1-91-
47. KICKDOWN SERVO AND BAND
inspection
Figure 104 shows a disassembled view of the kick-
down servo assembly.
NOTE: The large outer spring shown in Figure
104 i s not used in the Six Cylinder Vehicle transmis-
sion. Also, the large outer spring is not used in the
-t- maximum performance Eight Cylinder Vehicle trans-
missions.
Inspect the piston and guide seal rings for wear,
and make sure they turn freely in the grooves. It is
not necessary to remove the seal rings unless condi-
tions warrant. Inspect the piston for nicks, burrs,
scores and wear. Inspect the piston bore in the case
Fig. 103-Installing Overrunning Clutch Cam for scores or other damage. Inspect the fit of the guide
(Eight Cylinder Cars) on the piston rod. Inspect the piston spring for dis-
tortion.
(4) Place the spring retainer on the cam, making Inspect the band lining for wear and bond of
sure the retainer lugs snap firmly into the notches on lining to the band. Inspect the lining for black burn
the cam. marks, glazing, non-uniform wear pattern and flaking.
(5) Position the cam in the case with cam serra- If the lining is worn so the grooves are not visible at
tions aligned with those in the case. Tap the cam the ends or any portion of the bands, replace the
evenly into the case as for as possible with a soft band. Inspect the band for distortion or cracked ends.
mallet.
(6) Install Tool C-3863, as shown in Figure 103, 48. LOW AND REVERSE SERVO
tighten nut on the tool to seat the cam into the case. AND BAND
Make sure the cam is firmly bottomed, then install
the cam retaining set screw. Stake the case around Disassembly
the set screw to prevent it from coming loose. (1) Remove the snap ring from the piston and re-
SEAL RING
I SPRING
PISTON ROD
\ n
SEAL RINGS (2)
SNAP-RING
SPRI’NG
PISTONROD GUIDE
PISTION 62x168
Fig. 1OkKickdown Servo (Disassembled)

c
SNAP RING
60 x 175
Fig. 105-low and Reverse Servo (Disassembled)
move the piston plug and spring (Fig. 105). Eight Cylinder Vehicles: Insert the clutch hub (race)
inside the overrunning clutch cam, then install the
Inspect ion springs and rollers exactly as shown in Figure 106.
Inspect the seal for deterioration, wear and hard- Low and Reverse Servo and Band
ness. Inspect the piston and piston plug for nicks,
burrs, scores and wear; piston plug must operate (1) Carefully work the servo piston assembly into
freely in the piston. Inspect the piston bore in the the case with a twisting motion. Place the spring, re-
case for scores or other damage. Inspect the springs tainer and snap ring over the piston (Fig. 105).
for distortion. (2) Compress the low and reverse servo piston
Inspect the band lining for wear and bond of lining spring by using engine valve spring compressor Tool
to the band. If the lining is worn so the grooves are C-3422, then install the snap ring.
not visible at the ends or any portion of the band, (3) Position the rear band in the case, install the
replace the band. Inspect the band for distortion or short strut, then connect the long lever and strut to
cracked ends. the band (Fig. 107). Screw in the band adjuster just
enough to hold the struts in place. Install the low-
Assembly reverse drum.
(1) Lubricate and insert the piston plug and spring
in the piston, and secure with the snap ring.
49. INSTALLATION OF SUB-ASSEMBLIES

The assembly procedures given here include the <
ROLLER
\ .
/
SPRING I
installation of the sub-assemblies in the transmission i

5
case and adjusting the drive train end play. Do not
use force to assemble mating parts. If the parts do
not assemble freely, investigate the cause, and cor-
rect the trouble before proceeding with the assembly
procedures. Always use new gaskets during the as-
sembly operations.
IMPORTANT: Use only Automatic Transmission
Fluid Type “A” Suffix “A” to lubricate the transmie
sion parts during assembly.
K REVERSE LINK
Overrunning Clutch
(1) Six Cylinder Vehicles: Place the low and reverse
drum thrust washer inside the overrunning clutch
62x14
cam, then install the clutch hub (race) with its under-
cut end (inner diameter) next to the thrust washer.
Install the springs and rollers exactly as shown in Fig. 106-Overrunning Clutch, low and Reverse
Figure 106. Band link
graph 29, replace the thrust washer with one of prop-
ADJUSTING SCREW AND LOCKNUT
er thickness.
The following selective washers are available for
the Six Cylinder Vehicle transmission:
Thickness Color
.052-.054 inch Natural
.068-.070 inch Red
.083-.085 inch Black
lnput Shaft and Rear Clutch
(1) Invert the transmission and support in an up-
right position with the output shaft downward.
(2) Align the rear clutch plate inner splines, lower
the input shaft and clutch assembly into position in
the case.
(3) Carefully work the clutch assembly in a cir-
cular motion to engage the clutch splines over splines
of the front annulus gear.
(4) Coat one side of the fiber thrust washer with
Fig. 107-low-Reverse Band and linkage heavy grease, then position the washer in the recws
on front face of the rear clutch piston retainer.
Eight Cylinder Vehicles: Be sure the long lever and Front Clutch
strut assembly is installed, as shown in Figure 106
(1) Align the front clutch plate inner splines, lower
to provide the running clearance for the low and
the clutch assembly into position in the case.
reverse drum.
(2) Carefully work the clutch assembly in a cir-
Kickdown Servo cular motion to engage the clutch splines over splines
(1) Carefully push the servo piston into the case of the rear clutch piston retainer. Make sure the front
bore. Install the piston rod, the two springs and the clutch driving lugs are fully engaged in the slots in
guide (Fig. 104). The Six Cylinder Vehicle transmis- the driving shell.
sion uses one small spring only. Also, one small
Front Band
spring only is used in the maximum performance
Eight Cylinder Vehicle transmissions. Figure 108 shows a disassembled view of the kick-
(2) Compress the kickdown servo springs by using down band assembly.
engine valve spring compressor Tool C-3422, then (1) Slide the band over the front clutch assembly.
install the snap ring. (2) Install the band strut, screw in the adjuster
just enough to hold the strut and anchor in place.
Planetary Gear Assemblies,
Sun Gear, Driving Shell PLUG\
ANCHOR
(1) While supporting the assembly in the case, in-
sert the output shaft through the rear pump housing.
Carefully work the assembly rearward engaging the
rear planetary carrier lugs into the low-reverse drum
slots.
CAUTION: Be very careful not to damage the
ground surfaces on the output shaft during installa-
tion.
(2) Six Cylinder Vehicles: Apply a coat of grease
to the selective thrust washer (Fig. 96) and install the
washer on the front end of the output shaft.
62x1 7
NOTE: If the drive train end play was not within
specifications (.022-.071 inch), when tested in Para- Fig. 108-Kickdown Band and linkage (Disassembled)
Front Oil Pump and (4) Install the assembly in the case, tap lightly
Reaction Shaft Support with a soft mallet if necessary. Place the deflector
If difficulty was encountered in removing the front over the vent opening and install four pump body
oil pump assembly due to an exceptionally tight fit bolts, remove pilot studs and install the remaining
in the case, it may be necessary to expand the case bolts. Snug the bolts down evenly, then tighten to
with heat during the pump installation. Using a suit- 150 inch-pounds torque. The Six Cylinder Vehicle
able heat lamp, heat the case in the area of the front transmission does not use a deflector over the vent
pump for a few minutes prior to installing the front opening .
pump and reaction shaft support assembly. (5) Rotate the pump rotors with Tool C-3881 or
Eight Cylinder Vehicles: If the drive train end play Tool C-3756 until the two small holes in the handle
was not within specifications (.030-.069 inch) when of the tool are vertical (Fig. 51). This will locate the
tested in Paragraph 29, replace the thrust washer on inner rotor so the converter impeller shaft will engage
the reaction shaft support hub with one of proper the inner rotor lugs during installation.
thickness.
The following selective thrust washers are avail- Rear Oil Pump
able for the Eight Cylinder Vehicle transmission. (1) Place the outer rotor in the pump body.
Thickness Color (2) Turn the output shaft so the inner rotor driving
.043-.045 inch Natural ball pocket is up. Install the ball and slide the inner
.061-.063 inch Green rotor on the output shaft in alignment with the ball
.084-.086 inch Red (Fig. 45).
.102-SO4 inch Yellow (3) Install the oil pump cover with the retaining
(1) Screw two pilot studs, Tool C-3288 in the front bolts threaded in a few turns. Slide aligning sleeve,
oil pump opening in the case (Fig. 109). Install a Tool C-3762 (Six Cylinder Vehicles) or Tool C-3864
new gasket over the pilot studs. (Eight Cylinder Vehicles) all the way in until it bot-
toms against the rotors (Fig. 46), then tighten the
(2) Place a new rubber seal ring in the groove on cover bolts evenly to 140 inch-pounds torque.
the outer flange of oil pump housing. Make sure the
seal ring is not twisted. Coat the seal ring with grease Governor and Support
for easy installation. (1) Position the support and governor body as-
(3) Insert aligning Tool C-3756 (Six Cylinder sembly on the output shaft. Align the assembly so
Vehicles) or Tool C-3881 (Eight Cylinder Vehicles) the governor valve shaft hole in the governor body
through the pump body and engage the inner rotor. aligns with the hole in the output shaft, then slide
the assembly into place. Install the snap ring behind
the governor body (Fig. 43). Tighten the body to
support bolts to 100 inch-pounds torque. Bend the
ends of the lock straps against the bolt heads.
(2) Place the governor valve on the valve shaft, in-
sert the assembly into the body and through the gov-
ernor weights. Install the valve shaft retaining snap
ring.
Extension Housing
(1)Using a new gasket, carefully slide the exten-
sion housing into place. Install the retaining bolts
and washers, tighten bolts to 25 foot-pounds torque.
(2) Install the transmission output shaft flange. In-
stall washer with its three projections toward the
flange and the nut with its convoluted surface con-
tacting the washer. Hold the flange with Tool C-3281,
and tighten nut to 175 foot-pounds torque. Torque
reading must be taken as the nut passes over the
hump.
Fig. 109-Installing Front Pump and Reaction Shaft IMPORTANT: Inspect the drive train end play as
5upport Assembly described in Paragraph 29. Correct if necessary.
Valve Body Assembly and 110). Be careful not to cut or grind into the front
Accumulator Piston cover stamping.
(1) Clean mating surfaces and inspect for burrs on (2)Scribe a heavy line on the front cover next to
both the transmission case and the valve body steel the front face of the ring gear to aid in locating the
plate. new gear.
(2)Install the accumulator piston in the transmis- (3) Support the converter with the four lug faces
sion case and place the piston spring on the accumu- resting on blocks of wood. The converter must not
lator piston. rest on the front cover hub during this operation.
(3) Carefully position the valve body assembly in Using a blunt chisel or drift and hammer, tap down-
the transmission case, install the retaining bolts and ward on the ring gear near the welded areas to break
tighten finger tight. With the neutral starting switch any remaining weld material (Fig. 110). Tap around
installed, place the manual valve in the neutral posi- the ring gear until it comes off the converter.
tion. Shift the valve body if necessary to center the (4) Smooth off the weld areas on the cover with a
neutral finger over the neutral switch plunger. Snug file.
the bolts down evenly, then tighten to 100 inch- installing Ring Gear
pounds torque. Any of the following methods may be used to heat
(4) Connect the control cable adapter to the manual and expand the starter ring gear for installation on
lever and install the retaining nut. the converter:
(5)Install the seal, flat washer and throttle lever Oven: Place the ring gear in Oven C-794 and set
on the throttle shaft. Tighten the clamp bolt. the temperature at 200 degrees F. Allow the ring
(6) Adjust the kickdown, and low-reverse bands, gear to remain in the oven for 15 to 20 minutes.
as described in Paragraph 12. Boiling Water: Place the ring gear in a shallow con-
(7)Install the oil pan, using a new gasket. Tighten tainer, add water, and heat for approximately eight
the pan bolts to 1.50inch-pounds torque. minutes after the water has come to a boil.
Steam: Place the ring gear on a flat surface and
50. STARTER RING GEAR REPLACEMENT direct a steam flow around the gear for approximately
The starter ring gear is mounted directly on the two minutes.
outer diameter of the torque converter front cover. Flame: Place the ring gear squarely on a flat sur-
With the torque converter removed from the vehicle, face. Using a medium size tip, direct a slow flame
replacement of the gear is as follows: evenly around the inner rim of the gear. Do not apply
flame to the gear teeth. Place a few drops of water
Removing Ring Gear on the face of gear at intervals during the heating
(1) Cut through the weld material at the rear side process. When the gear is hot enough to just boil
of ring gear with a hack saw or grinding wheel (Fig. the water, installation of the gear on the torque con-
verter can be made.
(1)After the ring gear is expanded by heating,
place the gear in position on the converter front
cover. Tap the gear on the cover evenly with a plastic
or rawhide mallet until the face of the gear is even
with the scribed line (made during removal) on the
. !/ BRASS DRIFT front cover. Make sure the gear is even with the
scribed line around the full circumference of the front
cover.
(2)Reweld the ring gear to the torque converter
front cover, being careful to place, as nearly as pos-
sible, the same amount of weld material in exactly
the same location as was used in the original weld.
This is necessary in order to maintain proper bal-
ance of the unit. Place the welds alternately on op-
posite sides of the converter to minimize distortion.
(3) The following suggestions are offered as an
Fig. 1 IO-Removing Starter Ring Gear aid in making the weld:
-
a. Do not gas weld. d. Direct the arc at the intersection of the gear and
front cover from an angle of 45 degrees from the rear
b. Use a D.C. welder that is set at straight polarity
face of the gear.
or an A.C. welder if the proper electrode is available.
(4)Inspect the gear teeth and remove all nicks
c. Use a 1/8 inch diameter welding rod, and a weld- where metal is raised, weld metal splatter, etc., in
ing current of 80 to 125 amps. order to ensure quiet starter operation.
TRANSMISSION-TORQUEFLITE DIAGNOSIS 2 1-97
2 C 4 E R V I C E DIAGNOSl S
N O T E : T h e transmission should n o t be removed nor disassembled until a careful diagnosis is made,
t h e definite cause determined and all possible external corrections performed. I n diagnosing any
abnormal shift condition, always m a k e t h e hydraulic pressures test before disassembly or replacement
of parts.
TORQUEFLITE
Harsh Engagement (a) Engine idle speed too high. (a) Adjust the engine idle speed to 500 rpm.
in D, 1, 2 and R Readjust throttle linkage.
(b) Hydraulic pressures too high or (b) Check fluid level, then perform
low. hydraulic pressure tests and adjust to
specifications.
Low-reverse band out of (c) Adjust the low-reverse band.
adjustment.
Valve body malfunction or (d) Perform pressure tests to determine
leakage. cause and correct as required.
Accumulator sticking, broken (e) Inspect the accumulator for sticking,
rings or spring. broken rings or spring. Repair as required.
Low-reverse servo, band or (f) Inspect the servo for damaged seals,
linkage malfunction. binding. Repair as required.
Worn or faulty front and/or (g) Disassemble and inspect clutch. Repair
rear clutch. or replace as required.
Delayed Engagement (a) Low fluid level. (a) Refill to correct level with Automatic
in D, 1, 2 and R Transmission Fluid Type A, Suffix A.
(b) Incorrect control cable (b) Adjust the control cable.
adjustment.
(c) Oil filter clogged. (c) Replace the oil filter.
(d) Hydraulic pressures too high or (d) Perform the hydraulic pressure tests and
low. adjust to specifications.
Valve body malfunction or (e) Perform pressure tests to determine cause
leakage. and correct as required.
Accumulator sticking, broken (f) Inspect the accumulator for sticking,
Clutches or servos sticking (g) Remove the valve body assembly and per-
or not operating. form air pressure tests. Repair as required.
Faulty front pump. (h) Perform the hydraulic pressure tests.
Adjust or repair as required.
Worn or faulty front and/or (i) Disassemble and inspect clutch. Repair or
rear clutch. replace as required.
Worn or broken input shaft (j) Inspect and replace the seal rings as
and/or reaction shaft support required, also inspect respective bores
seal rings. for wear. Replace the parts as required.
Aerated fluid. (k) Inspect for air leakage into the front pump
suction passages.
Runaway or Harsh (a) Low fluid level. (a) Refill to correct level with Automatic
Unshift and 3-2 Transmission Fluid, Type A, Suffix A.
Kic kdown (b) Incorrect throttle linkage (b) Adjust the throttle linkage.
adjustment.
Hydraulic pressures too high (c) Perform the hydraulic pressure tests and
or low. adjust to specifications.
Kickdown band out of (d) Adjust the kickdown band.
adjustment.
Valve body malfunction or (e) Perform pressure tests to determine cause
Governor malfunction. (f) Inspect the governor and repair as
required.
21-98 TRANSMISSION-TORQUEFLITE DIAGNOSIS
SERVICE D I A G N O S I G ( Continued 1 TORQUEFLITE TRANSMISSION -
Accumulator sticking, broken (g) Inspect the accumulator for sticking,

Clutches or servos sticking (h) Remove the valve body assembly and
or not operating. perform the air pressure tests. Repair as
required.
Kickdown servo, band or (i) Inspect the servo for sticking, broken
linkage malfunction. seal rings, binding linkage or faulty band
lining. Repair as required.
Worn or faulty front clutch. (j) Disassemble and inspect clutch. Repair or
replace as required.
Worn or broken input shaft (k) Inspect and replace seal rings as
and/or reaction shaft support required, also inspect the respective bores
seal rings. for wear. Replace parts as required.
No Upshift Low fluid level. (a) Refill to correct level with Automatic
Transmission Fluid Type A, Suffix A.
Incorrect throttle linkage (b) Adjust the throttle linkage.
adjustment.
Kickdown band out of (c) Adjust the kickdown band.
adjustment.
Hydraulic pressures too high (d) Perform the hydraulic pressure tests and
Governor sticking. (e) Remove and clean the governor. Replace
if necessary.
Valve body malfunction or (f) Perform pressure tests to determine
leakage. cause and correct as required.
Accumulator sticking, broken (g) Inspect accumplator for sticking, broken
rings or spring. rings or spring. Repair as required.
Clutches or servos sticking or (h) Remove the valve body assembly and
not operating. perform the air pressure tests. Repair as
required.
Faulty rear oil pump. (i) Perform the hydraulic pressure test,
adjust or repair as required.
Kickdown servo, band or (j) Inspect the servo for sticking, broken
linkage malfunction. seal rings, binding linkage or faulty band
Worn or faulty front clutch. (k) Disassemble and inspect clutch. Repair
or replace as required.
Worn or broken input shaft (1) Inspect and replace the seal rings as
and/or reaction shaft support required, also inspect the respective bore:
No Kickdown or Incorrect throttle linkage (a) Adjust the throttle linkage.
Normal Downshift adjustment .
Incorrect control cable (b) Adjust the control cable.
adjustment.
Kickdown band out of (c) Adjust the kickdown band.
adjustment.
Hydraulic pressures too high (d) Perform the hydraulic pressure tests and
Governor sticking. (e) Remove and clean the governor. Replace
parts if necessary.
Valve body malfunction or (f) Perform pressure tests to determine cause
Accumulator sticking, broken (8) Inspect the accumulator for sticking,
TRANSMISSION-TORQUEFLITE DIAGNOSIS 2 1-99
~
SERVICE DIAGNOSIS- (Continued 1 TORQUEFLITE TRANSMISSION
(h) Clutches or servos sticking or (h) Remove the valve body assembly and
not operating. perform the air pressure tests. Repair as
required.
(i) Kickdown servo, band or linkage (i) Inspect the servo for sticking, broken
malfunction. seal rings, binding linkage or faulty band
(j) Overrunning clutch not (j) Disassemble the transmission and repair
holding. the overrunning clutch as required.
Shifts Erratic (a) Low fluid level. (a) Refill to the correct level with Automatic
Transmission Fluid, Type “A”, Suffix “A”.
(b) Aerated fluid. (b) Inspect for air leakage into the front pump
suction passages.
(c) Incorrect throttle linkage (c) Adjust the throttle linkage.
adjustment.
(d) Incorrect control cable (d) Adjust the control cable.
adjustment.
(e) Hydraulic pressures too high Perform the hydraulic pressure tests and
(f) Governor sticking. Remove and clean the governor. Replace
parts if necessary.
(g) Oil filter clogged. Replace the oil filter.
(h) Valve body malfunction or Perform pressure tests to determine cause
(i) Clutches or servos sticking Remove the valve body assembly and
or not operating. perform air pressure tests. Repair as
required.
(j) Faulty rear and/or front oil Perform the hydraulic pressure tests,
pump. adjust or repair as required.
(k) Worn or broken input shaft Inspect and replace the seal rings as
and/or reaction shaft support required, also inspect respective bores for
seal rings. wear. Replace the parts as required.
Slips in Forward (a) Low fluid level. Refill to the correct level with Automatic
Drive Positions Transmission Fluid, Type “A”, Suffix “A”.
(b) Aerated fluid. Inspect for air leakage into the front pump
suction passages.
(c) Incorrect throttle linkage Adjust the throttle linkage.
adjustment.
(d) Incorrect control cable. (d) Adjust the control cable.
adjustment.
(e) Hydraulic pressures too low. (e) Perform the hydraulic pressure tests and
adjust to specifications.
(f) Valve body malfunction or (f) Perform pressure tests to determine cause
(g) Accumulator sticking, broken (g) Inspect the accumulator for sticking,
(h) Clutches or servos sticking (h) Remove the valve body assembly perform
or not operating. air pressure tests. Repair as required.
(i) Worn or faulty front and/or (i) Disassemble and inspect clutch. Repair or
rear clutch. replace as required.
(j) Overrunning clutch not (j) Disassemble the transmission and repair
holding. the overrunning clutch as required.
(k) Worn or broken input shaft (k) Inspect and replace the seal rings as
and/or reaction shaft support required, also inspect the respective bores
21-1 00 TRANSMISSION-TORQUEFLITE DIAGNOSIS
SERVICE DIAGNOSIS--. ( Continued 1 TORQUEFLITE TRANSMISSION
SI ips in Reverse (a) Low fluid level. Refill to correct level with Automatic
only Transmission Fluid, Type “A”, Suffix “A”
Aerated fluid. Inspect for air leakage into front pump
suction passages.
Incorrect control cable Adjust the control cable.
adjustment.
Hydraulic pressures too Perform the hydraulic pressure tests and
high or low. adjust to specifications.
Low-reverse band out of Adjust the low-reverse band.
adjustment.
Valve body malfunction or Perform pressure tests to determine cause
Front clutch or rear servo, Remove the valve body assembly and
sticking or not operating. perform air pressure tests. Repair as
necessary.
Low-reverse servo, band or Inspect the servo for damaged seals,
linkage malfunction. binding linkage or faulty band lining.
Repair as required.
Faulty front oil pump. Perform the hydraulic pressure tests,
Slips in A l l Low fluid level. Refill to the correct level with Automatic
Positions Transmission Fluid, Type “A”, Suffix “A”.
Hydraulic pressures too low. Perform the hydraulic pressure tests and
Valve body malfunction or Perform pressure tests to determine cause
Clutches or servos sticking Remove the valve body assembly and per-
or not operating. form air pressure tests. Repair as required.
Worn or broken input shaft Inspect and replace the seal rings as
No Drive in Any Low fluid level. Refill to the correct level with Automatic
Position Transmission Fluid, Type “A”, Suffix “A”.
Hydraulic pressures too low. Perform the hydraulic pressure tests and
Oil filter clogged. Replace the oil filter.
Valve body malfunction Perform pressure tests to determine cause
or leakage. and correct as required.
Clutches or servos sticking Remove the valve body assembly and
or not operating. perform air pressure tests. Repair as
required.
No Drive in Hydraulic pressures too low. Perform the hydraulic pressure tests and
Forward Drive adjust to specifications.
Positions Valve body malfunction or Perform pressure tests to determine cause
Accumulator sticking, broken Inspect the accumulator for sticking, bro-
rings or spring. ken rings or springs. Repair as required.
Clutches or servos, sticking Remove the valve body assembly perform
or not operating. air pressure tests. Repair as required.
Worn or faulty rear clutch. Disassemble and inspect clutch. Repair
or replace as required.
TRANSMISSION-TORQUEFLITE DIAGNOSIS 21-1 01
SERVICE DIAGNOSIS--- ( Continued 1 TORQUEFLITE TRANSMISSION
Canditian Possible Cause Correction
(f) Overrunning clutch not (f) Disassemble the transmission and repair
holding. overrunning clutch as required.
(g) Worn or broken input shaft (g) Inspect and replace the seal rings as re-
and/or reaction shaft support quired, also inspect the respective bores
No Drive in Reverse (a) Incorrect control cable (a) Adjust the control cable.
adjustmen t.
(b) Hydraulic pressures too low. (b) Perform the hydraulic pressure tests and
(c) Low-reverse band out of (c) Adjust the low-reverse band.
adjustment.
(d) Valve body malfunction or (d) Perform pressure tests to determine cause
(e) Front clutch or rear servo, (e) Remove the valve body assembly and per-
sticking or not operating. form air pressure tests. Repair as required.
(f) Low-reverse servo, band or (f) Inspect the servo for damaged seals,
Repair as required.
(g) Worn or faulty front clutch. (g) Disassemble and inspect clutch. Repair or
Drives in Neutral (a) Incorrect control cable (a) Adjust the control cable.
adjustment.
(b) Valve body malfunction or (b) Perform pressure tests to determine cause
(c) Rear clutch inoperative. (c) Inspect the clutch and repair as required.
Drags or Locks (a) Kickdown band out of (a) Adjust the kickdown band.
adjustment.
(b) Low-reverse band out of (b) Adjust the low-reverse band.
adjustment.
(c) Kickdown and/or low-reverse (c) Inspect the servo for sticking, broken seal
servo, band, linkage rings, binding linkage or faulty band
malfunction. lining. Repair as required.
(d) Front and/or rear clutch (d) Disassemble and inspect clutch. Repair or
faulty. replace as required.
(e) Planetary gear sets broken (e) Inspect the condition of the planetary
or seized. gear sets and replace as required.
(f) Overrunning clutch worn, (f) Inspect the condition of the overrunning
broken or seized. clutch and replace parts as required.
Grating , Scraping (a) Kickdown band out of (a) Adjust the kickdown band.
or Growling Noise adjustment.
(b) Low-reverse band out of (b) Adjust the low-reverse band.
adjustment.
(c) Output shaft bearing or (c) Remove the extension housing and replace
bushing damaged. the bearing or bushing.
(d) Governor support binding or (d) Inspect the condition of the governor
broken seal rings. support and repair as required.
(e) Front and/or rear oil pump (e) Inspect the condition of the pump and
scored or binding. repair as required.
(f) Front and/or rear clutch (f) Disassemble and inspect clutch. Repair or
faulty . replace as required.
(g) Planetary gear sets broken (g) Inspect the condition of the planetary
or seized. gear sets and replace as required.
(h) Overrunning clutch worn, (h) Inspect the condition of overrunning
broken or seized. clutch and replace parts as required.
21-1 02 TRANSMISSION-TORQUEFLITE DIAGNOSIS
SERVICE DIAGNOSIS--. (Continued 1 TORQUEFLITE TRANSMISSION
Low fluid level. (a) Refill to the correct level with Automatic
Transmission Fluid, Type “A”, Suffix “A”.
Pumps sucking air. (b) Inspect the pumps for nicks or burrs on
mating surfaces, porous casting, and/or
excessive rotor clearance. Replace the
parts as required.
Valve body malfunction. (c) Remove and recondition the valve body
assembly.
Overrunning clutch inner race (d) Inspect and repair the clutch as required.
damaged.
Hard t o Fill, Oil High fluid level. (a) Drain the fluid to the correct level.
Flows o u t Filler Breather clogged. (b) Inspect and clean breather vent opening
Tu be in front pump housing.
Oil filter clogged. (c) Replace the oil filter.
Aerated fluid. (d) Inspect for air leakage into front pump
suction passages.
Transmission Low fluid level. (a) Refill to the correct level with Automatic
Overheats Transmission Fluid, Type “A”, Suffix “A”.
Kickdown band adjustment (b) Adjust the kickdown band.
too tight.
Low-reverse band adjustment (c) Adjust the low-reverse band.
too tight.
Faulty cooling system. (d) Inspect the transmission cooling system,
clean and repair as required.
Faulty rear and/or front oil (e) Inspect the oil pump for incorrect
pump. clearance, repair as required.
Insufficient clutch plate (f) Measure the clutch plate clearance and
clearance in front and/or correct with the proper size snap ring.
rear clutches.
Impossible t o Low fluid level. (a) Refill to the correct level with Automatic
Push S t a r t Transmission Fluid, Type “A”, Suffix “A”.
Low-reverse band slipping. (b) Adjust the low-reverse band.
Valve body malfunction or (c) Remove and recondition the valve body
leakage. assembly.
Rear oil pump faulty. (d) Inspect and repair the rear oil pump as
required.
Low-reverse servo, band or (e) Inspect the servo for damaged seals,
Repair as required.
Worn or faulty rear clutch. (f) Disassemble and inspect clutch. Repair or
Worn or broken input shaft (g) Inspect and replace the seal rings as
Starter Will N o t (a) Incorrect control cable (a) Adjust the control cable.
Energize in Neutral adjustment .
(b) Faulty or incorrectly adjusted (b) Test the operation of the switch with a
neutral starting switch. test lamp. Adjust or replace as required.
Broken lead to neutral switch. (c) Inspect the lead and test with a test
lamp. Repair the broken lead.
WHEELS, BEARINGS AND TIRES 22-1
GROUP 22
WHEELS, BEARINGS AND TIRES
CONTENTS
Page Page
Specifications. ................................ 1 Wheel Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tool list.. .................................... 1 Repairing Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Care of Tires.. ................................ 2 Front Wheel Bearings.. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire Rotation. ................................. 2 Tire Wear Patterns.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Measuring Wheel and Tire Runout.. . . . . . . . . . . . . . . . 2 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
~~~ ~
Plymouth Plymouth Plymouth Valiant

VP-2 VP-1 VP-1, VP-2 w-1
8 Cyl. 6 Cyl. Station Wagon All Models
WHEELS
Type ................................ Steel Disc
Rim.................................. Drop Center-Safety Rim
Size-Std.. ........................... 14 x 5 K 14 x 5K 14 x 5%K 13 x 14Y2J
Size-Special. ........................ 14 x 5%K** 14 x 5'/2K** - N/A
15 x 5'/2K*** 15 x 5'/2K*** 15 x 5'/2K*** N/A
No. of Wheel Bolts.. . . . . . . . . . . . . . . . . . . . 5 5 5 5
Stud Hole Circle. ...................... 4%" 4 Y2" 4 Y2" 4"
Stud Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . %"-20 Y2"-20 Y2"- 20 w-20
Wheel Nut Torque. .................... 65 ft.-lbs. 65 ft.-lbs. 65 ft.-lbs. 55 ft.-lbs.
TIRES
Type ................................ Super Cushion-Tubeless
Size-Std.. ........................... 7.00- 14 7.00- 14 7.00- 14 6.50- 13
Ply .................................. 2 2 4 2
Size-Special ......................... 7.50-1 4 7.50- 14 7.50-1 4 N/A
6.70-1 5*** 6.70-1 5*** 6.70-15*** N/A
TIRE PRESSURE-COLD
Pounds-Rear ......................... 22 22 26* 24*
Front......................... 24 22 24**** 24
*Increase Station Wagon rear tire pressure 4 pounds when fully loaded.
**14 x 5 % K rim used with 11 inch brakes.
***6.70-15 tires use 24 pounds pressure front and rear.
****22 pounds 6-Cy1 Sedans and Station Wagons.
TOOL LIST
C-3339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dial Indicator

C-3455A . . . . . . . . . . . . . ............................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TireBead Breaker
22-2 WHEELS, BEARINGS AND TIRES
WHEELS, BEARINGS AND TIRES

The safety rim wheel has raised sections between Tubeless tires have a uniformly smooth bead con-
the rim flanges and the rim well (Fig. 1). Initial tact area in order to form an air seal with the wheel
inflation Of the tire forces the beads Over these rim. Any foreign matter, accidentally forced between
raised sections. In case of a blowout, the raised
the tire bead and rim, may cause an immediate air
sections tend to hold the tire in position on the
wheel, thus permitting control of the vehicle until leak or the formation of rust which would eVentUally
it can be brought to a safe stop. cause an air leak.
SERVICE PROCEDURES
1. CARE OF TIRES (Fig. 2) should be followed to obtain maximum life

of all tires.
A protective, water-soluble coating is applied to
the white sidewalls of tires at the factory. Wash the
sidewalls with water only, to remove this coating. 3. MEASURING WHEEL A N D TIRE RUNOUT
DO NOT USE GASOLINE OR OTHER SOLVENTS. Wheels and tires may be measured for both radial
DO NOT USE A WIRE BRUSH. and lateral runout. Radial runout is the difference
After the vehicle is in service, the whitewalls between the high and low points on the treads of the
should be cleaned with soap or non-abrasive cleaners tire; while, lateral runout is the “wobble of the
and (if necessary) a soft bristle brush. wheel and/or tire.
Test the tire pressures regularly, including the Prior to measuring the wheel and tires for run-
spare when the tires are cool or cold. Inflate to the out, the face of the hub at the mounting bolts should
specified pressures and inspect for damage and em- be inspected for runout. The hub should be free to
bedded foreign matter at the same time. rotate but tight enough to prevent wobble. The
vehicle should be driven a short distance before
2. TIRE R O T A T I O N the measurement is made so that “flat-spotting” of
With increased road speeds and faster cornering, the tire (from being parked) does not affect the
runout measurement.
abnormal tire wear may exist on certain wheels. By
LEFT F R O N T IIGHT F R O M
rotating tires regularly, the tire life will be length-
I; .I
ened. Spare tires age and deteriorate almost as
much as tires in use, therefore, the rotation plan
r- -
33
Fig. 1-Safety Type Rim Fig. 2-lire Rotation

WHEELS. BEARINGS AND TIRES 22-3
(1) Attach the dial indicator Tool C-3339 to a firm A wheel and tire, to be in dynamic balance, must
base so it will be held steady while taking the runout first be in static balance and also be in balance
readings. from side to side when the wheel is at right angles
(2) Place the plunger of the dial indicator against to the axis of rotation. A wheel not in dynamic
one of the center ribs of the tire tread and rotate balance tends to wobble or shimmy.
the wheel slowly to measure the radial runout. This Correction for static unbalance is made by first
measurement should not exceed .060inch. finding the location of the heavy spot, then adding
(3) To measure the lateral runout (wobble), posi- sufficient weight to counterbalance it at a location
tion the dial indicator against the side of the tire. opposite the heavy section. Follow the equipment
This measurement should not exceed .080 inch. manufacturers recommendations.
Rotating the tire on the wheel may reduce the The total weight to be added should be divided
runout or it may be necessary to take dial indicator in half and the weights placed on the inside and
measurements of the wheel itself in order to deter- outside rim edges.
mine which unit has the excessive runout. Since
the exterior surfaces of the wheel rim may have 5. REPAIRING LEAKS
paint runs or bubbles, scratches or other imperfec- In case of slow air leakage, the puncturing object
tions, it is better to dial indicate the protected areas may be seen or the escaping air can be heard. At
“A” and “B”, Figure 3. The radial runout, “A”, times, it may be necessary to apply a soapy water
should not exceed .050 inch. The lateral runout solution to the tire or to submerge the tire and
(wobble), “B”,should not exceed .050 inch. rim in water in order to locate the leak.
NOTE: Under no circumstances should point Leaks, between the tire and wheel, require the
”C” (Fig. 3) be used for measuring the runout as removal of the tire. Leaks in the tire can often be
this metal has been sheared in the manufacturing repaired without removing the tire. Always follow
process and i s not an even surface. the equipment manufacturers recommendations.
4. WHEEL BALANCE 6. DISMOUNTING AND MOUNTING TIRES

The necessity for balancing wheels is indicated by Tools used for dismounting and mounting tires
heavy vibration of the steering wheel of the car, must be smooth, free from sharp edged or projec-
when driving at speeds above 40 miles an hour over tions which could damage the tire, or tire rim.
a smooth straight highway.
Static (still) balance is equal distribution of the Removal
weight of the wheel and tire around the spindle, (1) Remove the valve core and completely deflate
in such a manner that the wheel assembly has no the tire.
tendency to rotate by itself, regardless of its posi- (2) Carefully force both tire beads over the safety
tion. A wheel that has a heavy spot is statically out raised rim section, into the drop-center section.
of balance, resulting in a “hopping” or bouncing Tire bead breaker, Tool C-3455A may be used to
action.
Fig.3-Runout Checking Areas Fig. 4-Removing Tire With Car Jack

22-4 WHEELS, BEARINGS AND TIRES
force the tire beads over the raised rim section,
however, the car jack may be used as an alternate
method. (See Fig. 4.)
(3) While holding one bead in the center section,
pry the other bead off the wheel. Then remove the
remaining bead to complete the removal.
Cleaning and Inspection
(1) Remove all rust inside the wheel rim and any
roughness on the butt weld in the tire contact
area.
(2) The sealing areas of both tire beads must be
smooth and uniform.
lnst allation
(1) Apply a mild soap and water solution to both
tire beads.
(2) Place one bead over the rim of the wheel,
working the entire bead into the low section of the Fig. 6-Expanding Tire Beads (Rope Tourniquet)
rim.
(3) Place the other bead over the wheel rim and repacked with Wheel Bearing or Automotive Multi-
work the entire bead into the low section of the purpose Lubricating Grease whenever brake linings
rim. are replaced or the brake drums resurfaced. All
(4) While applying air through the valve stem,
the old lubricant should be cleaned thoroughly from
strike the tread sharply with a rubber hammer to the bearings and the wheel hubs and the bearings
force both beads outward over the raised rim sec- repacked with the new grease; the annular groove
tion. It may be necessary to use bead expander Tool of the wheel inner hubs should be filled with the
(2-3440 (Fig. 5) or a rope tourniquet (Fig. 6).
lubricant.
At other times, the lubricant in the bearings
(5) When both tire beads are fully seated, install should be inspected whenever the wheels are re-
the valve core and inflate the tire to the recom- moved to inspect or service the brake system. Do
mended pressure. not repack the bearings if the grease is adequate
in quantity and quality. If the grease either is low
7. FRONT WHEEL BEARINGS in quantity, contains dirt, or has been contaminated
with water to produce a milky appearance, the
The front wheel bearings should be cleaned and bearings and hubs should be cleaned and repacked
as described in the preceding paragraph. DO NOT
ADD GREASE TO THE WHEEL BEARINGS - R E
LUBRICATE COMPLETELY.
Removal
(1) Raise the vehicle so the front wheels are free
of the floor.
(2) Remove the wheel cover, grease cup, cotter
pin and bearing adjusting nut.
(3) Remove the thrust washer and outer bearing
from the hub.
(4) Slide the wheel, hub and drum assembly off
the spindle.
(5) Drive out the inner oil seal and remove the
bearing cone.
~ __ -
Cleaning and Inspeetion
Fig. 5-Expanding Tire Beads (Mechanical Load) (1) Clean the hub and drum assembly and the
WHEEL HUB GREASE CAVITY

6 2 x 41
Fig. 8-Adjusting Front Wheel Bearings
lip of the seal facing inward. Use a wood block

Fig. 7-Wheel Hub Grease Cavity
to drive the seal flush with the end of the hub on
all Valiant Models. Use Tool C-3893 to install the
seal on all Plymouth Models. The seal flange may
be damaged if the tool is not used.
bearings in kerosene, mineral spirits or other sim-
ilar cleaning fluids. Do not spin dry the bearings. (5) Clean the spindle and install the wheel, tire
and drum assembly.
(2) Examine the bearing cups for pits, brinell
marks or other imperfections. If cups are damaged, (6) Install the outer bearing cone, thrust washer
remove them from the hub using a soft steel drift and adjusting nut.
positioned in the slots in the hub.
(3) The bearing cup areas in the hub should be Adjustments
smooth, without scored or raised metal which
could keep the cups from seating against the shoul- (1) Tighten the wheel bearing adjusting nut to
ders in the hub. 70 inch-pounds torque (Valiant models) 90 inch-
pounds torque (Plymouth models), while rotating the
(4)The cones and rollers should have smooth,
wheel.
unbroken surfaces without brinell marks. The ends
of the rollers and both cone flanges should also be (2) Position the nut lock on the adjusting nut
smooth and free from chipping or other damage. so one pair of cotter pin slots aligns with the pin
hole in the spindle (Fig. 8).
lnstallat ion (3) Back off the adjusting and nut lock assembly
one slot and install the cotter pin. The resulting
(1) If the bearing cups were removed, start the adjustment should be zero (no preload) to .003”
new cups into the hub evenly, driving them flush end play.
with the hub, using a soft steel block and hammer. (4)Clean the grease cap, coat the inside with
Seat the cups against the shoulders in the hub, wheel bearing lubricant (do not fill) and install the
using a soft steel drift and hammer. cap.
(2) Fill the hub cavity with the recommended (5) Install the wheel covers and lower the vehicle
wheel bearing lubricant, as shown in Figure 7. The to the floor.
lubricant should be even with the inner diameter of
the bearing cups.
(3) Force the lubricant between the bearing 8. TIRE WEAR PATTERNS
cone rollers or repack with a “bearing packer” tool. For the various tire wear patterns, refer to Figures
(4)Install the cone and a new oil seal with the 9 through 13.
22-6 WHEELS, EEARINGS AND TIRES
37
I
Fig. 9-Camber Wear Fig. 11-Over Inflation Wear
SERVICE DIAGNOSIS
Side Wear (a) Outside (all wheels) excessive (a) Driver instructions.
(Figs. 9 and 10) cornering speed.
(b) Outside (front) excessive positive (b) Adjust camber to specifications.
camber.
(c) Inside (front) excessive negative (c) Adjust camber to specifications.
camber.
(d) Outside and inside-under inflation (d) Inflate tires (when cool) to
or vehicle overload. specified pressure and test vehicle
for overload.
Center Ribs Wear (a) Over-inflation. (a) Adjust tire pressure to

(Fig. 11) specifications (when tires are cool).
I
Fig. IO-Under Inflation Wear Fig. 12-Toe Wear
Fig. 13-Spotty Wear
Sharp Rib Edges (a) Inside edges-excessive toe-in. (a) Adjust toe-in to specifications.
(Fig. 12)
(b) Outside edges-excessive toe-out. (b) Adjust toe-in to specifications.
(c) One tire sharp inside, opposite (c) Inspect for bent arm or knuckle,
tire sharp outside-bent arm or replace parts as required.
knuckle.
Abrasive Roughness (a) Excessive cornering speed. (a) Driver instructions.

Across Tread
Heel and Toe Wear (a) High accelerations (Hot Rodding) (a) Driver instructions.
(b) Severe use of brakes. (b) Driver instructions.
U n i f o r m Spotty (a) Lack of tire rotation. (a) Rotate tires.

Wear (Fig. 13) (b) Tires and wheels out of balance. (b) Balance and rotate assemblies.
Irregular Spotty (a) Tires and wheels out of balance. (a) Balance and rotate assemblies.
Wear (b) Under-inflation. (b) Inflate tires to specified pressure
(when cool).
(c) Loose or worn parts. (c) Inspect front suspension for worn
parts replace as required.
BODY AND SHEET METAL 23-1
GRQUP 23
BODY AND SHEET METAL
CONTENTS
PART 1-BODY MAINTENANCE
Page
Interior Upholstery Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
Cleaning Vinyl Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
Removal Of Dirt From Ivory Plastic Trim Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
Care And Cleaning Of Convertible Coupe Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
Rear Window (Convertible Coupe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
PART 2-BODY ADJUSTMENT

Fitting And Alignment .............. ............................................. 06
Hood Alignment. . . . ........................................................................... 06
Fender Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
Door Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08
Deck lid Alignment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 09
Testing For A Correctly Fitted Deck Lid.. . . . ......................................................... 11
PART 3-BODY SEALING

Body Sealing Procedures. . . . . . . . . . . . . . . . . . ................. ......... ..................... 12
Door Openings And Door ........................................................................ 13
Front Door Vent Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Windshield Weatherstrip. ........................................................................ 13
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Deck l i d . . . . . . . . . . . . . ........................................................... 13
Tail Lamp Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 14
luggage Compartment. . . . . . . . . . ......................................................... 14
Station Wagon ...................................................... ................
Tail Gate Glass Run Channel.. .............................................................. 15
Tail Gate Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PART 4-MINOR B O D Y SERVICING

Fenders, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Radiator Core Support. . . . . . . . . . . . . . . . . . . . . . ............................. 16
Bumpers and Grille.. . . . . . . . . . . . . . . . . . . . . . . . .......................... 16
Front Door Trim And Hardware.. . . . . . . . . . . . . . .......................... 17
Headlining Replacement. . . . . . . . . ................................................................. 18
Custom Positioned Six-Way Manual Front Seat Adjustment.. . . . . . . . . .................................. 20
Front Seat ................................................................................. 21
Rear Seat . . . . . . . . . . . . . ........................................................................ 21
Rear Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............................. 21
Exterior Mouldings, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .............................. 21
Doors, Deck Lid, and Hardware.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 22
Door Hinges (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................ 23
Door Outside Handle.. . . . . . . . . . . . . ....................................................... 23
Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Window Regulator (Front Door). . . .................................................................. 24
Remote Control and Door lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................ 25
Rear Door Remote Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Deck Lid. . . . . . . . . . . . . . . . . . . . . ......................................... ......... 26
Deck Lid Hinges. . . . . . . . . . . . . . . .................................... 26
23-2 BODY AND SHEET METAL
C O N T E N T 6 (Continued1
Page
Deck Lid Torsion Bar Replacement....................................................................... 26
Deck Lid Lock Adjustment.............................................................................. 27
Deck Lid Lock Cylinder ................................................................................ 27
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Window (Plymouth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Door Ventilator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Door Glass Run Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Front Door Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Glass Lift Bracket Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear Door Window Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear Door Glass (4 Door Hard Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rear Door Glass (Plymouth Sedan Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Door Stationary Glass (Valiant Sedan and Station Wagon Models) ....................................... 33
Rear Door Glass Run Channels (4 Door Hard Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Door Lock and Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Quarter Glass (All Models Except Station Wagon and Valiant Two Door Hard Top Models) ........................ 35
Quarter Glass Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Quarter Glass Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Body Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacement Of Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removing Old Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Paint Refinishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dark Spots Appearing On Paint (Polychromatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Foreign Material In Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PART 54ONVERTIBLE COUPE

Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Convertible Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
To Lower The Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
To Raise TheTop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Top Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Top Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Top Header Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Correcting Top Header Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Roof Side Rail Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting Front Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rear Hinge Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Main Control Prop Link Bracket Adjustment................................................................ 43
Top ShiftsTo One Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Guide Link Adjustment (Plymouth Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Front Top Bow Adjustment (Plymouth Only) ................................................................ 44
Top Material Padding For Overhang .................................................................... 44
Roof Side Rail Weatherstrip Adjustment .................................................................. 44
Rear Bow Tension Cables .............................................................................. 45
Removing Wrinkles In Backlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Correcting Top Well Water Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Quarter Window Belt Water leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Servicing The Top Folding Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking Fluid Level In Reservoir......................................................................... 47
Top Will Not Raise or Lower ........................................................................... 47
Testing The Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Testing Wires Between Control Switch And Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
.
BODY AND SHEET METAL 23-3
CONTENTS---(Continued1
PART 6-STATION WAGON
Pam
Tail Gate (Plymouth and Valiant) ....................................................................... 48
Tail Gate Alignment (Plymouth and Valiant)............................................................... 48
Tail Gate (Plymouth).................................................................................. 48
Tail Gate (Valiant)................................................................................... 49
Tail Gate Glass (Plymouth and Valiant) .................................................................. 49
Tail Gate Run Channel (Plymouth and Valiant)............................................................. 49
Quarter Window (Plymouth and Valiant)................................................................. 50
Tail Gate Glass Alignment (Plymouth and Valiant).......................................................... 50
Station Wagon Rear Seats ............................................................................ 50
64x690
.
Fig 1-Unit Body Construction
23-4 BODY MAINTENANCE
PART 1 - BODY
The body and frame (Fig. 1) are combined into a a bleach as this could discolor the fabric. Most deter-
welded and reinforced shell of exceptional strength gents contain a certain amount of bleach, caution
and twist resistance. Sturdy reinforcements are used should be exercised as to the amount used.
throughout the lower body structure to carry driving, Some of the more common upholstery stains can
braking and suspension loads. They are formed of be removed as follows:
heavy box sections which distributes the major road Candy, Chocolate or Ice Cream Stains. Scrape off as
forces to broad areas of the body structure. The box much of the staining matter as possible with a dull
sections also provide solid supports for the bumpers, knife. Clean with one-half of 1% solution of laundry-
sprir.gs and shock absorbers. type detergent in warm water.
All door pillars, sills, roof rails, windshield headers,
and belt line rails are fully boxed to provide maximum General Instructions: Use a piece of Clean cotton
strength. The heavy gauge front fender side shield cheese cloth approximately 3” x 3”. Squeeze most of
are welded to the dash panel, side sills, and radiator the liquid from the fabric and it is less likely to leave
yoke to form a rigid front end structure. The side a ring. Wipe the soiled fabric very lightly with a lifting
shields also protect the engine from road splash. The motion. Always work from the outside toward the
deck lid and hood are reinforced for greater strength, center of the spot. Turn the cheese cloth over as soon
rigidity and twist resistance. More than 5300 spot as one side becomes stained to prevent working the
welds and seam welds are used to join the many steel staining matter back into the cleaned portion of the
stampings which make up the body structure. Two fabric. Use a new piece of cheese cloth as soon as
structural members are bolted in place, one is the both sides become stained.
K-shaped engine support crossmember, and the other Grease, Oil or Tar Stains. Scrape off as much of the
is the short member which supports the transmission. staining matter as possible with a dull knife. Clean
The front fenders and grilles are attached with bolts the fabric using the recommended cleaner. Be sure
which provides ease and low cost in replacement. the manufacturers instructions are as followed. Fol-
The bodies are subjected to a very intensive seven low General Instructions as listed above.
stage immersion anti-corrosion and a rustproofing If grease, oil or tar stains cannot be removed satis-
process. factorily with fabric cleaner on a certain type of
fabric, use carbon tetrachloride cleaning fluid. The
1. INTERIOR UPHOLSTERY CLEANING same procedure can be followed as with fabric
Most stains can be removed quite easily from cleaner.
fabrics while they are fresh and have not hardened CAUTION: Carbon tetrachloride i s very toxic to
and set into the fabric. An exception is mud or clay, breathe. Since fabric cleaner contains a large portion
which should be allowed to dry so that most of it can of carbon tetrachloride, adequate ventilation must
be brushed off. It is also very helpful, though often be provided when either of these cleaning fluids are
not possible, to know the nature of the staining used. A fan should be set to blow directly across the
matter so that the proper solvent may be used. Most area in which the cleaning is done. To prevent skin
common stains can be removed either with a dry cracking from the use of those cleaning fluids, apply
cleaning solvent, such as kar-kleen, fabric cleaner or a lanolin type skin cream to the hands after using
carbon tetrachloride cleaning fluid, or with water the cleaning fluids.
solution containing one-half of 1% of a laundry-type
detergent. Thus, if the nature of the staining matter Lipstick or Rouge Stains. First work white vaseline
can only be guessed at and a dry cleaning fluid does into the staining matter to loosen it. Then clean with
not remove the stain, it should then be cleaned with fabric cleaner or carbon tetrachloride cleaning fluid
a one-half of 1% solution of a detergent in water, or as recommended.
vice-versa. Mud or Clay. Allow the mud or clay to dry com-
When using a detergent, do not use one containing pletely. Then, brush it off with a soft bristled brush.
BODY MAINTENANCE 23-5
Clean with one-half of 1% solution of detergent in 3. REMOVAL OF DIRT F R O M I V O R Y

water. PLASTIC T R I M PANELS
When cleaning by any of the methods outlined The ivory plastic trim should be cleaned in the
above, never squeeze the liquid from the cleaning same manner as other vinyl interior trim, however,
cloth back into the container of cleaning fluid, and if the dirt has been rubbed into the grain so that it
never dip the cleaning cloth back into the container is not possible to remove with the detergent solution,
of cleaning fluid after the cloth has contacted the a cleaner may be used. Any abrasive cleaning ma-
stain. Be sure that the cleaning fluid has no impurities terial will cause the material to peel. To clean, use
and is not discolored before using it. If particles plain water or water with a mild soap solution.
of the staining matter become locked between the
fibres of the fabric, it may be necessary to use a clean 4. CARE A N D CLEANING OF
soft bristled brush instead of the cheese cloth with the CONVERTIBLE COUPE TOP
cleaning fluid. Frequent brushing and vacuuming will keep the
top free of abrasive dust and dirt. Wash top with
2. CLEANING V I N Y L T R I M warm water and mild soap, lathering well with a soft
cloth or sponge. Rinse with plenty of clean water to
The following are recommendations for remove all traces of soap. Allow to dry completely
plastic trim: before lowering.
Grease, Oil or Tar Stains. These stains should be
cleaned as soon as possible or they will migrate into 5. REAR WINDOW (Convertible C o u p e )
the plastic and leave a permanent discoloration on The rear window is made from flexible vinyl plastic
the plastic surface. These stains should be cleaned material and special attention should be given to
with either fabric cleaner or Kar-Kleen, as recom- cleaning and storage of the window. To clean the
mended above. window, rinse with a cold water spray to remove grit
The stain gained vinyl should be cleaned as soon as and dirt. Lather the surface with suds of a mild soap
it appears to be getting dirty. Otherwise the dirt using the palm of the hand. Rinse thoroughly and
particles will get rubbed into the small grain crevices allow to air dry. Do not use a towel, sponge, or
and be almost impossible to remove. The dirty vinyl cham& to apply suds or to dry the window. Other-
trim should be cleaned with a piece of clean cotton wise, the surface may be come scratched. If this
cheese cloth dipped in a sudsy solution of a non- procedure does not clean the window thoroughly, a
alkaline detergent in water. If the vinyl plastic trim solution of 40 per cent rubbing alcohol and 60 per
still does not clean up, a clean brush with many cent clean water should be used. Apply with palm of
fairly stiff bristles should be used in place of the hand and rub surface of window with a circular mo-
cheese cloth. tion. Use solution generously.
23-6 BODY ADJUSTMENT
PART 2
BODY ADJUSTMENT
6. FITTING AND ALIGNMENT
The appearance and weather sealing of all moveable
parts of the body assembly are controlled by built in
adjustments that permit the fit and alignment of
hood, front fenders, doors, movable glass, deck lid
and bumper face bars.
In fitting and aligning these movable parts, a
definite sequence of alignment should be followed to
insure the best in appearance and weather sealing.
It is best to start with hood to body cowl alignment,
hood to front fender and grille alignment, front fen-
der to body cowl, front door to body and front fender
to body cowl, front door to body and front fender,
rear door to body opening, front door glass to rear
door glass (hardtop models), deck lid to body, front
and rear bumper face bar alignment. Fig. 3--..30( Hinge Adjustments (L Jliant)
7. HOOD ALIGNMENT Valiant

The hood is counterbalanced by two torsion bars
PIymouth extending across the front of the cowl panel (Fig. 3).
The hood is attached to the cowl panel through two The hood is adjusted by means of oversize holes in
counterbalanced hinges (Fig. 2). The attaching bolt the hinge arm.
holes of the hinges are oversize, permitting movement
of both the hinge and the hood panel. Hood to Cowl IPIymouth and Valiant 1
Prior to making any hood adjustments inspect and (1)Inspect the cowl alignment for tightness, loose-
note clearances and alignment of all sides of the hood ness, uneven gap and high or low elevation at the
in relation to the cowl, fenders and grille. The cowl corners.
adjustment must be made first. (2) Prior to adjustment, scribe the hinge position
on the hood.
(3) Loosen the hood attaching bolts (Figs. 2 and
3) and move the hood to the desired position to cor-
rect the alignment at the cowl.
(4) Tighten the attaching bolts to 180 inch-pounds
torque.
( 567 A!
Fig. 2-Hood Hinge Adjustments (Plymouth) Fig. &Hood leveling Adjustment

BODY ADJUSTMENT 23-7
Unequal Spacing Between Rear of Hood
and Fenders IPlymouth and Valiant I
(1) Loosen the hinge to hood attaching bolts on
each side of the hood.
(2) Shift the hood (at rear) in the direction of the
wide space, until spacing appears to be equal on each
side.
(3) Tighten the hinge to the hood bolts, lower hood
and inspect for correct fit.
If the spacing is cofrect on one side but too little
or too much on the other side, loosen the bolts at-
taching the hood to hinge on the side to be adjusted.
If the hood needs to be moved out, insert a large
Fig. 5-HOOd Lock Assembly (Plymouth) screw driver between the upper hinge plate and the
hood flange. Force the hood out as required while
(5) Reinstall the hood and cowl alignment. holding pressure on the screw driver, and tighten
the bolts securely.
(6) If corners of the hood are found to be high or To move the hood in, apply pressure on the out-
low in relation to the cowl panel, scribe the hinge side edge of the hood, then tighten bolts securely.
location on the cowl panel (Plymouth only). Lower the hood and inspect the hood for proper fit.
(7)Loosen the hinge attaching bolts (Figs. 2 and
3) and raise or lower the hinge. Fender Below Level of Hood
(8) (After step 7, if the rear of the hood and If the hood has been properly adjusted and one
fender are not flush, it will be necessary to reset the fender is still below the level of the hood at the front,
fender to align with the cowl and hood.) the fender should be raised.
(1) Raise the hood, then loosen the bolts that hold
Hood to Fender IPlymouth and Valiant I the fender to the radiator support.
After completing the hood to cowl alignment, in- (2) Place a wood block or cloth pad on the lifting
spect the front of hood to fender clearance. The pad of the service jack and install under the front
height of the hood to fender can be adjusted by re- lower corner of the fender.
moving the hood bumper (Fig. 4), and turning the (3) Raise the jack slowly until the fender is in
adjusting screw in or out. It may be also necessary alignment. Leave the jack in place and tighten the
to loosen the fender attaching bolts and move the fender bolts securely.
fender up or down to the desired position.
(4) Lower the jack, close the hood and inspect the
Haad to Grille IPlymouth and Valiant I fit.
The height of the hood to grille clearance may be (5) Adjust the hood bumpers as required.
adjusted by lengthening or shortening the hood sup-
port studs (Fig. 4). The mounting of the hood lock is Adjustment of the Hood Striker and
adjustable to insure alignment with the hood striker Lock Assembly
(Figs. 5 and 6). The hood striker is mounted between the grille
support and the radiator core support. The hood latch
is mounted on the forward edge of the hood and
oversize attaching holes permit dignment of the
hood (Figs. 5 and 6).
8. FENDER ALIGMMENT
Gap Between the Rear Edge of the
Fender and Sill Panel-Spacing
'
Correct at Upper Sectton
Loosen the bottom fender to cowl attaching bolts.
Place a 2 x 4 board between the tire and the fender.
\
SAFETY CATCH 64x511
Protect the edge of the fender with a cloth pad. Pry
the fender back to close the gap then retighten the
Fig. &Hood Lock Assembly (Valiant) attaching bolts.
23-8 BODY ADJUSTMENT
Fender too Far Forward at

Upper Door Opening
Loosen the fender-to-cowl attaching bolts. Apply
pressure to the forward section of the fender until
the correct alignment is obtained. Then tighten the i
fender-to-cowl attaching bolts.
9. DOOR ALIGNMENT
Make a thorough inspection of the door before at-
tempting adjustment. A properly fitted door has even-
ly spaced gaps on all sides.
Test the engagement of the door latch with the c
striker plate. If the door raises as the latch passes Fig. 8-Front Door Hinge Adjustment (Plymouth Shown)
over the plate, the plate is too high and must be
lowered. The striker plate shown in Figure 7 can be tained then tighten the hinge bolts securely. Inspect
moved “In” or “Out” and controls the tightness of the scribe lines to make certain the rear portion of
the door against the body. The “Up” and “Down” the door did not move forward or rearward during
adjustment will determine the actual point of engage- the above operation.
‘
ment between the door lock rotor and the lower por-
tion of the striker plate. Moving Door Ahead or Back
After the door has been fitted properly to the (Front Door1
opening, adjust the striker plate as necessary. Moving the door ahead or back is accomplished by
loosening either the upper or lower hinge bolts.
To Raise or Lower the Door To move the upper portion of the door ahead or
(Front Doors1 (Fig. 81 back (kick panel removed), loosen the upper hinge
To raise or lower the door, remove the kick panel. strap bolts and either pull or push the upper portion
Then, place the jack under the door as near the hinge of the door in the desired direction. Tighten the
as possible. (Thiswill hold the weight of the door as hinge strap bolts and test the fit. When correct rein-
hinge bolts are loosened.) stall the cowl trim panel.
(1) Scribe a line around the upper and lower hinge To move the lower portion of the door ahead or
strap. back (kick panel removed), loosen the upper hinge
(2) Loosen the upper and lower hinge strap bolts.
strap bolts and either pull or push the lower portion
The amount of vertical movement in the door is of the door in the desired direction. Tighten the
limited; however, the amount of movement can be hinge strap bolts and test the fit. When correct, re-
determined by the scribed line previously made. Raise install the kick panel.
or lower the jack until the desired clearance is ob- Fitting the Front Door Flush with the
Adjacent Panels
If the door is not flush with the adjacent panels
correct by loosening the hinge strap bolts (on front
doors or hinge strap bolts on the rear doors).
TKER
It should be remembered that when loosening the
upper hinge and pulling “out” or pushing “in” on
the front upper corner of the door, the lower corner
of the door will be moved inward or outward also.
The opposite corners of the door will also be affected
in a similar manner when the lower hinge is moved
“in” or “out”. This applies to both the front and
rear doors.
Rear’ Door Adjustments I Fig. 9 1
To move the door up or down in the body opening
~ u i u nI
or move the door in or out to bring the door panel
64 x 425
flush with the body proceed as follows:
Fig. 7-Door Striker and Rotor (1) Loosen the hinge attaching bolts at “B” pillar.
BODY ADJUSTMENT 23-9
5 \ \
,
ADJUSTING SCREWS
Fig. 1 b D e c k l i d Hinge and Torsion Bar
hinges and is held closed by the lid latch and lock.

The weight of the lid is counterbalanced in all
Fig. 9-Rear Door Hinge Adjustment (Plymouth Shown) positions by spring tension of two torsion bars (see
Fig. 10). (On Convertible Models, the weight of the
(2) Move the door as required to obtain the proper lid is counterbalanced by four springs, two each side.)
fit with the door opening. (See Fig. 11.)The torsion bars are long, small diameter
(3) Tighten the bolts securely. steel bars, that are free at one end and anchored to a
Final Strlker Plate Adjustment
After the door has been centered in its opening and
all hinge bolts have been tightened 18 to 20 foot-
pounds torque. Test the door for easy opening and
closing.
Be sure the top surface of the striker plate is
parallel with the bottom of the door latch. The striker
plate is properly positioned when the door has a very
slight lift as it is closed. This also prevents door noise
when the vehicle is in motion.
If the proper adjustment cannot be obtained, the
use of shims between the latch plate and pillar
should be used. The shims are available in y32 and
l/lsinch thickness (The shims are used to bring the
latch plate closer to the door for the full engagement.)
The door weatherstrip seal can be tested by holding
a heavy piece of paper (similar to a shipping tag) on
the weather seal and then closing the door. A slight
drag should be felt as the paper is being pulled out.
If no drag is felt, move the striker plate in closer.
This paper test should be made all around the door at
about six inch intervals.
If no drag is felt on the paper, make the necessary
adjustments to either or both hinge or the striker
plate.
10. DECK LID ALIGNMENT

The rear deck lid is attached to the body with two [Fig. 1 1-Deck l i d Hinge (Convertible)
23-1 0 BODY ADJUSTMENT
support bracket at the other end. A roller sleeve on
the free end, operates against a “cam contour” on
the back face of the hinge. As the deck lid is raised,
action of the rollers against the hinges cause the
bars to twist, exerting a torsional spring resistance
that balances the lid. To permit adjustment of the
torsion bar tension, slots are located in each support
plate.
The torsion bar hinge mechanism applies lifting
force to the hinge arms. Moving the torsion bar to
the rear holes increases the force applied and pro-
vides greater assistance in lifting the deck lid. (A
tool to perform this operation can be made and used,
as shown in Figure 12.)
The torsion bar tension can be adjusted by placing
the end of the bar in one of the slots in the mounting Fig. 13-Deck l i d Adjusting Points
bracket. The upward travel of the deck lid is limited
by a stop on the bracket, which contacts the hinge ahead or back. When positioning, locate the lid so
arm. extreme rear portion along the sides are both flush
The torsion bar ends are lubricated at the factory with the body panel as well as equally spaced in the
and should not require lubrication; however, if the opening. To adjust, loosen the hinge bolts (one at
torsion bar is replaced or should squeak, the inside a time) as shown in Figure 13. Move the lid in the
roller at the torsion bar end should be coated with desired direction, retighten the bolts. Repeat this
lubricant. Refer to “Front Suspension.” Group 2. operation on the opposite side until the lid fits flush
CAUTION: Use extreme care when removing the with the body and quarter panels.
torsion bars. Due to the tension required to make the
bars effective, the bars will unwind. resting Latch and Striker Plate
Both the latch and striker plate are adjustable,
Center De:& Lid in Opening but better results can be obtained by adjusting the
The two bolts holes in each of the deck lid hinges striker plate. The striker plate is adjustable in two
are oversize, thereby permitting the lid to be moved directions, forward and backward, and to either side.
As the plate moves to the rear, it also rises making it
easier to close the lid. Moving the plate forward lowers
it and makes the lid harder to close.
Deck Lid Lock Adjustment
(Fig. 141
Vertical adjustment of the deck lid lock is made at
A
I . \j
-4
7
63x846
Fig. 12‘forsion Bar Removal or Installation dig. l d D e c k l i d l o c k

BODY SEALING 23-11
the lock attaching screws (Fig. 14). The side adjust- A test for the proper fitting and seal of the deck lid
ment is made at the deck lid striker attaching bolts. can be made with strips of paper. Insert the strips
of paper (about one inch wide) along the edge of the
deck lid opening, close the lid. If the papers fit snug
11. TESTING FOR A CORRECTLY all along the edges of the lid as they are pulled out, a
FITTED DECK LID good seal is evident. If the paper fits loosely on one
A correctly fitted deck lid is one that is centered side, and tight on the other, the deck lid should be
in the opening, and fits flush with the body panels. aligned.
W EATHERSTRIP
EW IN DIRECTION
IN CIRCLE Z BUTT JOINTS 64x459
Fig. 15-Front and Rear Door Weatherstrip (Sedan)

23-1 2 BODY SEALING
PART 3
BODY SEALING
12. B O D Y SEALING PROCEDURES Dash Panel (Outer1
Super Rubber Cement-This cement may be used
Inspect the dash panel seams, screws, clips and
where a strong bonding of rubber parts to painted or punch holes. Inspect the sealing of rubber grommets.
unpainted steel surfaces is desired. It can be used Cowl Panel Joints ( Inner I
for such purposes as the attachment of weatherstrip- Inspect the various openings in the cowl for possible
ping on doors and luggage compartment lid, or for leakage around the cowl vent and windshield opening.
the attachment of felt pads. Clean the seamed area thoroughly and apply Heavy
Sealing Putty or Body Seam Sealer. Be sure to apply
Windshield Rubber Sealer-A light viscosity, color- the sealer over the hood hinge bracket and along the
less rubber expander, this sealer can be used where seam to the rear end of the front fender.
rubber is confined between a glass and metal channel,
such as on the windshield and rear window glass Door Hinges
Inspect the sealer on the door hinges at the pillar
assembled in one-piece type weatherstrips. When ap-
post. The sealer should be filled flush with the pillar
plied to the edge of the rubber, it will expand the
post. This should be done after door fitting, as the
rubber within 15 to 20 minutes. This sealer will not
sealer may become cracked or loose. Reseal as nec-
harm paint or chrome finish and can easily be re-
essary.
moved with a cloth before it sets.
NOTE: Water testing a vehicle should be done by
NOTE: Before sealing, always clean all surfaces sections. Working on small areas, it is possible to
to be cemented with unleaded gasoline. Do not use locate the points which require sealing. The correct
kerosene, as this liquid leaves a thin film of oil which method of water testing a vehicle should be from the
will prevent adequate adhesion of the sealer. bottom up, not from the top down.
DRAIN TRPUGH DRAIN TROUGH
IEW IN DIRECTION
W EATHERSTRI
DIRECTION OF
ARROW X
VIEW IN DIRECTION
OF ARROW U
W EATHERSTRIP
VIEW IN
CEMENT VIEW IN CIRCLE Y VIEW IN CIRCLE V DIRECTION OF ARROW S 64x460
Fig. 16-Front and Rear Door Weatherstrip
(Hard Top)
BODY SEALING 23-13
A strong force of water should never be played Leaks around the pivots can be corrected by the
on the vehicle, since a perfectly sealed vehicle may use of black mastic. Fill the openings in the weather-
leak under this condition. strip. Seal around the upper pivot bracket at the door
It is advisable, when testing the leaks in a vehicle frame and at the junction of the division bar and door
to start with the windshield wiper pivots, windshield, frame.
vent wings and then the remainder of the body. The first and most important requirement to ob-
tain a good water tight seal between the door window
13. DOOR OPENINGS AND DOOR and the roof rail weatherstrip is precise adjustments
(Figs. 1 5 and 16) of the doors, and window frames and channels.
Adequate adjustments are provided for up and down,
Door openings contribute to water leaks in two in and out, and fore and aft adjustment of the win-
ways: First, there may be leaks at the metal joint dow frames. It is important that the weatherstrip has
seams and secondly, the &or weatherstrip may not be sufficient pressure against the frame, but too great
effecting a good seal. Prior to sealing, test the door pressure will push the window frame out of align-
sealing using a water or powder test. A visual in- ment and will prevent proper contact with the mating
spection may also aid in diagnosing the source of window weatherstrip.
the leak.
The door weatherstrip should show no bunched, 15. WINDSHIELD WEATHERSTRIP
kinked or stretched areas. The seal should be butt-
jointed with no opening. In event the door opening Seal the weatherstrip against the body opening by
weatherstrip surfaces are uneven, the weatherstrip carefully working a thin coating of Windshield Rub-
will not effect a good seal. Build up low areas, be- ber Sealer, or Body Seam Sealer, between the body
tween the weatherstrip and the door opening panel edge and the rubber moulding, or, lift the lip of the
with a closed cell rubber shim. rubber weatherstrip where it contacts the body metal,
When it is necessary to install a new weatherstrip, and use a nozzle-type applicator (sealer gun) to force
first remove all the old weatherstrip, sealers and the sealer deeply around the entire edge. It is rarely
cement. When solvents are used to remove the sealers necessary to reseal between the glass and the weath-
and cement, use only those types which will leave the erstrip, unless the glass has been replaced. If faulty
metal clean, free of oils and perfectly dry. Install a sealing of the glass to the weatherstrip has caused a
one piece design weatherstrip on the door opening leak, remove the windshield garnish moulding and
fence and index it at the sill to center pillar joint. apply sealer as far down as possible between the in-
Apply cement completely around the weatherstrip ner weatherstrip and the glass for a considerable dis-
and press it firmly onto the fence. The butt-joint of tance on each side of the leakage point. Clean off ex-
the weatherstrip should be thoroughly cemented at cess sealer with a rag. Reinstall the mouldings and
the mating ends and correctly aligned. After the test for proper seal.
cement has set up, test the door for leaks.
16. REAR WINDOW
14. FRONT DOOR VENT WINDOW If the water enters the luggage compartment under
the package shelf, remove the rear window lower
Leaks through the vent window can be located by trim moulding and clean out the old sealer from the
a water test. After locating the leak area, inspect the trough below the weatherstrip. Apply semi-fluid sealer
condition of the vent weatherstrip, the fit of the vent or rope type sealer along the entire length of the
glass in the vent opening, and the compression of trough. Seal the trough at both lower corners of the
the vent glass weatherstrip. window.
In most cases simple adjustments will correct To aid in the installation of the moulding, mark
leaks between the vent glass and the weatherstrip. the clip holes by placing balls of sealer to the rear of
To increase the pressure of the glass against the each moulding hole. This helps align the trim mould-
upper portion of the weatherstrip, install shims from
ing retaining studs with the holes and avoids the pos-
the closed cell rubber shim stock between the upper
sibility of moving the sealer or damaging the paint.
vent pivot bracket and the outside of the vent glass. Remove balls of sealer when moulding is installed.
Application of black mastic or body sealer to the
corners of the vent weatherstrip generally corrects
the leak in this area if the weatherstrip overlaps. If 17. DECK LID
the weatherstrip is severely damaged, install a new Before water testing the deck lid make certain the
vent window assembly. deck lid is properly fitted. Start the water test at the
23-14 BODY SEALING -
bottom and work slowly toward the top of each side. appear in the luggage compartment, floor extensions
Then work across the top of the lid. Test the two up- near the quarter panel.
per and lower welded joints for proper sealing. Before attempting to correct luggage compartment
If the leakage occurs at the seam between the leaks, carefully determine the source of the leak. As
weatherstrip trough and the deck upper panel and it was explained in the previous paragraphs, water on
quarter panel, fill any openings with a rope type sealer the upper portion of the wheel housing may be
and paint the sealer body color if necessary. coming in because of a leak at the lower moulding of
the rear window. A leak inside the luggage compart-
18. TAIL LAMP OPENINGS ment between the outer wheel housing and quarter
panel may originate at the corner of the rear quarter
Water test the tail lamp area for possible leakage window.
into the luggage compartment. Water will enter the
NOTE: Do not confuse condensation on metal
trunk area between the tail lamp housing and quarter
parts with water leaks.
panel openings. To secure a good seal use a hand type
caulking compound and seal the opening from inside When the actual source of the leaks has been traced
the luggage compartment. to the luggage compartment itself, correct as fol-
lows:
Be sure to obtain the proper fit and alignment of the
19. LUGGAGE COMPARTMENT luggage compartment deck lid before trying to cor-
Leaks may occur at medalions or clip-holes, tail rect the leak at the deck lid weatherstrip. Inspect the
lamps or the rear quarter panel which will generally luggage compartment deck lid drain trough and
TAI LGATE WEATHERSTRI P
PILLAR TO WHEEL
SE REINFORCEMENT
VIEW IN CIRCLE C
'Fig. 17-Tail Gate Weatherstvip
BODY SEALING 23-15
weatherstrip retainer joints for rough and porous ed to the sedans and coupe models.
welds. Seal with body caulking putty or body sealer
as required. Brush a continuous coating of weather- 21. TAIL GATE GLASS R U N CHANNEL
strip cement around the entire weatherstrip trough.
Install the deck lid weatherstrip into the retainer. Be Water leaking past the glass run around the chan-
sure weatherstrip retaining lips are engaged in the nel may be sealed off by applying sealer to indicated
retainer trough. Be sure to obtain the proper com- points. Water leaking around the glass run may be
pression of the deck lid weatherstrip. Adjust the deck sealed by removing the glass run and applying addi-
lid if necessary to obtain the proper compression. tional beads of sealer to the glass run channel. Press
Test with the use of slips of paper, trace powder and a bead of rope type seal into the moulding seams and
a testing bulb. clean off the surplus. While the rear pillar garnish
Leaks at the deck lid weatherstrip retainer trough moulding is removed, inspect the outer “0” shaped
joint bodies can best be sealed by loosening the weath- opening, if necessary seal. This opening should be
erstrip at the joint and applying sealer to the entire filled with caulking putty.
seam at the inside of the trough and then recementing
the weatherstrip. 22. TAIL GATE WEATHERSTRIP
Seal all openings and joint seams on the inside of ( Figure 1 71
the luggage compartment lower panel, especially The tail gate weatherstrip is designed to fit under
the back-up lamp wire grommets. Seal all luggage a lip and into a channel at the sides of the tail gate
compartment floor panel seams with liquid body seal- opening. At its upper end a piece extends out and fits
er. Seal between the luggage compartment lower up into the bottom of the pillar. Remove all weather-
panel and foor panel with black mastic sealer. strip that is not installed properly. Clean the chan-
nel and the weatherstrip with cement removing sol-
20. STATION W A G O N vent. Apply a coat of cement to each part and reinstall
Sealing procedures pertaining to the roof, cowl, weatherstrip. At the bottom of opening it is sometimes
firewall, fresh air vent, doors and openings are es- necessary to remove the weatherstrip and after clean-
sentially the same as contained in the section devot- ing, shim the weatherstrip surfaces and reinstall.
23-16 MINOR BODY SERVICING
PART 4
M I N O R BODY SERVICING
23. FENDERS Removal
Removal (1) Drain the radiator, remove the radiator hoses
and the radiator core attaching screws. Remove the
(1) Remove the outer headlamp door and headlamp
radiator from the engine compartment.
assembly.
(2) Remove the hood lock striker bar.
(2) Remove the fender to radiator core support at-
taching bolts. (3) Remove the horn and headlamp wiring from
the core support.
(3) Remove the bolts attaching the fender to the
stone shield. (4) From under the fenders remove the fender side
shield to core attaching screws.
(4) Disconnect the headlight ground wire at the
fender. (If the left fender is being removed, remove (5) Remove the core support to frame attaching
the battery cables from the battery and remove the screws.
battery.) (6) Remove the radiator core support up and out
(5) Remove the outside rear view mirror or the an- of the engine compartment.
tenna lead (if so equipped).
/nstallatton
(6) Remove the fender rear splash shield. (1) Position the radiator core support down into the
(7) Remove the bumper assembly. engine compartment. Install the frame to core sup-
(8) Remove the bolts attaching the fender to the port attaching screws finger tight.
splash shield, and remove the fender by pulling for- (2) From under the fender install the fender side
ward and outward. shield to core support attaching screws only finger
tight.
installation
(1) Place masking tape over the forward edge of (3) Attach the horn and headlamp wires to the
the front door to protect it from scratches during in- core support with the plastic straps.
stallation of the fender. (4) When all the attaching screws have been in-
(2) Position the fender on the splash shield and installed tighten them securely.
stall two or three bolts finger tight only to hold the (5) Install the radiator core, and radiator.
fender in position.
(3) Install the balance of the fender to splash 25. BUMPERS A N D GRILLE
shield bolts loosely. Refer to Figures 18, 19, 20, 21, 22 and 23 for the
(4) Align the fender and tighten all bolts securely. bumper and grille attaching points.
(5) Install the fender rear splash shield.
(6) Connect the headlamp ground wire.
(7) Install the headlamp assembly.
NI IT WASHERS GUARD __
(8) Install the headlamp door.
(9) Install the fender core support attaching bolts
and tighten securely.
(10) Install the bumper assembly.
(11) Install the battery assembly and connect the
'
battery cables.
-'?A
- ~~
BOLT
BUMPER
24. RADIATOR CORE SUPPORT

The radiator core support is the basic foundation
for all front end sheet metal. In the case of an acci-
dent it is best to replace the support if there is indi-
cation of sheet metal misalignment. Fig. 18-Front Bumper Attaching Points (Plymouth)
MINOR BODY SERVICING 23-17
BODY RAIL SUPPORTS BUMPER
G-UARD
64x513 '
NUT &BOLT
\
BUMPER 64x515
Fig. 19-Rear Bumper Attaching Points (Plymouth) Fig. 21-Front Bumper Attaching Points (Valiant)
26. FRONT D O O R T R I M A N D HARDWARE holes of the door frame and bump into place with the
heel of the hand.
lnside Handles
(6) Install the escutcheon washer, handles, and arm
Both the inside door and window regulator han-
rest.
dles are retained to the shaft by a screw in the hub
of the handle (Fig. 24.) Door Weatherstrip Assembly
Door Trim Panels (1) Remove the attaching screws and step plate
from the door sill.
(1) Rerr ve the inside handles and arm rests.
(2) Starting at one end of the trim and weather
(2) Inser, d wide blade screw driver between the
trim panel and the door frame next to the retaining
clips and snap out the retaining clips around the edge \ \
of the trim panel. Remove the trim panel from the

door.
(3) Before installing the door trim .panel, observe
the condition of the weather curtain cemented to the
door frame.
(4) Be certain escutcheon springs are placed on the
regulator and remote control shafts.
(5) Align the trim panel retaining clips with the SCREW 64x368
CFOSS BAR Fig. 22-Rear Bumper Attaching Points (Valiant)
SHIELD -.
.k'\
> ,
*
--2
Cig. 20-Grille Awaching Points (Plymouth)

64x514
Fig. 2 3 i G r i l l e Attaching Points (Valiant)
23-1 8 MINOR BODY SERVICING
WINDOW REGULATOR HANDLE
/
K!
rr
SPACER
SCREW
-. . . .^. . ......-
L
64 x 431 SCREW
3 REMOTE‘CONTROL
HANDLE
‘Fig. 26-Headlining Bows
Fig. 2 A l n s i d e Handle Attachment
er strip away from the roof rail above the doors.
seal, pull the assembly off the door opening flange The headlining is cemented in place over the wind-
(Fig. 25). shield header and at the rear window body opening.
(3) On installing the trim and seal assembly locate To remove the lining it will be necessary to remove
the ends at the center of the step plate. the cemented front and rear sections before remov-
(4) Place the weather seal over the door opening ing the headlining and the bows from the roof rails.
flange and bump the retaining clips into place with The roof rails on all models using cloth headlining
the heel of the hand. are strung through retaining loops sewed into the
(5)Install the door step plate and the attaching lining. Each bow is held in place by an attaching
screws. loop pressed into each roof rail (Fig. 26)and spring in
place when installed to keep the headliner taut.
27. HEADLINING REPLACEMENT (4) After pulling headlining from over doors and
Sedan Models-Removal package shelf, start at the windshield pull lining from
the header. Use care not to damage the lining.
Remove the dome light assembly and rear seat
cushion assembly as well as the sun visors, side and
upper windshield garnish moulding.
(1) Pull the rear of the headlining out at the top
and down the sides of the rear window opening.
(2) Pull the headlining from under the rear package
shelf and away from the rear panel and wheel hous-
ing.
(3) With a screw driver, pry the headlining retain-
Fig. 25-Door Weatherstrip Fig. 27-Trimming Excess listing

(8) Notch the headlining at the front and rear ends
to indicate the center of the material by making small
.V-shaped cuts, as shown in Figure 28. Use these
marks as guides to properly center the headlining.
(9) Begin at the rear of the vehicle. Install the rear
bow tension springs (Fig. 26).
(10) Install the bows in the correct location. Bows
are of different length and must be correctly posi-
tioned to prevent headlining from wrinkling.
Install the remaining bows, making sure to stretch
the headlining evenly so that approximately the same
amount of material hangs down both sides.
V-SHAPED CUT / Apply cement to the windshield header bar (Fig.
29). Wait until it becomes tacky. Then stretch the
headlining forward and over the cemented area,
and onto the barbs on the windshield header. Make
5SP1023 sure the first seam of the headlining is straight.
Cut holes in the headlining for the visor retaining
screws and pivot. Install the visors before tucking in
the corners of the headlining at the top of the wind-
Fig. 28-Marking Center of Headlining Ends shield posts to prevent tearing the headlining when
tightening the screws. Install the. garnish mouldings.
(5) Remove the headlining bows from the roof rail In most cases the listing is longer than necessary.
retainers. Cut the material at the ends to prevent wrinkling at
(6) Remove the bow retaining springs and remove
the seams when it is tucked or cemented in place.
the headlining from the roof, rear quarter and lower Cut the listing from the end up to the clip. Use care to
section under the package shelf. prevent cutting the listing too far up the bow and
ruining the fit of the headlining.
installation After the listings are cut, start at the front and
(7) Starting at the rear of the headlining, remove trim the headlining so that only 442 to 1 inch of mate-
each bow from the old listing and install it in position rial hangs down below the rear window opening.
in the new headlining. Use aidull putty knife to tuck the first' and second
This procedure assures correct installation of the seam between the roof side rail and retainer, as shown
bows. Before installing the bows in the new headlin- in Figure 30. Tuck the remaining material in place
ing, trim the excess listing even with the edges of the around the rear window opening and the lower pack-
headlining, as shown in Figure 27. age shelf.
i
PUTTY KNIFE
60x1266
Fig. 29-Applying Cement to Windshield Header Bar Fig. 3Y)-lnstalling Headlining at Roof Rails
will be necessary to remove both plastic mouldings
from the retainers, as shown in Figure 31.
Remove the front and rear window garnish mould-
ings. Starting at either end, pry the plastic moulding
off of retainer, using a screw driver. Pull down on the
moulding to release it from the retainer. Remove the
damaged section by pulling downward on the dam-
aged section to release it from the retainer (Fig. 32.)
To remove the headlining at the side, pull toward
the center of the vehicle and this will release the head-
lining from the small spring type clips at the outer
edges.
To install the side pieces of the headlining push
the headlining onto the small retainers at the sides
5 7 m
of the vehicle. Push the headlining up at the center
and properly center the moulding and snap it into
Fig. 31-Headlining Plastic Mouldings
place.
If the center section is to be installed push it into
When ofie man is performing the installation, al-
place on the retainers and snap the mouldings onto
ternate from one side to the other, completing one
the retainers and install the garnish mouldings.
section at a time; make certain the seams are
The headlining removal is the same except the head-
straight. As the work progresses, the material should
lining runs from side-to-side and it is only necessary
be kept free of wrinkles until all the headlining is
to remove the garnish mouldings when the front or
tucked in place between the roof and the retainer.
rear section of the headlining is being replaced.
Install the rear window glass, dome light, side and
upper windshield mouldings and the sun visor.
28. CUSTOM POSITIONED SIX-WAY
(12)Install the reir seat cushion. MANUAL FRONT SEAT
Hard Top Models ADJUSTMENT (Fig. 33 1
If either of the outer sections are to be replaced it The custom positioned six-way manual front seat is
is only necessary to remove one plastic moulding.
(See Fig. 31.) If the center section is to be replaced it
UP AND DOWN TILT FRONT TO REAR
SIX ADJUSTMENTS
STATIONARY SUPPORT PLA
-WAY SEAT TRACK
ADJUSTING BOLT
60x1337
Fig. 32-Removing Headlining Section Fig. 33-Six Way Slotted Track Seal
standard equipment on all Plymouth models and on two metal retaining strips at the lower edge of the seat
Valiant models equipped with bucket seats. All other back frame.
Valiant models, front seats are adjustable only fore (2) Raise the seat back straight up and disengage
and aft. the tangs from the package shelf and remove the
(1)Loosen the four adjusting bolts (two in each seat back from the vehicle.
seat base).
(2) The horizontal slots allow a fore or aft move- 32. EXTERIOR M O U L D I N G S
ment of 1%inches. Exterior mouldings are held in place by numerous
(3) The vertical slots allow up, down or tilt move-
clips “T” bolts, brackets and plastic retainers. The
plastic retainer is a button type retainer with expand-
ment of 1%inches.
ing legs that extend through holes in the sheet metal.
(4) Position the seat as desired and tighten the These are expanded by forcing a tapered pin through
bolts to lock it in place. the retainer and expanding the inner part of the re-
tainer. The moulding is then snapped over the outer
29. FRONT SEAT flange of the retainer. The mouldings may be pried off
Removal the retainer for replacement.
Reference to (Figs. 34, 35, 36 and 37) will demon-
(1) The front seat cushion is an integral part of the
seat frame. From under the vehicle remove the four RETAINER
nuts attaching the seat base to the floor pan.
(2) Remove the seat and base assembly.
Installat ion
(1) Place the seat and base assembly on’the floor
pan so that the studs in the seat base line up with
the holes in the floor pan.
(2) Install the four attaching nuts and tighten se-
curely.
30. REARSEAT
The rear seat cushion is held in place by inserting
the rear edge of the seat cushion under the lower
edge of the seat back. The front lower frame of the MOULDING‘ RETAINER 64x517
seat engages into a slotted bracket welded to the Fig. 3 A F r o n t Door Moulding AWaching Points
floor pan. (Plymouth)
Removal
(1) At the base of the seat frame midway from the
floor pan tunnel and the end of the seat, press firmly
toward the rear of the vehicle and disengage the seat
frame from the hold down brackets.
====zdY NUT
(2) Raise the front of the seat up and withdraw it

from under the seat back.
31. REAR SEAT BACK

The rear seat back is held in place by two tangs of
the upper edge of the seat frame being inserted into
slots in the package shelf. The lower edge of the seat
back is held in place by two metal strips of the floor
pan being bent over the lower edge of the seat back
frame.
Removal Fig. 35-Front Door Moulding Attaching Points
(1) With the seat cushion removed, bend up the (VaI iant)
nect the wires from the window regulator motor and
remove f,mm the door assembly.
Installat ion
NUT
(1) With the door inner hardware installed and the
-
hinges attached to the door panel, place the door in
position in the door opening, supported by a padded
jack.
(2) Locate the door hinge plates on the body “A”
MOU~DING ‘F$ I B I J I post and install the hinge attaching screws only finger
SCREW 6,
I .\\!Y I -7
tight.
(3) Adjust the jack to align the hinge plate scribe
marks on the “A” post and tighten the attaching
screws.
(4) Complete the door aligning procedure and in-
Fig. W u a r t e r Panel Moulding Attachment stall the weather shield, trim panel and inside han-
(Plymouth)
dles.
strate the type and location of retainers and clips NOTE: Prior to this installation, on electric win-
used to hold the various mouldings in place. dow lifts, install the wiring in the doors and attach to
the motor and control switch.
33. DOORS, DECK LID, AND HARDWARE
34. REAR DOOR
Front Door
Removal Removal ( 4 boor Sedan)
(1) With the door in the open position, place a (1) Open the rear door and place a padded jack un-
jack, with a block of wood or pad on the lifting plate der the door near the hinges.
of the jack, as near the hinge as possible. (This will (2) Remove the inside handles and door lock re-
hold the weight of the door as the hinge bolts are mote lever, upholstering trim panel and the weath-
loosened). er shield.
(2) Remove the inside handles, trim panel and (3) Scribe aligning marks around the hinge plates
weather shield. on the “B” post and on the door frame.
(3) Scribe a line around the upper and lower hinge (4) Remove the hinge attaching screws from the
plates on the “A” post and also on the door panel. “B” post and remove the door from the body.
(4) Remove the hinge attaching screws from the NOTE: On vehicles with electric window lifts dis=
“A” post and remove the door for further disassem- connect the wires from the motor and control switch
bly. and remove them from the door prior to door re-
NOTE: On vehicles with electric windows, discon- movaI.
Installat ion
(1) With the rear door inner hardware installed
and the hinges attached to the door panel, place the
door in position in the door opening.
(2) Place the hinge plates in location on the “B”
post and install the attaching bolts finger tight.
(3) Support the door on a padded jack and align
the hinges with the scribe marks.
(4) Tighten the attaching screws and test the door
for alignment.
(5) Install the weather shield, trim panel and in-
side handles.
Fig. 3 7 4 u a r t e r Panel Moulding Attaching Points NOTE: On vehicles with electric window lifts, dis-
(Valiant) connect the battery negative terminal at the battery,
insert the wiring into the door and attach the wiring 6-
to the motor and control switch prior to the installa- ONT DOOR LOC
tion of the trim panel.
(6) Open and close the door several times and test
the alignment.
Removal f 4 Door Hard Top Rear]
(1) Open the door and support it on a padded jack
placed near the hinges.
(2) Remove the “B” post trim panel and scribe
aligning marks around the hinges.
(3)Remove the door inside handles, remote lock
lever, upholstering trim panel and weather shield.
(4) Scribe aligning marks around the hinges on the
door panel and move the hinge attaching screws
from €he “B” post .
(5)Remove the door from the vehicle.
NOTE: On vehicles with electric window lifts
disconnect the battery negative terminal at the bat-
tery, remove the wires from the motor and withdraw
from the door panel prior to the door removal. Fig. 38-Door lock and Outside Handle
installation door and install the nut and washer and attaching
(1) With the rear door inside hardware installed in screw on the handle.
the door and the hinges attached, place the door as- (5) Snap the socket of the linkage onto the ball
sembly in the body opening. of the handle assembly.
(2)Support the door on a padded jack and align (6) Using Mopar All Purpose Cement install the
the hinges with the scribe marks in the “B”post. water shield, trim panel, inside handles, arm rest and
(3)Install and tighten the hinge attaching screws. remote control lock knob.
(4) On vehicles with electric window lifts insert the
wires into the door and attach to the motor and con- 37. LOCK CYLINDER ( Fig. 39)
trol switch. Removal
( 5 ) Install the weather shield, trim panel, inside (1) Remove the inside handles, trim panel and
handles and the remote lock lever. weather shield.
(6) Open and close the door several times and test (2) Using a screw driver through the access hole
the alignment.
35. DOOR HINGES (All Models) R O C K CYLINDER

The door hinge replacement should be followed as
suggested in paragraphs 34 and 35.
36. DOOR OUTSIDE HANDLE

(1) Remove the arm rest, inside handles, escutch-
eons, trim panel and the water shield.
(2) With the door glass in the “up” position,
through the inner door panel openings (Fig. 38) re-
move the attaching nut and washer and the attaching
screw and washer from the door handle. l (I
(3)Unsnap the ball and socket of the linkage from 63x850
the handle and remove the handle from the door.
(4) To install the handle, place the handle in the Fig. 39-Door lock Cylinder Replacement
of the door panel pry the “U” shaped retainer off of
the back of the lock cylinder.
(3) Withdraw the lock cylinder part way out of
the door panel and with a rotating motion of the lock
cylinder body, disengage the lock cylinder arm from
the link.
lnstallation
(1) Hold the lock cylinder hnk in alignment with
the lock cylinder hole in the door outer panel.
(2) Engage the hole of the lock cylinder arm with
the link and rotate the lock cylinder until the link is
locked in place. Fig. 40-DOOr Component Attaching Points
(3) Enter the lock cylinder into place. and install
the “U” shaped retainer into the grooves of the lock (3) Remove the regulator arm studs from the runs
cylinder. of the glass lower channel (where necessary).
(4) Using Mopar All Purpose Cement, install the (4) Prop the glass in the “up” position.
water shield, trim panel and inside handles. (5) Remove the window regulator attaching screws
(Fig. 40).
38. WINDOW REGULATOR ( Front Door 1 (6) Remove the link and mounting plate attach-
ing screws (Fig. 40).
Removal
(1) Remove the inside door handles, arm rest, (7) Slide the regulator arm link out of the pivot
remote lock knob, trim panel and the water shield. channel and remove the regulator from the door.
(2) Lower the door glass and remove the retain- Insfallafion
ing clips and leather washers from the regulator arm (1) Lubricate the channel of the regulator arm
studs (when so equipped). pivot and the slides of the glass lower channel with
TO RAISE FRONT OF WINDOW

ASSEMBLY RAISE MOUNTING P L
TOLOWER FRONTOFWINDOW
ASSEMBLY LOWER MOUNTING
PLATE.
FORE A N D A F T
INANDOUT
ADJUSTMENT
/ DOWN STOP ADJUSTMENT
6 2 X 651
Fig. 41-Front Doowsedan Adjubting Points

(Plymouth)
(6) Install the leather washer and new retaining
clips on the studs of the regulator arm studs (when
VENTWING FORE
so equipped).
AFT ADJUSTMENT
(7) Adjust the level of the glass as outlined in
Figures 41,42,43and 44.
(8)Using Mopar All Purpose Cement install the
water shield, trim panel, door handles, arm rest and
IN AND OUT
ADJUSTMENT
the remote control lock knob.
39. REMOTE CONTROL AND D O O R LOCK

( Front Door 1
DOWN STOP
ADJUSTMENT Removal
DIVISION CHANNEL FORE
/ (1)Remove the inside handles, arm rest, remote
AND AFT ADJUSTMENT AND OUT ADJUSTMENT
63x96
lock knob, trim panel and the water shield.
Fig. 42-Front Door-Sedan Adjusting Points (2) Remove the remote control attaching screws
Walia ntl and disconnect the link.
(3) Remove the attaching screws of the door lock
libriplate. assembly (Fig. 38).
(2) Insert the regulator and link into the door and (4) Disconnect the link from the lock assembly.
engage the pivot arm into the run of the pivot channel. (5) Rotate the lock assembly around the glass run
(3)Install the link and mounting plate screws channel and withdraw the lock from the door.
finger tight.
(4)Install the regulator screws and progressively
40. REAR D O O R REMOTE
tighten to 60 inch-pounds torque.
CONTROL ASSEMBLY
(5) Lower the door glass and engage the regulator
arm studs into the slides of the glass lower channel Removal
(where necessary). (1) Remove the arm rest assembly.
UP STOPS
WINDOW TILT
SCREW STUD IN TO T I L T
TOP OF WINDOW OUTBOARD
ALSO FORE AND AFT.
SCREW STUD OUTWARD
TO TILT WINDOW INBOARD
TO RAISE FRONT OF WINDOW

ASSEMBLY, RAISE MOUNTING PLAT
TO LOWER FRONT OF WIN
ASSEMBLY LOWER MOUNT
PLATE.
TO MOVE WINDOW
INBOARDMOVE
CHANNEL INBOARD
TO MOVE WINDOW
OUTBOARDMOVE
FORE ANDAFT
CHANNELOUTBOARD
ANDUP ANDDO
TO MOVE WINDOW
ASSEMBLY FORWARD
MOVECHANNEL FORWARD
TO HOVE WINDOW
INBOARDMOVE CHANNEL
TO MOVE WINDOW
OUTBOARDMOVECHANNEL
IN AND OUT ADJUSTMENT

62 X 6 4 9 FORWARD
Fig. 43-Front Door-Hard Top-Convertible
Adjusting Points (Plymouth)
VENTWING FORE AND

precautions as those taken during the removal pro-
cedures.
(1) Lift the lid and slide it down into position, in-
stall the attaching bolts.
(2) Do not tighten, just snug down.
(3) Lower the lid and test the fit.
(4) If necessary, adjust the lid, test adjustment
of the latch and striker plate. Adjustment of the deck
lid is obtained by loosening the bolts and shifting the
lid from side to side or front to rear. It is often possi-
ble, however, to properly fit the deck lid by adjusting
the striker plate, latch or both.
42. DECK LID HINGES

Fig. 44--Front Doo+Hard lop-Convertible
Adjusting Points (Valiant) Removal
The deck lid hinge is fastened to the deck lid by
(2) Remove the inside door handle and the regu- two bolts at each hinge. The bolt holes are slotted
lator handle. and slightly oversize to permit fore-and aft adjust-
(3) Remove the plastic knob from the door lock ment of deck lid.
rod. Should it become necessary to remove and install
(4) Remove the door trim panel. either of the rear deck lid hinges, for repair or com-
plete replacement, refer to Figures 10 and 11and pro-
(5) Carefully remove the door water shield.
ceed as follows:
(6) Remove the screws attaching the remote con-
trol unit to the door inner panel and remove the (1)Raise the deck lid and brace the lid on the
remote control assembly. corner where the hinge is to be removed.
(2) Remove the torsion bar (or springs) from the
lnstallation
side on which the hinge is to be removed.
(1) Position the remote control assembly on the
door panel and install the attaching screws. (3) Remove the bolts that hold the deck lid to the
(2) Test the operation of the remote control as- hinge arm.
sembly. (4) Remove the spring nut that holds the hinge
(3) Using Mopar All Purpose Cement install the pivot on the support bracket.
water shield. (5) Disengage the hinge from the bracket and re-
(4) Install the door trim panel, arm rest, door lock move it from the rear compartment.
rod knob, regulator handle and the remote control
handle.
lnstallation
(1) Slide the hinge into position in the trunk com-
41. DECK L I D partment and install the hinge spring nut.
Removal (2) Install the bolts that hold the hinge to deck
Should it become necessary to remove the deck lid lid. Do not tighten, just snug down.
for replacement or repair, refer to Figure 5, and pro- (3) Remove the prop and lower the lid to test fit.
ceed as follows:
(4) Make necessary adjustments to center the lid
(1) Raise the deck lid and remove one of the two in opening. Also, test adjustments of latch and striker
bolts in each hinge that attach the lid to the hinge plate. After adjustments have been made, prop the
arm. (Leave the remaining two bolts finger loose.) lid open and install the torsion bar or springs as
(2) Brace the deck lid in such a manner so as to necessary.
hold the lid in position while removing the last two
bolts. (This will keep the lid from sliding down and 43. DECK LID TORSION BAR
damaging the rear deck.) REPLACEMENT
(3) Remove the last two bolts and lift the deck lid (1) Using holding Tool C-3449 installed on torsion
up and away from the rear of the vehicle. bar, pry torsion bar out of the adjustment slots (Fig.
lnstallation 12).
When installing the deck lid, observe the same (2) Unwind the torsion bar.
(3) Unhook the torsion bar from the support (5) Remove the windshield upper moulding using
bracket. a fibre wedge.
(4) Push the torsion bar out of the roller in the (6) Unlock the windshield weatherstrip by prying
hinge arm and remove the torsion bar from the hinge the lip of the weatherstrip apart, inserting a fibre
support. wedge, and with a slight twist to the wedge unlock the
(5) To ipstall the torsion bar, insert the bar into weatherstrip by moving the tool around the weather-
the hinge support. strip.
(6) Insert the end of the torsion bar into roller in (7) Carefully loosen the weatherstrip from the
hinge arm. windshield inner and outer sides.
(7) Hook the torsion bar into the support bracket. (8) With an assistant supporting either end of the
windshield, exert pressure to force the windshield out
(8) Using holding Tool C-3449 wind the torsion
of the weatherstrip and carefully remove the wind-
bar and insert one end of the bar into first adjusting
shield from the vehicle.
slot.
(9) Place the deck lid in various opening positions installation Plymouth 1
and test tension of torsion bars. Before installing the windshield, inspect the wind-
(10) Adjust the torsion bars progressively until shield fence for burrs, high spots or bends. Correct
the deck lid stays in the open position. these conditions before installing the weatherstrip.
(1) Place the windshield in position on the cowl.
44. DECK LID LOCK ADJUSTMENT (2) With an assistant, slide the upper edge of the
Vertical adjustment of the deck lid lock is made at glass into the channel of the weatherstrip.
the lock attaching screws (Fig. 14). The side adjust- (3) Pound the glass, with the palm of the ‘hand,
ment is made at the deck lid striker attaching bolts. using an upward motion, until the glass is fully seated
in the channel of the weatherstrip at the top, bottom
45. DECK LID LOCK CYLINDER and sides of the glass.
The deck lid lock cylinder is retained in the deck After properly seating the glass in the weatherstrip,
lid by a spring steel “U” shaped clip attached from use a wedge shaped tool of hardwood or fibre (Fig.
within the deck lid. 46) inserted between the weatherstrip and glass at
either corner to strip the glass into weatherstrip. Slide
the tool across the top, bottom, and around the sides
,46. WINDSHIELD of the weatherstrip to properly seat the glass in place.
Removal t P lymouth 1 After sealing the glass in the weatherstrip, use a suit-
(1) Cover the cowl, hood and fender area with able tool over the locking strip with enough pressure
a protective coating. to force the fold into the locked position. Always work
the tool across the top, down each side and over the
(2) Remove the inside windshield glass opening
bottom.
garnish mouldings.
(3) Remove the “A” post outside chrome mould-
ings.
(4) Remove the windshield lower mouldings and
moulding center cap using a fibre wedge (Fig. 45).
Fig. 45-Removing Windshield lower Moulding Fig. 46-Seating Windshield in Weatherstrip

(4) Seal the weatherstrip. (6) Air dry the weatherstrip and apply weather-
(5)Align and install the upper windshield chrome strip cement between the glass and weatherstrip.
moulding over the top of windshield. Make sure to (7) Use mineral spirits as a lubricant and a fibre
exert sufficient pressure on center of moulding to wedge or other suitable tool and install the mylar
force moulding all the way down on clips. trim into the rubber. Start at the lower center of the
(6) Align and install the lower center chrome window and trim the strip to length after it is fully
mouldings. Install the lower mouldings center clip. inserted around the window.
(7) Install the "A" post mouldings. Be sure the (8) Remove the protective covering.
mouldings overlap the outer edges of the lower wind-
shield mouldings. 47. REAR WINDOW (Plymouth)
(8) Install the windshield wiper arms and blades. Removal f All Models Except Two Door
(9) Install the windshield inner garnish mouldings. Hard Top)
(10) Clean the windshield using the recommended (1) Cover the rear deck, rear window and quarter
solvent, then test for water leaks. panel areas with protective covering.
(11) Operate the windshield wipers and adjust as (2) Remove the chrome moulding end and center
necessary. caps.
(3) Remove the side, lower and top weatherstrip
Removal V a h n t 1 mouldings.
(1) Place a protective covering over the cowl,
hood and fender area next to the windshield. (4) Use a fibre wedge to unlock the weatherstrip.
After unlocking the weatherstrip, slide the tool up
(2) Remove the windshield wiper arms and blades. and completely around the weatherstrip to unlock
(3) Starting at the joint of the trim at the bottom the lip.
center of the windshield, pry out the edge of the strip ( 5 ) Loosen the weatherstrip from the rear window
and pull the mylar trim strip from the rubber. (Fig. 47).
(4) Insert the tapered end of a fibre stick between (6) Remove the glass by pushing on the glass from
the weatherstrip and the glass and work the weather- the inside.
strip from the glass.
(7) Use of gloves will protect hands against pos-
(5) With an assistant, apply hand pressure to the sible sharp edges.
upper side corner of the glass and push the glass out
from the windshield opening.
(6) Remove the windshield weatherstrip from the
body flange if found to be distorted, cut or torn. In-
spect the flange (fence) for bends and rough surfaces,
repair as required.
lnstallatton
(1) If the weatherstrip was removed, remove all
sealer and foreign material from the fence. Apply a
small bead of weatherstrip cement in the body flange
groove of the weatherstrip.
(2) Carefully position the new weatherstrip over ,
the body flange, making sure it fits smoothly and
evenly over the entire flange especially at the corners.
(3) Coat the groove of the weatherstrip with min-
eral spirits.
(4) With an assistant, insert the top edge of the
glass into the weatherstrip.
(5) Holding the glass centered in the opening, in-
sert the fibre wedge in the groove of the weatherstrip
and strip in the glass. Bump the glass into position
with the palm of the hand. Make sure the glass is Fig. 47-Unlocking Weatherstrip from Rear Window
properly seated and centered in the body opening. Glass
lnstallation (4) Place the glass on a cloth covered bench and

(1) Lubricate the weatherstrip groove with the carefully remove the weatherstrip from the glass.
soap solution. (5) Remove all sealer from the glass, weatherstrip
(2) Position the glass at the lower outside corners. and rear window fence.
(3) Work the lip of the weatherstrip over the glass lnstallation (Two boar Hardtop) Plymouth
along the lower edge. (1) Inspect the rear window fence to be certain it
After the glass is centered along the top and the is clean, smooth and straight.
lower corners, work the lip of the weatherstrip over (2) Flow a continuous ribbon of cement on each
the lower edge of the glass. lip and around the entire length of the glass groove of
Make sure the glass is properly seated by tapping the weatherstrip (Fig. 48).
the glass with the palm of hand, Do not use a rubber (3) Install the weatherstrip on the rear window.
mallet when installing rear window glass.
(4) Install twine into the groove of the weather-
(4) Lay a bead of sealer in the weatherstrip groove strip that seats on the rear window fence.
all around the rear window. (5) The ends of the twine should be at the top
(5) Brush the soap solution on the locking strip. center section of the weatherstrip (Fig. 48).
(6) Starting at the center of the upper edge, lock (6) With an assistant, position the rear window
the top edge and the sides. Lock the lower edge last. glass and weatherstrip in the rear window opening.
(7) Lubricate the upper groove in weatherstrip (7)With an assistant holding the glass in position,
with the soap solution and install the upper, lower, enter the car and pull the twine slowly to seat the
and side mouldings. weatherstrip on the fence.
(8) Install the upper and lower center moulding (8) With the palm of the hand, tap the rear window
clips and the side moulding caps. glass to make certain it is fully seated.
(9) Reseal the glass and test for water leaks. (9) Seal the weatherstrip to fence areas, on the
outside only. Remove all excess sealer.
Removal [ Two Door Hard Top-Plymouth 1
[Fig. 48 1 Removal I Valiant 1
(1) Place a protective covering over the deck lid, (1)Starting at the bottom of the rear window,
quarter panel and rear window areas. pry out the mylar trim strip from the weatherstrip.
(2) Using a fibre wedge, loosen the weatherstrip (2) Insert the fibre strick between the weather-
from the rear window fence, both inside and outside strip and the glass and strip the weatherstrip from the
lips. glass.
(3) With an assistant steadying the glass on the (3) With an assistant holding the glass, push out
outside, push against the glass at one of the upper the glass from either upper corner of the body open-
corners, from inside the car, and remove the glass ing.
and weatherstrip from the fence. Gloves should be (4) Remove the rear window weatherstrip from
worn as a precautionary measure. the body flange if found to be distorted, cut or torn.
Test the flange (fence) for bends and rough surfaces,
repair as required.
lnstallation
(1) If the weatherstrip was removed, remove all
old sealer from the flange. Apply a small bead of
weatherstrip cement in the body flange groove of the
weatherstrip.
(2) Carefully position the weatherstrip over the
body flange, making sure it fits smoothly and evenly
over the entire flange especially at the corners.
(3) Coat the channel of the weatherstrip with min-
eral spirits.
(4) Center the glass in the opening and insert the
top edge of the glass into the top channel of the
Fig. 4 L R e a r Window lnstallation weatherstrip.
(5) Using a tapered fibre stick, work the weather-
strip over the edge of the glass. Bump the glass into
place with the palm of the hand.
(6) Air dry the weatherstrip.
(7) Apply weathersealing compound between the
glass and weatherstrip.
(8) Use mineral spirits as a lubricant and a fibre
wedge or other suitable tool and work the trim strip
into the rubber.
(9) Clean all excess sealer from the rear window
glass.
48: D O O R VENTILATOR ASSEMBLY

Removal ( 4 Door Sedan) Fig. 5 b D o o r Component Attaching Points
(1) Remove the arm rest, inside handles, remote (Four Door Hard Top)
control lock knob, trim panel and the water shield.
(2) Disengage the lower end of the division bar (4) Tighten the vent frame lower attaching screws.
from the adjusting bracket (Figs. 41 and 42.) (5) With the door glass in the "down" position at-
(3) Remove the two attaching screws from the for- taching the lower end of the division bar to the ad-
ward and top edge of the door frame. justing bracket.
(4) Remove the two vent frame attaching screws (6) Operate the door glass and inspect for ease
from the base of the vent frame. of operation and alignment of the division bar.
(5) With the door glass in "down" position, tilt Removal (Hardtop Models 1
the vent frame to the rear and withdraw the vent
(1) Remove the arm rest, inside handles, remote
frame assembly up out of the door.
door lock knob, trim panel and water shield.
lnst allation (2) With the door glass in the "down" position dis-
(1) With the door glass in the "down" position, engage the division bar from the lower adjusting
tilt the vent frame assembly to the rear and insert the bracket (Figs. 49 and 50).
division bar and vent assembly into the door. (3) Remove the lock nut of the tilting adjusting
(2) Install the two lower vent frame attaching screw and turn the adjusting screw clockwise to dis-
screws finger tight. engage the screw from the door frame bracket.
(3) Install the two vent frame attaching screws (4) Remove the two attaching screws from the
in the forward and top edge of the door frame. base of the vent frame.
(5) Tilt the vent frame to the rear and remove
the vent frame assembly up and out of the door.
VENT---.-..,e !i UP STOP SCREWS
Installat ion
r A D J uSTME NT - I'Nw DO w REGuLATO

I R -
(1) With the tilt adjusting screw bottomed in the
vent frame and the door glass down, insert the vent
frame into the door.
(2) Turn the tilt adjusting screw counter-clockwise
and engage it into the bracket of the door.
(3) Install the two attaching screws in the base of
the vent frame finger tight.
=MOUNTING PMTT
(4) Attach the lower end of the division bar to the
adjusting bracket.
(5) Refer to Figures 43 and 44 for vent frame
adjustment.
Fig. 49-Door Component Attaching Points (6) Install the water shield, trim panel, inside door
(Two Door Hard Top) handles, arm rest and the remote door lock knob.
lator arm studs, then pull the regulator arm studs
from the glass lower channel.
(4) Loosen the division bar and front run chan-
nel mounting bolts.
(5) Move the division bar downward and disen-
gage from the door glass.
(6) Move the glass forward between the division
bar and the inner door pane and remove the glass
up and out of the door glass opening.
lnstallation f Plymouth1 4 Door Sedan and
Station Wagon
(1) Insert the door glass down into the door frame.
(2) Lubricate the slides of the glass lower channel
with lubriplate.
(3) Insert the glass into both front and rear run
channels.
(4) Insert the regulator studs into the slides of the
glass lower channel.
Fig. 51-Glass Run Channel
(5) Install the leather washers and new retaining
clips on the ends of the studs.
49. D O O R GLASS R U N CHANNEL (6) Locate the run channel anchor and adjusting
Removal ( 4 Door Sedan I screw into the door bracket and tighten the lock nut.
(7)Using Mopar All Purpose Cement install the
The door glass run channel is held in place by its
water shield, trim panel, inside handles, arm rest and
own expansion in the door frame.
remote lock button.
(1) With the door glass in the down position pry
the top of the run channel down, and out of the door Removal (Hardtops and Convertibles I
frame. ( 1 ) Remove the inside handles, arm rest, remote
(2) Pull the balance of the run channel up and lock knob, trim panel and the water shield.
out of the door frame. (2) Place the glass in the ”down” position and in-
sert a screw driver under the retainer ring and pry
lnstallation the retainer off of both regulator arm studs.
(1) Insert the run channel down into the rear of
(3) Remove the leather washers from the regula-
the door frame and align the end of the channel with
the end of the channel frame and press the channel tor arm studs, then pull the regulator studs from the
firmly into place. glass lower channel.
(4) Remove the two “up” stops.
(2) Work the channel tightly into the sharp corner
of the door (Fig. 51). (5) Remove the door glass up through the door
frame by tilting the glass slightly.
(3) Work the balance of the channel into the door
frame. lnstallation f Hardtop and Convertible I
(4) Using Mopar All Purpose Cement, install the (1) With the glass tilted slightly to the rear, insert
water shield, trim panel, inside handles, arm rest and the glass into the front and rear run channel and
the door lock knob. lower the glass down into the door.
(2) Lubricate the slides of the glass lower channel.
50. FRONT D O O R GLASS (3) Insert the regulator arm studs into the slides of
Removal (Plymouth 1 f 4 Door Sedan and the glass lower channel.
Station Wagon I (4) Place the leather washers over the regulator
(1) Remove the inside door handles, arm rest, arm studs and install new retaining clips.
remote lock knob, trim panel and the water shield. (5) Install the two “up” stops and adjust as neces-
(2; With the glass in the “down“ position, insert a sary.
screw driver under the retainer ring and pry the re- (6) Using Mopar All Purpose Cement, install the
tainer from both regulator arm studs. water shield, trim panel, inside door handles, arm
(3) Remove the leather washers from the regu- rest and the remote lock knob.
Removal
f Valiant Sedan Models 1
(1)Remove the door interior trim and hardware.
(2) Loosen the front run channel lower mounting
screws.
(3) Move the run channel forward and slide the
glass out of the channels.
(4) Remove the regulator arm from the lift bracket
channel.
(5) Remove the glass from the door.
Installation SEDAN MODELS CHANNEL
f Valiant Sedan Models 1 62x641
(1) Before installing the glass, lubricate the regula- Fig. 53-Rear Door Window Regulator
tor slide of the lower glass channel with lubriplate.
(2) Position the glass into the door frame. 52. REAR DOOR WINDOW REGULATOR
(3) Position the regulator arm roller into the lift Removal f Fig. 53 1
bracket channel. (1)Remove the arm rest.
(4) Position the glass into the glass run channels
(2) Remove the inside door handle and regulator
and adjust the door glass.
handle.
(5) Install the door interior trim and hardware.
(3) Remove the plastic knob from the door lock rod.
5 1. GLASS LIFT BRACKET REPLACEMENT (4) Remove the door trim panel.
( 5 ) Carefully remove the door water shield.
To separate the lift bracket (Fig. 52) from the glass,
just push the plug out of the rivet. Next, pinch the (6) Remove the door window stops.
expandable ends of the rivet together and push the (7) Disconnect the door glass from the window
rivet out of the glass. Save the plastic rivet and regulator and remove the door glass assembly.
plug and re-use. (8) Remove the glass front and rear channels.
To assemble the bracket to the glass, line up the
(9) Remove the regulator attaching screws and re-
holes in the glass, gasket and lift bracket. Push the
plastic rivet through from the lift bracket side. move the regulator assembly.
Just make sure that the head of the plastic rivet is Installation
tight against the bracket and the expandable end of (1) Lubricate all moving parts of the regulator as-
the rivet is all the way through the hole in the glass. sembly with lubriplate.
Then drive the plug into the rivet to lock the rivet in
(2) Position the regulator assembly into the door
place.
0 and install the attaching screws.
(3) Install the glass front and rear channels.
(4) Install the door glass and the glass stops.
(5) Operate the window regulator assembly and test
for ease of glass movement and alignment.
(6) Install the door water shield.
(7) Install the trim panel, arm rest, door handle,
regulator handle and lock rod plastic knob.
53. REAR DOOR GLASS

( 4 Door Hard Top)
\
PLASTIC RIVET Removal
64 x 374 (1) Remove the door arm rest, regulator handle,
remote control handle, lock rod plastic knob, trim
Fig. 5 2 4 l a s s lift Bracket panel and water shield.
(2) Remove the door glass stops. DIVISION CHANNEL
ASSEMBLY
(3) Disconnect the regulator arms from the glass
channel and remove the glass assembly.
(4) Roll the glass to the closed position and test the GLASS RUN
alignment.
(5) Install the water shield, trim panel, arm rest
and the other inside hardware. WEATHERSTRIP
54. REAR D O O R GLASS (Plymouth Sedan

Models1
Removal
(1) Remove the rear door arm rest, trim panel and
inside door hardware. SCREW AND WASH 64x390
(2) Remove the door water shield. Fig. +Rear Door Stationary Glass (Valiant)
(3) Lower the window and disconnect the regulator
arms from the glass channel. (5) Move the stationary glass rearward to disengage
(4) Remove the door glass upper stop. it from the weatherstrip and remove the glass from
(5) To remove the door glass, it is necessary to the door.
pivot the glass upward at the front end of the glass to /nstallatlon
free it from the glass run channels. (1) Inspect the condition of the stationary glass
(6) After the glass has been freed from the glass weatherstrip and replace if necessary.
run channels, pull the glass up and out of the door (2) Slide the stationary glass into the weatherstrip.
opening. Make sure it is fully installed.
lnstallation (3) Install the division bar and adjust as neces-
(1) Slide the door glass down into the door, rear sary.
portion of glass first and position the glass into the (4) Install the water shield, trim panel and hard-
glass run channels as it is pivoted into place. ware.
(2) Connect the regulator arms to the glass chan-
nel. 56. REAR D O O R GLASS R U N CHANNELS
(3) Lubricate the regulator roller area on the glass ( Four Door Hard Top)
channel with lubriplate. Removal-Front Channels
(4) Install the door glass upper stop. (1) Remove the door inside hardware trim panel.
(5) Operate the door glass and test for ease of op- (2) Carefully remove the water shield.
eration and for correct alignment.
(3) Remove the rear door glass stops.
(6) Install the door water shield.
(4) Disconnect the regulator arms from the glass
(7) Install the door trim panel, arm rest and inside channel and remove the door glass.
door hardware.
(5) Remove the nuts attaching the glass run chan-
nel to their mounting brackets and remove the rear
55. REAR D O O R STATIONARY GLASS glass run channel up through the top of the door.
(Valiant Sedan and Station Wagon
lnstallation
Models 1
(1) Insert the glass run channel into the door and
Removal on their respective mounting brackets. Install the
(1) Remove the door interior hardware, trim panel mounting nuts.
and water shield. (2) Slide the glass into the door and connect the
(2) Lower the glass. regulator arms to the glass channel.
(3) Remove the upper and lower division bar at- (3) Install the glass stops.
taching screws (Fig. 54). (4) Test the operation and alignment of the door
(4) Remove the division bar from the door. window.
(5) Install the door water shield. 57. REAR DOOR LOCK AND LINK
(6) Install the door trim panel, arm rest and the ASSEMBLY
other inside door hardware. Removal I Fig. 38 I
Removal Rear Channel (1) Remove the plastic knob from the top of the
(1) Remove the door trim panel, arm rest and in- door lock rod.
side door hardware. (2) Remove the door trim panel, arm rest and in-
(2) Carefully remove the door water shield. side door hardware.
(3) Remove the door window stops and window. (3) Remove the door water shield.
(4) Remove the nuts attaching the glass run chan- (4) Lower the window to the full open position.
nel to their mountings and pull channel straight up (5) Remove the screws attaching the locking con-
out of the door to remove. trol to the door.
(6) Disengage the door lock control link from the
installation rear door lock assembly.
(1) Slide the glass run channel into the door and
(7) Remove the door lock control rod.
position the channel on its mountings. Install the re-
taining nuts. /nstallatfon
(2) Slide the door glass down into the door and con- (1)Lubricate all moving parts of the door lock link
nect the regulator arms to the glass channel. assembly with lubriplate.
(3) Test the operation and alignment of the door (2) Slide the link assembly down into the door and
glass. connect the lock control link to the lock assembly.
(4) Install the door water shield. (3) Position the locking control to the door panel
(5) Install the door trim panel, arm rest and the and install the attaching screws.
inside door hardware. (4) Test the operation of the door lock assembly and.
LASS ATTACHING
NUTS AND WASHERS
LOWER GLASS FRAME 62x652

DOWN STOP
Fig. 55-Quarter Window Attaching Points ,(Sedan Shown)

-
if satisfactory, install the door water shield. (2) Remove the regulator handle, trim panel and
(5) Install the door trim panel, arm rest, door lock water shield.
arm control knob and inside door hardware. (3) With the glass lowered two-thirds of the way,
remove the screw and washer from the hinge assem-
58. QUARTER GLASS (All Models Except bly.
Station Wagon and Valiant Two Door (4) Lower the glass fully and remove the spring nut
Hard Top Models) and washer attaching the regulator stud to the glass
lower channel.
Removal f Fig. 55 I (5) Remove the regulator stud from the glass low-
(1) Remove the rear seat cushion. er channel.
(2) Remove the rear seat back. (6) Remove the glass and lower channel assembly.
(3) Remove the quarter glass handle, escutcheon,
lnstallat ion
arm rest, trim panel and water shield.
f Valiant Two Door Hard Top1
(4) Remove the two retaining clips from the studs (1) Position the glass into the quarter panel.
of the lower frame and roller assembly.
(2) With the regulator in the down position, insert
(5) Disengage the quarter glass from the lower the regulator arm stud into the glass lower channel
frame. and install the washer and spring nut.
(6) Remove the glass up through the quarter panel. (3) Raise the glass one-third and install the hinge
hstallation to the glass lower channel.
(1) Insert the quarter glass down through the quar- (4) Test the operation and alignment of the quarter
ter panel. glass.
(2) Engage the glass onto the lower frame and in- (5) Install the water shield, trim panel, regulator
stall new retaining clips. handle and rear seat assembly.
(3) Lubricate the rollers and run tracks and inspect
for alignment of track and ease of operation. 59. QUARTER GLASS TRACK
(4) Install the water shield, trim panel, escutcheon, Removal
handle and the arm rest. (1) Remove the rear seat cushion and seat back.
( 5 ) Install the rear seat back and the rear seat cush- (2) Remove the regulator handle, escutcheon, arm
ion. rest, trim panel and the water shield.
(3) With the window in the down position, remove
Removal f Fig. 56 I the retaining clips from the studs of the lower
f Valiant Two Door Hard Top1 frame.
(1) Remove the rear seat cushion and back. (4) Disengage the glass from the lower frame and
/-
UP
RE AND AFT
IN ELECTRIC
AD WINDOW
DOWN STOP
REGULATOR IN AND OUT

64 x 760 64x447 DOWN STOP ADJUSTMENT
Fig. 56-Quarter Window Attaching Points Fig. 5 7 4 u a r t e r Glass Adlusting Points
(Valiant Two Door Hard Top) (Plymouth Hard Top)
Fig. 5 8 4 u a r t e r Glass Adjusting Points (Plymouth Sedan)
remove the glass from the quarter panel. move the track from the quarter panel.
(5) Raise the lower frame and rollers and disengage
l n s tallation
the regulator arms from the frame.
(1) Position the tracks down in the quarter panel.
(6)Pull the frame up off the track. (2) Align the lower attaching screw scribe marks
(7) Scribe aligning marks on the lower track brack- and install the screws.
et and remove the lower track attaching screws. (Figs. (3) Install the upper track attaching nuts.
56, 57, 58 and 59.)
(4) Lubricate the track and rollers and engage the
(8) Remove the track upper sleeve nuts and re- lower frame and rollers on the track.
(5) Engage the frame and roller assembly to the
DOWN
regulator arms.
REGULATOR
ADJUSTING\
ADJUSTMENT
Fig. 5 9 4 u a r t e r Glass Adjusting Points Fig. 6 M u a r t e r Glass Adiusting Points

(Valiant Hard Top1 [Valiant Sedan)
1 FRONT OF DASH
- 1 1 I I
I I'
0-
7 - O
BOTTOM OF BODY
. 62x631-
Fig. 61-Under Body Dimensions (Plymouth)
.
FRONT
I
1
I I 'F
I
"K" MEMBER ATTACHING BOLT
BOTTOM VIEW
I
GAUGE' 7%
41 'k
59%
-.
60x149
SIDE VIEW
Fig. 62-Under Body Dimensions (Valiant)

(6) Place the frame and roller assembly in the

"down" positions.
(7) Lower the glass and install it on the studs of
the lower frame.
(8) Install new retaining clips on the studs.
(9) Refer to (Figs. 57, 58, 59 and 60) and adjust the
glass and track.
(10) Install the water shield, trim panel, escutch-
eon handle, arm rest, seat back and the seat cushions.
60. QUARTER GLASS REGULATOR

Removal
(1) Remove the seat cushion, seat back, arm rest,
handle and escutcheon, trim panel and the water
shield.
(2) Remove the pivot slide attaching screws and re-
move the slide from the pivot.
(3) Remove the regulator arms from the lower
frame. 62 x 614
(4) Prop the window in the "up" position. Fig. 63-Header Moulding Attachment
(5) Remove the regulator down and out of the
quarter panel. Upper body alignment may be measured by diag-
onal measurements from various points of the door
lnstallation opening sills to the roof rail of the opposite side of
(1) Place the regulator up into position and in- the body. Equal dimensions of these check points
stall the attaching screws. made at both sides of the body will assure proper
(2) Insert the regulator arms into the lower frame body alignment.
runs.
(3) Place the pivot slide on the pivot arm and in- 62. REPLACEMENT OF BODY PANELS
stall the attaching screws finger tight. When repairing accident damage it may be found
(4) Adjust the pivot slide and tighten the attaching advisable to replace damaged panels. The sturdy re-
screws. inforced box sections ahead of the cowl will be of
(5) Install the weather shield, trim panel, arm rest, vital concern as they carry the suspension load and
escutcheon and handle, seat back and the seat cush- engine support. All body and underbody dimensions
ion.
61. BODY ALIGNMENT

(Figures 6 1 and 62 1
Body alignment may bd accurately measured by
the following method. Elevate the vehicle to a level
position on a clean and smoc .h flooi
Refer to (Figs. 63 and 64) and place the line of a
plumb-bob on point "A" with the plumb-bob just con-
tacting the floor. Mark the plumb-bob contact point
on the floor. Repeat the process at points B, C, D, E
and F at both sides of the body. Snap a chalk line be-
tween points as illustrated.
Compare dimensions with specifications, all match-
ing point-to-point dimensions should agree within
1/4 inch. Care should be taken that all diagonals com-
~
pared represent corresponding check points. Fig. 64-Adjusting the latching Mechanism Hooks
should be measured before any of the body panels low bake enamel has been developed and has the same
are removed for replacement. characteristics of appearance and durability as the
With unitized body construction, it may be advis- original baked enamel. Repainting a complete fender,
able to measure body alignment in the event of ex- door or body panel is recommended and will be found
tensive collision damage. to be more satisfactory than to try and do a touch up
The box sections of the body are also of vital con- on a large surface.
cern. The door pillars, sills, roof rails, rear window The use of lacquer for spot painting will usually
and windshield headers provide added strength to prove unsatisfactory as the sheen or gloss of lacquer
assist the lower body reinforcing members. and enamel do not match. Lacquer has a tendency
Jacking or stretching equipment should be used to to oxidize and fade over long exposures to weather.
bring the body dimensions back to specifications The finished paint job will be no better than the sur-
before damaged body panels or sub-assembly parts face that it covers. Therefore, particular attention
are removed. Separation of damaged panels may be should be paid to the priming and surfacing of the
accomplished by drilling cutting the spot welds with metal. It is advisable to apply two or three medium
a chisel. Welded seams may be separated with the aid coats of primer rather than one heavy coat. This
of a cutting torch or grinder. will reduce the drying time between coats. Use No.
When replacing large panels requiring long welds, 320 or 360 paper and sand each coat to remove any
care should be taken to prevent distortion due to ex- blemishes or scratches. Finish the last coat with No.
cessive heat. Spot weld the panel at the center of the 400 wet paper.
joint and tack weld toward each end. Alternately
tack welding approximately 12 inches apart. Wet as- 65. DARK SPOTS APPEARING ON
bestos putty surrounding the weld will help prevent PAINT (Polychromatic 1
heat distortion. Make certain that sufficient welds are This condition can be caused by foreign particles
applied to maintain the original strength. that arc carried through the air and settle on the
flat surfaces of the paint.
63. REMOVING OLD FINISH If any of this foreign substance, containing acid-
The old finish is usually removed by grinding. A like particles, is allowed to remain on the paint for
No. 16 open coat grinding disc removes paint with a any length of time, it may result in a spotting cQn-
minimum clogging of the paper. The exposed metal dition. This spotting condition is caused by the reac-
should be sanded with No. 50 paper then followed tion of such particles with the aluminum, used in all
with No. 220 paper and all edges of the paint film polychromatic paints, causing the aluminum, flakes
should be feather edged with No. 320 and finished to disappear, leaving the base color. These same
with No. 400 wet and dry paper. acid-like particles can also attack a non-metallic paint,
On large areas and complete panels it is sometimes but it will usually result in an etched condition rather
more efficient to use paint remover. Be sure to select than a discoloration.
a paint remover that is water neutralizing. In view of the foregoing, it is advisable to wash
Sand blasting is an excellent method of removing vehicles frequently to prevent the possibility of such
paint, particularly on complete refinish jobs. When conditions occurring.
sand blasting it is advisable to remove all mouldings
and trim. Thoroughly mask all glass. 66. FOREIGN MATERIAL IN PAINT
A vibrating feather edger may also be used to fin- In instances where minute particles of foreign
ish small areas or panels. material have embedded themselves in the horizontal
After the metal has been properly sanded it should surfaces of the paint, they are quite likely abrasives,
be thoroughly washed with a good wax and grease re- such as metal particles, that have been carried
mover. through the air.
CAUTION: After the metal has been cleaned do If these particles are allowed to remain on the
not rub the metal with bare hands as the normal oil paint surfaces for any length of time in the presence
of the skin may leave a thin film on the metal and of moisture, a chemical reaction will take place, re-
cause poor adherence or peeling. sulting in the metal particles eating into the paint
surface. Early removal of this material by a thorough
64. PAINT REFINISHING washing will prevent this from happening.
Plymouth and Valiant vehicles are finisned with a NOTE: When the above described condition is
Luster-Bond Super Enamel. These super enamels pro- encountered in the field, it is often mistakenly diagb
vide the utmost in appearance and durability. nosed as rust coming up from the metal below the
To repair individual or small panels, an air dry or paint.
23-40 CONVERTIBLE COUPE
PART 5
CONVERTIBLE COUPE
67. WINDSHIELD 68. CONVERTIBLE TOP
Removal Care and Cleaning of Top
(1) Cover the adjacent cowl, hood and fender Frequent brushing and vacuuming will keep the
area with a protective covering. top free of abrasive dust and dirt. Wash the top with
(2) Release the top locking mechanism and push warm water and mild soap, lathering well with soft
the top header from the windshield frame to expose cloth or sponge. Rinse with plenty of clean water to
the screws holding the mouldings. remove all traces of soap. Allow to dry completely
before lowering.
(3) Remove the windshield wiper arms and
blades. CAUTION: Never lower the top when it is wet.
The top cover should be placed in the top cover bag
(4) Remove the upper moulding attaching screws
and stored in the luggage compartment. Never store
and remove the moulding. the top cover in the top well compartment.
(5) Remove the screws attaching the inner and
outer side “A” post side mouldings. 69. TO LOWER THE TOP
(6) Remove the sun visors. Release the safety catch on the end locking handle,
(7) Remove the screws attaching the header trim pull the handles down and to the rear. Then push the
cap to the header (Fig. 63). header free of the windshield. Be sure the convertible
(8) Pry the header moulding up slightly to clear top storage compartment is free of articles. The rear
the moulding from the weatherstrip then disengage window need not be unzipped. Operate the engine in
from the header and remove. NEUTRAL at a speed above idle. Turn the top control
switch located on the instrument panel to the right
(9) Remove the windshield glass.
and hold in this position until the top is fully lowered.
Installation WARNING: Never attempt to raise or lower the
Install the windshield on the convertible in the top while the vehicle is in motion. It i s advisable to
same manner as described for other models, then raise and lower the top at least once a month to
continue as follows: keep the top mechanism in working condition.
(1) Slide the header cap moulding up against the
weatherstrip (Refer to Fig. 63). 70. TO RAISE THE TOP
(2) Force the moulding against the weatherstrip, Unsnap the top boot at the sides and rear and
then press the rear edge down over the header. carefully fold into the storage compartment. Turn the
top control switch to the left and hold in this position
(3) Install the screws to hold in position, then rap
until the header rests on the windshield. Pull the top
slightly with a rubber hammer to seat (Be sure the down firmly on the top header. Push the locking
cap is evenly spaced across the header). handles all the way forward until the safety catch
(4) Install the screws and tighten securely. engages.
( 5 ) Install the side trim mouldings.
(6) Press tightly against the weatherstrip, engage 71. TOP ADJUSTMENTS
with the header, and lower the mounting, then press Convertible top adjustments are of two general
down over the “A” post and install the retaining classifications - minor and major. The minor ad-
screws. justments are easily accessible and can be made
(7) Seal the windshield. without any major disassembly.
( 8 ) Install the sun visor, wiper arm, check for Minor Adjustments
water leaks and clean the windshield. The minor adjustments are provided to assist in
(9) Install the windshield wiper arms, then clean aligning the top header in relation to the windshield
the windshield, using a suitable solvent. Test the header to prevent water and air leakage into this
windshield for water leaks. area; to improve top frontal area appearance and
(10) Operate the windshield wiper and adjust the assure ease of operation in raising and lowering the
arms if necessary. top. They are also provided to assure correct align-
CONVERTIBLE COUPE 23-41
ment of the roof side rails with door and quarter glass mechanism is adjustable to control the pressure on
to prevent air and water leakage. Adjustments are the weatherstrip.
also provided to eliminate wrinkles in the top ma- The latching mechanisms are adjusted for correct
terial. latching effort by unlatching the mechanisms and
turning the locking hooks in or out as necessary (Fig.
Major Adjustments 64).
The only major adjustment is at the prop control
link bracket at the rear quarter panel. It is used to 73. TOP HEADER ADJUSTMENT
improve roof side rail alignment if minor hinge ad- Incorrect alignment between the top header and
justments do not completely correct the condition. the windshield finish mouldings may result in air or
Making this adjustment involves removing the rear water leakage. Inspect the clearance between the
seat and quarter pocket panels. header and the finish moulding for uniformity. If
the top header is too far forward at one end or all
Door and Glass Alignment
across the finish moulding, the interference between
It is important to remember that before making the header and the finish moulding may prevent
any top adjustments, doors, vent wings and door and proper pressure on the weatherstrip when the top
quarter glass must be properly aligned. Misalignment header is latched. This condition will also cause ob-
in any of these areas would make it impossible to jectionable high locking and unlocking effort. The
obtain satisfactory results from top adjustments alone. misalignment may also result in making it difficult to
Adjust Up-Stops engage the top header locating dowels in their
sockets.
Up-stop adjustments should be made after the
To eliminate the interference between the header
correct roof side rail alignment to limit the upward
and the finish moulding, loosen the two vertically
travel of the glass. This is necessary to assure effective
positioned header-to-side-rail screws in the header,
sealing between the roof side rail weatherstrip and
inboard of the header panel (Fig. '65). Adjust the
glass.
header, as required, to provide the proper clearance.
Forward movement of the header will be limited
72. TOP HEADERSEAL by the amount of top material. Inspect the top header
The entrance of water and air between the top dowel engagement in the windshield before securing
header and windshield header is eliminated by a the screws. If there is interference between the dowels
closed cell weatherstrip secured to the underside of and sockets, adjust the header, as required. Tighten
the top header. The lip on the forward edge of the the screws securely.
weatherstrip contacts the windshield header outside CAUTION: When servicing the top linkage, keep
firish moulding. a watchout for any sharp edges or burrs on the top
linkage or mouldings that can damage the top
Header Locating Dowels
Good weathersealing at the frontal area is depend-
ent upon proper positioning of the top header on
the windshield header. Two steel locating dowels,
one assembled in each end of the top header, engage
sockets in the windshield header to correctly position
the top header. The sockets are slightly oversize to
permit fore-or-aft or lateral top header movement
for proper positioning.
The top header is adjustable at the front roof side
rails to permit fore-or-aft and lateral movement. The
header is attached to the side rails by two header-to-
side rail screws on each side.
Top Header Latching Mechanisms
The amount of pressure exerted by the weather-
strip against the finish moulding is controlled by top
latching mechanisms attached to the top header.
The locking and unlocking effort of the latching Fig. 65-Top Header Ad'jurting Points
material. Dress or file them down. Also, watch for

screws that are too long and can damage the top
material. Cut off the excess length, or replace with
shorter screws.
74. CORRECTING TOP HEADER WATER

LEAKS
If adjusting the top header for uniform spacing
and the latching mechanisms for proper header ten-.
sion on the header weatherstrip does not provide
satisfactory sealing, additional sealing on the under-
side of the header will be necessary.
Remove Weatherstrip Retainer
Lower the top and fold it back into the top well. Fig. 66-Roof Side Rail Structure
Remove the small curved black metal weatherstrip
retainer and screws at each corner of the header and ing the weatherstrip in place will hold it securely and
discard them. If the weatherstrip shows signs of enable the lip to provide a good seal at the windshield
distortion in this area due to the retainer, discard it. finish moulding.
The weatherstrip cannot be reshaped to provide an Secure the weatherstrip at the corners with No.
effective seal. 8-18 x ?hffround washer head screws and plain
Punch a three-sixteenths-inch hole at each corner washers, I/D x 5/” x 1/32”, using the three-
of the weatherstrip, midway between the two corner sixteenths-inch holes punched in the weatherstrip.
retainer screw holes. Drill a number twenty-eight Raise the top and carefully water test the area on
hole in the top material retainer, at each corner, in the work performed.
line with the punched hole in the weatherstrip.
Remove the weatherstrip retainer and the top 75. R O O F SIDE RAIL ALIGNMENT
material retainers from the top header and discard
The roof side rail structure (Fig. 66) consists of
the screws. New, longer screws must be used when
three separate rails, hinged together to enable the
the retainers are reinstalled.
top to fold into the well when not in use. Hinges are
Header-To-Roof -Rail Joint Sealing provided between the front and center rails and the
Seal the joints between the top header and the center and rear rails. The rails must be in good
front roof side rails by applying one-inch balls of alignment and parallel to the top edges of the vent
body sealer to the notches formed by the joint be- wings, door and quarter glass to provide a good
tween side rail and the top header. weatherseal. Alignment of the rails is controlled by a
Cement a strip of polyethylene foam seal, Part set screw arrangment which consists of a socket-type
No. 2484159,across the header, close to the corners, set screw in one rail and a steel drive stud in the
and extending out one-quarter inch from the header adjoining rail.
inner panel at the ends. Install the top material and
Side Rail Hinge Locations
weatherstrip retainers, using round washer head
screws, No. 8-18x Y2”. The front hinge set screw is accessible from the top
surface of the front rail and angles downward to the
Sealing Ends of Top Material Retainers rear. It contacts the steel drive stud in the center rail
It is important to seal at both ends of the two to open or close the hinge, as required. The rear
curved top material retainers. Use a one-half inch hinge set screw is located in the underside of the
ball of body sealer under the offset tab at the end center rail and angles upward and to the rear. It
of the curved retainer. Apply a four-inch length of contacts the drive stud in the rear rail. Access to the
sealer to the joint formed by the curved retainer and set screw can be made by removing the center roof
the header weatherstrip retainer. side rail weatherstrip and retainer.
Cementing Weatherstrip to Retainer Front Hinge Misadjusted
Apply a light coating of rubber cement on the Water and/or air leaks between the top and door
inside of the weatherstrip retainer and the weather- or quarter glass may be caused by poor contact
strip. Allow cement to become tacky on retainer and between the roof side rail weatherstrip and the glass
weatherstrip before installing weatherstrip. Cement- or only a partial contact between the roof rails and
ALLEN WRENCH 7
y 7
2.
64x452
V
PARTIAL SEAL
Fig. 67-Front Hinge Jack Knifed

Fig. 69-Rear Hinge Adjusting Screw
the top edge of the glass. If inspection shows the
leakage is due to a jack knifed condition (Fig. 67)
at the quarter glass. If additional clearance is noted in
at the hinge, it will be necessary to adjust the hinge
this area, as indicated by the hinge being jack knifed
set screw to close the joint.
open, again unfasten the top header. Remove the
CAUTION: To avoid stripping the set screw side rail weatherstrip and retainer and adjust the
threads, unfasten the top header latches to relieve rear hinge set screw (Fig. 69) from the underside of
tension on the top linkage, before adjusting the set the center rail until proper alignment and clearance
screws. is obtained.
Adjusting the two hinge set screws will normally
76. ADJUSTING FRONT HINGE correct any roof side rail alignment problems, how-
If the front hinge is jackknifed, use a one-eighth- ever, if an alignment problem still exists, and addi-
inch Allen wrench and turn the set screw (Fig. 68) tional leveling of the roof side rails is required, the
in a counter-clockwise direction to close the joint linkage through the main control prop link bracket
until the front and center rails are parallel. Fasten can be adjusted.
the top temporarily to inspect parallelism and align-
ment with the door glass. Readjust the set screw, if 78. M A I N CONTROL PROP LINK
necessary. BRACKET ADJUSTMENT
To gain access to this bracket, remove the rear
77. REAR HINGE ADJUSTMENT
Inspect the center and rear roof side rail alignment
-
1/8" ALLEF WRENCH
--- 1
'ER RAIL
64x451 6 - - - . .l- -. -
Fig. 68-Front Hinge Adjusting Screw Fig. 70-Main Control Prop link Bracket Adjustment
seat and the pocket panels on both sides. Unfasten

the top header latches to relieve the tension from
the linkage. The door glass and quarter glass must
be raised to prevent the side rail structure from
dropping when the adjusting bracket screws are
loosened.
The serrated prop link adjusting bracket is at-
tached to the quarter panel reinforcement by two
screws threaded into a tappet plate (Fig. 70). Loosen
the screws just enough to permit moving the bracket
up or down, as required. Raising the bracket and
E
link causes the center rail to rotate on its pivot in
the rear rail, lowering the front and center rails to
improve the weatherstrip fit with the door and quarter
Fig. 71-Front Top Bow Adjustment
glass. When proper alignment has been obtained,
tighten the adjusting bracket screws. Inspect the side
rail hinge adjustments, and adjust as necessary. assumes its normal position due to leak-back in the
hydraulic system.
79. TOP SHIFTS T O ONE SIDE
81. FRONT TOP BOW ADJUSTMENT
If it is necessary to pull the top to one side to
engage the locating dowels in their jackets in the (Plymouth Only)
windshield header or the top shifts to one side when If the top material at the front bow appears to
raising the header from the windshield header, in- hang down too low and interfere with the top edge
spect the main prop link bracket adjustments. Brack- of the door glass when the door is closed, adjust the
ets not adjusted uniformly, changes the operating number one top bow at the adjusting plate attached
angle of the linkage causing the top to twist when it to the outer ends of the top bow (Fig. 71). This
is raised. permits the bow to be moved up or down, as required.
When one bracket is adjusted, be sure that the If the roof side rails are exposed below the top
position of the bracket on the opposite side is in- material, the bow can be lowered. To adjust the bow,
spected and adjusted, if necessary. loosen the screw at each end and move the bow up or
down, as required.
80. POWER GUIDE LINK ADJUSTMENT
82. TOP MATERIAL PADDING FOR
(Plymouth Only) OVERHANG
NOTE: It should not be necessary to adjust the
power guide link supports unless the top assembly On Valiant models, excessive top material over-
has been removed for servicing or replacement of hang can be corrected by installing temporary pad-
linkage parts. When this is done, be sure both sup- ding between the stay padding and top material. These
parts are adjusted to provide identical travel of the temporary pads can be removed later when they
piston rods. are no longer required. When making this adjustment,
inspect the upper end of the door glass moulding
The link adjusting support is attached to the panel for sharp edges that can cut the top material. Dress
by two screws, which when loosened, permit forward down or file off any sharp edges.
or rearward movement of the support. It is im-
portant that the supports on both sides be positioned
at approximately the same position. If one support is 83. ROOF SIDE RAIL WEATHERSTRIP
positioned rearward of the other one, it would cause ADJUSTMENT
the power piston rod linked to that support to start After the roof side rails have been aligned, inspect
to actuate the linkage slightly ahead of the piston rod the side rail weatherstrip to make sure it is providing
on the opposite side. This can cause one side of the a good seal at the top of the door and quarter glass.
top to twist slightly. If the weatherstrip is not sealing properly, the
The rearward position of the support also increases retainer and weatherstrip can be adjusted to improve
the travel of the power piston rod, resulting in a the seal. The retainer has elongated attaching screw
small amount of overtravel when the top is fully holes which permit the retainer and weatherstrip to
raised. When the power is turned off, the power piston be moved in or out.
CONVERTIBLE COUPE 2345
unfasten the top header latches to relieve tension on
the linkage.
Testing Cable Adjustment

On the inside of the car, locate the centerline of the
top on the rear bow and the ledge of the top well.
From the centerline, measure 20 inches (Plymouth),
17% inches (Valiant) each side of the centerline at
the bow and the ledge. These are locating points for
backlight depth dimensions that govern the cable
tension.
Measure down from the rear edge of the rear bow
to the top well ledge on each side.
If the spacings between the bow and the ledge
Fig. 72-Roof Side Rail Weatherdrip Adjustment are not 25% inches (Plymouth), 24a/,, inches
(Valiant), the cables must be adjusted. With an
To adjust the seal fit along the edge of the glass, assistant holding a tape measure at one location,
loosen the retainer screws under the weatherstrip remove one cable attaching screw. While holding
and adjust the retainer, as required (Fig. 72). the top bow in the measured position, turn the upper
Raise the glass until the top edge of the glass curls end of the cable in the proper direction until the eye
the outer lip of the weatherstrip inward just enough of the cable is in line with the screw hole. Install the
to contact the inner lip. Adjust the up-stops to limit screw. Repeat the procedure, if required, on the
further upward travel of the glass. opposite cable.
84. REAR B O W TENSION CABLES 85. R E M O V I N G WRINKLES IN BACKLIGHT
Two steel cables attached to the rear bow and the Cable adjustment may cause wrinkles in the back-
top well are provided to keep the bow from moving light area. To correct this condition, it will be neces-
forward and wrinkling the top material. They also sary to remove the mouldings and retainers and
prevent excessive tension on the backlight zipper. relocate the backlight and quarter trim.
The upper end of the cables are attached to the bow Before removing the moulding screws, place a strip
by screws. The lower end is threaded into a clinch of masking ta?e on the deck, directly behind the
nut attached to a bracket at the top well which mouldings. Mark the screw locations on the tape to
permits the cables to be shortened or lengthened to aid in reassembly.
increase or decrease tension (Fig. 73). The degree Remove the moulding screws, moulding, retainer
of tension is determined from a measurement taken screws and retainer. Restretch the backlight and
between the lower rear edge of the bow and the ledge quarter trim to remove the wrinkles. Trim off excess
of the top well under the backlight. backlight and quarter trim material that extends
NOTE: Before attempting to adjust the cables, beyond the retainer. Reinstall the retainers and
- mouldins.
I 86. CORRECTING TOP WELL WATER LEAK
Water leaking into the top well may be entering
between the lower edge of the backlight and the
deck opening upper panel. To correct, seal the area
with body sealer and a polyethylene foam seal. Apply
a strip of masking tape on the deck panel directly to
the rear of the finish moulding to facilitate the in-
stallation of the retainer and moulding screws.
Remove the moulding and retainer screws. Lift off
the mouldings, retainers and top material from the
deck panel. Carefully clean the deck panel surface.
Spread a bead of body sealer along the edge of the
panel. Place the top well material back in position
6 on the sealer. Position a 104-inch x %-inch wide x
Fig. 73-Rear Bow Tension Cable Adjustment %-inch polyethylene foam seal on the top material.
PUMP AND RESERVOIR
T1-1 18”
T-
1
64x458
Fig. 74-Quarter Window Belt Water Seal Dimensions
Install the retainers. Install an additional No. 8 ,

self-tapping screw with a plain washer through the
top material and deck panel, midway between the ‘Fig. 76-Hydraulic Folding Top Mechanism
center and end retainers to provide a tight seal. Install (Plymouth Shown)
the mouldings. Water test the area and inspect for
leaks. Cut a seal from a piece of closed-cell rubber
according to the dimensions shown in Figure 74.
87. QUARTER WINDOW BELT WATER Coat the inside and top surface of the-sealwith rubber
LEAK cement. Apply a coating of rubber cement to the
This condition can be corrected by cementing a lower, rear inside surface of the side rail weather-
rubber baffle on the lower end of the rear side rail. strip and the lower end of the side rail. When the
From the inside, slit the top fabric flap to the cement has dried tacky, press the seal firmly in place
bottom edge of the rear roof side rail and then fold (Fig. 75) on the side rail. Repeat the operation on
the lower flap outward to provide enough room to the opposite side.
install the seal.
TOP LIFT SWITCH
30 AMP.CKT. BREAKER
TERMINAL
TOP LIFT MOTOR 11.
(CONV. ONLY) I+
n 1L
- 1
STARTER
SOLENOID
63 x 95A
Fig. 77-Hydraulic Top Wiring Diagram
88. SERVICING THE TOP

I! FOLDING MECHANISM
The electric-hydraulic top folding mechanism (Fig.
76) consiSts of two cylinders, a piping system, an
electric motor, a pump and reservoir assembly, and
Fig. 75-Quarter Window Belt Water Seal Installed a double-throw rotary switch. The wiring and motor
are protected by a separate circuit breaker as shown red wire terminal on the control switch. The top (if
in Figure 77. raised) should start to lower. Repeat this test with the
The pump is a two-direction, reversing motor type green wire. The top (in lowered position) should start
and is connected to the cylinders by flexible lines and to raise. If the top operates during these tests, but
tubing. A valve and port assembly in the reservoir fails to operate when the control switch lever is
directs flow of fluid in the system. The motor pump, moved to the right or left, the switch is at fault and
and reservoir assembly can be replaced as a unit, should be replaced. If the top fails to operate during
or electric motor can be replaced separately. The these tests, follow the procedure outlined for Ad-
cylinders are sealed units and must be replaced as justing the Top, Checking Fluid Level in Reservoir
assemblies. If difficulty is encountered in raising or and Testing Wires Between the Control Switch and
lowering the top with the motor running, with suffi- the Pump Motor.
cient fluid in the reservoir, and with the pivot points
operating freely without binding, the cause is prob- 92. TESTING WIRES BETWEEN CONTROL
ably improper linkage alignment and adjustment. SWITCH AND PUMP M O T O R
This test can be made from the luggage compart-
89. CHECKING FLUID LEVEL ment. Test the pump motor ground wire (black wire
IN RESERVOIR between the pump motor and ground) to make cer-
Insufficient fluid in the system may cause the top to tain it has a good, clean ground connection. Hook one
raise slowly or cause noise in the pump and motor wire of the test lamp to the black wire terminal on the
during operation. If low, inspect for a leak due to a pump motor and ground the other wire of the test
broken line or loose connections. Replace the line or lamp. Move the top control lever to the right. The
tighten the connection as necessary. Fill the reservoir test lamp should light. If the test lamp does not light,
until fluid runs out of the filler hole. Use type “A” the black wire between the pump motor and the con-
suffix “A” automatic transmission fluid. trol switch is faulty and should be replaced. Repeat
this test at the green wire terminal, moving the top
NOTE: After filling reservoir, raise and lower control lever to the left. If the test lamp lights in both
the top several times to force out air that may be cases but the pump motor fails to operate, repair or
trapped in the system. Always check fluid level when replace the pump motor as necessary.
the top is lowered.
93. REAR WINDOW
90. TOP W I L L N O T RAISE O R LOWER The rear window is made from flexible vinyl plastic
, Hook one wire of a test lamp to a good ground and material and special attention should be given to
the other wire of the test lamp to the feed terminal on cleaning and storage of the window. To clean the
the control switch. The test lamp should light. If the window, rinse with cold water spray to remove grit
test lamp does not light, tighten all electrical connec- and dirt. Lather the surface with suds of mild soap,
tions, test on each side of the circuit breaker, and re- using the palm of hand. Rinse thoroughly and allow
place the faulty wire or circuit breaker, and repair to air dry. Do not use towel, sponge, or chamois to
or replace the wire. apply suds or to dry the window. Otherwise, the sur-
face may become scratched. If this procedure does
91. TESTING THE ELECTRICAL CIRCUITS not clean the window thoroughly, a solution of 40
per cent rubbing alcohol and 60 per cent clean water
Testing the.Top Control Switch should be used. Apply with palm of the hand and
Disconnect the black wire at the top convertible rub the surface of the window with a circular motion.
control switch and hold it firmly against the black and Use the solution generously.
23-48 STATION WAGON-BODY
PART 6
94. TAIL GATE (Plymouth and Valiant 1 glass into the upper run channel. Leveling of the tail
gate in the “open” position is made by raising or
The tail gate of the Station Wagon Model is hinged
lowering the tail gate leveling guide. Lateral adjust-
at the lower corners and is counterbalanced by one
ment to center the tail gate in the body opening is
torsion bar to aid in raising and lowering. The 3 seat
controlled by the tail gate attaching screws under the
Station Wagon is equipped with an electric window
base of the tail gate.
which is optional on the other models. The electric
window is controlled by a switch on the instrument
panel. An externally operated lock cylinder switch 96. TAIL GATE (Plymouth)
provides for external operation of the window. Removal
A pull type handle is located in the center of the (1) Remove the rear bumper face bar to enable
upper inside garnish moulding to unlatch the tail the tail gate to be removed down and out of the body
gate. The tail gate is held closed by two rotary type opening.
locks mounted on the sides of the tail gate. These (2) Under the tail gate door, remove the torsion
rotary locks engage two-stage strikers attached to the bar brackets from the pillar post.
pillar posts.
(3) Open the tail gate and support it on jacks or
stands.
95. TAIL GATE ALIGNMENT (4) Loosen the hinge pivot pin locking screws
( Plymouth and Valiant 1 (Fig. 79).
Tail gate alignment is essential to insure ease of (5) Use a pencil and outline the hinge plate posi-
window operation and weather sealing. tion on the pillar post for future assembly.
Prior to changing the alignment of the tail gate, NOTE: On vehicles with electric windows, dis-
scribe an aligning mark around the tail gate hinge connect the battery negative terminal a t the battery,
plate, tail gate leveling guide and the tail gate latch. remove the trim panel and disconnect the terminals at
Repeat this on both pillar posts. This provides marks the control switch on the left edge of the tail gate.
to show the amount of movement. Vertical adjustment (6) Remove the hinge plate attaching bolts from
and “in” and “out” adjustments (Fig. 78), are made the pillar post (Fig. 78).
in at the hinge plate. “In” and “out” alignment of the
(7) Slide the hinge plate and torsion bar in
top of the tail gate is adjusted by moving the latch
“in” or “out” to permit ease of entry of the tail gate
through the guide toward center of the tail gate.
(8) Lower the tail gate down and out of the body
opening.
TORSION
HINGE
1 ADJUSTING SCREWS
63x848
Fig. 78-Tailgate Alignment Points Fig. 79-Hinge Pivot Anchor Screw

STATION WAGON-BODY 23-49
Installation (7) Remove the tail gate from the body.

(1) With the torsion bars and hinge plates pushed Installation
in toward the center of the tail gate, engage the hinge (1) Place the tail gate on padded jacks or stands.
plates into the lower opening of the body.
(2) Align the hinge with scribe marks and install
(2) Attach the hinge plate attaching bolts into the the attaching bolts finger tight.
pillar posts and locate the hinge plates in relation to
(3) Attach the left tail gate support arm.
the previous pencil marked positions.
(4) Using the torsion bar holding Tool C-3449,
(3) Tighten the attaching bolts firmly enough to align the torsion bar support and guide bracket with
hold the position and inspect the alignment. the scribe marks, install and tighten the attaching
(4) Close the tail gate and center in the opening. bolts.
(5) Attach the torsion bar bracket to the pillar (5) Inspect the tail gate hinge alignment and
post. tighten the attaching bolts.
(6) Open the tail gate and tighten the locking
screws on the hinge pivot pin (Fig. 79). 98. TAIL GATE GLASS
( Plymouth and Valiant 1
(7) Connect the wires to the control switch and in-
stall the trim panel. Removal
(8) Operate the tail gate window and inspect the (1)Lower the tail gate glass and open the tail
alignment. gate.
(2) Remove the attaching screws and remove the
97. TAIL GATE (Valiakt) garnish moulding and handle.
(3) Remove the inside trim panel.
Removal
(4) With an assistant holding the instrument panel
(1) On the electric operated tail gate window, re- switch in the “up” position, operate the control switch
move the inside trim panel and disconnect the wiring. on the left side of the tail gate and support the glass
(2) Place padded jacks or stands under the fully as it emerges.
opened door. (5) Remove the regulator arms from the window
(3) Scribe the location of the torsion bar support frame and remove the glass from the tail gate.
and guide.
l n s tallation
(4) Using the torsion bar holding Tool C-3449 re-
move the tail gate support and guide attaching bolts (1) Insert the glass into the tail gate run channels
from the right pillar post. deep enough to engage the regulator arms into the
window frame.
( 5 ) Remove the left tail gate support arm from the
left pillar post. (2) Install the inside trim panel.
(6) Remove both hinge attaching bolts from the (3) Install the garnish moulding and handle.
pillar posts. (4)Operate the window and inspect for misalign-
ment.
99. TAIL GATE RUN CHANNEL

( Pymouth and Valiant 1
Removal and Installation
(1) With the tail gate glass removed, remove the
channel attaching and adjusting bolts (Fig. 80).
(2) Install the run channels and attach with the
LOW’ER RUN adjusting bolts. Tighten only finger tight.
(3) Run the glass to the bottom stop and close the
tail gate.
(4) Operate the glass up and down several times
to center the run channel.
(5) If the glass binds in the run channel loosen the
64x465 VIEW IN ‘ CIRCLE A regulator attaching bolts.
Fig. 80--Tail Gate Run Channel Attaching Points (6) Tighten the regulator and run channel bolts.
23-50
- STATION WAGON-BODY
r
t52x607
Fig. 83-Installing Mylar Strip
101. TAIL GATE GLASS ALIGNMENT

( Plymouth and Valiant 1
Fig. 81-Removing Mylar Strip from Weatherstrip
(1) Remove the inner trim panel from the tail gate
door.
100. QUARTER W I N D O W
(2) Loosen the four window regulator attaching
( Plymouth and Valiant)
screws.
Removal (3) Close the tail gate door and run the tail gate
(1) Using a wedge shaped fibre tool, remove the glass u? to within ?hinch of the closed position.
mylar locking strip from the quarter window weather- (4) From inside the vehicle position the window
strip (Fig. 81).
regulator assembly so that the top edge of the glass is
(2) Unlock the weatherstrip from the quarter win- parallel with the top of the window opening in the tail
dow using a fibre wedge (Fig. 82). gate door.
(3) With an assistants help, remove the quarter (5) Tighten the four window regulator attaching
window from the weatherstrip. screws and test the operation of the window.
lnstallation (6) Install the inner trim panel on the tail gate
(1) Position the quarter window on the weather- door.
strip and using a fibre wedge install the quarter glass
into the weatherstrip. 102. STATION W A G O N REAR SEATS
(2) Install the mylar locking strip using Tool C- Removal (Second Seat Backl
3840 (Fig. 83). Start the installation at the bottom of (1) Remove the screws attaching the second seat
the weatherstrip. back to the hinge assemblies (Fig. 84).
(3) Clean the quarter window with a suitable sol- (2) Release the spring type retainer catches from
vent and test for water leaks. the seat back and remove the seat back assembly.
TAPPING PLATE
SEAT CUSHION
Fig. 82-Unlocking Weatherstrip from Quarter Witidow Fig. 84-Station Wagon Second Seat Installation
STATION WAGON-BODY 23-51
Installation f Second Seat Back I

(1) Position the second seat back on the hinge as-
semblies.
(2) Install the hinge to seat back screws and tight-
en to 80-120 inch pounds torque.
(3) Test the engagement of the seat back catches
on the seat back and adjust as necessary. Adjustment
of the catches is possible only in the IN and OUT
directions.
Removal f Second Seat Cushion I 64x523
(1) Raise the rear floor hinged panel at the rear of
Fig. 86-5eat Back Attachment
the seat cushion assembly (Fig. 84) to expose the seat
cushion to floor pan attaching bolts.
port hinge pin (Fig. 86) and remove the seat back
(2) Remove the bolts attaching the seat cushion to assembly.
the floor pan.
(4) The seat back cushion is retained to the seat
(3) Move the seat cushion slightly rearward to dis- back panel (Fig. 87) with screws.
engage the locking bars at the front bottom side of
the seat cushion, from the floor brackets. Installation f Third Seat BackI
(4) Remove the seat cushion assembly. (1) Position the seat back hinge on the support
panel hinge and install the retainer pins and retainers.
Installation f Second Seat Cushion I (2) Position the seat back and support panel as-
(1) Place the seat cushion in position, making cer- sembly on the studs (Fig. 85).
tain the locking bars at the bottom of the front seat (3) Install the retainers on the stud.
cushion are engaged in the brackets on the floor pan.
(2) Raise the hinged portion of the rear floor, at Removal f Third Seat Cushion I
the rear of the seat cushion, and install the bolts at- (1) The third seat cushion is attached to hinges
taching the seat cushion mounting straps to the floor which in turn are attached to the quarter inner
pan. panels by screws.
(2) Remove the screws attaching the hinges to the
Removal f Third Seat BackI f Fig. 85 I quarter inner panel.
(1) With the third seat back in the UP position,
(3) Remove the rear seat cushion assembly.
remove the retainers from the seat hinge support
studs. Installation f Third Seat Cushion I
(2) Remove the seat back and support panel as- (1) Position the cushion assembly on the rear floor
sembly.
(3) Remove the retainer from the seat back sup-
SUPPORT PANEL
pan.
SCREW -- BRAZET:
SEAT BACK
HINGE
HINGE
FRON?'OF CAR
I'
RETAINER 64x522
BACK 'CUSHION 64x524
Fig. 85-Third Seat Back Assembly Fig. 87-Seat Back Cushion Attachment
23-52 DIAGNOSICBODY
(2) Install the hinges on the quarter inner panel fit and alignment.
and tighten securely. (4) Adjust as necessary by loosening the hinges
(3) Test the operation of the seat and inspect the and moving the seat as required.
SERVICE DIAGNOSIS
CONVERTIBLE COUPE TOP
Folding Top Header (a) Incorrect front and rear side (a) With the top in the up position and the
and Windshield rail adjustment. header locked in, turn the square head
Header n o t Meeting screw at the front side rail hinge and the
a t Correct Angle set screw at the rear side rail hinge until
they contact the head.
“Jack Knifing” of (a) Improper alignment of the (a) Adjust by moving the serrated adjustment
t h e Side Rails a t t h e side rails to the top of the plate up or down to hold the side rails in
Rail Hinges. window glass. their correct relationship to the window
frame. Adjust both sides to the same
height to maintain parallelism of the
side rails.
Improper Meeting (a) Improper adjustment of the (a) Adjust the power link “fore and aft”
(fore and a f t ) of the power link. across the serrated plate. Adjustment is
Folding Top Header w i t h in direction of movement desired.
t h e Windshield Header.
Folding Top Header (a) Improper adjustment of the (a) Adjust the folding top header “fore and
N o t in Alignment w i t h folding top header. aft” until alignment with the guide
t h e Guide Dowels on dowels is accomplished.
the Windshield Header.
Top Fabric Too (aj Improper adjustment of the (a) Adjust the roof bow up or down on the
Loose or Too Tight. Number 1 roof bow. bow support.
Air or Water Leaks (a) Folding top header torsion bar (a) Adjust the folding top header torsion bar
a t t h e Windshield not properly adjusted. to accomplish a 30 pound locking
Header . handle effort.
AIR CONDITIONING 24-1
GROUP 24
AIR CONDITIONING
CONTENTS
Page Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Radiator Pressure Cap.. . . . . . . . . . . . . . . . . . . . . . . . . 27
Torque Reference . . . . . . . . . . . . . . . . . . Vacuum Control System Adjustments and Tests
Air Condition-Operation (Plymouth Mo (Plymouth) ................... 28
Electrical Controls and Circuits. . . . . . . . . . . . . . . . . A/C and Heater Temperature Selector Switch Test. . . 30
Thermostatic Valves. . . . . . . . . . . A/C and Heater Temperature Control Cable
Temperature Selector Switch. . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Owners Operating Instructions. . . . . . . . . . Thermostatic Valve Tests.. . . . . ........... 31
Air Conditioning-Operation (Val Heater Thermostatic Valve Test. . . . . . . . . . . . . . . . . . . 31
tnspection and Adjustments-Plymouth. . . . . . . . . . Air-conditioning Thermostatic Valve Test.. . . ... 32
Blower Switch Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Thermostatic Valve Replacement. . . . . . . . . . . . . . . . . . 32
Push Button Control Chart.. . . . . . . . . . . . . . . . . . . . . . . 12 Magnetic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inspection and Adjustment-Valiant . . . . . . . . . . . . Compressor. . . . . . . . . . . . . . . . ... 35
Gauge Set Manifold-Installation and Tests.. . . . Expansion Valve, Heater Core, and Evaporator and
Test 1-Test System Pressure. . . . . . . . . . . . . . . . . . . . . 14 Evaporator and Blower Replacement (Plymouth). . . . 39
Test 2-Refrigerant level. . . . . . . . . . . . . . . . . . . . . . . . 15 Expansion Valve, Evaporator and Blower
Test 3-Testing the System for leaks. . . . . . . . . . . . . . 16 Replacement (Valiant). . . . . . . . . . . . . . . . . . . . . . . . 41
Test 4-Correcting low Refrigerant. .... Refrigerant Service. . . . . . . . . ........... 42
Test 5-Over-All Performance Test. . . . . . . . . . . . . . . . 18 Discharge the System. . . . . . . . . . . . . . . . . . . . . . . . 43
Test 6-Evaporator Pressure Regulator Valve Test Sweep-Test Charge. . . . . . . . . ........... 43
(Plymouth). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Testing the System for Leaks. . . . . . . . . . . . . . . . . . . . . 44
Test 7-Compressor Capacity Test. . . . . . . . . . . . . . . . 21 Remove Sweep-Test Charge. . . . . . . . . . . . . . . . . . . . . . 45
Test 8-Expansion Valve Test. . . . . . . . . . . . . . . . . . . . 23 Replace the Receiver-Drier Strainer. . . . . . . . . . . . . . . . 45
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Evacuate the System.. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Handling, Tubing and Fittings.. . . . . . . . . . . . . . . . . . . . 26 Charging the System.. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Drive Belt Adjustment. . . . . . . . . . . . . . . . . 27 Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
AntiFreeze Recommendations-Plymouth . . . .
SPECIFICATIONS
COMPRESSOR
location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l e f t of Center on Cylinder Block

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cylinder "V" Type
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2% inch
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
! inch
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.45 cubic inch
Type Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reed Type
Speed (depends on axle ratio and tire size). ................................ Approximately 1250 rpm at 25 mph
Oil Capacity (Refrigerant Oil). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ounces
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stationary Coil
Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Compressor Discharge Line
In Compressor and Suction Line
24-2 AIR CONDITIONING
SPECIFICATIONS- ( Continued 1
CONDENSER
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................... Front of Radiator
RECEIVER-DRIER-STRAINER
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylindrical Steel Container

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Front of Radiator Plymouth
In Engine Compartment Valiant
REFRIGERANT
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant 12
Total Charge
Plymouth . . . . . . . . . ................ ............... ......... 45 ounces
Valiant. . . . . . . . . . . ................ ........................ 36 ounces
TORQUE REFERENCE
Compressor Bearing Housing Bolt. . . . . . . . . . . . . . . . . . . ............ 10-13

Compressor to Bracket Bolt. . . . . . . . . . . ........................... 50
Compressor Connecting Red Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52-56
Compressor Cylinder Head Cover Bolt. . . . . . . . . . . . . . . . . . . . . . 23-27
Compressor Cylinder Head Cover (Nameplate) Bolt. . . . . . . . . . . . . . . . . . . . . . . 20-24
Compressor Discharge Adapter Bolt. . . ............................. 14-18
Compressor to Engine Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compressor Oil Pump Cover Bolt.. . . . . . . . . ................. 10-13
Compressor Oil Sump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-19
Compressor to Strut Bolt. . . . . . ......................... 30
Compressor Suction Adapter Bolt, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Magnetic Clutch to Compressor Bolt.. . . . . ........................... 20
“0” R I N G N U T TORQUES
l i n e Size Foot-Pounds line Size FoobPoundr
% SA€. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14 ’/2 SA€. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-35

% SA€. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-25 % SA€. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-65
AIR CONDITIONING
There are two types of Air-conditioning units avail-
able on the Plymouth and Valiant Models. BLOWER SWITCH
Blower, it selects the amount and type of air flowing in
A combination Air-conditioning and heating unit the car during air conditioning, heating, or defrosting. Four
is available on Plymouth Models which is dash mount- fl switch positions w e avoiloble as indicoted by the white index
marks:
ed and operated by controls conveniently located on
the instrument panel. Moxirnurn Speed-recirculoted .rai
On Valiant Models, a separate Air-conditioning unit [31 Medium Speed-recirculated air
is used from the heater. The Air Conditioning unit is
Medium Speed-fresh air
mounted on the bottom of the instrument panel, cen-
[II Low Speed-fresh air
trally located and has no additional air ducts and
the controls are integral with the unit.
Fig. 2-Blower Switch (Typical)
1. AIR CONDlTlONlNG4PERATION
to be operated with the ”Blower” switch in either the
( Plymouth Models 1
No. 3 or No. 4 positions; therefore, the blower will
A simple and versatile control system provides the not operate for these settings.
driver with a wide choice of comfort conditions. Four
Directional air conditioning outlets on the instru-
push-buttons marked “Off”,“Heat”, “Defrost”, “Cool”
(Fig. 1) control vacuum actuators which position the ment panel also serve for defrosting. Two spot coolers
outlet dampers for correct air distribution. The tem- also are provided; one at the left lower edge of the
perature control lever adjusts the setting of a pair of instrument panel, the other at the right kick panel
thermostatic valves, which maintains the tempera- area (Fig. 3). Additional outlets under the instrument
ture of the vehicle at a comfortable level in heat, panel direct cooling air down to floor level.
defrost, and cool. Rotary blower switch has four posi- Air Flow For Each Push Button Position
tions as indicated by the white index marks (Fig. 2). When testing or adjusting the doors in the distri-
These provide: bution system, it is necessary to know the correct po-
(1) Low speed-fresh air heating, defrosting, or fresh sition of each door for each push-button position. It
air conditioning. is also necessary to know which vacuum hoses are ac-
(2) Medium speed-fresh air heating, defrosting, or tivated for each push-button position. In the illustra-
fresh air conditioning. tions (Figs. 4 thru 9) which follow; air flow is indicat-
(3) Medium speed-recirculating air conditioning. ed, also which vacuum actuator hoses are activated
for each push-button position.
(4) High speed-recirculating air conditioning.
Ventilation
NOTE: The heater and defroster are not intended
Pushing either the “Heat” or “Defrost”, with blow-
er switch on positions 1 or 2 and moving temperature
control lever to off position, will set the system for
PUSH BUTTONS fresh-air ventilation-a desirable setting when tem-
-
‘OFF” to shut off system. perature conditions are such that neither cooling nor
-
“HEAT‘ to be used when heating the car.
-
“DEFROST“ to be used when defrosting the windshield
~-
” COOL’- to be used when cooling the car.
Adius!able Vanes /-
__----. ..
/j‘f
___--&-7’
,/
TEMPERATURE CONTROLLEVER
Marked “WARM” it maintains the temperature of your car
at any desired level like the thermostat in your home. The i
Raised Lowered
TEMPERATURE CONTROL LEVER can be used with air
UPPER O U T L E T S I
conditioning, heating, and defrosting. (manually controlled)
,Adjustable
/ Vanes
With the lever in the up position, the air is not heated.
Moving the lever downward increases the air temperature. Air outlets oliow air to be directed Plr from the spol Oulle+s con be
With the lever in the down position. maximum heating of ot the cor accupanls during cool
directed from side IC sideondup
the air occurs. or dawn by ad!ustinq Ibe “ones
62 x 668A down and away from the OCCupOntS
62x670 or r o t o ! i i g !he borrei
offer comfort has been achieved
Fig. 1-Push Button and Temperature Control

lever (Typical) Fig. 3-Directional Outlets
244 AIR CONDITIONING
"OFF" POSITION FRESH AIR THRU COWL VENT

MAXIMUM COOL SWITCH
NOT ACTIVATED
BLACK HOSE ACTIVATED
SPOT COOL DOOR (CLOSED)

DEFROSTER DOOR (CLOSED)
62x672
Fig. &Air F l o w 4 f f Position
"HEAT" POSITION FRESH AIR THRU COWL VENT

MAXIMUM COOL SWITCH
NOT ACTIVATED
HEATER CORE
SPOT COOL D O O R (CLOSED) FRESH AIR

DEFROSTER DOOR (CLOSED) DOOR
HEATER DOOR
62x673
Fig. 5-Air Flow-Heat Position

~ ~~ ~ ~~~
AIR CONDITIONING
~~~
24-5
"DEFROST" POSITION FRESH AIR THRU COWL VENT

MAXIMUM COOL SWITCH
NOT ACTIVATED
SPOT COOL DOOR (CLOSED)

DEFROSTER DOOR (OPEN)
2
MAXIMUM COOL SWITCH
(ACTIVATED WHEN '3
BLOWER SWITCH IS IN POSITIONS
POSITION 3 OR 4) HEATER DOOR
REAR VIEW OF SWITCH
62x674
Fig. &Air Flow-Defrosting Position
"COOL" (FRESH) POSITION FRESH AIR THRU COWL VENT

MAXIMUM COOL SWITCH
NOT ACTIVATED
HEATER CORE
SPOT COOL DOOR (OPEN) FRESH AIR
DEFROSTER DOOR (OPEN) BL0W
, ER DOOR
"COOL" (MAX.) POSITION FRESH AIR THRU COWL VENT

M A X I M U M COOL SWITCH
ACTIVATED
-
REAR VIEW OF SWITCH 62x676
Fig. 8-Air Flow-Recirculating Cool Position
"OFF" POSITION FRESH AIR THRU COWL VENT

M A X I M U M COOL SWITCH
ACTIVATED
HEATER CORE
EV
BLOWER
\\ FRESH AIR
DOOR
7'"'
-2
62x677
Fig. 9-Air Flow-Off

heating is desired. The only difference between the

operation of the heat system with the “Heat” or “De-
frost” buttons pushed in is the circulation of the dis-
charge air. With the “Heat” button in, most of the air
is discharged through the ‘floor level. With the“De-
frost” button in, most of the air is discharged through
U
the instrument panel outlets.
/
2. ELECTRICAL CONTROLS A N D CIRCUITS
With air conditioning there are two switches, the Fig. 1 1-Thermostatic Valves
push button switch assembly controls the clutch cir-
cuit. The push button switch also controls the “Feed” ditioning stat governs reheating when the air con-
circuit to blower motor speed control rotary switch ditioning is operating. This valve has two green dots
mounted on the instrument panel. on the end.
Push Button Control The temperature control lever at the instrument
panel is connected to both valves by a short control
The power “feed” circuit is shown in Figure 10.
cable. Because the two stat valve levers are linked
A 20 ampere fuse in the fuse block heater trim
together, they both move when the temperature con-
controls the blower speeds and the clutch feed.
trol lever is moved. Inside the evaporator housing,
The clutch circuit is energized (“hot”) only when
the lever operates a cam which varies the tension on
the “Cool” push button is depressed. The power
a U-shaped bimetal thermostat spring. This spring
“feed” circuit to blower motor speed control switch is
opens and closes the vacuum valve in response to
energized (“hot”) when any button other than the
changes in the temperature of the air being dis-
“Off” button is depressed.
charged from the unit. Except for the contours of
Blower M o t o r Speed Control S w i t c h the cams, both thermostatic valves are identical. The
The power “feed” line from the push-button switch cam shape determines the effective operating range
to blower speed control switch is energized only when of each valve.
the ignition is on and any push button other than Heat stat control. When either the defrost or heat
“Off” is depressed. button is pushed, the spot cooler doors are closed.
The blower speed control rotary switch has no off The lever on the spot cooler shaft depresses the tem-
position. perature selector switch plunger. This routes vacuum
Position No. 1 Low Speed and No. 2 Medium Speed from the left-hand or heat stat to the water flow
are in the “heat” and “cool” range. Position No. 3 valve.
Medium and No. 4 High Speed are in the “cool” range
(Fig. 2). The design of the blower control electrical
circuit prevents the blower switch operation in posi-
tions No. 3 and No. 4 except when the “cool” push
button is depressed.
Attached to the blower motor speed control switch
is a maximum cool vacuum switch. This switch closes
the fresh air door when the rotary movement of the
speed control switch is turned to the No. 3 or 4 posi-
tion.
3. THERMOSTATIC VALVES
Mounted on the face of the evaporator housing
are two thermostatic valves (Fig. 11). These valves
sense the temperature of the air leaving the heater
core and modulate the valve which controls the water
flow valve. The left-hand thermostatic valve or heat
stat is for heating and defrosting operation. It is
identified by two yellow dots on the end of the
valve. The right-hand thermostatic valve or air con- Fig. 12-Temperature Selector Switch
Air-conditioning stat control. When the cool button (1) Move the temperature control lever to the ex-
is pushed, the spot cooler doors open. The lever on treme opposite position of the “warm” arrow. Start
the spot cooler shaft releases the temperature selector the engine.
switch plunger. Vacuum from the right-hand or air- (2) Push the “cool” button.
conditioning stat is routed to the water flow valve.
(3) Turn the “blower” knob to the No. 4 position
(maximum-recirculated air).
4. TEMPERATURE SELECTOR SWITCH
(Fig. 12) (4) Raise the upper outlets and adjust the vanes to
direct air to the area to be cooled.
It is necessary to have two thermostatic valves for
(5) Adjust side outlets to direct air to body and lap
the different heat requirements for heating and air area to be cooled.
conditioning. Although both valves operate contin-
ually, the vacuum from only one, controls the water (6) Floor air outlet doors may be manually opened
flow valve at any given time. Vacuum from the proper to obtain additional cooling for the feet.
thermostatic valve is routed to the water flow valve Motion of vehicle and blower will flush hot air from
by the temperature selector switch. This switch is the vehicle.
mounted on the right rear edge of the air conditioning After approximately one minute, close the windows.
housing. Operation in Traffic
Vacuum outlet hoses from both thermostatic valves
(1) If extremely slow traffic is encountered, 10 to
are connected to the temperature selector switch.
15 miles per hour, additional cooling can be obtained
The position of the switch determines which hose
by operating the transmission in the lowest range
will supply the vacuum to control the water flow
(No. 1button).
valve. A lever on the shaft for the spot cooler doors
actuates the temperature selector switch. (2) For moderate traffic operation, 20 to 30 miles
per hour, operate transmission in intermediate range
5. O W N E R S OPERATING INSTRUCTIONS (No. 2 button).
( Plymouth Models 1 (3) At stop lights and other stops, press transmis-
The purchaser of an air-conditioning equipped ve- sion (“N’) Neutral button and increase engine speed
hicle should be instructed on proper operation of the with the foot accelerator.
controls at the time of new vehicle delivery. It should (4) At higher speeds, press the transmission (“D”)
never be assumed that the new owner will study the Drive button.
Owner’s Manual or that his experience with the past Normal Cooling (Cooling with Fresh AlrJ
models provides a complete understanding of the new
controls. Customer satisfaction can be increased and When the temperature is comfortable, turn the
“blower” switch to the No. 2 position (medium speed
complaints minimized by instructing the owner on
operation as well as his service responsibilities. The fresh air). If less cooling is desired turn the “blower”
switch to the No. 1 position (low speed fresh air). Re-
following suggestions cover special operating condi-
adjust the upper outlets to obtain indirect cooling and
tions and preventive service suggestions.
maintain comfort. If warmer air is desired, move the
Fast Cool Down I Fig. I 3 J temperature control lever down. If desired the side
Open the window if the vehicle has been sitting in outlets and floor outlets can be manually closed.
the hot sun. Coohg for Special Conditions
If the outside air is extremely humid or too warm
for fresh air cooling, turn the “blower” switch to the
No. 3 position (medium recirculated air). This is also
recommended when driving through areas which are
extremely dusty or have objectionable odors.
Use your air conditioner during the hay fever sea-
son to filter out the pollen and enjoy driving in com-
plete comfort, choosing any of the four “blower”
switch positions to suit the cooling requirements.
MAXIMUM COOLING 62 x 671A Off-season Operation
During the off-cooling season, suggest to owners
Fig. 13-Fast Cool Down (Typical) that they operate the air-conditioning system for at
least a few minutes once a week, with the “cool’’ but-

ton in and the temperature control lever in the
“warm” position. This will cause the air-conditioning
compressor to pump oil to the compressor seal, pre-
venting the seal from drying out and causing loss of
refrigerant.
Antifreeze Required for
Summer Operation
Air conditioned vehicles must be protected with
permanent type anti-freeze during the summer to
+ 15’ or lower to prevent the heater core from
freezing. Do not use the same anti-freeze for more
than one year. Fig. 14-cool Aire Evaporator Installed
Bug Screens In the extreme left position, the switch is open and no
Bug screens should not be installed on vehicles cooling can be obtained. Moving the lever from the
equipped with air conditioning. A bug screen installed left side to the right side progressively increases the
in front of the condenser will reduce air flow and af- amount of cooling. Maximum cooling is obtained when
fect air conditioning performance. Under severe heat the lever is at the extreme right side, as indicated by
conditions a bug screen may cause the engine to over- the arrow.
heat.
Blower Control
6. A IR C O NDITI ONING-0 PERAT1ON The blower switch is used to select three blower
(Valiant Models 1 speeds and turn the system off. Four horizontally
The VALIANT Air-conditioner is available as a fac- spaced push buttons, marked “Off”, “Lo,” “Med,” and
tory installed option and is an economy vehicle air “Hi,” offer a choice of cooling air flows to suit all
conditioner which will provide the vehicle owner with requirements. High blower speeds provide rapid cool-
the finest in summer comfort. Important improve- ling in slow moving city traffic while lower speeds
ments in passenger comfort and convenience are maintain comfortable temperatures on the highway
reflected in the many advance features of its design. or under mild climatic conditions. In addition to in-
It is mounted on the bottom of the instrument creased cooling capacity, the high-velocity air flows
panel (Fig. 14), centrally located and has no addi- obtainable with the Cool Aire blower system give
tional air ducts and the controls are integral with the rapid relief from heat by creating an evaporative
unit. In this position, the unit is accessible for serv- cooling effect on the vehicle occupants.
icing and still allows the driver and front seat pas-
Air Distribution Control
senger enough leg room space. The remainder of the
air conditioning system is conveniently located in the The air distribution grille has multiple horizontal
engine compartment. The air conditioner is used for and vertical louvers. These can be adjusted manually
cooling only; when heat is required, it has to be to direct the flow of cool air up or down, left or right,
provided by a separate heating system. for precise distribution throughout the vehicle. The
vertical louvers are adjusted in groups of three by the
temperature Control four control levers at the top of the grille. The
All of the controls necessary for operation of the three horizontal louvers are divided in two groups
air conditioning systems are located to the left of the (left and right) and are adjusted by the knob molded
air distribution grille convenient to the driver’s right on the center louver. Additional air can be obtained
hand (Fig. 14). The controls are simple, easy to un- by turning the dials located at either side of the
derstand, and easy to operate. Only two adjustable unit. These can be set by the driver or passenger to
controls are used to operate the entire system; a suit individual comfort.
temperature control slide-type lever and a push-
button operated blower speed switch. 7. O W N E R S OPERATING INSTRUCTIONS
The horizontal temperature slide-type lever is used (Valiant Models 1
to set the temperature of the air flowing from the With the engine operating, the following control
evaporator coil. This lever is attached to a tempera- settings may be used to cool the vehicle under various
ture control switch which activates the compressor. weather and driving conditions:
AIR CONDITIONING 24-1 1
NOTE: Move the heater temperature control Cruising-Hot Weather

lever to the “Off” position. Push the “Off“ button on Move the temperature control lever to the extreme
the heater control switch, to make certain that the right for maximum cooling and press the “Hi” blower
. ventilation door is closed, preventing outside air from speed push button.
entering the vehicle.
F a s t Cool Down Fresh Air

If the vehicle has been standing in the hot sun, With a factory-installed fresh air heater, PUSH
move the temperature control lever to the extreme the “Lo” button. The two independent fresh air vent
right for maximum cooling and press the “Hi” blower doors, located under the instrument panel at the left
speed push button, drive with the windows open for and right side must be closed.
two or three minutes to expel the hot air, then close NOTE: On the initial cool-down or while driving
the windows and the Cool Aire system will quickly through heavy traffic where maximum cooling capac-
provide a comfortable temperature. ity is required, the fresh air control should be closed.
Slow City Driving
When driving in traffic where there are frequent Off-Season Operation
stops, move the temperature control lever to the ex- During the off -cooling season, suggest to owners
treme right for maximfim cooling and press the “Hi” that they operate the air conditioner system for a t
blower speed push button. In extreme heavy or slow least five minutes once a week. This will cause the
moving traffic better results will be obtained when air-conditioning compressor to pump oil to the com-
driving in intermediate (second) or low gear. presser seal, preventing the seal from drying out and
causing loss of refrigerant.
Cruising-Normal W a r m Weather
When cruising on open highways where there are IMPORTANT: To assist in maintaining proper en-
only intermittent stops, move the temperature con- gine temperature, when the outside temperature ex-
trol lever to obtain a comfortable temperature flowing ceeds looo F., it i s recommended that while the air
from the evaporator distribution grille. Press the “Lo” conditioner is in operation the engine idle period be
or “Med” blower speed push button. limited to 10 minutes.
INSPECTION, TEST PROCEDURES AND DIAGNOSIS

Satisfactory performance of the combined air-condi- perature control lever to the top.
tioning and heating system is dependent upon proper (4) Test the blower operation at all four positions.
operation and adjustment of all operating controls, (See “Blower Switch Chart.”)
as well as proper functioning of all refrigeration sys-
tem units. The inspections, tests and adjustments BLOWER SWITCH CHART
should be used to locate the cause of a malfunction. ~
COOL
The inspection and tests have been arranged in a
HEAT MAX. COOL”
logical sequence that has proved to be the surest and
shortest route to accurate diagnosis. It is recom- 1 2 3 4
mended that they be followed and performed in the
LOW MED. MED. HIGH
order in which they are presented.
OFF OFF OFF OFF OFF
8. INSPECTION A N D ADJUSTMENTS
HEAT ON ON OFF OFF
( Plymouth1
Operation of All Controls DEFROST ON ON OFF OFF
Operating controls must be tested as described in COOL ON ON ON ON
the following sequence:
*The design of the blower control electrical circuit
(1) Inspect the compressor drive belt tension-ad- prevents the blower operation in the position No. 3
just if necessary, remove the radiator cap. and 4 except when the cool button is depressed.
(2) Start the engine and adjust the engine speed If the blower does not operate correctly, refer to
to 1250 rpm. Use a reliable tachometer. “Electrical Control Circuit” (Fig. 10). Leave the blow-
(3) Push the “Cool” button in, and move the tem- er in the No. 2 position.
24-1 2 AIR CONDITIONING
(5) The compressor clutch should be engaged, the tioned vehicle to be equipped with a radiator cap
compressor operating, and the air conditioning system having a holding pressure of 15 to 16 psi, for hot
in operation. If the clutch does not engage, test the weather operation. If the radiator cap does not test
circuit. Refer to “Electrical Control Circuit” (Fig. 10). within these specifications, replace with a cap which
does.
Push Button Operation
Reduce the engine speed to normal idle. With the Condenser
engine operating at idle speed, the vacuum will be Inspect the condenser fins for obstructions by for-
high and the vacuum actuators should operate quickly. eign matter. Clean if necessary. Any obstructions to
If the actuator operation is slow, inspect the source the free flow of air across the condenser will de-
hose connection at the engine manifold. Push each crease heat dissipation from the condenser, decrease
button to test the over-all operation of the electrical the efficiency of the condenser, and in turn, decrease
and vacuum controls. The “Push Button Control the evaporator’s efficiency. These conditions result
Chart” summarizes the actions that should take place in increasing the discharge pressure and horsepower
when each button is pushed. load on the engine. The use of a bug screen is not
If all controls operate in the proper sequence but recommended as it, too, will decrease the free flow
action of dampers and doors is slow or incomplete, of air.
inspect, for mechanical misalignment, binding or im- Be sure the fan shroud is properly positioned. (If
proper linkage adjustment. so equipped.)
The maximum cool vacuum switch is operated in
position No. 3 and 4. Operation of this switch causes 9. INSPECTION A N D ADJUSTMENT
the fresh air door to close. ( Valiant 1
Water Valve NOTE: If the vehicle is equipped with a heater,
Test the water valve by momentarily disconnecting test the water temperature control valve.
the hose from the outlet (lower) side of the water W a t e r Temperature Control Valve Test
valve.
A slight spillage of water when the hose is removed Move the heater control lever on the instrument
is normal. Excessive water flow indicates that the panel to the extreme “Warm” position, and then back
valve is not closing properly. Remove the vacuum to the “Off’position. At the same time, test control
line at the water valve and if excessive water flow cable action and the movement of the water temper-
continues then water valve is faulty. If the water ature control valve lever. The valve should be moved
flow rate is acceptable with the vacuum line dis- to the wide-open position and back to the fully closed
connected, this indicates an improperly adjusted con- position.
trol cable or faulty. temperature thermostat. Adjust If the temperature control valve does not close
the control cable or replace the water valve or thermo- completely, reposition the control cable housing in
static valve assembly as necessary, and retest. the retaining clip so that the valve does close com-
plet ely.
Radiator Cap Test the operating controls as described in the
It is an absolute necessity for the 1964 air-condi- following sequence:
PUSH BUTTON CONTROL CHART
OFF HEAT DEFROST COOL COOL *OFF

FRESH AIR DOOR CLOSED OPEN OPEN OPEN CLOSED CLOSED-
NO VACUUM
HEAT DOOR OPEN OPEN BLEED CLOSED CLOSED OPEN
SIDE OUTLET DOOR CLOSED CLOSED CLOSED OPEN OPEN CLOSED
~~~ ~~ _ _ _ ~
~
UPPER OUTLET CLOSED CLOSED OPEN OPEN OPEN CLOSED
BLOWER SWITCH POSITION 1 OR 2 1 OR 2 1 OR 2 1 OR 2 3 OR 4 3 OR 4
*Fresh Air Door is under no vacuum in this position. Over-center spring will keep door closed.
(1) Remove the radiator cap. weather operation. If the radiator cap does not test
(2) Move the heater temperature control lever to within these specifications, replace with a cap which
the “Off”position. does.
(3) Start the engine and adjust engine speed to Condenser
1250 rpm. Inspect condenser fins for obstructions by foreign
(4) Test the water valve by momentarily disconnect- matter. Clean if necessary.
ing the heater outlet hose at the upper side of the Any obstructions to the free flow of air across
heater housing. A slight spillage of water when the the condenser will decrease heat dissipation from
hose is removed is normal. (The radiator cap was the condenser, decrease the efficiency of the con-
removed at the start of this test to minimize pres- denser. These conditions result in increasing the dis-
sure in the cooling system.) A continuous flow of charge pressure and horsepower load on the engine.
water indicates that the valve is not closing properly. The use of a bug screen is not recommended, as it
This may be caused by an improperly adjusted control too will decrease the flow of air.
cable or a faulty valve. Readjust the control cable or Inspect condenser for bent, or damaged fins. Bent
replace the valve, as necessary, and retest. fins on the condenser deflect air flow across the bent
portions, decreasing the condenser area.
Radiator Cap
It is an absolute necessity for the 1964 air-condi- 10. THE GAUGE SET MANIFOLD
tioned vehicle to be equipped with a radiator cap INSTALLATION AND TESTS
having a holding pressure of 15 to 16 psi, for hot The Gauge Set Manifold is an indispensable test
EVAPORATOR SUCTION GAUGE
DISCHARGE PRESSURE GAUGE
COMPRESSOR INLET GAUGE
SUCTION GAUGE VALVE
CENTER MANIFOLD OUTLET
DISCHARGE GAUGE VALVE
DISCHARGE LINE
DISCHARGE SERVICE PORT
SUCTION LINE
601268A
Fig. 15-Gauge Set Manifold Connections-Plymouth

and diagnosis instrument. The new gauge set mani- adapter. This gauge is used, when checking the EPR
fold Tool c-3740 has two compound suction gauges Valve on the Plymouth system, and is not used on the
and one discharge pressure gauge. Two accurately Valiant Cool Air Conditioner (Fig. 16).
calibrated suction pressure gauges are required for Center Manifold Outlet provides the necessary
the evaporator pressure regulator valve test. A modi- connection for a long service hose used when dis-
fication kit Tool C-3741 contains all of the parts charging the system, using a vacuum pump to “pull
necessary to convert the previous gauge set manifold a vacuum” before charging the system, and for con-
Tool (2-3627 for testing the Air-conditioning System. necting the supply of refrigerant when charging the
(Refer to Figs. 15 and 16). sytem. When performing the “Compressor Capacity
Evaporator Suction Gauge at the left side of the Test,” TEST 7, the hose is removed and a special test
manifold is calibrated to register 0 to 30 inches of cap is installed in its place.
vacuum and 0 to 150 psi. This gauge is connected to Manifold Gauge Valves should be closed when con-
the suction service port of the compressor. A special necting the gauge set manifold to the service ports
service port adapter, supplied with the gauge set, of the compressor. The suction gauge valve at the
provides the means of connecting the gauge set mani- left is opened to provide a passage between the suc-
fold hose to the service port. When the adapter is tion gauge and the center manifold outlet. The dis-
installed at the port and tightened, the stem of the charge gauge valve at the right is opened to provide
valve in the service port is depressed, opening the a passage between the discharge pressure gauge and
service port valve. the center manifold outlet.
Discharge Pressure Gauge at the center of the The detailed instructions for the proper use of the
manifold is calibrated to register 0 to 300 psi. For gauge set manifold are contained in the test covering
all tests this gauge is connected to the discharge serv- each test and service operation employing these
ice port of the compressor. A service port adapter gauges.
is used to make this connection. The needle valve,
located below the discharge pressure gauge, is used TEST 1
to damp out gauge needle oscillations so that accurate
readings can be obtained. TEST SYSTEM PRESSURE
(Engine not Running 1
Compressor Inlet Gauge is mounted at the right
side of the manifold. This mounting is for conve- Install the gauge set manifold. For identification
nience only. There are no passages between this gauge of the test hose connections at service ports see
and the gauge manifold. The compressor inlet gauge Figures 15 and 16. After tightening the service port
is calibrated to register 0 to 30” of vacuum and 0 to adapters, make sure that the needle valve located
150 psi. This gauge and the evaporator suction gauge below the discharge pressure gauge is open. Purge
must be accurately calibrated so that the needles of air from the gauge hoses (Fig. 17) as follows:
both gauges are exactly at 0 before making test. The
compressor inlet gauge is connected to the com-
pressor inlet service port by a special service port
VALVE NOT USED
Fig. 16-Gauge Set Manifold Connections-Valiant Fig. 17-Purge Gauge Hoses

(1) Open the suction gauge valve momentarily, then necessary to evacuate, charge with a sweep-test
close it. charge, locate and correct the leak, purge the test
(2) Open the discharge gauge valve momentarily, charge, replace the drier, vacuum the system and
then close it. charge the system with the proper amount of re-
frigerant 12.
(3) Loosen the compressor inlet suction hose con-
nection at the manifold momentarily, then tighten it.
TEST 2
NOTE: Step three not necessary with the Valiant
Cool Aire Conditioner.
REFRIGERANT LEVEL
If the vehicle has been parked and the system not The system must be operated at high blower speed,
operating, the gauge pressure should be normal for when this test is made, and when adding to the charge
temperature of the system. Refer to the “Tempera- with and windows Open.
ture-Pressure Relationship Chart.” On Plymouth, the sight glass is an integral part
If no pressure is indicated on the gauges it means of the receiver-strainer-drier. The outlet line (liquid)
that the system is empty, due to a leak. It will be from the condenser must be attached to the connec-
TEMPERATURE-PRESSURE RELATIONSHIP CHART
(FOR REFRIGERANT 12 1
Temp. Press. Temp. Press. Temp. Press. Temp. Prdss. Temp. Press.
F. PSI F. PSI F. PSI F. PSI F. PSI
0 9.1 35 32.5 60 57.7 85 91.7 110 136.0

2 10.1 36 33.4 61 58.9 86 93.2 111 138.0
4 11.2 37 34.3 62 60.0 87 94.8 12 40.1
6 12.3 38 35.1 63 61.3 88 96.4 13 42.1
8 13.4 39 36.0 64 62.5 89 98.0 14 44.2
10 14.6 40 36.9 65 63.7 90 99.6 15 46.3

12 15.8 41 37.9 66 64.9 91 101.3 16 48.4
14 17.1 42 38.8 67 66.2 92 103.0 17 51.2
16 18.3 43 39.7 68 67.5 93 104.6 18 52.7
18 19.7 44 40.7 69 68.8 94 106.3 19 54.9
20 21.0 45 41.7 70 70.1 95 108.1 20 57.1

21 21.7 46 42.6 71 71.4 96 109.8 21 59.3
22 22.4 47 43.6 72 72.8 97 1 1 1.5 22 61.5
23 23.1 48 44.6 73 74.2 98 113.3 23 63.8
24 23.8 49 45.6 74 75.5 99 115.1 24 66.1
25 24.6 50 46.6 75 76.9 100 1 1 6.9 125 168.4

24 25.3 51 47.8 76 78.3 101 1 18.8 126 170.7
27 26.1 52 48.7 77 79.2 102 120.6 127 173.1
28 26.8 53 49.8 78 81.1 103 122.4 128 175.4
29 27.6 54 50.9 79 82.5 104 124.3 129 177.8
30 28.4 55 52.0 80 84.0 105 126.2 130 182.2

31 29.2 56 53.1 81 85.5 106 128.1 131 182.6
32 30.0 57 55.4 82 87.0 107 130.0 132 185.1
33 30.9 58 56.6 83 88.5 108 132.1 133 187.6
34 31.7 59 57.1 84 90.1 109 135.1 134 190.1
If pressures are normal, proceed with the next test and adjustment.
TEST 3
TESTING THE SYSTEM FOR LEAKS
The Leak Detector Torch Tool C-3569 is a propane
gas-burning torch used to locate a leak in any part
of the refrigeration system. Refrigerant gas drawn
into the sampling or “snifter” tube will cause the
flame to change color in proportion to the size of
the leak. A very small leak will produce a flame
varying from yellowish-green to bright green. A large
leak will produce a brilliant blue flame.
CAUTION: Do not use the lighted detector in any
place where explosive gases, dust or vapors are
present. Do not breathe the fumes that are produced
by the burning of refrigerant gas. Large concentra-
tions of refrigerant in the presence of a live flame
63x105 become dangerously toxic. Observe the flame through
the window of the burner shield, not through the top
Fig. 18-Sight Glass (Plymouth) of the shield.
If the flame remains bright yellow when the tester
tion marked IN. The word IN is stamped on the top is removed from the possible leak point, insufficient
fa.ce of the inlet connection (fig. 18). If the receiver- air is being drawn in through the sampling tube, or
strainer-drier is reversed and the lines are connected the reaction plate is dirty.
wrong, the system must be purged, the lines reversed
(1) Open the torch valve until you hear a faint
and the system recharged.
hiss of escaping gas. Light the test torch and adjust
Block the air flow across the condenser to raise the the valve until the flame is very small. A small
discharge pressure to 225 to 250 psi, and check the flame will detect large as well as small leaks, whereas
sight glass for foam. There should be no foam. If a large flame will detect only large leaks. As soon as
sight glass is clear, remove the air restriction from the reaction plate seen through the window in the
the condenser and allow the discharge pressure to burner shield becomes red hot, the tester is ready for
return to normal. use.
If the foam shows in the sight glass when the dis- (2) Examine all tube connectors and other possible
charge pressure is 225 to 250 psi, it indicates the leak points by moving the end of the sampling hose
system is low on refrigerant. The proper amount of from point to point. Since refrigerant 12 is heavier
refrigerant required to complete a full charge may than air, it is good practice to place the open end of
be added to the system as follows: Maintaining the the sampling hose directly below the point being
discharge pressure at 225 to 250 psi, add refrigerant tested. Be careful not to pinch the sampling tube since
gas through the suction side of the system until foam this will shut off the air supply to the flame and cause
is cleared from sight glass, then add exactly one-half a color change.
(Y2) pound of refrigerant.
NOTE: The sight glass used with Valiant Cool Aire
Conditioner has no arrow. With the engine operating
at 1250 rpm, check temperature on the inlet side
and on the outlet side of the receiver-strainer-drier
(Fig. 19). If the temperature i s the same on both ends,
this indicates that the unit i s functioning properly.
However, if the temperature i s cooler on the outlet
end than it is on the inlet end, the receiver-strainer-
drier is faulty (partially plugged) and must be re-
RECEIVER STRAINER DRIER 63x1 11
placed, purge the refrigerant from the system, replace
the receiver-strainer-drier and recharge. Fig. 19-Sight Glass (Valiant)
(3) Watch for a change in the color of the flame. TEST 4
Small leaks will produce a green color and large leaks
a bright blue color. If leaks are observed at the tube CORRECTING LOW REFRIGERANT LEVEL
fittings, tighten the connection, using the proper flare Since the refrigeration system is completely sealed,
wrenches, and retest. refrigerant level will not be low unless there is a leak
If the system is free of leaks, or after correcting a in the system or refrigerant has been allowed to
leak, if no air conditioning components have been escape by depressing one of the service port valves.
removed, add necessary refrigerant as described For detailed instructions on the proper procedure for
under TEST 4 “Correcting Low Refrigerant Level”. checking refrigerant level, refer to “Refrigerant
If any parts of the refrigerant system were discon- Level”. TEST 2.
nected, remove the sweep test charge. Close the Before adding refrigerant where cause of low level
refrigerant manifold valve so that any refrigerant is not known, the system should be tested for leaks.
remaining in the container is sealed. Remove the long Assuming no leaks are present, or that leaks have
test hose from the refrigerant manifold. Insert the been corrected without discharging the system, pro-
free end of this test hose into an exhaust system out- ceed with partial charge.
let. Open the right-hand gauge set manifold valve a Install and connect the gauge set manifold valves,
fraction of a turn to let the sweep-test charge escape as shown in Figure 20.
slowly. Allow the system to discharge until the dis- (1) Close both of the gauge set manifold valves.
charge pressure gauge registers zero. Open the left- Open the gauge set manifold needle valve.
hand gauge valve to allow any refrigerant trapped in (2) Connect the evaporator suction gauge test hose
the suction side of the system to escape. to the suction service port of the compressor, the dis-
DISCHA RGE
SERVICE P O R T
COMPRESSOR
60x1 001A
Fig. 20-Adding Partial Refrigerant Charge

24-1 8 AIR CONDITIONING
charge gauge test hose to the discharge service port Meter flow of refrigerant by adjusting the suction
of the compressor. service gauge valve so that the pressure registered
(3) Connect one end of the long test hose to the at the suction service gauge does not exceed 50 psi.
center manifold outlet, the other end to the refrig- Keep the refrigerant container upright.
erant dispensing manifold. (10) Add refrigerant gas until there is no foam
(4) Close two of the’dispensing manifold valves visible at the sight glass. As soon as all foam clears,
and open the remaining dispensing manifold valve. note the weight registered on the refrigerant scale.
Remove the protective cap from the opened valve. (11) Watch the refrigerant weighing scale and add
(5) Screw a can of refrigerant 12 to the opened exactly ‘/z pound more refrigerant to the system.
manifold valve. Be sure the gasket is in place and Close the suction gauge valve.
in good condition. Tighten the refrigerant can and NOTE: Too much refrigerant in the system can
the manifold locking nut to insure a good seal. Do cause abnormally high discharge pressures. Care must
not over-tighten since 6 to 8 foot pounds is sufficient be used so that exactly 1/2 pound of refrigerant is
if the gasket is in good condition. added after foam clears in the sight glass.
(6) Turn the manifold valve (above the refrigerant (12) Close the dispensing manifold valve. Remove
can) completely clockwise to puncture the can. This the test hoses and adapters from the service ports
closes the valve and seals the refrigerant in the can. of the compressor, and install the protective caps at
(7) Place the refrigerant in a large pan of water the service ports.
heated to 125OF. Place pan of water containing the
refrigerant can on an accurate scale Tool C-3429 so TEST 5
that the amount of refrigerant added can be weighed.
O V E R - A l l PERFORMANCE TEST
Open the refrigerant manifold valve.
(8) Purge all air from test hoses. Air in the system Humidity (the amount of moisture in the air) has
will be trapped in the condenser causing abnormally an important bearing on the temperature of the air
high discharge pressures and interfering with con- delivered to the vehicle’s interior. This is true of
densation of the refrigerant. all air-conditioned systems whether in home, office
or vehicle. It is important to understand the effect
a. Loosen the test hose adapters at both the suction humidity has on the performance of the system.
service port and the discharge service port. When humidity is high, the evaporator has to perform
b. Loosen the charging hose connection at the a double duty. It must lower the air temperature and
gauge set manifold. This will purge air from the the temperature of the moisture carried in the air.
charging hose. Tighten the connection as soon as the Condensing the moisture in the air, transfers a great
air is purged. deal of heat energy into the evaporator fins and
c. Open the left gauge set manifold valve to purge tubing. This reduces the amount of heat the evap-
the air from the suction service test hose. Close the orator can absorb from the air. In other words, high
valve and tighten the test hose adapter at the suction humidity greatly reduces the evaporator’s ability to
service port. lower the temperature of the air delivered to the
d. Open the right gauge set manifold valve to purge vehicle interior.
the air from the discharge test hose. Close the valve Evaporator capacity used to reduce the amount of
and tighten the discharge test hose adapter at the moisture out of the air entering the vehicle adds
discharge service port. materially to the comfort of the passengers. How-
Operate the engine at 1250 rpm with the vehicle ever, an owner may expect too much from his air-
doors, windows open and the hood up. conditioning system on humid days. A performance
On Plymouth push in the “Cool” button, blower test is the best way to determine whether or not the
on the number 2 position. system is performing up to standard. This test also
On Valiant Cool Aire set the evaporator tempera- provides valuable clues to the possible cause of
ture control lever to the coolest position, push in the trouble.
“Hi” blower button. The preliminary inspections in TESTS 1 thru 4
If necessary, block the condenser to maintain a outlined previously should be made before the “Over-
discharge pressure of 225 to 250 psi. The system All Performance Test”. Install gauge set, as shown
must be charged through the evaporator suction serv- in Figures 15 and 16.
ice port as follows: NOTE: Air temperature in test room must be
(9) Slowly open the suction service gauge valve. 7 5 O F minimum for this test.
the pointer. Do not close the needle valve completely
since this would prevent the discharge pressure gauge
from registering pressure.
This test should be performed with the discharge
pressure from 190 to 210 psi. The 190 to 210 pound
pressure is for test puposes only. To increase pres-
sure restrict the air flow across the condenser using
cardboard, paper, etc. to decrease pressure, increase
air flow across condenser with external floor fans.
Observe and record both the “Inlet Dry Bulb Tem-
perature” and “Inlet Wet Bulb Temperature” as reg-
istered on the psychrometer.
Fig. 21-Psychrometer and Thermometer (Typical) Observe and record the “Discharge Air Temper-
ature” registered by the thermometer at the right
hand grille outlet.
Performance Test ( Plymouth I From the “Performance Temperature Chart” (Fig.
Start the engine, open the windows, the temper- 22), determine the maximum allowable discharge air
ature control lever must be in the off position. temperature for the prevailing “Dry” and “Wet” bulb
Push in “Cool” button, turn blower switch to posi- temperatures recorded. If the vehicle’s discharge air
tion No. 2. The floor air doors should be fully open temperature is at or below the temperature given on
and the right and left side outlet cooler grilles fully the Performance Chart, the air-conditioning is deliver-
open and directed straight back. ing its cooling capacity. However, to assure trouble-
Adjust engine speed to 1250 rpm. Arrange the gauge free operation, continue with the “Evaporator Pres-
set manifold hoses and tachometer leads to allow the sure Regulator,” TEST 6.
hood to be lowered, and close the hood. If the discharge air temperature at the outlet grilles
Place the motor-driven psychrometer Tool (2-3704 is above the maximum allowable on the Performance
at the cowl inlet opening (Fig. 21). Distilled water Chart, perform the following operations in the order
should be used with this meter to prevent drying indicated until proper performance is obtained.
out and hardening the wet sock. (1) “The Evaporator Pressure Regulator Test.”
Place the thermometer Tool C-3623 fully into the (2) “The Compressor Capacity Test.”
right outlet grille opening. The left outlet should
be fully extended and directed towards the rear of (3) “The Expansion Valve Test.”
the vehicle. COOL AlRE Performance Test (Valiant)
Operate the air-conditioning system until a stabi- (1) Start the engine and operate at 1250 rpm.
lized condition on the gauges and thermometers has
(2) Test both the heater control button and tem-
been established. One of the most important steps
perature control lever to make sure that they are in
in making the over-all performance test is that the
“off” position.
engine must be operated at 1250 rpm for approxi-
mately five minutes to allow all the under-hood com- (3) Push the air conditioning blower on “Hi”.
ponents of the system to reach their operating tem- (4) Move the air conditioning control lever to the
perature. extreme right for maximum cooling.
Partially close the needle valve, located below the (5) Place thermometer Tool C-3623 in the evapor-
discharge pressure gauge, to minimize oscillation of ator outlet distribution grille (Fig. 23).
I
I-
AIR CONDITIONING PERFORMANCE CHART
WET BULB INLET AIR TEMPERATURE

II
52 53 54 55 56 57 58 59 60 6 1 6 2 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 7a 79 a0 8 1 a2 a3 a4 a5 86 87 88 a9 90
63 X 773A
Fig. 22-Performance Temperature Chart

Turn the blower switch to position No. 2, push
the “Cool” button.
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 port and the compressor inlet service port
will be approximately the same. It is normal for the
compressor inlet pressure to be slightly lower than
- 1
the evaporator suction pressure.
Observe the evaporator suction gauge and the com-
pressor inlet gauge. Both should register 26 psi or
slightly higher. This indicates that the “EPR” valve
Fig. 23-Checking Temperature at Outlet Grille is open. The next step is to determine the minimum
evaporator suction pressure maintained in the suction
(6) Close the vehicle doors and windows. line by the “EPR” valve.
(7) Observe the suction pressure gauge. As suction The “EPR” valve action can be accelerated by re-
pressure lowers due to the cooling of the evaporator, ducing the heat load on the evaporator. This is ac-
the clutch should disengage when the pressure drops complished by turning the blower switch to position
to approximately 10-15 psi. The clutch should re- No. 1 (“Low-Speed”), thus reducing the volume of
engage as the suction pressure increases to approxi- air passing through the evaporator. Immediately the
mately 35 psi. evaporator will start to get colder. It is necessary to
(8) Observe the thermometer temperature. It watch both suction gauges for the following reactions.
should register between 30-35 degrees F. depending (1) Pressure registered at the evaporator suction
on the ambient temperature. If the thermometer gauges will become progressively lower.
lowers to these temperatures, the system is func- (2) At the same time the compressor inlet gauge
tioning properly and requires no further tests. will start to fluctuate. This fluctuation is caused by the
If the system fails to pass the performance test, alternately opening and closing of the “EPR” valve.
proceed with: It indicates that suction pressure is reduced to the
a. “The Compressor Capacity Test.” point where it just about balances the internal gas
b. “The Expansion Valve Test.” pressure in the bellows. The “EPR” valve is actually
operating as a modulating valve.
TEST 6 (3) When fluctuation at the compressor inlet gauge
EVAPORATOR PRESSURE REGULATOR stops and the pressure registered drops steadily, the
VALVE TEST ( Plymouth 1 “EPR’ valve is maintaining minimum suction line
pressure. Allow pressure registered at the compres-
The “EPR” valve is calibrated to produce the maxi-
sor inlet gauge to drop 15 psi or lower, then read the
mum “cooling” possible without causing frost or ice evaporator suction gauge.
on the evaporator fins and tubing. If for any reason
the factory calibration has been disturbed, the “EPR” NOTE: If, and only if the compressor inlet pres-
valve may restrict the flow of refrigerant at an evapor- sure will not pull down to 15 psi, increase engine
ator pressure which is either too high for maximum speed to approximately 2000 rpm.
performance or too low to prevent coil freeze up.
(4) The suction gauge pressure should be 22 to
The evaporator pressure regulator test determines
26 psi. This indicates that the suction pressure main-
whether or not the valve is functioning properly.
tained by the “EPR” valve is correct. Again, deter-
This test is not necessary as the “EPR” valve is
mine the pressure at which the valve is fully open.
not used on the Valiant “Cool Aire”.
(5)Turn the blower switch to position No. 2, push
EPR Valve Test Conditions the “Cool” button to increase the heat load on the
Normally, this test is performed after completion evaporator. This will increase suction pressure, caus-
of the Over-all Performance Test. The gauge set ing the “EPR” valve to open fully.
manifold will be connected, as shown in Figures 15 (6) Watch both the evaporator suction and the com-
and 16. pression inlet pressure gauge. The pressure registered
Adjust engine speed to 1250 rpm. Close the hood at the compressor inlet gauge will increase quite
for this test. Open the windows. rapidly. Both suction gauges should again stabilize
at a pressure of 26 psi or slightly higher within a If the system failed to pass the Over-All Perform-
few minutes. ance Test but passed the “EPR’ valve test, proceed
If the minimum suction pressure registered step with the Compressor Capacity Test 7.
(4) above is 22 to 26 psi and the suction pressure
registered with the valve fully open step (6) above TEST 7
is 26 psi or slightly higher, the “EPR” valve is func-
tioning normally. A system which passes both the COMPRESSOR CAPACITY TEST
Over-All Performance Test and the “EPR” Valve Test The Over-All Performance Test and the Evaporator
requires no further tests. Pressure Regulator Valve Test should be performed
Suction Pressure Above 26 psi. If the minimum before testing the compressor capacity. These tests
suction pressure is higher than 26 psi step (4) above, are made with the system fully charged with refrig
the evaporator will not get as cold as it should for erant. It is necessary to discharge the system before
maximum performance. It will be necessary to re- making the Compressor Capacity Test. It is also neces-
place the “EPR” valve. Repeat the “EPR” valve test sary to discharge the system in order to perform the
and the Performance Test. Expansion Valve Test. It is recommended that tests
Suction Pressure Below 22 psi. If suction pressure be made in the order in which they are presented in
goes below 22 psi step (4) above, the evaporator is this manual. Experience has proven to be the surest
too cold. The correction is to replace“EPR”va1ve and quickest way to locate and correct the cause of
and repeat the “EPR’ valve test. unsatisfactory performance.
62x371
Fig. 24-Compressor Test Connections (Plymouth)

sweep some of the refrigerant oil out with the re-

frigerant.
(4) Allow system to discharge until discharge pres-
sure gauge registers zero.
(5) Open the suction (left-hand) gauge valve to re-
lease any vapor trapped at the suction side.
_----
/ ___-e-
OMPRESSOR
. _ Test Preparation and Connections
After the system is completely discharged, isolate
the compressor and connect the gauge set manifold
as follows:
63x103 g
(1) Disconnect the discharge (muffler) line from the
Fig. 25-Compressor Test Connections (Valiant) compressor discharge adapter. Cap the discharge
adapter outlet with a VZ inch cap. Seal the discharge
If the Compressor Capacity Test (Fig. 24 and 25)
(muffler) line.
is performed immediately after completing the Evap-
orator Pressure Regulator Valve Test, the compressor (2) Disconnect the evaporator suction line (hose)
will be up to operating temperature and most of from the suction muffler. Cap the suction muffler
the refrigerant oil will have been returned to the inlet with a v8 inch cap. Seal the suction line.
compressor crankcase. The compressor is now isolated from the system
If the system has been standing any length of time, and sealed at both the suction and the discharge
it will be necessary to perform the following opera- sides. Refer to Figure 24 and 25, and make the fol-
tions before starting the Compressor Capacity Test: lowing gauge set manifold connections:
1. Attach the gauge set manifold. (3) On PLYMOUTH Disconnect the test hose and
adapter from the compressor inlet port. On Valiant
2. Start the engine and adjust speed to 1250 rpm. Cool Aire, remove the cap from the inlet port, as
On Plymouth, turn blower switch to position No. 2,
the test hose is not used on the compressor inlet
move temperature control to “Off’ and push the port.
“Cool” button.
On Valiant Cool Aire, push the “Hi” air conditi- (4) Remove the valve body from the compressor
tioning blower button and move the air-conditioning inlet port. The tire valve stem, Tool C-3788 can be
control lever to the extreme right. used for this purpose.
3. Allow the air-conditioning system to operate at (5) Disconnect the test hose and adapter from the
full capacity for at least 15 minutes. This will cause suction service port of the fitting.
most of the compressor oil in the system to be re- (6) Install test cap (SP-2922) at the center manifold
turned to the compressor crankcase. It will also insure outlet.
that the compressor is up to operating temperature
which is very important when making this test. NOTE: Be sure that the test cap i s perfectly clean.
Particles adhering to the cap or the metering orifice
Discharging the System
can restrict tlow and cause false readings. Never use
When making the Compressor Capacity Test, the a wire or probe of any kind to clean the cap. Wash
compressor must be disconnected from the rest of it with clean solvent and blow dry with compressed
the system. That means the system must be dis- air.
charged.
(1) Insert the manifold discharge hose into an ex- (7) Make sure both the left and right gauge valves
haust ventilation system or to the outside of the are open.
building so that the service area will not be filled with The compressor can now be operated as an air
refrigerant vapor. pump. Air will be drawn through the compressor
(2) Fully open the manifold needle valve. inlet port, compressed and delivered (through the
(3) Open the discharge (richt-hand) gauge valve a
test hose attached to the discharge port.) to the
small amount. This will allow the refrigerant vapor gauge set manifold. Compressor capacity is deter-
mined by noting the pressure registered at the dis-
to discharge slowly.
charge gauge when the compressor is driven at an
CAUTION: Do not open the valve fully and allow engine speed of exactly 500 rpm. THE TACHOMETER
the system to discharge rapidly, since this would USED MUST BE ACCURATE. Compressor capacity
test results are dependent upon controlling engine discharge line to the discharge muffler. When con-
speed at exactly 500 rpm. necting these lines use new “0”rings and lubricate
both male and female connections with clean refrig-
Test Pressures and Results erant oil. Continue with the “Expansion Valve Test.”
(1)Start the engine and adjust speed to exactly
500 rpm. TEST 8
(2) Slowly close the left-hand gauge valve. All air EXPANSION VALVE TEST
delivered by the compressor will now be discharged The following procedure permits testing the ex-
through the metering orifice in the test cap. Pressure pansion valve without removing it from the system.
registered at the discharge gauge should build up to This test is made with the system completely dis-
at least 190 psi (Fig. 26). charged.
(3) The load on the compressor may affect engine IMPORTANT: It Is Absolutely Necessary For The
speed. If necessary, readjust engine speed to exactly Compressor To Pass The Compressor Capacity Test
500 rpm. The discharge pressure should build up to a Before Testing The Expansion Valve In Its Installed
minimum of 190 psi. Position.
(4) Open the left-hand gauge valve momentarily to A compressor which does not pass the Compressor
allow the pressure to drop. The close the valve to Capacity Test may have leaking reed valves or a frac-
make sure the pressure again builds up to a minimum tured head gasket. Such a leak would allow refriger-
of 190 psi with the engine operating at 500 rpm. ant gas, used in the “Expansion Valve Test,” to leak
CAUTION: To prevent possible compressor dam- from the discharge side of the compressor back into
age from excessive heat, do mot operate compressor the suction side of the compressor. An internal leak
more than a total of five minutes. between the discharge and suction side of the com-
If the compressor does not develop a minimum of pressor will upset the “Expansion Valve Test” results.
190 psi at 500 engine rpm, both compressor valve Test Preparation and Connections
plate assemblies and gaskets must be replaced. See (1) Close both the left and right gauge set manifold
Paragraph “Compressor”. valves. Open the manifold needle valve.
After repair, the compressor capacity must be
tested before charging the system and repeating the (2) Install a VI”connector and a VI’’tee fitting at
“Over-All Performance Test.” the left side of the gauge manifold. Install the test
A compressor that consistently builds up to a min- cap (SP-2922)on the tee fitting, and connect the test
imum of 190 psi at exactly 500 engine rpm is de- hose to the lower end of the tee fitting.
livering the rated capacity. Reconnect the evapor- (3) Connect the other end of the suction test hose
ator suction line to the suction muffler and the to the suction service port, using the special adapter
to keep the suction service valve open.
ENGINE EXACTLY 500 RPM (4) Connect the discharge test hose to the discharge
service port, using a special adapter to hold this serv-
ice valve open.
(5) Connect one end of the long test hose to the
center of the gauge manifold, and the other end to
the refrigerant dispensing manifold.
(6) Close two of the dispensing manifold valves
(turn clockwise). Open the remaining dispensing mani-
fold valve (fully counterclockwise). Remove the pro-
tective cap from the opened valve.
(7) Screw a refrigerant can to the opened manifold
valve, and tighten 6 to 8 foot-pounds maximum.
Tighten the manifold locking nut against the shoulder
of the can, again using 6 to 8 foot-pounds maximum
to insure a good seal.
(8) Turn the manifold valve (about the refrigerant
can) completely clockwise to puncture the can. This
also closes the valve and seals the refrigerant in the
Fig. 26-Compressor lest Pressure can.
This completes all test connections necessary for lower the temperature of the ice and water, add small
the “Expansion Valve Test.” Compare the test set-up quantities of salt while stirring until the desired tem-
against those illustrated in Figure 27. perature of 32 degrees F. i s obtained.
Then, proceed with the following preparation steps. Maximum Flow Test-
(9) Remove the expansion valve thermal bulb from Thermal Bulb W a r m
its well inside the evaporator housing. (1) Warm the thermal bulb by holding it in your
hand. This will produce the same effect as a warm
(10) Prepare a large pan of water heated to 125 de-
evaporator . . . it will open the expansion valve for
grees F. and place the refrigerant can upright in the
maximum flow.. .
water. Use enough water to provide the heat neces-
sary to insure ample refrigerant pressure throughout (2) Open the refrigerant manifold
this test. counterclockwise) to allow the refrigerant vapor to
flow to the gauge set manifold.
(11) Prepare a container Of ice and water to provide (3) Adjust the right-hand gauge set manifold valve
a known temperature Of 32 degrees This be to maintain exactly 75 psi on the discharge gauge.
used to test the expansion valve in its ‘‘minimum
(4) On all Plymouth units, the suction gauge should
flow” position.
register 60 to 70 psi when pressure registered at the
NOTE: Under extreme conditions of high heat and discharge gauge is maintained at exactly 75 psi. On
humidity the temperature of the ice and water may Valiant Cool Aire units the suction gauge should reg-
not be reduced to 32 degrees F. Use a thermometer ister 32 to 42 psi, when pressure registered at the
to test the actual temperature. If it i s necessary to discharge gauge is maintained at exactly 75 psi.
M A I N T A I N EXACTLY 75 PSI
T O 24 PSI TH
0 70 PSI THE
SP-2922
60x319 B
Fig. 27-Expansion Valve Test
Minimum Flow Test- must be replaced. For detailed instructions on ex-

Thermal Bulb at 32”F pansion valve replacement, refer to “Expansion Valve
(1) Close the right gauge valve to reduce pressure Replacement” in Paragraph 33.
on the expansion valve. This will accelerate move- An expansion valve which passes the above tests
ment of the valve toward the ‘‘minimum flow” posi- has the proper super heat setting, the proper pressure
tion. limit calibration, the correct rated capacity and has
(2) Insert the thermal bulb in the container of ice not lost its thermal bulb charge, therefore, it will
and water. Use sufficient ice to insure a water temper- give satisfactory performance.
ature of 32O F. This will cause the expansion valve Since the system is without refrigerant, it is good
to move to the “minimum flow” position. practice to remove the expansion valve inlet screen,
(3) Adjust the right gauge valve to maintain exactly clean it if necessary and reinstall it before charging
75 psi as registered at the discharge pressure gauge. the system. Clean the thermal bulb, the thermal bulb
well and the brass thermal bulb wedging strips.
(4) On Plymouth units the suction gauge should Wedge the bulb into its well so that the brass strips
register 21 to 24 psi when discharge pressure is main- force the bulb toward the suction line. The fit must
tained at exactly 75 psi. On Valiant units the suction be mechanically tight and all surfaces clean to insure
gauge should register 16.5 to 19.5 psi when discharge good thermal contact.
pressure is maintained at exactly 75 psi.
To put the system into operation it will be neces-
Test Results and Corrections sary to sweep, test for leaks, vacuum and recharge
If the expansion valve does not pass these tests, it the system.
SERVICE PROCEDURES
1 1. SAFETY PRECAUTIONS sorbed by the oil. Next, wash the eyes with the weak
The refrigerant used in all 1964 air-conditioning solution of boric acid. Call your doctor immediately
installations is refrigerant 12. It is transparent and even though irritation has ceased after first aid treat-
colorless in both the liquid and vapor state. Since it ment.
has a boiling point of 21.7 degrees F. below zero, it
CAUTION: Do not heat refrigerant 12 above 125
will be a vapor at all normal temperatures and pres-
sures. The vapor is heavier than air, non-flammable degrees F.
and nonexplosive. It is nonpoisonous except when it In most instances, moderate heat is required to
is in direct contact with open flame. It is noncorrosive bring the pressure of the refrigerant in its container
except when combined with water. It is a safe refrig- above the pressure of the system when charging or
erant. The following precautions, however must be adding refrigerant. A bucket or large pan of hot
observed when handling refrigerant 12. water not over 125 degrees F. is all the heat required
CAUTION: Wear safety goggles when servicing for this purpose. Do not heat the refrigerant con-
tainer with a blow torch or any other means that
the refrigeration system.
would raise temperature and pressure above this tem-
Refrigerant 12 evaporates so rapidly at normal at- perature. Do not weld or steam clean on or near the
mospheric pressures and temperatures that it tends system components or refrigerant lines.
to freeze anything it contacts. For this reason, ex- CAUTION: Keep refrigerant 12 containers up-
treme care must be taken to prevent any liquid re- right when charging the system.
frigerant from contacting the skin and especially the
When metering refrigerant 12 into the refrigera-
eyes.
tion system, keep the supply tank or cans in an up-
Always wear safety goggles Tool (2-3355 when serv-
right position. If the refrigerant container is on its
icing the refrigeration part of the air-conditioning
side or upside down, liquid refrigerant will enter the
system. Keep a bottle of sterile mineral oil and a
system and damage the compressor.
weak solution of boric acid handy when working on
the refrigeration system. Should any liquid refrig- CAUTION: Always work in a well-ventilated room.
erant get into the eyes, use a few drops of mineral Always maintain good ventilation in the working
oil to wash them out. Refrigerant 12 is -rapidly ab- area. Always discharge the refrigerant into the serv-
ice bay exhaust system or outside the building. Large
quantities of refrigerant vapor in a small, poorly ven-
tilated room can displace the air and cause suffoca-
tion.
Although refrigerant 12 vapor is normally non-poi-
sonous, it can be changed into a very poisonous gas
if allowed to come in contact with an open flame. Do
not discharge large quantities of refrigerant in an
area having an open flame. A poisonous gas is pro-
duced when using the flame-type leak detector. Avoid
inhaling the fumes from the leak detector.
CAUTION: Do not allow liquid refrigerant to touch
bright metal.
Refrigerant will tarnish bright metal and chrome
surfaces. Avoid splashing refrigerant on any surface.
Refrigerant in combination with moisture is very cor- COMPRESSION NUT
NEOPRENE “0” RING I
rosive and can cause great damage to all metal sur-
faces.
12. HANDLING TUBING AND FITTINGS

Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are
produced in the system when it is operating. Ex- Fig. 28-lubricate with Refrigerant Oil
treme care must be exercised to make sure that all
connections are pressure tight. Dirt and moisture can The use of proper wrenches Tools C-3358 and
enter the system when it is opened for repair or C-3363 when making connections is very important.
replacement of lines or components. The following Improper wrenches or improper use of wrenches can
precautions must be observed. damage the fittings. Always use two wrenches when
The system must be completely discharged before loosening or tightening tube fittings to prevent dis-
opening any fitting or connection in the refrigeration torting of lines and components.
system. Open fittings with caution even after the sys- The internal parts of the refrigeration system will
tem has been discharged. If any pressure is noticed remain in a state of chemical stability as long as
as a fitting is loosened, allow trapped pressure to pure-moisture-free refrigerant 12 and refrigerant oil
bleed off very slowly. Use a suitable tube bender Took. is used. Abnormal amounts of dirt, moisture or air can
C-3362 when bending the refrigerant lines to avoid upset the chemical stability and cause operational
kinking. Never attempt to rebend formed lines to fit. troubles or even serious damage if present in more
Use the correct line for the installation you are serv- than minute quantities.
icing. When it is necessary to open the refrigeration sys-
A good rule for the flexible hose lines is keep the tem, have everything you will need to service the
radius of all bends at least 10 times the diameter of system ready so that the system will not be left open
the hose. Sharper bends will reduce the flow of any longer than necessary. Cap or plug all lines and
refrigerant. The flexible hose lines should be routed fittings as soon as they are opened to prevent the
so that they are at least 3 inches from the exhaust entrance of dirt and moisture. All lines and com-
manifold. It is good practice to inspect all flexible ponents in parts stock should be capped or sealed
hose lines at least once a year to make sure they are until they are ready to be used.
in good condition and properly routed. All tools, including the refrigerant dispensing mani-
“0”rings and fittings must be in good condition. fold, the gauge set manifold and test hoses should be
The slightest burr or foreign material may cause a kept clean and dry.
leak. “0” rings and fittings must be coated with The special refrigeration oil supplied for the system
refrigerant oil to allow the connections to seat is as clean and dry as it is possible to make it. Only
squarely and to be tightened evenly to the proper refrigeration oil should be used in the system or on
torque. Fittings which are not oiled with refrigerant the fittings and lines. The oil container should be
oil are almost eure to leak (Fig. 28). kept tightly capped until it is ready for use, and then
tightly capped after use to prevent entrance of dirt during the winter season operation, but the chemical
and moisture. Refrigerant oil will quickly absorb any inhibitors for rust and corrosion prevention are weak-
moisture with which it comes in contact. ened and finally exhausted by extended use. Do not
add new inhibitor to used antifreeze in hope of re-
13. COMPRESSOR DRIVE BELT vitalizing the used antifreeze.
ADJUSTMENT The chemical inhibitors come in various chemical
compositions, some are compatible, some neutralize
Satisfactory performance of the air-conditioning
each other, and some form violent reactions to each
system is dependent upon drive belt condition and
other causing foaming and other undesirable reac-
tension. If the proper tensions are not maintained,
belt slippage will greatly reduce air-conditioning per- tions. Play it safe and use new permanent-type anti-
freeze.
formance and drive belt life. To avoid such adverse
effects, the following service procedure should be
followed: 15. RADIATOR PRESSURE CAP
(1) Any belt that has operated for a minimum of It is absolutely necessary for the 1964 air-condi-
a half-hour is considered to be an “in use” belt. tioned vehicle to be equipped with a 15 to 16 psi
Adjust air-conditioning drive belts at the time of new- radiator cap.
car preparation. Using the torque method, tension A radiator pressure cap testing below these speci-
should be 55 foot-pounds for models equipped with fications will permit loss of coolant during a hard pull
318 cubic-inch engine; 40 foot-pounds for all other on a hot day, or in slow moving traffic, or when the
V-8 engines: 25 foot-pounds for 6 cylinder engine. engine is stopped after a fast run on a hot day.
Test the radiator pressure cap, using Tool C-3499
(2) Measure the drive belt tension at regular service
(Fig. 29). Before assembling the adapter and radiator
intervals, using the torque method, and readjust as
pressure cap to the pump, dip the radiator cap and
needed.
both ends of the adapter into clean water to assure
(3) On all new-belt installations, new-belt tension a tight seal.
specifications should be used when the belt is first Hold the assembled tester in a vertical position with
installed to obtain proper tension. Thereafter, these the radiator cap downward, as shown in Figure 32.
replacement belts should be serviced according to the Stroke the tester pump plunger until the gauge in-
above procedure. Always replace belts in pairs if dicates the pressure cap is relieving pressure. It must
so equipped, otherwise the old belt will have insuffi- relieve at a pressure between 15 and 16 psi. If within
cient tension and the load will be primarily on the these specifications, reinstall on the radiator.
new belt. Proper tension for new belts is 75 foot-
pounds for 318 cubic-inch engine; 60 foot-pounds for NOTE: These test specifications are for caps tested
all other V-8 engines; 35 foot-pounds for 6 cylinder a t average altitudes. In high altitudes, the test speci-
engines. fications are lowered about one (1) psi for each 2,000
feet above seal level.
14. ANTIFREEZE RECOMMENDATIONS-
(Plymouth 1
The Air-conditioning System requires the engine’s
cooling system to be protected to +15O F. with a
permanent type antifreeze for summer operation.
This is to prevent freezing of the coolant in the heater
core.
In the springtime, after the winter’s operation with
the cooling system protected with permanent-type
antifreeze for the temperatures of the area, it is sug-
gested the system be drained and flushed out with
water. When draining, flushing and refilling, have
the temperature control lever in the extreme hot posi-
tion so the heater core is drained, flushed and refilled.
Install a gaIlon of permanent type antifreeze in the
system, and add enough water to fill the system.
Do not re-use the old antifreeze. The permanent
type antifreeze does not lose its antifreeze qualitites Fig. 29-Radiator Cap Tester
If the radiator cap does not test within these speci-
fications, replace it with a cap which does.
16. V A C U U M CONTROL SYSTEM,

ADJUSTMENTS A N D TESTS
(Plymouth1
Maximum Cool Vacuum
Switch Adjustment
clearance is necessary for the shaft rotation
between the cam and the plunger.
The lack of clearance could break the switch lever,
also too much clearance would fail to close the fresh
air door and open the recirculating door in the No. 3
Fig. 31-Adjust Vacuum Test Bleed Valve
and 4 positions.
With the blower switch on No. 4 position, adjust
are properly connected and the controls are function-
the vacuum switch by placing a ,060 inch spacer
ing properly. However, it is possible that a vacuum
between the cam and the switch plunger. Move the
control system that operates perfectly at the high
switch toward or away from the cam. Move the switch
vacuum provided at engine idle speed may not func-
until the plunger is fully depressed, and tighten the
tion properly at high engine speeds. Before starting
switch in this position and remove the spacer.
this test, stop the engine. Make certain that the
Recirculation and Fresh Air Door Linkage vacuum source hose at the engine intake manifold
To adjust the fresh air door connecting rod, re- is tight on its connector.
move the glove box, push “Cool” button, blower Start the vacuum pump Tool C-3652 and connect to
switch on No. 4 position. The recirculating door will the vacuum test set Tool C-3707. Adjust the bleed
be open, and the connecting rod is then readily ac- valve on the test set to obtain exactly 8 inches of
cessible. vacuum, with a finger blocking the prod on the end
The connecting rod is provided with a turnbuckle of the test hose (Fig. 31).
nut and lock nut (Fig. 30). The fresh air door should It is absolutely essential that the bleed valve be
be adjusted to completely closed. adjusted so the vacuum gauge pointer will return to
Turn the blower switch to No. 1 or 2 position and exactly 8 inches when the prod is covered by a finger.
inspect to see that the recirculating door is fully Otherwise a false reading will be obtained when the
closed. Replace the glove box. control circuit is tested.
Vacuum Control System Test CAUTION: Alternately release and reblock the
The test of the push-button operation determines hose prod several times. Make sure the bleed valve is
whether or not the vacuum and electrical circuits adjusted so the vacuum gauge pointer returns to
exactly 8 inches of vacuum when the prod i s covered
with a finger.
Disconnect the engine vacuum source hose at the
“T” connector under the instrument panel, and insert
the vacuum tester hose prod into the source hose
leading to the control switch.
Start the test by pushing the “Heat” button. The
vacuum tester gauge needle will drop until the actua-
tor has operated, and then will return to 8 inches.
Continue to push button “Defrost”, “Cool”, and “Off”
allowing time for actuators to operate after each but-
ton is pushed, and note the vacuum drop below 8
inches after each operation. The maximum allowable
vacuum drop below 8 inches after each operation is
% inch.
1x210
If the vacuum drop is more than % inch, first re-
Fig. 30-Recirculation and Fresh Air Door linkage check the tester for reading exactly 8 inches. If
in the holes of the connector plug. This will allow the
plug to slide completely on switch,prods.
Retest: If vacuum drop is now within limits, pro-
ceed with TEST 1, “Test System Pressure”. If vacuum
drop is still in excess of % inch, remove connector
plug from switch. Insert the vacuum test prod alter-
1
nately in each of the connector holes except the
source hose connector hole (Fig. 33). Note the amount
of vacuum drop below 8 inches after each actuator
has operated. If vacuum test gauge comes back to
8 inches at each of the 6 holes, the hoses and actuators
are not leaking. The control switch is faulty and
must be replaced. If excessive vacuum drop shows
up at one or more holes in the connector plug, isolate
the faulty hose or actuator.
If the vacuum drop occurs at number 2 or 4 holes
first inspect connector plug fit to Maximum Cool
Vacuum switch prods (switch located on Blower Con-
trol). If vacuum drop is now within limits, proceed
Fig. 32-Connector Plug Installed (Typical)
with TEST 1 “Test System Pressure”. If vacuum
drop is still in excess of % inch, remove the connector
correct, inspect the fit of the 7-hole connector plug plug from the switch. Insert the vacuum test prod
on the control switch (Fig. 32). This plug must be posi- alternately in each of the connector holes (Fig. 34).
tioned all the way on the 7 prods on the control Number 8 and 9 hoses operate the fresh air door act-
switch. uator. Test whether the actuator or hose is at fault;
CAUTION: Do not use lubricant on the switch use the test hose on the actuator involved (Fig. 35).
prods or in the holes in the ptug, as lubricants will A leak in a hose may be detected with the leak
ruin the vacuum valve in the switch. If it is impossible tester by running the fingers along the hose and
to properly position the connector plug all the way watching the vacuum gauge reading. A faulty spot
on the switch prods, put a drop or two of clean water may be cut out and hose spliced, using % inch 00
copper tubing.
A vacuum drop in excess of ?4 inch below the 8
inches needed in this test would not interfere with
Fig. 33-Vacuum Tube Assembly Test

1. Spot cool door actuator open
62x681
5. Defroster door actuator open

I Fig. 3 L M a x i m u m Cool Vacuum Connector Test
62x682
2. To maximum cool vacuum switch 6. Vacuum source

3. Spot cool door actuator closed 7. Defroster door actuator closed 2. To maximum cool vacuum switch 8. Fresh air door octuotor open
4. To maximum cool vacuum switch 4. To maximum cool vacuum switch 9. Freah air door actuator closed
in vacuum indicates excessive leakage, either in the
vacuum lines and connections, or in the switch itself.
A vacuum hose leak may be located by running your
fingers along the suspected area while watching the
vacuum gauge. If the hose is otherwise in good condi-
tion, the faulty spot can be cut out and the hose
spliced, using a short length of 3/1 ,-inch-diameter
thin-walled copper tubing.
If inspection of the vacuum hoses doesn’t uncover
the leak, replace the temperature selector switch.
Before you install the replacement switch, it’s a good
idea to connect the vacuum hoses to it and repeat
the test.
A/C & Heater lernperature
Selector Switch Adjustment
(1) The switch is operated by the heat do-when
the “cool” button is depressed. The turnbuckle should
be adjusted so that the rubber edge of the heater door
Fig. 35-Vacuum Actuator Test (Typical)
seals along its full length with minimum deformation.
The heater door will be open Y’ inch in the defrost
the engine operation, other than perhaps to cause a position.
rough idle. It could, however, interfere with the
proper operation of the air-conditioning and heating (2) After step 1 depress the heater button. Adjust
controls at high speeds and during acceleration. the vacuum switch by placing a .060” inch spacer be-
tween the switch plunger and the depression lever.
17. A/C & HEATER TEMPERATURE Move the switch until the plunger is fully depressed,
SELECTOR SWITCH TEST and tighten the switch in this position and remove
the spacer (Refer to Fig. 12).
To test the Air Conditioning and Heater Temper-
ature Selector Switch, disconnect the small yellow 18. A/C & HEATER TEMPERATURE
stripe and green stripe hoses on the outlet side of the CONTROL CABLE ADJUSTMENT
two temperature thermostats. Tie these together To adjust the temperature control cable do so at
through a tee, and connect to vacuum test set Tool the lever end of the cable. Make sure the cable hous-
C-3707. Disconnect the vacuum hose at the water ing extends 5/32 inch beyond the retainer clip at the
valve and seal the vacuum hose end (Fig. 36). stat assembly. If the cable is badly out of adjustment
Push and release the plunger on the temperature at the thermostatic valve end, it may not be possible
selector switch a few times while watching the vacuum to get the proper adjustment at the lever end. To
gauge Fig. 37). A drop of more than one-half inch adjust the control cable:
L A 63x107 \
63x109 ‘
Fig. 3LTemperature Selector Switch Test Fig. 37-Testing Switch
1. Remove the retainer clip and cable at the control

lever end.
2. Pull out on the control cable wire to move the
thermostat valves to the full off or closed posi-
tion.
3. Hold the temperature control lever in the “Off”
position, install control cable wire eyelet on the
lever arm.
4. Install the retainer clip to hold the adjustment.
19. THERMOSTATIC VALVE TESTS

A complaint of erratic heat output, or no heat at
all, could be traced to a faulty thermostatic valve.
Before you perform the following tests, always inspect
first for pinched or leaking vacuum hoses and test
-=I L
m
--
Fig. 39-The
1 L, - -“&e.
rmosta t Mid- Position

-“.-
the temperature selector switch to be sure it isn’t
leaking. Also make sure the vacuum line fitting at gauge test set with a special test hose attached. The
the top of the water flow valve isn’t leaking. dimensions of this test hose are very important; it
Test preparations. Turn the ignition switch to the must be exactly forty-eight inches long and have an
“Accessory” position, turn the blower switch to the inside diameter of three-sixteenths inch. The speci-
number two position and push the “Cool” button. The fications for this test have been calibrated for this
blower should be kept running for the entire test. specific hose, so don’t try to substitute another size!
Place a thermometer in the upper grille outlet so
you’ll know when the temperature is stabilized. Don’t 20. HEATER THERMOSTATIC VALVE TEST
begin the test until the air temperature remains con- (Fig. 38)
stant within one degree per minute. While you’re
waiting for the temperature to level out, remove the To test the heater thermostatic valve - left - hand
radio speaker grille and the speaker to make it easier thermostat - connect the test hose from the vacuum
to get at the thermostatic valves. Then remove the gauge test set to the outlet side of the heater thermo-
small-diameter vacuum hoses from the right-hand side stat. The heater thermostat and its inlet and outlet
of the two thermostats. hoses are identified by yellow color coding: a yellow
stripe on the hoses and two yellow dots of paint on
Also, disconnect the vacuum source hose for the the body of the thermostat. Also remove the large
air-conditioning unit from the intake manifold. Con- diameter vacuum source hose from the other thermo-
nect the hose to vacuum pump Tool C-3652 and start stat and plug the end of it to prevent any air from
the pump. A vacuum of at least twenty inches is re- entering. This hose has a green stripe.
quired for this test.
Thermostat mid-position setting. Put the temper-
In addition, you’ll need the Tool C-3707 vacuum ature selector lever in the “Off” position, then move
it slowly toward the center of its slot. Stop when the
vertical line on the cam lever arm is aligned with
the raised vertical line on the end of the valve body
(Fig. 39). If you over-shoot the mark, don’t move the
lever directly back to the proper setting. Instead,
move the temperature selector lever back to the
“Off’position and start over. The test which follows
is based on having the thermostat cam precisely in
its mid-position point.
Calibration test. When the heater stat is set
precisely on the mid-position and the air temperature
at the upper grille outlet is stabilized, read the ther-
mometer and vacuum gauge. For any given tem-
~- perature, the vacuum should be within the limits
Fig. 38-Heater Thermostatic Valve Test shown on the following chart.
HEATER THERMOSTAT MID-POSITION AIR C O N D I T I O N I N G THERMOSTAT

V A C U U M CALIBRATION CHART MID-POSITION V A C U U M CALIBRATION
CHART
Degrees Fahrenheit Vacuum Range
Degrees Fahrenheit Vacuum Range
65 7.75-9.50
65 7.75-9.50 65 5.25-7.00
66 7.75-9.50 66 5.25-7.00
67 7.50-9.50 67 5.00-7.00
68 720-9.50 68 5.00-7.00
69 7.50-9.25 69 5.00-6.75
70 7.50-9.25 70 5.00-6.75
71 7.25-9.00 71 4.75-6.50
72 7.25-9.00 72 4.75-6.50
73 7.25-9.00 73 4.75-6.50
74 7.00-9.00 74 4.50-6.50
75 7.00-8.75 75 4.50-6.25
76 7.00-8.75 76 4.50-6.25
77 6.75-8.50 77 4.25-6.00
78 6.75-8.50 78 4.25-6.00
79 6.75-8.50 79 4.25-6.00
80 6.50-8.50 80 4.00-6.00
81 6.50-8.25 81 4.00-5.75
82 6.50-8.25 82 4.00-5.75
83 6.25-8.00 83 4.00-5.75
84 6.25-8.00 84 3.75-5.50
85 6.25-8.00 85 3.75-5.50
Check valve test. To be sure that the vacuum check assembly, complete with the mounting plate. So if
valve in the thermostatic valve assembly is working either stat doesn’t test out akay, replace the assembly.
correctly, disconnect the source hose from the vacuum Don’t attempt to adjust or replace individual stats.
pump. This will release all vacuum in the vacuum Remember to disconnect the battery and remove
source lines up-stream from the valve. If the vacuum the fuse block before you remove the stats. To remove
gauge reading drops less than one inch in one minute, the assembly, remove only the six screws around the
the check valve is satisfactory. perimeter of the mounting plate; never disturb the
four screws that hold the individual thermostatic
21. AIR-CONDITIONING THERMOSTATIC valves to the mounting plate. Tightening or loosening
VALVE TEST (Fig. 40) them, even very slightly, may upset the calibration
The air-conditioning thermostatic valve is the right- of the stat. To remove or install the assembly, roll it
hand valve. The valve and its hoses are identified by
green color coding - green stripes on the hoses and
two green paint dots on the valve itself. To test this
valve, attach the test hose from the vacuum gauge
to the outlet fitting at the right-hand side of the
valve. Disconnect the vacuum source hose from the
heater stat and plug the hose. Connect the large-
diameter vacuum source hose with the green stripe
to the air-conditioning thermostatic valve.
Repeat the thermostat mid-position setting and then
read the thermometer and vacuum gauge again. Refer
to the following chart for vacuum limits for the air-
conditioning thermostat calibration test. Then test the
vacuum check valve as described for,tlie heater stat.
22. THERMOSTATIC VALVE REPLACEMENT
The two thermostatic valves are serviced only as an Fig. 40-Air-conditioning Thermostatic Valve Test
in or out of the evaporator housing from the bottom
of the mounting plate. This will avoid damage to the PULLER
thermostatic springs and cam followers. C-3787
When you’re handling the assembly, be careful not
to damage the bimetal thermostatic springs in any
way. Avoid touching the springs since contamination
could cause corrosion and affect calibration. After the
replacement assembly is installed, don’t forget to
remove the strip of tape that was placed on the link
connecting the two cam levers to keep it from moving
during shipping. When you attach the vacuum source
hoses to the stats, be sure the temperature control
cable is routed between the hose and the evaporator A-
housing. If it’s the other way around, with the cable
over the hose, there’s a good chance that the hose h
will be pinched, affecting the temperature control
system. After the stats are installed, remember to
adjust the temperature control cable as described
earlier.
23. MAGNETIC CLUTCH Fig. 42-Removing the Hub and Shoe Assembly
The magnetic clutch (Fig. 41) uses a stationary elec- (Typical)
tromagnet attached to the compressor. Since the elec-
tromagnet does not rotate, the collector rings and the (3) Insert a cap screw into the threaded portion of
brushes are eliminated. the hub and shoe assembly.
Testing Electromagnet Current Draw (4) Support the clutch with one hand, then tighten
the cap screw until the clutch is removed.
To test the coil for a short or open circuit, connect
an ammeter (0-10 ampere scale) in series with a fully (5) Remove the three hex field coil assembly mount-
charged 12-volt battery and the field coil lead. The ing screws and lift off the assembly.
current draw should be 2.5 to 2.9 amperes at 12 volts. Disassembly
(1) Remove the small snap ring from the drive hub
Removal with Tool C-3128 or equivalent.
(1) Loosen and remove the belts. Disconnect the
(2) Install the drive hub puller Tool C-3787 aligning
field coil lead wire.
the three pins of the tool in the three holes in the
(2) Remove the special locking bolt and the washer hub and shoe assembly. Tighten the hex head bolt
from the compressor crankshaft at the front center down until the drive hub is removed from the bearing
of the chtch. (Fig. 42).
LEAD WIRE
v=- - \
_-
/ TOOL (REMOVER
CLUTCH FIELD
ASSEMBLY
BEARING SNAP RING TOOL
(SUPPORT)
PULLEY ASSEMBLY 61x32
61 x 6 3
Fig. 41-hagnetic Clutch-Stationary Field Type Fig. 43-Removing the Bearing from the Pulley
(Typical) Assembly
inner race of the bearing and press the bearing from

the pulley assembly (Fig. 43).
NOTE: A new bearing must be installed every
time the magnetic clutch is disassembled.
Assembly
(1) Install the pulley assembly with the pulley side
up on an arbor press and insert a new bearing into
the bore. Install the Tool C-3807 against the bearing
and press into position (Fig. 44).
(2) Install the pulley assembly with pulley side
facing down on Tool C-3807.
(3) Start the drive hub into the inner bearing race,
and press the hub into position with an arbor press.
Fig. 44-lnstalling a New Bearing in the Pulley
Asrem bly (4) Install the bearing snap ring and the hub snap
ring.
(3) Remove the bearing snap ring from the pulley CAUTION: The pulley assembly and hub assembly
assembly. are mated parts. They are burnished at the factory
(4) Place the pulley assembly on an arbor press, before shipment. No attempt should be made to re-
with the pulley side down, and the bearing hub cen- place either unit separately as this may reduce the
tered on Tool C-3835. Install the Tool SP-3496 on the initial torque of the clutch.
HEAD
GASKET
L O C K 4
ROD--++
\\ SPI/ING-AT'NG
VALVE
..A. .r
GASKET-
CORE
W *-
".--.\...-
RFAPlNr.
-BOLT
-- 7\
SEAL
1. 1
\ WASHEY \COVER
ROTOR
SHAFT
ROTOR
* '-USING
SEAL
-n A I I
/ CAP 4
T CRANKSHAFT BOLT
HOUSING b-.
c
BOLT 61x329
Fig. 4'5-Compressor (Disassembled View) (Typical)

AIR CONDITIONING -
24-35
lnstalSat ion bearing. Wash the bearing in clean mineral spirits

(1) Install the field assembly on the base of the and shake out all excess cleaning fluid. Saturate the
compressor bearing housing. Make sure the coil as- bearing with clean refrigerant o i l and assemble im-
sembly is positioned so that the lead wire points up mediately. Any dirt in the front main bearing assem-
and can be routed between the compressor cylinder bly will cause noisy operation and possible damage
head. Install the three mounting screws and tighten to the bearing.
to 17 inch-pounds torque. CAUTION: Before reassembly o f any unit, a l l con-
(2) Insert the woodruff key in the crankshaft. tact surfaces must be liberally coated with clean re-
(3) Install the clutch assembly onto the crankshaft. frigerant oil. Refrigerant o i l must be k e p t in a sealed
container until ready f o r use t o prevent entrance o f
(4) Install the washer and a new self-locking bolt,
moisture and dirt. Never use engine o i l as a substitute
and tighten to 20 foot-pounds torque.
f o r refrigerant oil.
(5) Connect the field lead wire.
(6) Install the belts, tighten to the specified tension. EPR Valve-Replacement I Except Valiant J
(1) Remove the two EPR valve suction line fitting
24. COMPRESSOR bolts, the fitting which also contains the compressor
The compressor is a two-cylinder, reciprocating-type suction screen, spring, and the gasket.
designed specifically for the Chrysler Air-Condition- (2) Remove the “EPR” valve and “0”ring from
ing System. Service parts are available so that the the compressor using Tool C-3822, by rotating the
compressor can be repaired in the field. valve counterclockwise slightly, as shown in Fig. 46.
Fig. 45 is a disassembled view of the compressor (3) To install, place the “0”ring on the “EPR”
with the nomenclature of the parts. Some parts are valve.
serviced individually and some are serviced in pack- (4) Lubricate the “0”ring with refrigerant oil and
ages which include two or more service parts. Refer install the “EPR” valve in the compressor with Tool
to the parts book for this information. (2-3822 and rotating the valve counterclockwise.
CAUTION: T h e refrigerant o i l used in the com- (5) Install the compressor suction screen in the
pressor i s carried t h r o u g h t h e entire system by the “EPR” valve suction line fitting.
refrigerant. Some o f t h i s o i l will be trapped a n d (6) Install the suction line fitting gasket, spring,
retained in t h e system w h e n the refrigerant i s dis- fitting, and attaching bolts.
charged f o r testing o r unit replacement. If t h e com-
pressor i s t o be removed for repair o r replacement, Compressor-Removal
measure t h e refrigerant o i l level in t h e compressor (1) Discharge the system. Refer to “Discharging
before t h e compressor i s removed f r o m the vehicle The System”, TEST 7 in INSPECTION, TEST PROCE-
so that the same oil level can be established when the DURES AND DIAGNOSIS.
n e w o r repaired compressor i s installed o n t h e vehicle. (2) Measure and record refrigerant oil level so that
l o o m u c h refrigerant o i l in t h e system can cause ab- the oil level of a replacement or repaired compressor
n o r m a l operating pressures a n d reduce t h e perform-
ance of the entire system.
Complete disassembly and assembly of the com-
pressor must be performed with the compressor re-
moved from the vehicle. However, on some models
the valve plate and crankshaft gas seal assemblies can
be replaced with the compressor installed on the
-- .
vehicle.
CAUTION: T h e system must b e completely dis-
charged before attempting t o p e r f o r m any disassem-
bly o r repair service t o t h e compressor.
Cleanliness is extremely important. The work area
must be clean and free of air-borne dust and dirt. All
parts must be thoroughly cleaned and blown dry be- 6”
fore reassembly.
Do not use air to dry the crankshaft front main Fig. 4 L R e m o v i n g or Installing EPR Valve
can be adjusted to the exact level in t h e cornpressor compressor. If original o i l level i s n o t known, adjust
removed from the vehicle. the level to two inches if positioned a t the vehicle
(3) Disconnect the suction and discharge lines at installation angle measured through o i l f i l l e r opening.
the muffler fittings. Cylinder Head and Valve Plate-Removal
CAUTION: Plug o r cap a l l lines as soon as they a r e (1)Remove the cylinder head bolts and the head
disconnected t o keep moisture o u t of t h e system. and valve plate assembly. If the plate does not sepa-
(4) Disconnect the magnetic clutch-to-control-unit rate from the head, tap the removing lip on the valve
wire. plate lightly with a plastic hammer (Fig. 47). Do not
pry apart.
(5) Loosen and remove the compressor pulley belts.
(6) Remove the compressor-to-bracket attaching Inspection
bolts, and remove the compressor. After removal of the head, plate and gaskets, ex-
amine the valves. If the valves are broken and damage
lnstallatlon extends to cylinder bores, examine the bores to see
(1) Install the compressor to bracket, and tighten if they can be repaired by removing light scoring,
the attaching bolts. scuffing or scratches with crocus cloth. After con-
(2) Install the compressor pulley belts.
ditioning the cylinder bores, clean the surfaces of
the cylinder block, valve plate and head thoroughly
(3) Connect the magnetic clutch-to-control-unit with mineral spirits.
wire. Use care to remove all shreds of old gasket from
(4) Remove the caps or plugs, connect the suction the plate, block and head surfaces. Clean the attach-
and discharge lines to the compressor. ing stud holes in the block. If the valve plate or
CAUTION: When replacing t h e compressor as-
cylinder head is damaged, replace, using a complete
sembly, t h e crankshaft should be rotated by hand a t compressor valve plate replacement package.
least t w o complete revolutions, t o clear o i l accumula- installation
t i o n f r o m compressor head before t h e clutch is ener- (1) The valve plate and cylinder head must be as-
gized t o avoid damaging the compressor reed valves. sembled with the reed valve assembly positioned, as
NOTE: A f t e r t h e compressor is installed, it is shown in Figure 48.
imperative t h a t t h e o i l level in t h e compressor be (2) Dip gaskets in clean refrigerant oil. Using pilot
adjusted t o t h e level registered before removing t h e studs as a guide, install valve plate gasket, valve
plate, cylinder head gasket and cylinder head, as
shown in Figure 49.
(3) Install attaching bolts. Tighten each bolt alter-
nately and evenly 23 to 27 foot-pounds torque.
REED VALVE ASStMBLY
Fig. 47-Valve Plate and Head Removing l i p Fig. 48-Valve Plate-Installed Position
VALVE PLATE GASKET
nn
_ _ _ _ _ I
\\ VALVE PLATE ASSEMBLY

CYLINDER HEAD
GASKET
A PILOT STUDS
-
RELIEF
SPR ING
-- -2-
'
CYLINDER r889A
HEAD -
Fig. 50-Installing Sump
61 x 95
(5) Install the sump over the pilot studs (Fig. 50),
Fig. 49-Installing Valve Plate and Cylinder Head making sure that the oil pressure relief spring de-
presses uniformly as the sump is lowered on the case.
Piston and Connecting Rod-Removal
(6) Tighten the sump bolts finger tight to prevent
(1) Drain the oil from the compressor. spring misalignment, then tighten 15 to 19 foot-
(2) Remove the sump attaching bolts. pounds torque.
(3) Separate the sump from the case by tapping (7) Refill with new refrigerant oil after the com-
with a plastic hammer being careful not to distort the pressor is installed on vehicle. Do not re-use the oil
oil pressure relief spring. that was previously drained.
(4) Remove the oil relief spring and (rubber) ball NOTE: If the original oil level is known, adjust
from the crankcase. level to two inches after installation.
(5) Remove the cylinder heads and valve plates. Crankshaft Bearing Housing and
Gas Seal-Removal
NOTE: Before removing the pistons, rods or rod (1) Remove the crankshaft housing seal bolts.
caps, mark all parts to insure reassembly in the
original position.
(2) Remove the bearing housing from the case,
using two screw drivers inserted in slots provided to
(6) Remove the rod caps; remove the piston and pry housing from the case. Fig. 51.
rod assembly from the cylinder. (3) Remove the crankshaft bearing housing seal
face plate from the bearing housing. This is part of
Inspection the gas seal replacement package and must be re-
Inspect the piston and rings for score marks. In- placed when the gas seal assembly is replaced.
spect rod bearing for pits and for chipping. Replace
parts if damaged.
Installat ion
(1)Remove the bearing cap and install the piston
in the bore. Use the piston ring compressor to prevent
ring damage.
(2) Install the bearing caps, and tighten screws 52
to 56 inch-pounds torque. Be sure each cap is installed
in its original position.
(3) Install the valve plates and the cylinder heads.
(4) Turn the compressor upside down. Install the
pilot studs, gasket, oil pressure relief ball and spring. Fig. 5'1-Crankshaft Bearing Housing Removal
(4) Remove the gas seal from the crankshaft.
Installation
The crankshaft gas seal replacement 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 Figure 52. If the replacement package contains the
cartridge-type seal, follow the entire installation pro-
cedure given below. If the replacement package con-
tains the unitized-type seal, steps 1, 2 and 4 will not
apply-
(1) Before installing the cartridge-type gas seal as-
sembly, insert the assembly to make sure that the
tangs index the slots of the mating part. This will
insure proper spring action. The carbon seal must be
assembled, as shown in Figure 52.
(2) Hold the seal firmly on the outside edge to m
u
t' "J
prevent it from rotating out of the index slots. I --'-"'
-' -
(3) Lubricate the crankshaft with refrigerant oil.
Slide the seal on the crankshaft with the smooth Fig. S3-Checking indexing of Tangs
(carbon seal) surface up, or toward the front of the
compressor. (6) Install the bearing housing oil seal, using plenty
of refrigerant oil.
(4) When the seal bottoms against the crankshaft
bearing, test indexing of tangs again by pressing down (7)Install the housing, making sure that it is in
with thumbs to see if it has the proper spring action proper alignment with the screw holes. The gas seal
(Fig. 53). assembly may be damaged if the bearing housing is
rotated after the housing seal contacts the carbon seal
(5) Lubricate and install the crankshaft bearing (8) Install bolts and tighten 10 to 13 foot-pounds
housing seal face plate with the smooth (micro-finish) torque.
side up. Use a sleeve with the minimum inside diame-
ter of l3/8 inches to avoid damaging the micro-finish Crankshaft and Ball Bearing-Removal
sealing surface of the face plate. Tap sleeve lightly (1) Remove the cylinder heads and valve plates.
until the seal face plate is fully seated in the housing.
(2) Remove the pistons and connecting rods.
(3) Remove the crankshaft bearing housing and gas
seal.
NOTE: The pistons and rods must be completely
removed before the crankshaft removal.
(4) Remove the crankshaft and thrust washer from
the crankcase.
(5) To remove the crankshaft ball bearing, use a
small arbor press. Make sure the bearing is properly
supported before pressing the bearing from the shaft.
Inspection
Clean and inspect all parts. Replace questionable
parts as required. If the crankshaft ball bearing is
in good condition and clean, protect it against entry
of dirt and re-use it. If bearing is serviceable but
dirty, or there is evidence of dirt, clean it carefully
Fig. 5'2-Gas Seal Identification with mineral spirits and shake dry. Saturate bearing
(2) Install the inner rotor on the drive shaft, en-
-7 1
gaging the drive.
(3) Install the outer rotor, rotate it until it will slide
forward over the inner rotor cams. Turn the com-
pressor crankshaft with the oil pump in this position
to determine that the rotors do not bind.
(4) Install the oil pump cover plate and oil seal.
(5) Tighten the bolts 10 to 13 foot-pounds torque.
(6) Rotate the crankshaft again to assure free op-
eration.
25. EXPANSION VALVE, HEATER CORE

AND EVAPORATOR, AND BLOWER-
REPLACEMENT ( Plymouth)
b3A
Expansion Valve Removal
The system must be complately discharged before
Fig. 54-Checking Crankshaft Axial Movement opening any of the refrigerant lines.
(1) Remove the equalizer line from the evaporator
with clean refrigerant oil and assemble immediately.
If a new bearing is to be installed, leave it wrapped suction line fitting.
in its protective package until ready for installation. (2) Disconnect the valve from the %I inch inlet
line and from the 1/2 inch outlet line. Use two
NOTE: Do Not Wash a New Bearing Assembly wrenches to loosen each of these connections.
Before Installation.
(3) From the evaporator engine-side housing, care-
Installation fully pull the thermal bulb (Fig. 55) from the well
(1) Press the crankshaft ball bearing on the crank- located inside the evaporator housing.
shaft using a sleeve which bears on the inner race
only. Installat ion
Clean the thermal bulb well, wedging shims and
(2) Install the crankshaft, making sure that the
thermal bulb before installing the expansion valve.
thrust washer is on the rear bearing journal before
The valve will not function properly unless there is
placing the crankshaft in the crankcase. a good thermal contact between the bulb and its well.
(3) Rotate the crankshaft to engage the oil pump Clean parts and a tight fit of the bulb in the well
shaft in the crankshaft slot. will insure a good thermal contact.
(4)Install the gas seal and crankshaft bearing hous-
ing. Use suitable tool, as shown in Figure 54,to assure
free axial movement.
(5)Install the pistons and connecting rods.
(6) After the pistons and connecting rods are in-
stalled, turn the crankshaft to test freeness. The shaft
should turn without binding.
(7) Install oil sump, valve plates and cylinder heads.
Oil P u m F R e m o v a l
It is not necessary to drain the refrigerant oil from
the crankcase to remove the oil pump.
(1) Remove the oil pump cover plate and oil seal.
(2) Remove the drive shaft and rotors.
l n s tallat ion
(1) Install the oil pump drive shaft by rotating the 60x897
shaft until the tang end engages in the crankshaft
slot. Fig. 55-Thermal Bulb Installed (Typical)
(1) Install the thermal bulb, making sure it is a Heater Core Removal
tight mechanical fit in the well. (1) Remove the vacuum hoses from the thermostats
(2) Lubricate all expansion valve and line fittings and the water valve vacuum block from the switch.
with clean refrigerant oil. Install the expansion valve, (2) Loosen the side outlet actuator mounting nuts,
using two wrenches to prevent rotation and twisting disconnect the retainer clip from the rod and remove
of the lines. the actuator.
(3) Connect the equalizer tube to the fitting on the (3) Remove the linkage from the side outlet door
evaporator suction line. shaft.
(4) Using two wrenches, inspect all connections for (4) Loosen the upper outlets mounting nuts, discon-
tightness. nect the retainer clip from the rod and remove the
After the expansion valve is installed, it must be actuator.
completely tested. Then the system must be tested (5) Remove the sheet metal screws and remove the
for leaks and recharged. cover.
Heater Core and Evaporator Assembly (6) Remove the fillet from the lower right corner
Removal from Vehicle of the case.
The heater core and evaporator are compactly (7) Remove the attaching metal screw and pull out
packaged forward of the instrument panel and must the heater core being careful not to damage the heat-
be removed as a single unit. The system must be er door (Fig. 56).
completely discharged before opening any of the Heater Core installation
refrigerant lines and the cooling system drained. Re-
(1) Install the heater core being careful not to
move front carpet for additional clearance.
damage the heater door.
(1) Disconnect the battery and remove the air
CAUTION: Be sure the seals on the heater core to
cleaner.
evaporator are in place, bottom and both sides.
(2) Disconnect the equalizer line from the evapo-
(2) Install the fillet in the lower right corner.
rator suction line fitting. Disconnect the 9's inch inlet
line, V2 inch outlet line, and remove the expansion (3) Install the cover with sheet metal screw. Cover
valve. Cap all the refrigerant lines to prevent the to case has to be an air tight seal.
entrance of dirt and moisture. (4) Install the upper outlet and retainer clip.
(3) Disconnect the heater hoses, plate and seal, (5) Install the side outlet actuator, retainer clip
vacuum hose from the water valve and push through and the linkage.
the firewall. (6) Install the vacuum hoses to thermostats and the
(4) Remove the drain tubes, two nuts and washers water valve vacuum block to the switch.
-
from the studs, and mounting bolt.
Evaporator Removal
(5) Remove the sound deflector cover under the
(1) With the heater core removed from the case,
glove box, remove the glove box assembly, radio grille remove the heater core right mounting bracket (metal
and speaker. screws).
(6) Remove the blower motor flexible duct, upper
and side cooler tubing. CTE HEATER CORE
(7) Remove the temperature control cable from the I 1. .b" /.,---.
thermostat, the vacuum hose connectors from the
push button switch, the blower switch and the engine
vacuum hose.
(8) Remove the electrical wires from the resistor
block and relay.
(9) Remove 2 mounting brackets, one top center,
one upper left side.
(10) Remove the assembly with the blower motor
as a single unit. HEATER' DOOR
(11) Remove the blower motor mounting bracket 62x683
from the mounting studs. Fig. 56-Removing Heater Core
tube opening, heater hoses, vacuum hose to the water

HEATER DOOR
EVAPORATOR valve.
C\SE \ (9) Use new “0”rings with clean refrigerant oil
on all connections then install expansion valve,
equalizer line, inlet line, outlet line and suction line.
(10) Connect the battery cable and install the air
cleaner.
After the evaporator assembly is installed in the
vehicle it will be necessary to sweep the system, test
for leaks and charge the system with the proper
amount of refrigerant. It is recommended that the
operation of all controls be tested and an overall
Fig. 57-Evaporator Removal performance test be made after repair or replacement
of the evaporator assembly.
(2) Remove two nuts attaching the evaporator to
Blower-Removal
the case.
(1) Disconnect the battery ground cable.
(3) Remove the metal screw (upper left side) evapo-
rator to the case. (2) Remove the radio grille and speaker to discon-
nect the motor “hot” wire from the resistor block,
(4) Remove the evaporator inlet, outlet retainer the ground wire from the case mounting bracket.
plate (metal screws) and the sealer.
(3) Remove the sound deflector cover under the
(5) Remove the evaporator from the case (Fig. 57). glove box.
Evaporator Installation (4) Remove the glove box assembly, blower motor
(1) Place the sealer in the case for the evaporator duct (rubber).
sealing and position the evaporator in the case, se- (5) Remove the blower motor.
curing with the screw, and two nuts.
lnstallation
(2) Install the sealer and retainer plate, secure with (1) Install the wires into the case and out through
metal screws. the wire opening before positioning the blower
(3) Install the heater core right mounting bracket motor.
in the case (metal screws).
CAUTION: Make certain the grommet is installed
lnstallation in the Vehicle properly.
(1) Install the blower motor to the mounting (2) Install the blower motor duct, and the glove
bracket. box assembly.
(2) Install the assembly with the blower motor (3) Connect the motor “hot” wire to the resistor
beneath the instrument panel, securing the mounting block, ground wire to case mounting bracket.
brackets (upper’ left side and top center of case). (4) Install the radio speaker, grille, and the sound
deflector.
NOTE: Be sure the motor ground wire is attached
to the top center bracket. (5) Connect the battery ground cable.
(3) Install the mounting bolt and nuts to studs (6) Test the operation of blower motor.
through the firewall. 26. EXPANSION VALVE, EVAPORATOR
(4) Install the electrical wires to the resistor block AND BLOWER-REPLACEMENT
and relay. (Valiant 1
(5) Install the temperature control cable thermo- Removal-Expansion Valve
stat, vacuum hose connectors to the push button The system must be completely discharged before
switch, blower switch and the engine vacuum hose. opening any of the refrigerant lines.
(6) Install the upper, side cooler tubing, blower (1) Remove the equalizer tube from the evaporator
motor flexible duct. suction line.
(7) Install the radio speaker, grille, glove box as- (2) Carefully pull the thermal bulb and thermal
sembly, and sound deflector. bulb wedging shims from the well located on the
(8) Install the drain tubes, seal with plate for heater evaporator suction line.
(3) Disconnect the valve from the inlet and outlet (4) Install the grille with switches, positioning the
lines. Use two wrenches to loosen each of these temperature control sensing tube through the hole in
connections. the top plate.
(5) Install the blower and base assembly.
lnstallation
Clean the thermal bulb well, wedging shims and (6) Install the assembly in the vehicle.
thermal bulb before installing the expansion valve. (7) Connect the drains, clutch and the feed wires.
The valve will not function properly unless there is a (8) Lubricate the fittings and lines with clean re-
good thermal contact between the bulb and its well. frigerant oil. Install the expansion valve, equalizer
Clean parts and a tight fit of the bulb in the well tube, suction and discharge lines using two wrenches
will insure good thermal contact. to prevent rotation and twisting of the line.
(1) Install the thermal bulb in its well, using brass (9) Connect the battery ground cable.
wedging strips to insure a tight mechanical fit. After the evaporator assembly is installed in the
(2) Lubricate all expansion valve and line fittings vehicle, it will be necessary to sweep the system, test
with clean refrigerant oil. Install the expansion valve, for leaks, and charge with the proper amount of
using two wrenches to prevent rotation and twisting refrigerant. An Over-All Performance Test should be
of lines. made after repair or replacement of the evaporator
(3) Connect the equalizer tube to evaporator suc- assembly.
tion line.
Removal-Blower
(4) Using two wrenches, retest all connections for
tightness. (1) Disconnect the battery ground cable.
After the expansion valve is installed, it must be (2) Disconnect the clutch and feed wires from the
completely tested. The system must then be tested switch.
for leaks and recharged. (3) Disconnect the drains.
(4) Remove the mounting bolts and swing the as-
Removal-€vaporator sembly out.
The evaporator assembly, expansion valve, blower (5) Remove the blower housing end plate and the
motor, switches, outlet grille are compactly packaged base plate from the evaporator.
as a single unit.
The system must be completely discharged before (6) Remove one wheel housing from the base
opening any refrigerant lines. plate and motor.
(1) Disconnect the battery ground cable. (7)Remove the motor from the second wheel hous-
ing.
(2) Disconnect the equalizer line, suction line, dis-
charge line. Cap lines to prevent the entrance of dirt lnstallation
and moisture. ( 1 ) Install the motor to the housing and the wheel
(3) Disconnect the clutch and feed wires. to the motor.
(4) Disconnect the drains, remove the mounting (2) Install the second housing to the motor and the
bolts and remove the assembly from the vehicle. base plate, second wheel to the motor, be sure both
(5) Remove the blower and base plate assembly. wheels are free and do not rub.
(6) Remove the grille, top plate, and expansion (3) Cement the rubber gasket to the base.
valve. (4) Install the blower assembly to the evaporator.
(7)Remove the sub frame and the evaporator from (5) Swing the assembly into position and bolt down
the case. (6) Connect the drains, clutch and feed wires to the
(8) Remove the evaporator from the sub frame. switch.
(7) Connect the battery ground cable.
lnstallation
(8) Test the operation of the blower motor.
(1) Install the evaporator to the sub frame.
(2) Install the evaporator and the sub frame to the 27. REFRIGERANT SERVICE
case. Use only refrigerant 12 in the 1964 air-conditioning
(3) Install the top plate with the hole in lower left system. Refrigerant 12 is available in bulk tanks or
corner. in sealed 15 ounce cans. The use of canned refrigerant
is preferred by most technicians because it provides a The Valiant Cool Aire unit requires 2% pounds of
very quick and simple means of adding refrigerant or refrigerant 12 for a complete charge.
charging the system completely. NOTE: An accurate scale must be used to insure
All 1964 Plymouth units require 2% to 2% pounds charging with the proper amount of refrigerant,
of refrigerant. Three 15 ounce cans of refrigerant 12
provide-a complete charge without the necessity of Since the use of canned refrigerant is preferred
weighing the refrigerant as it is dispensed. universally, only that method is described.
COMPLETE SYSTEM DISCHARGE AND RECHARGE

Before the system can be opened for replacement (7)Allow the system to discharge until the dis-
of lines or components, the system must be com- charge pressure gauge registers zero. Open the left-
pletely discharged. It is also necessary to discharge hand valve to release any vapor trapped at the suction
the system before performing the Compressor Capac- side of the system.
ity Test and the Expansion Valve Test. Whenever the
system has been opened, it must be swept with a 29. SWEEP-TEST CHARGE
partial charge, and the entire system tested for leaks. The purpose of the sweep-test charge is to pres-
The drier should be replaced and the system evacu- surize the system so that a leak test can be made.
ated using a vacuum pump to remove all air and The sweep-test charge also serves the purpose of
moisture. The system should then be charged with drying the system or sweeping out trapped mois-
the proper amount of refrigerant. Detailed instruction ture. Repairs and component replacement must be
for performing these operations follow. completed before charging with the sweep-test
charge.
28. DISCHARGE THE SYSTEM
(1) Close both gauge set manifold valves and open
(1) Be sure the valves of the gauge manifold set the gauge set manifold needle valve.
are closed before attaching the gauge set manifold
(suction test hose to the suction service port and (2) Attach the free end of the long hose used for
discharge test hose to the discharge service port). discharging to the refrigerant dispensing manifold.
Attach the long test hose to the center connection of (3) Attach a single can of refrigerant 12 to the
the gauge set manifold. Lead the other end of this dispensing manifold. Place the refrigerant in 125
hose into an exhaust ventilation system outlet or to degree water. For detailed instructions on attaching
the outside of the building. refrigerant can for charging, see “Charging the Sys-
(2) Open the gauge set manifold needle valve and tem”.
close both of the gauge set manifold gauge valves. (4) Operate engine at 1250 rpm, vehicle doors, the
(3) Operate the engine at 1250 rpm, windows open windows open and the hood up.
and the hood up. (5) On Plymouth push in “Cool” button, blower on
(4) On Plymouth push in “Cool” button, blower on number 2 position.
number 2 position. (A) On Valiant Cool Aire set the evaporator tem-
(A) On Valiant Cool Aire set the evaporator temperature control lever to the coolest position, push
perature control lever to the coolest position, push in in “Hi” blower button.
“Hi” blower button. (6) Slowly open the left-hand gauge set manifold
valve to meter the refrigerant into the system. When
(5) Allow the system to operate at full capacity for the full can of refrigerant has been metered into the
at least 15 minutes. This will cause most of the com- system, close the gauge set manifold valves and the
pressor oil in the system to return to the compressor refrigerant manifold valve.
crankcase.
If the system has been opened for repair or replace-
(6) Open the discharge right-hand gauge valve a
ment, a complete leak test must be made to make sure
small amount. This will allow the refrigerant vapor the system is sealed. Also, if the systeni has accident-
to discharge slowly. ally lost its charge it will be necessary to perform a
CAUTION: Do not allow the system to discharge leak test while the sweep-test charge is in the system.
rapidly since this would sweep some of the refrigerant Stop the engine and disconnect the test hoses and
oil out of the compressor. adapters from the compressor service ports.
30. TESTING THE SYSTEM FOR LEAKS valve until the flame is very small. A small flame will
detect large as well as small leaks, whereas, a large
The leak detector torch Tool C-3569 is a propane
flame will detect only large leaks. As soon as the re-
gas-burning torch used to locate a leak in any part of
action plate seen through the window in the burner
the refrigeration system. Refrigerant gas drawn into
shield becomes red hot, the tester is ready for use.
the sampling or “snifter” tube will cause the flame to
change color in proportion to the size of the leak. A (2) Examine all the tube connectors and other pos-
very small leak will produce a flame color varying sible leak points by moving the end of the sampling
from yellowish-green to bright green. A large leak hose from point to point. Since refrigerant 12 is
will produce a brilliant blue flame. heavier than air, it is good practice to place the open
end of the sampling hose directly below the point
CAUTION: Do not use the lighted detector in any being tested. Be careful not to pinch the sampling
place where explosive gases, dust, or vapor are tube since this will shut off the air supply to the flame
present. Do not breathe the fumes that are produced and cause a color change.
by the burning of refrigerant gas. Large concentra-
tions of refrigerant in the presence of a live flame
(3) Watch for a change in the color of the flame.
become dangerously toxic. Observe the flame through
Small leaks will produce a green color and large leaks
the window of the burner shield, not through the top
a bright blue color. If leaks are observed at the tube
of the shield.
fittings, tighten the connection, using the proper flare
wrenches, and retest.
(1) Open the torch valve until you hear a faint hiss If the flame remains bright yellow when the tester
of escaping gas. Light the test torch and adjust the is removed from a possible leak point, insufficient air
6Ox1002A
Fig. 58-Evacuating the System

is being drawn in through the sampling tube, or the 32. REPLACE THE RECEIVER-DRIER-STRAINER
reaction plate is dirty.
CAUTION: Replacement receiverdrier-strainer
units must be sealed while in storage. The drier used
3 1. REMOVE SWEEP-TEST CHARGE in these units is so hungry for moisture that they can
saturate quickly upon exposure to the atmosphere.
If the system is free of leaks, or after correcting a
When installing a drier, have all tools and supplies
leak, if no air-conditioning components have been
ready for quick reassembly to avoid keeping the
removed, add the necessary refrigerant as described
system open any longer than necessary.
under “Correcting the Low Refrigerant Level”. If any
parts of the refrigerant system were disconnected re-
move the sweep-test charge. Close the refrigerant 33. EVACUATE THE SYSTEM
manifold valve so that any refrigerant remaining in Whenever the system has been opened to atmos-
the container is sealed. Remove the long test hose phere, it is absolutely essential that the system be
from the refrigerant manifold. Insert the free end swept with refrigerant and evacuated or “vacuumed”
of this test hose into an exhaust system outlet. Open to remove all the air and the moisture. If any ap-
the right-hand gauge set manifold valve a fraction of preciable amount of air remains in the system when
a turn to let the sweep-test charge escape slowly. it is charged, the trapped air will concentrate near
Allow the system to discharge until the discharge the top of the condenser and cause abnormally high
pressure gauge registers zero. Open the left-hand discharge pressures. Air in the system will reduce the
gauge valve to allow any refrigerant trapped in the condenser’s ability to condense the refrigerant gas
suction side of the system to escape. and supply adequate liquid refrigerant to the evapo-
Fig. 59-Complete System Charging

rator. To evacuate the system, proceed as follows: refrigerant-can-to-refrigerant-manifold gaskets on
(1) Connect the gauge set manifold to the compres- hand so that gaskets can be replaced periodically.
sor and the long test hose from the gauge set mani- This will insure a good seal without excessive tight=
fold center connection to the vacuum pump Tool C- ening of the can or the manifold nuts.
3652,as shown in Figure 58. (1)Attach the center hose from the gauge set mani-
(2) Open both gauge set manifold valves and the fold to the refrigerant dispensing manifold. Turn the
needle valve. refrigerant manifold valves completely counterclock-
wise so that they are fully open. Remove the protec-
(3) Start the vacuum pump and operate until the
tive caps from the refrigerant manifold.
evaporator suction gauge registers at least 26 inches
of vacuum. If the system is tight and the pump in (2)Screw the refrigerant cans into the manifold.
good condition, the vacuum will go as low as 28 Be sure the manifold-to-can gasket is in place and
inches. in good condition. Tighten the can and the manifold
nuts to 6 to 8 foot-pounds.
(4) Allow the vacuum pump to operate with suc-
tion gauge registering 26 to 28 inches of vacuum for (3) Turn the three refrigerant manifold valves com-
a minimum of five minutes. pletely clockwise to puncture the cans and close the
manifold valves.
(5) Close both gauge set manifold valves, turn off
the vacuum pump and remove the test hose from the (4) Turn the refrigerant manifold valves counter-
vacuum pump. Leave the gauge set manifold con- clockwise to open them.
nected to the compressor. Charge the system with the (5) Momentarily loosen the charging hose at the
proper amount of refrigerant 12. gauge set manifold to allow the refrigerant gas to
NOTE: Failure to pull at least 26 inches of vacuum purge air out of the charging hose.
indicates a leak in the refrigeration system or a de- (6)Place the three cans of refrigerant into a pan
fective vacuum pump. Locate and correct the trouble containing hot water at a temperature of 125 de-
before recharging the system. grees F.
(7) Start the engine and adjust the speed to 1250
34. CHARGING THE SYSTEM (Fig. 5 9 )
rpm.
All Plymouth models only require three cans or
45 ounces of refrigerant 12. The Valiant Cool Aire (8) Charge the system through the suction side of
units require 2% pounds of refrigerant 12. the system by slowly opening the left-hand gauge set
manifold valve. Adjust the valve as necessary so the
NOTE: An accurate scale must be used to insure charging pressure does not exceed 50 psi. Maintain
charging with the proper amount of refrigerant. The the temperature of the water in the pan by adding
special refrigerant dispensing manifold permits warm water as necessary.
charging three full cans of refrigerant at one time.
When all three cans of refrigerant are completely
NOTE: Keep the refrigerant manifold valves empty, close the gauge set manifold valves and the
capped when not in use. Keep a supply of extra refrigerant manifold valves.
SERVICE DIAGNOSIS
NOTE: N o attempt should be made to use t h e diagnosis information as a method of trouble shooting
or spot testing. When properly used (as a n aid t o complete test procedure), the diagnosis will be of
considerable value t o the service man.
Blower N o t Operating (a) Blown fuse, boken wire, faulty (a) Test the electrical circuit with point to
switch motor, loose or dity point voltmeter test repair or replacing
connections. the faulty parts.
SERVICE D I A G N O S I L (Continued1
-
Blower and Compressor (a) Low refrigerant, moisture, (a) Add refrigerant, test for leaks and repair,
Operating-No Cooling frozen, stuck or faulty replace the strainer-drier, clean or
expansion valve, stuck or replace expansion valve, replace E.P.R.
faulty E.P.R. valve. valve.
(b) Low compressor capacity. (b) Repair or replace the compressor.
(c) Kinks in lines. (c) Repair or replace the lines.
(d) Faulty water valve or out of (d) Adjust cable and/or replace the valve.
adjustment.
Blower Operating (a) Moisture, low refrigerant, low (a) Replace strainer-drier, add refrigerant
Partial Cooling compressor capacity. test for leaks and correct, repair or
replace the compressor.
(b) Slipping clutch. (b) Repair or replace.
(c) Water valve out of adjustment (c) Adjust the cable or replace.
or faulty.
(d) Obstruction of condenser. (d) Clean the condenser, repair, replace and
no Bug Screens.
Low Suction and (a) Low refrigerant, moisture in (a) Add refrigerant, test for leaks and
Low Discharge Pressure system, expansion valve frozen correct, replace strainer-drier, clean or
or stuck, thermal bulb lost replace expansion valve, repiar or replace
charge, restriction in liquid liquid line, repair or replace compressor,
bad compressor valves, too remove the excess oil.
much oil.
High Discharge (a) Too much refrigerant. (a) Purge the system for 10 seconds.
Pressure (b) Air in system. (b) Purge the system for 10 seconds.
(c) Dirty condenser. (c) Clean the condenser, no bug screens.
(d) High ambient temperature. (d) NOTE: Discharge and Suction pressures
will vary with the ambient temperature
and the heat load applied to the evapora-
tor. Normal Suction pressure will vary
between 25 to 40 psi. Normal Discharge
pressure a t 1200 engine rpm as indicated
below:
Ambient Discharge
Tern perat ure Pressure
60°F 100-150 psi
80°F 140-190 psi
100°F 190-240 psi
110°F 230-280 psi
High Suction Pressure (a) Moisture in system. (a) Change the strainer-drier-recharge.
(b) Expansion valve frozen or stuck (b) Change the strainer-drier-recharge,
open. clean or replace expansion valve.
(c) Expansion valve equalizer tube (c) Clean or replace the expansion valve.
plugged.
(d) Bad compressor valves. (d) Replace the valve plates.
(e) Not enough oil. (e) Add oil.
PLYMOUTH-VALIANT
GROUP O - L U B R I C A T I O N A N D GROUP 1-ACCESSORIES (RADIOS. HEATER.
MAINTENANCE MIRRORS.. (Continued)
Page Page
Air Cleaners .................................. 7 Clock ....................................... 2

Alternator .................................... 10 Fader Control ................................. 9
Battery ...................................... 10 Fresh Air Ducts ................................ 7
Body Maintenance ............................. 10 Heater Assembly .............................. 5
Brakes ...................................... 11 Heater Blower ................................ 3
Capacities ................................... 4 Heater Control Cables (Adjustment). . . . . . . . . . . . . . . . . 7
Carburetor Choke Linkage and Shaft . . . . . . . . . . . . . . . . 8 Heater Core .................................. 4
Certified .Car Care-Brake System Maintenance Heater Core Replacement ........................ 7
Every 20, 000 Miles ........................... 22 Heater Motor or Fan Replacement .................. 7
Certified Car Care-Engine Performance Evaluation Heater Vacuum Actuator ......................... 3
Every 10, 000 Miles .......................... 22 Interference Elimination ......................... 9
Certified Car Care-Front Suspension Alignment ....... 23 Nozzle Adjustment ............................. 16
Certified Car Care-Semi-Annual 'Maintenance ........ 22 On-Off 'Switch and Volume Control . . . . . . . . . . . . . . . . . 9
Chassis Lubrication ............................. 11 Push Button Adjustment ......................... 9
Clutch and Gearshift Linkages..................... 13 Radio Removal and Installation .................... 8
Cooling System ............................... 13 Radio Speaker Reverberator ..................... 11
Crankcase Ventilator Valve ...................... 8 Radio Wiring Diagrams ......................... 16
Distributor ................................... 14 Rear Window Defroster ......................... 5
Engine Oil ................................... 6 Service Diagnosis .............................. 17
Engine Oil Filter ............................... 9 Speaker Removal and Installation . . . . . . . . . . . . . . . . . . 9
Frequency of Oil Change ......................... 6
Front Wheel Bearings .......................... 14 GROUP 2-FRONT SUSPENSION
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front Suspension Height Adjustment ................ 4
Headlamps ................................... 16 Front Suspension "'K" 'Member .................... 12
Hoisting ..................................... 16 Front Wheel Alignment ......................... 5
Hoodtatch ................................... 19 Lower Ball Joints .............................. 9
lubrication and Maintenance Service . . . . . . . . . . . . . . . . 5 Lower Control Arm and Shaft . . . . . . . . . . . . . . . . . . . . . 6
Manifold Heat Control Valve ...................... 10 Lower Control Arm Strut ......................... 9
Parts Requiring No 'Lubrication .................... 16 Preparation for Inspecting the Front
Passenger Car Maintenance Schedule for Certified Wheel Alignment ............................ 4
Car Care .................................. 20 Service Diagnosis .............................. 13
.Passenger Car Trailer-Towing Service Recommendations 2 1 .. Specifications ................................. 1
Propeller Shafts and Universal Joints . . . . . . . . . . . . . . . .16 Sway Bar .................................... 12
Rear Axle and Sure.Grip ......................... 17 Tool'List ..................................... 2
Recommended Services at Mileage Intervals . . . . . . . . . .21 Torque Reference .............................. 3
Selection of 'Lubricant ........................... 6 Torsion Bars .................................. 5
Speedometer Cable ............................ 19 Upper Ball Joints .............................. 11
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Upper Control Arm ............................. 9
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 GROUP 3-REAR AXLE
Windshield Wipers ............................. 19
Axle Ratios .................................. 3
Axle Shaft ................................... 5
GROUP 1-ACCESSORIES ( RADIOS. HEATER 1 ....................
Carrier Assembly-Installation 15
AM.. FM Radio ................................. 11 Differential-Assembly .......................... 10
Antenna Trimmer .............................. 10 Differential Bearing 'Preload-
Antenna Replacement .............................. 10 Pinion with Bearing Spacer ..................... 11
INDEX- (Continued1
GROUP 3-REAR AXLE-(Continued) GROUP 6-CLUTCH-(Continued)
Page Page
Differential-Removal .......................... 7 Release Bearing. 'Removal and Installation . . . . . . . . . . . .11

Gear Tooth Contact Pattern ...................... 15 Service Diagnosis .............................. 14
Pinion Bearing Cup ............................. 10 Special Tools ................................. 1
Rear Axle Assembly-Removal .................... 5 Specifications ................................. 1
Service Diagnosis .............................. 30 Steam Cleaning Precautions ...................... 13
Special Tools ................................. 3 Torque Reference .............................. 1
Specifications-Plymouth ........................ 1 Torque Shaft Pivot Bushing ....................... 12
Specifications-Valiant ......................... 2
Torque Reference .............................. 4
Welding Rear Axle Housing ....................... 15
Belt Deflection .Method .......................... 11
Engine Water Temperature Gauge .................. 10
GROUP 5-BRAKES Fan ........................................ 4
Bleeding the b a k e System ....................... 8 Fluid Drive Fan ................................ 4
Booster Brake-(Bendix) (Valiant) . . . . . . . . . . . . . . . . 20 Pressure Flushing the Cooling System . . . . . . . . . . . . . . . . 8
Booster Brake-Removal (Bendix) .................. 14 Pressure Testing the Cooling System ................ 10
Booster BrakMRemoval (Midland Ross) ............. 17 Proper Belt Tension ............................. 11
Brake Drum-Removal .......................... 4 Radiator ..................................... 7
Brake Shoe-Installation ........................ 6 Radiator Hoses ................................ 9
. Brake Shoe-Removal .......................... 5 Radiator Pressure Cap .......................... 9
Brake Support Plate ............................ 10 'Service Diagnosis .............................. 12
Cleaning .................................... 21 Specifications ................................. 1
Front Parking Brake Cable ........................ 12 Thermostat ................................... 9
Grinding Recommendations ...................... 6 Tool List ..................................... 3
Inspecting the Brake Shoes ....................... 6 Torque 'Method ................................ 12
Inspection ................................... 21 Torque Reference .............................. 3
Installing the Booster Brake in the Vehicle . . . . . . . . . . . .23 Transmission Oil Cooler ......................... 8
Master Cylinder ............................... 8 Water Pump .................................. 4
Parking Brake Adjustment ........................ 11
Rear Parking Brake Cable ........................ 12
Removing the Booster Brake from the Vehicle . . . . . . . . . 20
Service Brake Adjustment . . . . . . : . . . . . . . . . . . . . . . . . 3
Adjusting Horns .............................. 91
Adjusting Starter Drive Gear Clearance . . . . . . . . . . . . . 21
Service Diagnosis .............................. 23
Adjusting the Headlamps ....................... 71
Servicing the Booster Brake ....................... 20
Aimer Calibration ............................. 69
Special Tools ................................. 2
Aiming the Headlamps ......................... 69
Specifications ................................. 1
Test for Fluid Contamination ...................... 8
Alternator Removal ............................ 39
Assembling Wiper 'Motor ....................... 89
Testing Automatic Adjuster Operation . . . . . . . . . . . . . . . 4
Battery Visual Inspection ....................... 11
Torque Reference .............................. 2
Wheel Cylinder ............................... 9
Bench Tests-Alternator ........................ 39
Wheel Stud Tightening .......................... 11
Body Wiring (Except Station Wagon)-Plymouth ......108
Body Wiring (Except Station Wagon)-Valiant . . . . . . .104
Body Wiring (Station Wagon)-Plymouth . . . . . . . . . . . . 109
GROUP 6 d l U T C H Body Wiring (Station Wagon)-Valiant ............. 104
Clutch Cover (Auburn) ........................... 9 Brushes and Springs Replacement ................. 18
Clutch Cover (Borg and Beck) ...................... 5 Charging the Battery .......................... 13
Clutch 'Fork. Removal and Installation . . . . . . . . . . . . . . . .11 Circuit Breakers .............................. 79
Clutch Housing Alignment ........................ 12 Cluster Components ........................... 78
Clutch 'Pedal Free 'Movement...................... 12 Compensating and Mounting the Aimers ............ 70
Clutch. Removal and Installation ................... 3 Construction and Operation-
Clutch Shaft Pilot .Bushing ........................ 10 Alternator and Regulator ..................... 35
INDEX 3
INDEX- (Continued 1
GROUP 8-ELECTRICAL-(Continued) GROUP 8-ELECTRICAL-(Continued)
Page Page
Directional Indicator Switch-Plym, outh . . . . . . . . . . . . 80 Replacing the Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . 44
Directional Indicator Switch-Valiant . . . . . . . . . . . . . . 82 Replacing Wiper Pivot . . . . . . . . . . . . . . . . . . . . . . . . . 90
Disassembly of Wiper Links ...................... 87 Seat Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Distributor Disassembly ......................... 52 Secondary Circuit Inspection-8 Cylinder . . . . . . . . . . . 58
Distributor Lubrication ......................... 56 Service Diagnosis-Alternator . . . . . . . . . . . . . . . . . . . 48
Distributor Point Dwell-6 Cylinder . . . . . . . . . . . . . . . . 51 Service Diagnosis-Battery ..................... 14
Distributor Point Dwell-8 Cylinder . . . . . . . . . . . . . . . . 59 Service Diagnosis-Directional Indicators . . . . . . . . . . 82
Distributor Removal-6 Cylinder . . . . . . . . . . . . . . . . . 52 Service Diagnosis-Electric Window Lifts . . . . . . . . . . . . 94
Distributor Removal-8 Cylinder . . . . . . . . . . . . . . . . . 60 Service Diagnosis-Headlamps . . . . . . . . . . . . . . . . . . 72
Distributor Resistance Test-6 Cylinder . . . . . . . . . . . . . 50 Srevice Diagnosis-Horns ...................... 92
Distributor Resistance Test-8 Cylinder . . . . . . . . . . . . . 98 Service Diagnosis-Ignition System . . . . . . . . . . . . . . . 68
Drive Unit and Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 98 Service Diagnosis-Instruments . . . . . . . . . . . . . . . . . . 79
Dual Breaker Points . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Service Diagnosis-Power Seats . . . . . . . . . . . . . . . . . . 99
Dwell Variation-6 Cylinder .................... 51 Service Diagnosis-Starting Motor . . . . . . . . . . . . . . . . 32
Dwell Variation-8 Cylinder . . . . . . . . . . . . . . . . . . . . 60 Service Diagnosis-Windshield Wipers . . . . . . . . . . . . 90
Electric Window Lift Wiring-Plymouth . . . . . . . . . . . . . 1 10 Servicing the Bushings . . . . . . . . . . . . . . . . . . . . . . . . . 20
End Play Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Servicing the Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Compartment Wiring-Plymouth . . . . . . . . . . . . 106 Servicing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine Compartment Wiring-Valiant . . . . . . . . . . . . . 102 Servicing the Starter Clutch Unit . . . . . . . . . . . . . . . . . . 29
Flexible Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Shaft and Bushing Wear Test . . . . . . . . . . . . . . . . . . . . . 52
Front Seat Assembly and Adjuster . . . . . . . . . . . . . . . . . 96 Slave Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fuel Level Indicating System . . . . . . . . . . . . . . . . . . . . . 74 Spark Plugs-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 58
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Spark Plugs-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 67
Headlamp Sealed-Beam Replacement . . . . . . . . . . . . . . 71 Specific Gravity Test . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Rate Discharge Test of Battery Capacity . . . . . . . . 12 Specifications-Alternator ...................... 5
Idle R.P.M. Test-6 Cylinder . . . . . . . . . . . . . . . . . . . . . 51 Specifications-Battery ........................ 4
Idle R.P.M. Test-8 Cylinder . . . . . . . . . . . . . . . . . . . . . 59 Specifications-'Starting Motor . . . . . . . . . . . . . . . . . . . 4
Ignition Coil-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 58 Specifications-6 Cylinder Ignition . . . . . . . . . . . . . . . . . . . 6
Ignition Coil-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 67 Specifications-8 Cylinder Ignition ................... 7
Ignition Timing-6 Cylinder . . . . . . . . . . . . . . . . . . . . . 51 Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ignition Timing-8 Cylinder . . . . . . . . . . . . . . . . . . . . . 60 Starter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspecting Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . 88 Starter Ground Circuit Test . . . . . . . . . . . . . . . . . . . . . . 23
Installing the Distributor-6 Cylinder . . . . . . . . . . . . . 57 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Instrument Cluster Bulb Replacement. . . . . . . . . . . . . . . 7 7 Starting Motor Cirucit Tests . . . . . . . . . . . . . . . . . . . . . . 16
Instrument Cluster-Plymouth .................... 77 Starting Motor Removal-Direct Drive . . . . . . . . . . . . . . 16
Instrument Cluster-Valiant ..................... 78 Starting Motor Removal-Reduction Gear . . . . . . . . . . . 23
Instrument Panel Wiring-Plymouth . . . . . . . . . . . . . . .106 Tail Gate Window-Lift Wiring . . . . . . . . . . . . . . . . . . . 109
Instrument Panel Wiring-Valiant . . . . . . . . . . . . . . . .103 Test Breaker Arm Spring Tension . . . . . . . . . . . . . . . . . . 56
Measuring Headlamp Aim . . . . . . . . . . . . . . . . . . . . . . 70 Testing Distributor Advance . . . . . . . . . . . . . . . . . . . . . 56
Motor (Except 2 Door Hardtop Quarter Window) . . . . . 93 Testing Field Coils for Ground . . . . . . . . . . . . . . . . . . . . 17
Mounting and Adjusting the Aimers . . . . . . . . . . . . . . . . 70 Testing Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Oil Pressure Warning Lamp . . . . . . . . . . . . . . . . . . . . . . 77 Testing Starter Resistance and Current Draw . . . . . . . . . 21
Operation-Power Seats . . . . . . . . . . . . . . . . . . . . . . . 95 Testing the Alternator System . . . . . . . . . . . . . . . . . . . . 35
Parking Spring Lubrication-Variable Speed . . . . . . . . . 86 Testing the Armature (Direct Drive) . . . . . . . . . . . . . . . . 19
Power Seat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Testing the Armature (Reduction Gear) . . . . . . . . . . . . . 27
Printed Circuit Board Testing . . . . . . . . . . . . . . . . . . . . . 78 Testing the Rectifiers with Tool C-3829 . . . . . . . . . . . . . 42
Quarter Glass Regulator (2 Door Hardtop) . . . . . . . . . . . 94 Testing the Rectifiers without Tool C-3829 . . . . . . . . . . . 43
Replacement of Brushes and Springs . . . . . . . . . . . . . . . 27 Testing the 'Secondary Circuit-6 Cylinder . . . . . . . . . . 50
Replacing the Field Coils (Direct Drive) . . . . . . . . . . . . . 20 Testing the Starting Motor-Bench Test-
Replacing the Field Coils (Reduction Gear) . . . . . . . . . . 27 (Reduction Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
I INDEX
INDEX-( Continued 1
GROUP 8-ELECTRICAL-(Continued) GROUP 9-ENGINE-(Continued)
Page Page
Testing the Starting Motor (Direct Drive) . . . . . . . . . . . 17 Oil Pump-8 Cylinder .......................... 65
Top L i f t Switch Wiring .......................... 109 Piston and Connecting Rod Assembly-8 Cylinder . . . . .61
Visual Headlamp Adjustment-Single Beam . . . . . . . . . 72 Piston and Rings-8 Cylinder ..................... 57
Voltage Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Pistons-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Voltage Regulator ............................ 35 Piston Pins-6 Cylinder ......................... 22
Voltage Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PJston Pins-8 Cylinder ......................... 58
Window Lift (Except 2 Door Hardtop Rear Engine Mount-8 Cylinder . . . . . . . . . . . . . . . . . . . 41
Quarter Window) . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Rear Main Bearing Oil Seal-6 Cylinder . . . . . . . . . . . . 25
Wiper Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 86 Rear Main Bearing Oil Seals-8 Cylinder . . . . . . . . . . . . 62
Wiper Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Refacing Valves and Valve Seats . . . . . . . . . . . . . . . . . . 15
Wiper Motor Bench Testing . . . . . . . . . . . . . . . . . . . . . . 88 Rocker Arm and Shaft Assembly-6 Cylinder . . . . . . . . . 13
Wiper Motor Disassembly ...................... 87 Rocker Arms and Shaft-8 Cylinder . . . . . . . . . . . . . . . . 44
Wiper Motor Park Switch Timing . . . . . . . . . . . . . . . . . . 86 Service Diagnosis-Engine ....................... 69
Wiper Motor-Plymouth ....................... 87 Service Diagnosis-Engine Oiling . . . . . . . . . . . . . . . . . . 71
Wiper Motor-Valiant ........................ 87 Special Tools-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . 6
Wiper Parking Operation Test-Variable Speed . . . . . . 86 Special Tools-8 Cylinder (All Except
Wiper Switch (Instrument Panel Mounted) . . . . . . . . . . . 88 318 Cu. In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wiring Diagrams-Directional Indicators . . . . . . . . . . . 82 Special Tools-3 1 8 Cu. In........................ 36
Wiring Test-Electrical Window 'Lifts. . . . . . . . . . . . . . . 93 Specifications-6 Cylinder ....................... 2
Specifications-8 Cylinder ....................... 30
GROUP 9-ENGINE Testing Valve Springs-6 Cylinder . . . . . . . . . . . . . . . . . .15
Testing Valve Timing-6 Cylinder . . . . . . . . . . . . . . . . . . 16
Camshaft-6 Cylinder .......................... 19 Testing Valve Timing-8 Cylinder . . . . . . . . . . . . . . . . . . 50
Camshaft-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Timing Chain Case Cover Oil Seal-6 Cylinder ........ 17
Camshaft Bearings-6 Cylinder . . . . . . . . . . . . . . . . . . . 19 Timing Chain Case Cover Oil Seal-8 Cylinder ........ 52
Camshaft Bearings-8 Cylinder . . . . . . . . . . . . . . . . . . . 54 Timing Sprockets and Chain-6 Cylinder . . . . . . . . . . . . .16
Connecting Rods-6 Cylinder ..................... 23 Timing Sprockets and Chain-8 Cylinder . . . . . . . . . . . . .50
Connecting Rod Bearing Clearance-6 Cylinder . . . . . . . 23 Torque Reference-6 Cylinder .................... 7
Connecting Rod Bearing Clearance-8 Cylinder ....... 60 Torque Reference-8 Cylinder (All Except
Crankshaft Main Bearings-6 Cylinder . . . . . . . . . . . . . . 24 .
318 Cu In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Crankshaft Main Bearings-8 Cylinder . . . . . . . . . . . . . . 61 Toraue Reference-3 1 8 Cu. In..................... 38
Crankshaft Main Journals-6 Cylinder . . . . . . . . . . . . . .24 Tune-Up-6 Cylinder ........................... 9
Crankshaft Main Journals-8 Cylinder . . . . . . . . . . . . . . 61 Tune-U~-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Crankcase Ventilator Valve-8 Cylinder . . . . . . . . . . . . . 68 Valve and Valve Springs-6 Cylinder . . . . . . . . . . . . . . . 13
Cylinder Block-6 Cylinder ...................... 20 Valve and Valve Springs-8 Cylinder . . . . . . . . . . . . . . . 45
Cylinder Block-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . 56
Cylinder H e a d 4 Cylinder ...................... 11
Cylinder Head Assembly-8 Cylinder . . . . . . . . . . . . . . .43 GROUP 1 1-EXHAUST SYSTEM
Distributor Drive Shaft Bushings-8 Cylinder . . . . . . . . . . 55 Exhaust Manifold (8-Cylinder) ...................... 3
Engine Assembly-8 Cylinder .. . . . . . . . . . . . . . . . . . . 42 Exhaust Pipes. Mufflers and Tail Pipes . . . . . . . . . . . . . . . . 5
Engine Replacement-6 Cylinder . . . . . . . . . . . . . . . . . . 10 Intake and Exhaust Manifold Assembly
Front Engine Mounts-8 Cylinder . . . . . . . . . . . . . . . . . . 41 (6-Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Heli-Coil Insert-Worn Threads-6 Cylinder . . . . . . . . . .29 Intake 'Manifold (8-Cylinder) ....................... 3
Heli-Coil Insert-Worn Threads-8 Cylinder . . . . . . . . . .68 Manifold Heat Control Valve (6.Cylinder) . . . . . . . . . . . . . 2
Hydraulic Tappets-8 Cylinder . . . . . . . . . . . . . . . . . . . . 48 Manifold Heat Control Valve (8-Cylinder)
Main Bearing Clearance-6 Cylinder . . . . . . . . . . . . . . . 24 . .
318 Cu In Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Filter-6 Cylinder .............................. 29 Manifold 'Heat Control Valve (8-Cylinder)
Oil Pan-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . .
361 Cu In Engine ............................. 4
Oil Pan-8 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Service Diagnosis ............................... 7
Oil Pump-6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Torque Reference ............................... 1
INDEX-(Continued 1
GROUP 14-FUEL SYSTEM (PUMP. G R O U P 17-SPRINGS AND
CARBURETOR. T A N K ) SHOCK ABSORBERS
Page Page
Automatic Choke-AFB ......................... 5 7 Front Shock Absorbers ........................... 6
Automatic C h o k d B D ........................ e37 Leaf Spring Interliner Replacement.................. 5
Automatic Choke-BIBS ......................... 27 Measuring Rear Spring Height ...................... 4
Automatic C h o k e - 4 olley ....................... 16 Rear Shock Absorber Replacement .............. . . . .7
Automatic C h o k ~ W ........................
3 69
Rear Springs .................................. 4
Carburetor Ad just ments-AFB .................... 54 Rear Spring Front Pivot Bushing Replacement . . . . . . . . . . .4
Carburetor Adjustments-BBD .................... 34 Service Diagnosis ............................... 7
Carburetor Adjustments-BBS ........................ 24
Carburetor Adjustments-Holley . . . . . . . . . . . . . . . . . .14 Specifications .................................. 1
Carburetor Adiustments-WW3 . . . . . . . . . . . . . . . . . . .66 Testing the Shock Absorber ........................ 7
Carburetor Disassembiy-AFB .................... 48 TOO1 'List ...................................... 1
Carburetor Disassembly-BBD .................... 36 Torque Reference ............................... 2
Carburetor Disassemlbly-BBS ..................... 20 Zinc Interleaf Replacement ........................ 6
Carburetor 'Disassembly-Holley .................. 10
Carburetor Disassembly-W3 ...................60
Closed Crankcase Vent System-AFB ................5 7
Closed Crankcase Vent System-BBD ............... 3 7
GROUP 19-STEERING (MANUAL, POWER,
Closed Crankcase Vent System-BBS ................27
PUMPS A N D LINKAGE)
Closed Crankcase Vent S y s t e m 4 o l l e y .............. 1 7 ...................................
Adjustments 4
Closed Crankcase Vent System-W3 .............. 69
Fuel Tank-Removal-1 06" W/B .................79
Ball Nut Rack and Sector Meash Adjustment (In Vehicle) .. 5
Ball Nut Rack and Sector Meash Adjustment
Fuel Tank-Removal-1 06" W/B Sta. Wag ...........8 1
(Out of Vehicle) ............................. 10
Fuel Tank-Removal-1 16" W/B ................. 80
Fuel Tank-Removal-1 16" W/B Sta. Wag .......... 8 1 Cross Shaft Oil Seal Replacement . . . . . . . . . . . . . . . . . . .9
Service DiagnosisAarburetor .................... 83 Flow Control Valve Replacement . . . . . . . . . . . . . . . . . . .42
Service DiagnosisLFuel pump ................... - 8 4 Gear Shaft Adjustment-Unit in Vehicle ......... . . . . 22
Specifications-AFB ............................ 6 Gear Shaft Oil Seal Replacement.............. . . . .22
Specifications-BBD ............................ 5 lnstallaing the Power Steering Pump . . . . . . . . . . . . . . . .4 6
Specifications-BBS ............................ 3 Measuring Fluid ILevel ........................... 38
Specifications-Fuel Pump ....................... 2 Operation ................................... 38
Specifications-Holley .......................... 1 power Steering pump Discharge Fitting
Slpecifications-W3 .......................... 6 Ferrule Replacement ......................... 42
Testing the Fuel Pump ........................... 75
Power Steering Gear-Removal . . . . . . . . . . . . . . . . . . .24
.
Throttle Linkage-1 70-225 Cu In. . . . . . . . . . . . . . . . . . .71
Power Steering Pump-- Removal . . . . . . . . . . . . . . . . . . .40
Throttle 'Linkage-225 Cu In . ...................... 72
Pressure Test ................................. 38
.
Throttle L i n k a g e 3 1 8 Cu In...................... 73
Pump Flow Test ............................... 39
.
Throttle Linkage-361. 383 Cu In.................. 7 4
Service Diagnosis-Manual Steering Gear ............ 13
Service Diagnosis-Power Steering Gear . . . . . . . . . . . .34
GROUP 16-PROPELLER SHAFT A N D Service Diagnosis-Power Steering Pump ............ 46
UNIVERSAL JOINTS Slipper Spring Replacement ...................... 43
Specifications ................................. 2
Ball and Trunnion Universal Joint .................... 4
Steering Colunm Gearshift-Removal ........... . . . .13
Cross and Roller Universal Joint ..................... 5
Steering Gear-Removal ........................ 5
Propeller Shaft ................................. 4
Propeller 'Shaft Angularity ........................ 3 Steering Knuckles .............................. 20
Service Diagnosis ............................... 6 Steering 'Linkage .............................. 20
Special Tool Usage Chart ......................... 1 Testing Worm Bearing PreLLoad ..................... 4
Specifications .................................. 1 Worm Bearing Pre-Load Adjustment . . . . . . . . . . . . . . . . .5
Torque Reference ............................... 1 Worm Shaft Oil Seal Replacement.................. 23
6 INDEX
INDEX-(Continued)
G R O U P 21-TRANSMISSION (TORQUE GROUP 21-TRANSMISSION (TORQUE
CONVERTER 1 CONVERTER 1-Continued
3-Speed Manual Transmission Page Page
Gearshift Interlock Adjustment .................... 11 Lubrication ................................... 41

Gearshift Linkage ............................. 10 ................41
Maintenance. Adjustments and Tests
Rear Oil Seal ................................ 10 Neutral Starting Switch......................... 47
Service Diagnosis ............................. 24 Neutral Starting Switch......................... 62
Specifications .................................. 2 Operating Instructions .......................... 41
Speedometer Pinion Usage Chart .................. 11 Output Shaft Oil Seal ........................... 57
Torque Reference ............................. 2 Overrunning Clutch ............................ 89
Transmission Removal .......................... 3 Parking 'Lock Cable (Transmission End) .............. 46
Parking Lock Components ....................... 61
4 Forward Speed Manual Transmission Parking Sprag and Lever ........................ 74
Rear Oil Seal ................................ 23 Planetary Gear Assemblies. Sun Gear and Driving
Shift 'Linkage-Adiustment....................... 14 'Shell (Eight Cylinder Vehicles)...................88
Special Tools ................................. 12 Planetary Gear Assemblies. Sun Gear and Driving
Specifications ................................. 12 Shell (Six Cylinder Vehicles) .................... 87
Transmission-Assem bly ......................... 21 Push Button and Console Shift 'Lamp Replacement ..... -45
Transmission-Disassembly ....................... 17 Push Button Control Unit ......................... 43
Transmission-Installation in the Vehicle............. 23 Rear Clutch (Eight Cylinder Vehicles) ............... 81
Transmission-Removal ......................... 15 Rear Clutch (Six Cylinder Vehicles) .................79
Rear Oil Pump ................................ 60
TorqueFlite Transmission (Torque Converter) Rear Oil Pump ................................ 75
Accumulator Piston and Spring .................... 73 Recondition Sub-Assemblies ...................... 69
.............................. 56
Air 'Pressure Tests Recondition Transmission Unit Out of Vehicle ......... 66
Aluminum Thread Repair ........................ 66 Special Tools ................................. 26
Back-up Lamp Switch Replacement ................. 45 Specifications ................................. 25
Band Adjustments ............................. 48 Speedometer Pinion ........................... 57
Console Gearshift Unit ......................... 44 Starter Ring Gear 'Replacement .................... 95
Extension Housing ............................. 58 Throttle Linkage Adjustment ...................... 53
Extension Housing Bearing and Oil Seal Torque Reference .............................. 27
(Eight Cylinder Vehicles) ...................... 74 Transmission and Converter Removal and Installation ... 63
Extension Housing Bushing and Oil Seal Valve Body Assembly .......................... 70
(Six Cylinder Vehicles) ........................ 74 Valve Body Assembly and Accumulator 'Piston ........ 62
Flushing the Torque Converter .................... 64
Front Clutch (Eight Cylinder Vehicles). . . . . . . . . . . . . . .81 GROUP 22.WHEELS. BEARINGS
Front Clutch (Six Cylinder Vehicles) ................79 A N D TIRES
Front Oil Pump and Reaction Shaft Support
(Eight Cylinder Vehicles) ...................... 78
Care of Tires ..................................... 2
Front Oil Pump and Reaction Shaft Support

Front Wheel Bearings ............................... 4
ISix Cylinder Vehicles) ........................ 75

Measuring Wheel and Tire Runout ...................... 2
Front Pump Oil Seal............................ 66 Repairing Leaks ................................... 3
Gearshift Control Cable (Transmission End). . . . . . . . . . .45 Service Diagnosis .................................. 6
. . . . . . . . . . . . . . .31
Specifications ..................................... 1
Gearshift and Parking Lock Controls
.................................... 60
Tire Rotation ...................................... 2
Governor Tire Wear Patterns................................. 5
Governor and ;Support .......................... 74 Tool List......................................... 1
Hydraulic Control Pressure Adjustments ............. 54 Wheel Balance .................................... 3
Hydraulic Control Pressure Tests ...................53
Hydraulic Control System ........................ 3 1
lnstallation of Sub-Assemblies .................... 92 GROUP 23-BODY A N D SHEET METAL
Kickdown Servo and Band ....................... 91 Adjusting Front Hinge .......................... 43
low-Reverse Servo and Band ..................... 91 Body Alignment ............................... 38
INDEX 7
INDEX- (Continued1
GROUP 23-BODY AND SHEET METAL- GROUP 23-BODY AND SHEET METAL-
(Continued 1 ( Continued )
Page Page
Body 'Sealing Procedures ........................ 12 Rear Bow Tension Cables ........................ 45
Bumper and Grille ............................. 16 Rear Door ................................... 22
Care and Cleaning of Convertible Coupe Top ........ 5 Rear Door Glass (four Door Hard Top) . . . . . . . . . . . . . .32
Checking Fluid Level in Reservoir .................. 47 Rear Door Glass Run Channels
Cleaning Vinyl Trim ............................ 5 (Four Door Hard Top) ......................... 33
Convertible Top ............................... 40 Rear Door 'Glass (Sedan) ........................ 33
Correcting Top Header Water Leaks . . . . . . . . . . . . . . . .42 Rear 'Door 'Lock and Link Assembly ................ 34
Correcting Top Well Water 'Leak . . . . . . . . . . . . . . . . . . .45 Rear Door Stationary Glass-Valiant
Dark Spots on Paint ............................. 39 (Except Hard Top) ........................... 33
Deck Lid .................................... 26 Rear Door Window Regulator .................... 32
Deck Lid Alignment ............................ 9 Rear Hinge Adjustment ......................... 43
Deck Lid Hinges .............................. 26 Rear Seat ................................... 21
Deck Lid Lock Adjustment ....................... 27 Rear Seat Back ................................ 21
Deck Lid Lock Cylinder ......................... 27 Rear Window4onvertible ...................... 47
Deck Lid Sealing .............................. 13 Rear Window MaintenancEConvertible ........... 5
Deck Lid Torsion Bar ............................ 26 Rear Window-Plymouth ........................ 28
Door Alignment ............................... 8 Remote Control and Door 'Lock .................... 25
Door Glass Run Channel ......................... 31 .........
Removal of 'Dirt from 'Ivory Plastic Trim Panels 5
Door Hinges (All Models) ........................ 23 Removing Old Finish ........................... 39
Door Opening and Door ......................... 13 Removing Wrinkles in Backlight ................... 45
Door Outside Handle ........................... 23 Replacement of Body .Panels ...................... 38
Door Ventilator Assembly ....................... 30 Roof Side Rail Alignment ........................ 43
Doors, .Deck Lid and Hardware .................... 22 Roof Side Rail Weatherstrip Adjustment ............. 44
Exterior Mouldings ............................. 21 Service Diagnosis ............................. 52
Fender Alignment ............................. 7 Servicing the Top Folding Mechanism ............... 47
Fenders ..................................... 16 Station Wagon ............................... 15
Fitting and Alignment .......................... 6 Station Wagon Rear Seats ....................... 50
Foreign .Material in Paint ........................ 39 Tail Gate Alignment ........................... 48
Front Door Glass ............................. 31 Tail Gate Glass ............................... 49
Front Door Trim and Hardware ................... 17 Tail Gate Glass Alignment ....................... 50
Front Door Vent Window ........................ 13 Tail Gate-Plymouth ........................... 48
Front Seat ................................... 21 Tail Gate Run Channel .......................... 49
Front Top Bow Adjustment-Plymouth . . . . . . . . . . . . . . .44 Tail Gate Run Channel Sealing .................... 15
Glass !Lift Bracket 'Replacement.................... 32 ............................
Tail G a t e v a l i a n t 49
Headlining Replacement ........................ 18 Tail Gate Weatherstrip ......................... 15
Hood Alignment .............................. 6 Tail Lamp Openings ........................... 14
Interior Upholstery Cleaning ..................... 4 ..............
Testing Electrical C i r c u i t s 2onvertible 47
Lock Cylinder ................................ 23 ..............
Testing for A Correctly 'Fitted Deck 'Lid 11
Luggage Compartment ......................... 14 Testing Wires Between Control Switch and
h a i n Control Prop Link 'Bracket Adjustment . . . . . . . . . . .43 .....................
Pump . M o t o r 4onvertible 47
Paint Refinishing .............................. 39 To Lower the Top .............................. 40
Power Guide Link Adjustment-Plymouth . . . . . . . . . . . .44 To Raise the Top .............................. 40
Quarter Glass All 'Except Station Wagon and Top Adjustments ............................... 40
Valiant Two Door Hard Top) .................... 35 Top Header .................................. 41
Quarter Glass Regulator ........................ 38 Top Header Adjustments ........................ 47
Quarter Glass Track ........................... 35 Top IMaterial Padding for Overhang ................ 44
Quarter Window .............................. 50 Top Shifts to One Side .......................... 44
Quarter Window Belt Water Leak . . . . . . . . . . . . . . . . . .46 Top Will Not 'Raise or lower ..................... 47
Radiator Core .Support .......................... 16 Window Regulator (Front Door) ...................24
a INDEX
INDEX- (Continued1
GROUP 23-BODY AND SHEET METAL- GROUP 2 A A I R C O N D I T I O N I N b
(Continued 1 ( Continued1
Page Page
Windshield ................................... 27 ................12
Inspection and Adjustments (Valiant)
Windshield-Convertible ........................ 40 Magnetic Clutch ............................... 33
Windshield Weatherstrip........................ 13 Owners Operating Instructions .................... 9
Push Button Control Chart ........................ 12
GROUP 2 A A I R CONDITIONING Radiator Pressure Cap ......................... 27
Air Conditioning and Heater Temperature Refrigerant Service ............................ 42
Control Cable Adjustment ..................... 30 Remove Sweep-Test Charge ..................... 45
Air Conditioning and Heater Temperature Replace the Receiver-'Drier Strainer................45
..........................
Selector 'Switch Test 30 Safety 'Precautions ............................. 25
Air Condition4peration (Plymouth Models) ......... 3 'Service. Diagnosis ............................. 46
...........
Air Condition4peration (Valiant 'Models) 10 Specifications .................................. 1
............
Air Conditioning Thermostatic Valve Test 32 Sweep-Test Charge ............................ 43
AntiFreeze .Recommendations-Plymouth ............ 27 Temperature Selector Switch ..................... 9
Blower Switch Chart ............................ 11 Test 1T e s t 'System Pressure .................... 14
Charging the System ........................... 46 Test 2-Refrigerant ....................... 15
Level
Compressor .................................. 35 Test 3-Testing ...............16
the System for leaks
. ............... . .
Compressor Drive Belt Adjustment 27 ............... 1 7
Test 4 4 o r r e c t i n g Low Refrigerant
Discharge the System .......................... 43 Test 5-Over-All Performance Test ................ 18
Electrical Controls and Circuits .................... 8 Test 6-Evuporator Pressure Regulator Valve
Evacuate the System ........................... 45 Test (Plymouth) ............................. 20
Expansion Valve, Evaporator and (Blower Test 7-Compressor Capacity Test ................ 21
Replacement (Valiant) ........................ 41 Test 8-Expansion Valve Test .................... 23
Expansion Valve. Heater Core. and Evaporator and Testing the System for 'leaks ..................... 44
Evoporator and Blower Replacement (Plymouth). . . . .39 Thermostatic Valves ............................ 8
Gauge Set Manifold -Installation and Tests ......... 13 Thermostatic Valve 'Replacement ..................32
Handling Tubing and Fittings...................... 26 Thermostatic Valve Tests ........................ 31
Heater Thermostatic Valve Test.................... 31 Torque Reference ............................. 2
...............
Inspection and Adjustments (Plymouth) 11 Vacuum Control System Adjustments and Tests ........ 28

1964 Plymouth Valiant Service Manual

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1964 Plymouth Valiant Service Manual

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2 INTRODUCTIUN AND GENERAL SPECIFICATIONS

PLYMOUTH SPORT FURY CONVERTIBLE

VALIANT SIGNET 200 CONVERTIBLE COUPE

VALIANT V-100 TWO-DOOR SEDAN

Chrysler Corporation Chrysler - Plymouth Division

MASTER TECHNICIANS SERVICE CONFERENCE

VEHICLE AND ENGINE NUMBERS m---

1rt Digit 2nd Digit 3rd Digit 4th Digit

Valiant Plymouth 1964 1 and 3 Detroit

ENGINE NUMBER The 170, 225, 361, 383 and 426

BODY NUMBER The body number plate is located

Fig. &Engine Number location (318 Cu. In. Eng.)

GENERAL DATA AND SPECIFICATIONS

VP-1 Plymouth 6-Cyl. VP-2 Plymouth 8-Cyl. W - 1 Valiant.6-Cyl.

'Item Body Style

Wheelbase All Models 116" 116" 106"

Tread (Front) All Models 59.5" 59.5" 55.9"

Tread (Rear) All Models 59.6" 59.6" 55.6"

length with All Models except

Width with All Models except

mar Axle All Models except

Tire Size All Models except

LUBRICATION AND MAINTENANCE CHART

Battory (Check Level) every 2 months.

MCLSpeodometer Cable Lubricant

LUBRICATION AN*D MAINTENANCE CHART

S U M M A R Y OF LUBRICATION AND MAINTENANCE SERVICES

Service Inspect InIpect

2 Months Engine crankcase oil X

6 Months Engine oil filter X

1 Year Engine Performance Evaluation

2 Years Brake linings

32,000 Miles Ball joints, front suspension

When Body mechanisms X

Lubricants which do not have both an SAE des-

4. AIR CLEANERS a new element should be installed every 2 years not

W Run the engine at idle to clean out any excess

FLOW CONTROL VALV

THIS WASHER IS COLOR CODED TO IDENTIFY VENT

Fig. &Closed Crankcase Valve Schematic (6 & 8 Cyl.)

If the valve does not click when shaken or if the

7. ENGINE OIL FILTER

Fig. 11-Fuel Filter (8-Cyl.)

at least every 16,000miles or once each year. Loss of

Fig. 13-Manifold Heat Control Valve (8-Cyl.)

Itern Type of Lubricant Remarks

All external lock cylinders MoPar Lubriplate Apply directly.

13. BRAKES Hydraulic Brake System

Fig. 16-Foot Operated Parking Brake (Disassembled) (Plymouth)

Fig. 17-Hand Operated Parking Brake (Disassembled) (Valiant)

Fig. 18-Steering linkage location of lubricating

18. FRONT WHEEL BEARINGS

Fig. 22-Wheel Bearing (Schematic) Fig. %Front Wheel Bearing Installation

FRONT WHEELS $,REAR WHEELS

SECTION A-A -32.7"-

Fig. 25-Support Location for Frame Contact Hoisting (Valiant)

Anticipated Temperature Range Viscosity Grade

24. SPEEDOMETER CABLE 26. TIRES

CERTIFIED CAR CARE-SEMI-ANNUAL MAINTENANCE SERVICE